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5.2 Plant maintenance: Pressure Vessel Repair
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Operation stage
Operator: Ensure these vessels operates within their specified design limits and measures shall be Index of posts
taken to ensure no overpressure beyond the specified allowable times. Not more than 500h/yr for 1.0 Welcome (2015-01-05)
20% overpressure and not more than 100h/yr for 33% overpressure.
3.1 Piping specifications (2015-01-17)
Mechanical Integrity: Ensure these vessels are constantly monitored on-stream visually, check all 3.2 Valve Spec & Purchase (2016-09-23)
vessel body paint, nozzles, stud bolts, supports and anchors are in good condition without distortion 3.3 Valve types, parts, accessories and application,
or corrosion, inspect under insulation if any suspected damage to insulation are observed and apply (2015-01-29)
suitable non-destructive testing over time time of operation to observe any signs of material failure, 3.4 Insulation (2015-03-29)
especially in processes susceptible to such failure modes. Read API 570 for the recommended 3.5 Stud bolts / Hex nuts and their relation to
inspection intervals and API 571 damage mechanisms for some examples of damages with photos. Flanges (2015-08-04)
3.6 Steam traps (2015-11-28)
4.1 Welding Terminologies (2015-02-09)
Repair stage 4.2 Welding rod, filler wires and materials
(2015-02-19)
What constitutes to a Repair?
4.3 Weld & Fabrication: Non-Destructive Testing
A method to restore the equipment condition to where it can operate safely within the Maximum Allowable Basics (2015-06-12)
Operating Pressure (MAWP) and Allowable operating temperatures. 4.4 Welding discontinuties (2016-12-02)
4.5 Weld & Fabrication: Pressure vessel basics
Adding of nozzles can also constitute to a repair, if (2015-06-06)
- It does not require a reinforcement pad 4.6 Weld & Fabrication: Reviewing PV Elite
- It is smaller than any existing nozzles on the vessel Datasheets (2015-06-06)
5.1 Plant Maintenance: Static Equipment and
typical maintenance jobs (2015-02-19)
Adding of any other nozzles are termed an "Alteration", which usually comes with rerating as the vessel
strength could be significantly reduced. 5.2 Plant maintenance: Pressure Vessel Repair
(2015-06-01)
5.3 Plant Maintenance: MOM Statutory Inspections
(Singapore) (2016-09-24)
Avoiding Repairs 5.4 Plant Maintenance: Valve Repair (2016-04-26)
First thing when problems are identified, management point of view may be safety, cost, operational we don't 5.5 Plant Maintenance: Refractory Repair
know. But these are all the potential problems to avoid a repair, can we actually avoid? (2016-12-02)
The number one reason for a repair would be corrective maintenance. This is usually carried out as follows:
Pipe Cap/Nozzle - Welding a pipe cap or nozzle to seal in the leaking spot.
These are non-penetrating.
Leak sealing - Possible for very small pressure vessels, usually below 8"
diameter. The leaking spot could be box in or wrap sealed by epoxy-metal
binders.
Lap band repair - A huge band is attached around the vessel body, this is not
recommended unless the repair needs to remain in place for a longer period
of time.
Strip lining - a thin layer of sheet metal, usually of a superior material is lined
internally. Cheaper than the other methods.
Insert Plate - A piece of the pressure vessel is cut out and replaced with a
new piece of metal plate of the same profile over the spot of leakage. The
edges should always be grounded unless the side falls on an existing weld
seam. In contrary to the sketch, the corners of the insert plates shall be
rounded to eliminate residual stresses.
Weld overlay - Adding a layer of weld filler metal over the thinned down
sections of the vessel to restore the wall thickness. Very tedious and time
consuming. Watch the manhours. Take note that the repair thickness shall
not be more than 50% of the minimum required thickness of the vessel
(exclude Corrosion Allowance)
Groove Repair - This method usually used for cracks and pinhole leakages.
The section where leakage is present is grind down to a U or V groove. Weld
metal is then deposited to restore the surface.
Additional Considerations
Materials
SS Cladding/Plate lining to P3, P4, P5 materials tends to crack when
excessive heats are applied during welding. Check for delayed cracking with
UT 24h after job completion.
Hydrogen service vessels shall be outgassed and checked for its hardness
after welding
Post Weld Heat Treatment
Check API 510 Section 8 for the full requirements of PWHT by alternative methods, as there are certain
material tests which needs to be performed, certain requirements to welding procedures on top of ASME IX
WPS/PQR requirements, certain requirements for temperature, certain requirements for welding electrode type
and not forgetting material considerations.
For additional repair procedures and guidelines on top of API 510, refer to ASME PCC-2.
7 comments:
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Electrode
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more about SMAW Welding.
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