Presented by: Gary Scribner Manager of Technical Services. Shanghai April The National Board of Boiler and Pressure Vessel Inspectors

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1 Presented by: Gary Scribner Manager of Technical Services Shanghai April 2016

2 1. Provides administrative and technical rules, and guidelines to follow for repairing or altering a pressure retaining item. These rules are Comprehensive; uncomplicated; and in a user-friendly format 2. Provides requirements for jurisdictional oversight 3. Requirements for third party oversight including training, experience, qualifications 4. Provides alternative methods NDE, heat treatment, testing, design, repair methods

3 5. Provides requirements for documentation utilizing specific forms and requirements for registration and retention of records 6. Provides for verification of work 7. Requires a QA Program easily adapted to fit other codes of construction for repairs and alterations; international codes

4 Table of Contents Section 1 General Section 2 Welding Section 3 Repairs and Alterations Section 4 Examination and Testing Section 5 Documentation and Stamping Section 6 Supplements Section 7 - Policy for Metrication Section 8 Technical Inquiries Section 9 - Glossary Section 10 - Interpretations Section 11 Index 4

5 Term Definition Reference Repair Work necessary to restore pressure-retaining items to a safe and satisfactory operating condition. Part 3, Section 9, Glossary of Terms Alteration A change in the item from the original design which affects the pressure containing capability (Mfg. Data Report). Nonphysical changes such as an increase in MAWP or design temperature shall be considered an alteration. A reduction in minimum temperature is also considered an alteration. Part 3, Section 9, Glossary of Terms 5

6 NBIC Part 3 can be utilized for either ASME or other Codes: When repairs or alterations are performed to the ASME Boiler and Pressure Vessel Code, the repair or alteration shall conform insofar as possible to the section and edition most applicable to the work planned. 6

7 When the standard is not the ASME Code, the repair or alteration shall: Conform to the edition of the construction standard or specification most applicable. Where this is not possible or practical, other codes, standards, or specifications, including the ASME Code, can be used, provided: The R Certificate Holder has the concurrence of the Inspector; & The Jurisdiction where the item is. 7

8 Inspection and certification shall be made by a National Board Commissioned Inspector employed by an: Authorized Inspection Agency (AIA) Owner-User Inspection Organization Federal Inspection Agency Repairs require prior authorization of the Inspector. This Inspector shall determine that the repair methods are acceptable. 8

9 Shall be by the Inspector authorizing the repair or alteration. (or another Inspector employed by the same AIA) Before signing the R Form, the Inspector shall: review drawings, ensure work was performed to the original Code of Construction/Standard, witness pressure testing (or an acceptable alternative). verify required NDE completion, perform other functions necessary to ensure Code compliance. 9

10 Organizations performing repairs or alterations shall be accredited as described in Part 3 and NB-415, Accreditation of Repair Organizations R NB

11 Welding shall be performed: in accordance with the original Code of Construction; to a Welding Procedure Specification (WPS), qualified in accordance with the original Code of Construction. When not possible or practicable, may be qualified in accordance with ASME Section IX. 11

12 R Certificate Holder may use the SWPS listed in Table 2.3 provided: No changes to the SWPS are made. The Certificate holder accepts the SWPS by certification; & use of the SWPS shall be documented in their QC manual accepted by the AIA of record. 12

13 13

14 Shall be qualified in the welding process in accordance with the original Code of Construction or ASME Section IX. Use of SWPS shown in Table 2.3 is permitted for performance qualification testing. 14

15 R Certificate Holder shall establish a system to describe: assignment of unique identification marks for each qualified welder. And provide documentation so all welded joints can be identified to the welder making the weld (e.g., low stress stamp, weld maps, tabulation sheets, travelers). 15

16 Performance qualifications for a specific process are affected when one of the following occurs: when the welder has not welded in a specific process during a period of 6 months or more. there is specific reason to question their ability. A continuity record shall be maintained and available to the Inspector. The record retention period shall be described in the Quality Control (QC) manual. 16

17 Minimum recommended temperatures for Preheat Post Weld Heat Treatment (PWHT) Procedures for Local PWHT Alternative Welding Methods Without PWHT Under certain conditions when PWHT in accordance with the original code of construction is inadvisable or impractical Methods 1-5 Method 1- increased pre-heat Methods 2-5 temper bead 17

18 Materials Shall conform to the requirements of the original Code of Construction. Materials with a carbon content of more than 0.35% cannot be welded. The R Certificate Holder is responsible for verifying existing materials and condition of the base material: Existing material identification; Manufacturer s data reports original data drawings records. 18

19 If existing material cannot be verified, agreement for the method of establishing design basis shall be obtained from the Inspector and the Jurisdiction. Minimum requirements include: o Perform a chemical analysis and hardness testing, as a minimum to determine weldability and strength; - OR o Qualify a weld procedure If there is a question, seek competent technical advice. 19

20 Replacement parts may be supplied as material or welded parts. Materials supplied as new parts formed by casting, spinning, forging, die forming, and on which no welding was performed shall be marked with the material and part identification and the name or trademark of the Manufacturer. A coded marking system traceable to the required marking may be used. Examples: seamless or welded tubes, pipe caps, forged nozzles or HDS (weld caps). 20

21 Replacement parts subject to internal or external pressure, preassembled by attachment welds shall have welding, and certification performed in accordance with the original Code of Construction. Examples: water wall, floor panel assemblies, inspection openings, burner openings, soot blower openings. 21

22 The Manufacturer must possess the applicable ASME Stamp. Must be inspected during fabrication by an Authorized Inspector. The Manufacturer must certify the part and supply a Manufacturer s Partial Data Report. The part must be stamped with the ASME Code Symbol Stamp. 22

23 They shall be manufactured as required by the original Code of Construction. They shall be inspected, stamped, and certified as required by the original Code of Construction. When not possible or practical, an R stamp holder may fabricate the part and document the fabrication on the Form R-3. Certification is made by applying the R symbol stamp. 23

24 The R Certificate Holder establishes controls that document how: design requirements are complied with; How design drawings, calculations, and specifications are prepared or obtained, & How they are controlled, and interpreted to provide the basis for alteration in accordance with the original Code of Construction. 24

25 A set of calculations shall be completed prior to the start of physical work. All design work shall be completed by an organization experienced in the design portion of the standard. Calculations are made available for review by the Inspector accepting the design. 25

26 Before a repair is made to a defect in a welded joint or base metal, care should be taken to investigate its cause, extent, and likelihood of recurrence. Defects shall be completely removed before welding. (examinations) 26

27 27

28 The R Certificate Holder is required to include in thier Quality System Program specific information regarding routine repairs in order to establish: controls responsibilities scope and extent. 28

29 Routine Repairs are limited to categories listed in NBIC Part 3, e) 29

30 in-process involvement of the Inspector and stamping may be waived. (Subject to acceptance of Jurisdiction and concurrence of Inspector.) Form R-1 under the Remarks section shall state Routine Repair. 30

31 Specific examples of repairs are given in paragraphs a) thru t). Cracks, blisters, wasted areas, access openings, external overlay weld buildup, riveted joints, re-ending or replacement of tubes, flush patches, tube window patches. 31

32 The user shall prepare a detailed repair plan: Plan is certified by an engineer to compatibility with original user s design specifications and design report. Inspector accepts the design plan and signs the appropriate R Form. 32

33 Revised calculations are required. Caution: Establishing higher joint efficiencies to rerate a PRI is not permitted. Established in accordance with original Code of Construction. Require current satisfactory inspection records to support the proposed work. Shall be pressure tested for the new service, or alternative methods may be used to verify structural integrity subject to jurisdictional approval. 33

34 Nondestructive examination (NDE) shall be in accordance with the original code of construction The basic requirements shall include: technique extent of coverage procedures personnel qualification acceptance criteria 34

35 When NDE is required by the original Code of Construction and is not possible or practicable, an alternative method may be used. The alternate method shall be acceptable to the Inspector, and the Jurisdiction where the PRI is installed, (when required). 35

36 The calibration program shall meet the same requirements as the applicable standard used for construction. This program shall include calibration and documentation for: pressure gages, measurement devices, examination and test equipment. 36

37 The integrity of all repairs, alterations, and replacement parts shall be verified by examination or test. The R Certificate Holder is responsible for all activities. Examinations and tests used shall be subject to acceptance of the Inspector, and where required, the Jurisdiction. 37

38 Based on the nature and scope of the repair activity, one or a combination of the following examination and test methods shall be applied: a) Liquid Pressure Test To verify leak tightness, not more than 150% of MAWP. If test pressure exceeds 90% of set pressure of pressure relief device, the device shall be removed or spindle restraint applied. Metal temperature shall be in accordance with the original Code of Construction but not <60 F (16 C) nor >120 F (49 C). Minimum hold-time of test is 10 minutes. Test pressure reduced to MAWP for inspection. Hold as necessary for complete examination by Inspector. 38

39 b) Pneumatic Test Requires concurrence of owner, Jurisdiction, and Inspector. Conducted at the minimum test pressure to verify leakage. Shall not exceed maximum test pressure of the original Code of Construction. Precautionary requirements shall be followed. 39

40 c) Initial Service Leak Test As permitted by original Code of Construction, the same test may be used for repair. d) Vacuum Test Shall be suitable to verify leak tightness of the repair. e) Nondestructive Examination NDE methods used shall provide meaningful results to verify the integrity of the repair. 40

41 Liquid Pressure Test Pneumatic Test Nondestructive Examination (NDE) 41

42 Provides requirements for certification, stamping, and documentation of repairs and alterations. Forms may be obtained from the National Board web site. 42

43 Form R-1, Report of Repair Form R-4, Report Supplementary Sheet 43

44 Form R-2, Report of Alteration (Page 2) 44

45 a) R Certificate Holder is responsible for preparation, certification, and distribution. b) Information describing the work to repair or alteration a PRI shall be documented on Form R-1/2 and extended to Form R-4 as needed. c) Inspector shall indicate acceptance by signing Form R- 1/2 and Form R-4, if attached. d) Attachments to Form R-1/2: Form R-3, Report of Parts Fabricated by Welding (Part ) Manufacturer s Data Report Certificates of Compliance 45

46 The completed Form R-1 & R-2, along with attachments, shall be distributed to: Owner or User Inspector Jurisdiction, if required AIA responsible for inservice inspections of the pressureretaining item (upon request). Organization performing the repairs is responsible for distribution R Forms and attachments. 46

47 a) Organizations performing repairs or alterations may register R Forms with the National Board. b) Some jurisdictions may require registration. c) Alterations shall be registered if the original Manufacturer s data report was registered. 47

48 Indicates work performed in accordance with the requirements of the NBIC. Done only with the knowledge and authorization of the Inspector. The Certificate Holder shall apply the stamping to the PRI directly or to a nameplate. Required stamping and information shown in NBIC Part 3,

49 Thank you! 49

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