Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

This is a Controlled Document that complies with CSBP Limited formatting and Quality Control guidelines. Please check that this is the latest available version before use. Title:

REPAIRS AND MINOR ALTERATIONS TO EXISTING PRESSURE EQUIPMENT, PIPING AND TANKS DP-05-095-06
Ron Caporn Phil Talbot Fully reviewed - Minor change to Section 3.b.c.2, and line item 5 added to Section 4.c.

Number: Owner: Authoriser: Version Details:

TABLE OF CONTENTS
1. 2. 3. 4. PURPOSE .................................................................................................................................. 2 OVERVIEW .............................................................................................................................. 2 PROCEDURE FOR PRESSURE PIPING, VESSELS AND TANKS.................................. 2 DEFINITIONS .......................................................................................................................... 4

APPENDIX 1 EXAMPLE OF THE MINIMUM REQUIREMENTS FOR A REPAIR PROCEDURE ITP 8

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

1.

PURPOSE

The purpose of this procedure is to set out the actions and documentation required to ensure that repairs and minor alterations (refer Section 4 Definitions) are carried out in accordance with good engineering practices and that the QA/QC requirements of the applicable codes and standards are met. Welding Quality Management (GM-05-050-03) defines the requirements for the quality management of welding processes.

2.

OVERVIEW

Repairs and minor alterations are to be treated the same. As a minimum, repairs and minor alterations to piping are carried out in accordance with the following CSBP Engineering Standards whereas repairs and minor alterations to pressure vessels and tanks are carried out in accordance with the relevant design, welding and quality assurance codes. ES-14-601-01 Basis for Design Piping

ES-14-602-01 Fabrication and Installation of Piping ES-14-602-02 Inspection and Testing of Piping Systems ES-14-603-01 Piping Material Specifications

3.
a.

PROCEDURE FOR PRESSURE PIPING, VESSELS AND TANKS

The Plant Engineer: 1. Prepares the following documents prior to issuing a contract or commencement of work: and forwards them to the Senior Plant Inspector: (a) Repair Procedure using form SF2014 (refer Section 4 Definitions) (refer RM-05-095-09 for Standard Repair Procedures and ITPs) Scope of Work (refer Section 4 Definitions) Inspection & Test Plan (ITP) - using form SF2013 (refer Section 4 Definitions) (refer Appendix 1 for example of the minimum requirements in an ITP) (refer RM-05-095-09 for Standard Repair Procedures and ITPs)

(b) (c)

b.

Contractor / Supervisor 1. Prepares the following documentation: (a) (b) (c) Welding Procedure Qualifications (refer Section 4 Definitions) Welding Procedure Specifications (refer Section 4 Definitions) Welder Performance Qualifications (refer Section 4 Definitions)

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

c.

Senior Plant Inspector: 1. Authorises the following documents prior to commencement of work: (a) (b) (c) (d) (e) 2. Repair Procedure Scope of Work ITP Welding Procedure Specifications and Qualifications Welder Performance Qualifications

Approves name of the Fabrication Inspector.

d.

Fabrication Inspector 1. 2. Ensures all inspection and testing requirements are performed, as per the ITP, when the work is carried out. Progressively signs off all Holds and Witness Points on the ITP until completion.

e.

Contractor / Supervisor 1. Ensures all work is carried out in accordance with approved documents and that all nominated Holds and Witness Points on the ITP are signed, prior to proceding to next stage, until all work is completed. Compiles all QA/QC documentation into a Manufacturers Data Report (refer Section 4 Definitions) and forwards it to the Senior Plant Inspector.

2. f.

Plant Engineer 1. Signs off the completed Inspection & Test Plan to confirm that the work is competed and that the equipment can be commissioned or re-commissioned.

g.

Senior Plant Inspector 1. Verifies that the Manufacturers Data Report is complete and correct.

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

4.
a.

DEFINITIONS
Fabrication Inspector Is a person qualified and experienced as shown in AS 3920.1, table 5.1, and is competent in the application of ASME 9 and AS 3992 when reviewing and approving welding procedures and welder performance qualifications

b.

Inspection and Test Plan (ITP) Is a plan of the inspections and tests that are to be carried out during repairs or fabrication. It includes: 1. 2. 3. 4. 5. The points at which inspection or testing is to be performed and by whom. Acceptance criteria for each inspection and test (i.e. applicable codes & standards). Whether the inspection or test point is a witness, hold or verify point. QA documentation requirements. Provision for the signature of the Plant Engineer confirming that the repairs are completed and that the equipment can be re-commissioned.

c.

Manufacturers Data Report (MDR) Is a file containing all the QA/QC documentation and essential engineering data. For repairs and minor alterations it is to include at least: 1. 2. 3. 4. 5. 6. The Repair Procedure Material certificates Approved welding procedure specifications (WPS) and qualifications (WPQ) Approved welder qualifications. Welding consumables certificates. A Weld Map, consisting of a drawing and spreadsheet which identifies for each weld joint the date, WPS, Welder, NDT reports, heat treatment reports, and pressure test certificate. NDT reports. Heat treatment charts and recorder calibration certificate. Pressure test certificate (CSBP Certificate of Pressure Test or equivalent, is to be used). Non-conformances and concessions. Completed Inspection and Test Plan (ITP)

7. 8. 9. 10. 11.

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

d.

Minor alteration Is an alteration that does NOT: 1. 2. 3. 4. 5. Affect the maximum allowable working pressure or temperature. Add new nozzles or openings. Change the dimensions or contour. Change the heating surface area of a heat exchanger. Replace a pressure component with a material of different tensile strength.

e.

Repair Procedure Is a procedure that states all the fabrication requirements and sequence of events for a carrying out a specific repair. It includes 1. 2. 3. A brief description of the repair (eg. Renew 50NB cracked drain nozzle on V1234). How the repair is to be carried out. Including sketches or drawings and equipment number. Sequence of events with the following matters to be considered and stated: (a) Codes and standards to be used. (eg AS1210 or ASME 8 for pressure vessels, AS 1228 for boilers, ASME/ANSI B31.3 for piping, and API 620, API 650, API 653 for tanks). What materials are to be used. Is heat treatment required prior to carrying out the repair necessary (e.g. Normalising or solution annealing to ensure weldability of the material). How is the heat treatment to be applied and the temperature monitored. How is the failed component to be removed and what processes are to be used. What preparation for welding is required, including oxide removal (consult code for required amount) and any special cleaning requirements. What weld joint preparation is required (i.e. single vee, double vee, a detailed sketch for more complicated joints). Is NDT to clear preparations required (e.g. dye penetrant (DPI) or magnetic particle inspection (MPI) to confirm crack is totally removed). What welding procedures are to be used, including the weld run sequence (particularly for double vee joints or insert patches). Is pre-heat required, including how it is applied and temperature monitored.

(b) (c) (d) (e) (f) (g) (h) (i) (j)

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(k) (l) (m) (n) (o) (p)

Do special conditions apply to the welding procedure qualification (e.g. welding aged material to new material). Is back gouging or grinding required to complete the weld, including oxide removal where applicable. Is NDT during the welding process required (e.g. DPI or MPI of root runs). Is grinding or blending of completed welds required to remove stress raisers and to improve stress flow. Is post weld heat treatment (PWHT) required, including how heat it is applied and the temperature monitored. Is final NDT, including after PWHT where used, required (e.g. hardness testing, radiography, ultrasonics, magnetic particle or dye penetrant inspection). Is treatment of completed welds required (e.g. passification, special cleaning). Is pressure testing required, to what pressure and how (see AS 4037.1992, section 17). At what stages is visual inspection required.

(q) (r) (s) f. Scope of Work

Is a document describing all the work and requirements for a project, repair or alteration and is used as the work instructions for the team or contractor performing the work. It includes (if applicable): 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. A brief description of the work and location. Work included in itemised form. Work excluded (e.g. supply of scaffold). Limits of the work. Free issue materials. Specific testing & commissioning requirements, including the ITP. Clearances and special permit requirements. Standards and drawings applicable to the work. Schedule for the work. Documentation requirements (e.g. MDRs, ITPs, Vendor Manuals). Time and date for site inspection.

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

g.

Welder Performance Qualification A documented test, carried out by a welder, working to an approved welding procedure, to determine the welders ability to deposit sound weld metal using the fabricators available equipment. Refer to AS 3992 or ASME 9 for full requirements.

h.

Welding Procedure Qualification (WPQ) Covers the making and testing of a welded joint and recording of welding parameters to prove that the following are suitable for its intended use in production and includes: 1. 2. 3. 4. 5. 6. 7. 8. Welding processes Joint type and preparation Joint position Parent materials Welding consumables Run sequence Welding parameters (e.g. voltage, amps, polarity, travel speed) Heat treatment (preheat and PWHT as applicable)

Refer to AS 3992 or ASME 9 for full requirements. Note: i. WPQ may also be referred to as WPQR or PQR)

Welding Procedure Specification (WPS) A documented qualified welding procedure, prepared to provide detailed direction for making production welds within the essential variables of the WPQ. Refer to AS 3992 or ASME 9 for full requirements.

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Repairs and Minor Alterations to Existing Pressure Equipment, Piping and Tanks DP-05-095-06

APPENDIX 1 EXAMPLE OF THE MINIMUM REQUIREMENTS FOR A REPAIR PROCEDURE ITP

CSBP INSPECTION AND TEST PLAN FOR REPAIR PROCEDURE
Contractor:
Inspection No 1 2 3 4 5 6 7 8 9 10 11 Description Review and approve Repair Procedure, Scope of Work and ITP. Review and approve WPS, WPQR, and Welder Qualifications. Verify materials against specifications. Verify that Repair Procedure and ITP are on the job. Visual inspection of weld preparations. Verify correct welding procedure is being used. Visual inspection of completed welds. NDT of completed welds. Pressure test. Review applicable documentation (eg. NDT, heat treatment, hardness and pressure test reports). Verify all work is complete and all witness and review points are signed off on ITP. Equipment can be recommissioned. Review and approve MDR. - Witness, Mandatory Hold Point - Random Inspection RA R Requirement/ Acceptance Criteria GM-05-050-03 DP-05-095-06 GM-05-050-03 DP-05-095-06 Approved Repair Procedure & ITP Approved Repair Procedure & ITP As per WPS As per WPS Approved Repair Procedure & applicable code Approved Repair Procedure Approved Repair Procedure & applicable code Approved Repair Procedure & applicable code Approved Repair Procedure & ITP Work Order No.: Equipment No.: Description: A - SENIOR PLANT INSPECTOR B - FABRICATION INSPECTOR Date Action / Actionee Completed A B C D RA RA RI RI RI RI W RI W R W W W W W W W R R C - CONTRACTOR D - PLANT ENGINEER Initial: Actioned by/ Document Witnessed Reference No. A B C D

12 W RI

GM-05-050-03 DP-05-095-06 - Review and Sign Documentation - Review Documentation

RA Shading indicates documentation to be supplied

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