Italy September 2016

Presented by: Gary ScribnerManager of Technical Services

Italy September 2016

The National Board of Boiler and Pressure Vessel Inspectors

1. Provides administrative and technical rules and guidelines to follow for installation, inspection, repair/alterations—general and specific.◦ These rules are comprehensive;

uncomplicated; user-friendly format2. Requirements for jurisdictional oversight3. Requirements for third party oversight—

training, experience, & qualifications4. Provides alternative methods—NDE, heat

treatment, testing, design, repair methods

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

Table of Contents

Section 1 – GeneralSection 2 – WeldingSection 3 – Repairs and AlterationsSection 4 – Examination and TestingSection 5 – Documentation and StampingSection 6 – SupplementsSection 7 - Policy for MetricationSection 8 – Technical InquiriesSection 9 - Glossary Section 10 - InterpretationsSection 11 – Index

4The National Board of Boiler and Pressure Vessel Inspectors

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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 (Mfg. Data Report) which affects the pressure containing capability. 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

The National Board of Boiler and Pressure Vessel Inspectors5

NBIC Part 3 can be utilized for either ASME or other Codes of Construction:

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.


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 installed has concurred

with the proposed repair or alteration.


Inspection and certification shall be made by a National Board Commissioned Inspector employed by an:

Repairs require prior authorization of the Inspector, who shall determine that the repair methods are acceptable.

Authorized Inspection Agency (AIA) Owner-User Inspection

Organization Federal Inspection Agency


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.


Organizations performing repairs or alterations shall be accredited as described in Part 3 as appropriate for the scope of the work planned.


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.


“R” Certificate Holder may use SWPS as shown in Table 2.3 provided: • Changes to the SWPS are not

permitted.• The Certificate holder

accepts the SWPS by certification &

• use shall be documented in their QC manual accepted by the AIA of record.

Note: PQR will not be supplied for the SWPS.


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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.


“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).


Performance qualifications for a specific process are affectedwhen 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.

A record retention period shall be described in the Quality Control (QC) manual.


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


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 from: Manufacturer’s data reports

• original data• drawings• records


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 well as minimum to determine weldability and strength;

- OR –

oQualify a weld procedure

If there is a question, seek “competent” technical advice.


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).


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.


◦ The Manufacturer possesses the applicable ASME Stamp.

◦ Must be inspected during fabrication by an Authorized Inspector.

◦ The Manufacturer certifies and supplies a Manufacturer’s Partial Data Report.

◦ The part is properly stamped with the applicable Code Symbol Stamp.


◦ 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 and certify on Form R-3.◦ Certification is made by applying the “R” symbol

stamp.


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 originalCode of Construction.


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.


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.

Shall be completely removed before welding.

(examinations)


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


Routine Repairs are limited to categories listed I the NBIC Part 3, 3.3.2 e)

e) Repairs falling within one or more of the following categories may be considered routine:◦ 1) Welded repairs or replacements of valves, fittings, tubes, or pipes NPS 5 (DN

125) in diameter and smaller, or sections thereof, where neither postweld heat treatment nor NDE other than visual is required by the original code of construction. This includes their attachments such as clips, lugs, skirts, etc., but does not include nozzles to pressure-retaining items;

◦ 2) The addition or repair of nonload bearing attachments to pressure-retaining items where postweld heat treatment is not required;

◦ 3) Weld buildup of wasted areas in heads, shells, flanges and fittings not exceeding an area of 100 sq. inches (64,520 sq. mm) or a thickness of 25% of nominal wall thickness or ½ inch (13 mm), whichever is less;

◦ 4) Corrosion resistance weld overlay not exceeding 100 sq. in. (64,520 sq. mm).

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◦ 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.”


Specific examples of repairs are given in paragraphs 3.3.3 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.


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 plan and signs the appropriate R Form


Revised calculations are required.

Caution: Establishing higher joint efficiencies to re-rate 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.


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 requirements◦ acceptance criteria


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.


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.


NOTE: The integrity of the repair, alteration, 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.


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.


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.


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 available to verify leak tightness of the repair.

e) Nondestructive Examination NDE methods used shall be available for providing

meaningful results to verify the integrity of the repair.


Liquid Pressure Test

Pneumatic Test

Nondestructive Examination (NDE)


Provides requirements for certification, stamping, and documentation of repairs and alterations.

Forms may be obtained from the National Board web site.


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


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


a) “R” Certificate Holder is responsible for preparation, certification, and distribution.

b) Information describing the work to repair a PRI shall be documented on Form R-1 and extended to Form R-4 as needed.

c) Inspector shall indicate acceptance by signing Form R-1 and Form R-4, if attached.

d) Attachments to Form R-1: Form R-3, Report of Parts Fabricated by Welding

(Part 3 – 3.2.2) Manufacturer’s Data Report Certificates of Compliance


The completed Form R-1, along with attachments, shall be distributed to:◦ Owner or User◦ Inspector◦ Jurisdiction, if required◦ AIA responsible for inservice

inspections of the pressure-retaining item. (upon request)

Organization performing the repairs is responsible for distribution of Form R-1 and attachments.


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 Manufacturers data report was registered.


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, 5.7.


www.nationalboard.org

The National Board of Boiler and Pressure Vessel Inspectors 48

Thank you!

Documents

Italy September 2016