API 510 CODE

OVERVIEW
 SECTION 8
Repairs, Alterations, and Rerating of
Pressure Vessels

7.2.3
Preheat or Controlled Deposition Welding Methods as
Alternatives to Postweld Heat Treatment
 Definition Controlled Deposition

• 3.19 controlled-deposition welding:

• Any welding technique used to obtain controlled

grain refinement and tempering of the underlying
heat affected zone (HAZ) in the base metal.
 Definition Controlled Deposition

• Various controlled deposition techniques, such as

temper-bead (tempering of the layer below the current
bead being deposited) and half-bead (requiring removal
of one-half of the first layer), are included.
 Definition Controlled Deposition

• Controlled-deposition welding requires control of the

entire welding procedure including the joint detail,
preheating and post heating, welding technique, and
welding parameters. Refer to supporting technical
information found in Welding Research Council
Bulletin 412.
 Preheat/Controlled Deposition
• Benefits
• May allow welded repairs to a vessel that was
constructed to the ASME Section VIII Div.1 which
required PWHT to be repaired without further PWHT of
the vessel’s material.
• Preheat and controlled deposition welding, as described
in 7.2.3.1 and 7.2.3.2, may be used in lieu of post-weld
heat treatment where PWHT is inadvisable or
mechanically unnecessary.
• Prior to using any alternative method, a metallurgical
review conducted by a pressure vessel engineer shall
be performed.
 Preheat/Controlled Deposition

• The review should consider factors such as the reason

for the original PWHT of the equipment, susceptibility of
the service to promote stress corrosion cracking,
stresses in the location of the weld, susceptibility to high
temperature hydrogen attack, susceptibility to creep, etc.

• Selection of the welding method used shall be based on

the rules of the construction code applicable to the work
planned along with technical consideration of the
adequacy of the weld in the as-welded condition at
operating and pressure test conditions.
 Preheat/Controlled Deposition

• When reference is made in this section to materials by

the ASME designation, P-Number and Group Number,
the requirements of this section apply to the applicable
materials of the original code of construction, either
ASME or other, which conform by chemical composition
and mechanical properties to the ASME P-Number and
Group Number designations.
• Vessels constructed of steels other than those listed in
7.2.3.1 and 7.2.3.2 that initially required PWHT shall be
post-weld heat treated if alterations or repairs involving
pressure boundary welding are performed. When one of
the following methods is used as an alternative to PWHT,
the PWHT joint efficiency may be continued if it has been
used in the currently rated design.
 Preheat/Controlled Deposition

7.2.3.1
Preheating Method (Notch Toughness
Testing Not Required)
Preheating Method Notch Toughness Not Required

a. Notch toughness testing is not required when this

welding method is used.
b. The materials shall be limited to P-No. 1, Group 1, 2, and
3, and to P-No. 3, Group 1 and 2 (excluding Mn-Mo
steels in Group 2).
c. The welding shall be limited to the shielded-metal-arc
welding (SMAW), gas-metal-arc welding (GMAW), and
gas tungsten-arc welding (GTAW) processes.
 Preheating Method Notch Toughness Not
Required
d. The weld area shall be preheated and maintained at a
minimum temperature of 300°F during welding.
• The 300°F temperature should be checked to assure
that 4 in. of the material or four times the material
thickness (whichever is greater) on each side of the
groove is maintained at the minimum temperature during
welding. The maximum interpass temperature shall not
exceed 600°F.
• When the weld does not penetrate through the full
thickness of the material, the minimum preheat and
maximum interpass temperatures need only be
maintained at a distance of 4 in. or four times the depth
of the repair weld, whichever is greater on each side of
the joint.
 Controlled Deposition Notch Toughness Required

a. Notch toughness testing, such as that established by

ASME Code Section VIII Division 1, parts UG-84 and
UCS-66, is necessary when impact tests are required by
the original code of construction or the construction code
applicable to the work planned.
b. The materials shall be limited to P-No. 1, P-No. 3, and P-
No. 4 steels.
c. The welding shall be limited to the shielded-metal arc
welding (SMAW), gas-metal-arc welding (GMAW), and
gas tungsten-arc welding (GTAW) processes.
 Controlled Deposition Notch Toughness Required

d. A weld procedure specification shall be developed and

qualified for each application. The welding procedure
shall define the preheat temperature and interpass
temperature and include the post heating temp.
requirement in f (1) below. The qualification t for the test
plates and repair grooves shall be in accordance with
Table 7-1.
 Table 7-1
Welding Methods as Alternatives to Postweld Heat Treatment

• Qualification Thicknesses For Test Plates and Repair Grooves

_______________________________________________________________________
Depth t of Test Repair Groove Thick. T of Test Thick. Base Metal
Groove Welded Depth Qualified Coupon Welded Qualified
___________________________________________________________________________________________________________________

t <t <2 in. <T

t <t > 2 in. 2 in. to unlimited

Note: The depth of the groove used for procedure qualification must be
deep enough to allow removal of the required test specimens.
Controlled Deposition Notch Toughness Required
 Controlled Deposition Notch Toughness Required

d. (cont’d) The test material for the welding procedure

qualification shall be of the same material specification
(including specification type, grade, class and condition
of heat treatment) as the original material specification
for the repair.
• If the original material specification is obsolete, the test
material used should conform as much as possible to the
material used for construction, but in no case shall the
material be lower in strength or have a carbon content of
more than 0.35%.
 Controlled Deposition Notch Toughness Required

e. When impact tests are required by the construction code

applicable to the work planned, the PQR shall include
sufficient tests to determine if the toughness of the weld
metal and the heat affected zone of the base metal in the
as-welded condition is adequate at the minimum design
metal temperature (such as the criteria of ASME Section
VIII Div. 1, parts UG-84 and UCS 66).
• If special hardness limits are necessary (for example, as
set forth in NACE RP 0472, and MR 0175) for corrosion
resistance, the PQR shall include hardness tests as well.
 Controlled Deposition Notch Toughness Required

• f. The WPS shall include the following additional

requirements:
• 1. The supplementary essential variables of ASME
Code, Section IX paragraph QW-250, shall apply;
• 2. The maximum weld heat input for each layer shall not
exceed that used in the procedure qualification test;
• 3. The minimum preheat temperature for welding shall
not be less than that used in the procedure qualification
test;
 Controlled Deposition Notch Toughness Required

• 4. The maximum interpass temperature for welding shall

not be greater than that used in the procedure
qualification test;
• 5. The preheat temperature shall be checked to assure
that 4 in. of the material or four times the material
thickness (whichever is greater) on each side of the weld
joint will be maintained at the minimum temperature
during welding.
• When the weld does not penetrate through the full
thickness of the material, the minimum preheat
temperature need only be maintained at a distance of 4
in. or four times the depth of the repair weld, whichever
is greater on each side of the joint;
 Controlled Deposition Notch Toughness Required
6. For the welding processes in 7.2.3.2 (c), use only
electrodes and filler metals that are classified by the filler
metal specification with an optional supplemental
diffusible-hydrogen designator of H8 or lower. When
shielding gases are used with a process, the gas shall
exhibit a dew point that is no higher than -60°F.
• Surfaces on which welding will be done shall be
maintained in a dry condition during welding and free of
rust, mill scale and hydrogen producing contaminants
such as oil, grease and other organic materials;
7. The welding technique shall be a controlled-deposition,
temper-bead or half-bead technique. The specific
technique shall be used in the procedure qualification
test;
 Controlled Deposition Notch Toughness Required

8. For welds made by SMAW, after completion of welding

and without allowing the weldment to cool below the
minimum preheat temperature, the temperature of the
weldment shall be raised to a temperature of 500°F plus
or minus 50°F for a minimum period of two hours to
assist out-gassing diffusion of any weld metal hydrogen
picked up during Welding.

• This hydrogen bake-out treatment may be omitted

provided the electrode used is classified by the filler
metal specification with an optional supplemental
diffusible-hydrogen designator of H4 (such as E7018-
H4); and;
 Controlled Deposition Notch Toughness Required

9. After the finished repair weld has cooled to ambient

temperature, the final temper bead reinforcement layer
shall be removed substantially flush with the surface of
the base material.
 Nondestructive Exam of Welds 7.2.4

• Prior to welding, the area prepared for welding shall be

examined using either the magnetic particle &(MT) or the
liquid penetrant (PT) examination method to determine
that no defects exist.
• After the weld is completed, it shall be examined again
by either of the above methods to determine that no
defects exist using acceptance standards acceptable to
the Inspector or code of construction most applicable to
the work planned.
• In addition, welds in a pressure vessel that was originally
required to be radiographed by the rules of the original
code of construction, shall be radiographically examined.
 Nondestructive Exam of Welds 7.2.4

• In situations where it is not practical to perform

radiography the accessible surfaces of each non-
radiographed repair weld shall be fully examined using
the most appropriate nondestructive examination method
to determine that no defects exist and;
• the maximum allowable working pressure and/or
allowable temperature shall be reevaluated to the
satisfaction of the authorized pressure vessel inspector
and jurisdiction at the location of installation.
 Repairs to SS Overlay/Cladding 7.2.6

• The repair procedure (s) to restore removed, corroded,

or missing clad or overlay areas shall be reviewed and
endorsed prior to implementation by the pressure vessel
engineer and authorized by the inspector.
• Consideration shall be given to factors which may
augment the repair sequence such as stress level, P
number of base material, service environment, possible
previously dissolved hydrogen, type of lining,
deterioration of base metal properties (by temper
embrittlement of chromium-molybdenum alloys),
minimum pressurization temperatures, and a need for
future periodic examination.
 Repairs to SS Overlay/Cladding 7.2.6

• For equipment which is in hydrogen service at an

elevated temperature or which has exposed base metal
areas open to corrosion which could result in a
significant atomic hydrogen migration in the base metal,
the repair must additionally considered by the pressure
vessel engineer for factors affecting the following:
a. Outgassing base metal.
b. Hardening of base metal due to welding, grinding, or arc
gouging.
c. Preheat and interpass temperature control.
d. Postweld heat treatment to reduce hardness and restore
mechanical properties.
 Repairs to SS Overlay/Cladding 7.2.6

• Repairs shall be monitored by an inspector to assure

compliance to repair requirements. After cooling to
ambient temperatures, the repair shall be inspected by
the liquid penetrant method, according to ASME Code,
Section VIII, Division 1, Appendix 8.
• For vessels constructed with P-3, P-4, or P-5 base
materials, the base metal in the area of repair should be
examined for cracking by the ultrasonic examination in
accordance with ASME Code, Section V, Article 5,
paragraph T-543.
 Repairs to SS Overlay/Cladding 7.2.6

• This inspection is most appropriately accomplished

following a delay of at least 24 hours after completed
repairs for equipment in hydrogen service and for
chromium-molybdenum alloys that could be affected
by delayed cracking.
 Design 7.2.7

• Temporary repairs using fillet-welded patches shall

be approved by the authorized pressure vessel
inspector and a pressure vessel engineer competent
in pressure vessel design; and the temporary repairs
should be removed and replaced with suitable
permanent repairs at the next available maintenance
opportunity.
 Design 7.2.7

• Refer to API Publication 2201 when making on-

stream repairs.
• A full encirclement lap band repair may be
considered a long term repair if the design is
approved , and documented by the pressure vessel
engineer and the authorized API pressure vessel
inspector and the following requirements are met:
 Design 7.2.7

• a. The repair is not being made to a crack in the

vessel shell.
• b. The band alone is designed to contain the full
design pressure.
• c. All longitudinal seams in the repair band are full
penetration butt welds with the design joint
efficiency and inspection consistent with the
appropriate code.
 Design 7.2.7

• d. The circumferential fillet welds attaching the band

to the vessel shell are designed to transfer the full
longitudinal load in the vessel shell, using a joint
efficiency of 0.45, without counting on the integrity
of the original shell material covered by the band.
Where significant, the eccentricity effects of the
band relative to the original shell shall be considered
in sizing the band attachment welds. Other than
visual examination, fillet weld examination may be
done at the next shutdown if conditions and
necessary access do not permit complete
examination at the time of an on stream repair.
 Design 7.2.7

• e. Fatigue of the attachment welds, such as fatigue

resulting from differential expansion of the band
relative to the vessel shell, should be considered if
applicable.
• f. The band material and weld metal are suitable for
contact with the contained fluid at the design
conditions and an appropriate corrosion allowance
is provided in the band.
• g. The degradation mechanism leading to the need
for repair shall be considered in determining the
need for any additional monitoring and future
inspection of the repair.
 Design 7.2.7

• Non-penetrating nozzles (including pipe caps

attached as nozzles) may be used as long term
repairs for other than cracks when the design and
method of attachment comply with the applicable
requirements of the appropriate code. The design
and reinforcement of such nozzles shall consider the
loss of the original shell material enclosed by the
nozzle.
 Design 7.2.7

• The nozzle material shall be suitable for contact with

the contained fluid at the design conditions and an
appropriate corrosion allowance shall be provided.
The degradation mechanism leading to the need for
repair shall be considered in determining the need
for any additional monitoring and future inspection
of the repair.
 Design 7.2.7

• For the purposes of future inspection, it may be

necessary to consider repair bands and non-
penetrating nozzles to be separate zones when
addressing the on-stream inspection requirements in
6.4.
 Inspection 7.2.9

• Acceptance criteria for a welded repair or alteration

should include nondestructive examination techniques
that are in accordance with the applicable sections of the
ASME Code or another applicable vessel rating code.
Where use of these nondestructive examination
techniques is not possible or practical, alternative
nondestructive examination methods may be used
provided they are approved by the pressure vessel
engineer and the authorized pressure vessel inspector.
 Inspection 7.2.9

• For vessels constructed of materials that may be

subject to brittle fracture (per API RP 579, or other
analysis) from either normal or abnormal service
(including startup, shutdown, and pressure testing),
appropriate inspection should be considered after
welded repairs or alterations.
 Inspection 7.2.9

• Flaws, notches, or other stress risers could initiate a

brittle fracture in subsequent pressure testing or
service.
 Inspection 7.2.9

• Magnetic particle testing and other effective surface

NDE methods should be considered. Inspection
techniques should be designed to detect critical
flaws as determined by a fitness-for-service
assessment.
 Testing 7.2.10

• After repairs are completed, a pressure test shall be

applied if the authorized pressure vessel inspector
believes that one is necessary. A pressure test is
normally required after an alteration.
 Testing 7.2.10

• Subject to the approval of the jurisdiction (where the

jurisdiction's approval is required), appropriate
nondestructive examinations shall be required where
a pressure test is not performed.
 Testing 7.2.10

• Substituting nondestructive examination procedures

for a pressure test after an alteration may be done
only after a pressure vessel engineer experienced in
pressure vessel design and the authorized pressure
vessel inspector have been consulted.
 Testing 7.2.10

• For cases where UT is substituted for radiographic

inspection, the owner-user shall specify industry-
qualified UT shear wave examiners for closure welds
that have not been pressure tested and for weld
repairs identified by the pressure vessel engineer or
authorized inspector.
 Testing 7.2.10

• The requirement for use of industry-qualified UT

shear wave examiners becomes effective two years
after publication in this code or addendum.
 Filler Metal 7.2.11

• The filler metal used for weld repairs should have

minimum specified tensile strength equal to or
greater than the minimum specified tensile strength
of the base metal.
 Filler Metal 7.2.11

• If a filler metal is used that has a minimum specified

tensile strength lower than the minimum specified
tensile strength of the base metal, the compatibility
of the filler metal chemistry with the base metal
chemistry shall be considered regarding weldability
and service degradation. In addition, the following
shall be met:
 Filler Metal 7.2.11

• a. The repair thickness shall not be more than 50

percent of the required base metal thickness,
excluding corrosion allowance.
• b. The thickness of the repair weld shall be
increased by a ratio of minimum specified tensile
strength of the base metal and minimum specified
tensile of the filler metal used for the repair.
 Filler Metal 7.2.11

• c. The increased thickness of the repair shall have

rounded corners and shall be blended into the base
metal using a 3-to-1 taper.
• d. The repair shall be made with a minimum of two
passes.
 Rerating 7.3

• b. If the vessel was designed to an edition or

addendum of the ASME Code earlier than the 1999
Addenda and was not designed to Code Case 2290
or 2278, it may be rerated to the latest edition/
addendum of the ASME Code if permitted by Figure
7-1.
 Rerating 7.3

• d. If the pressure vessel has at some time has been

pressure tested to a test pressure equal to or higher
than the pressure test pressure required by the
latest edition or addendum of the ASME Code, or the
vessel integrity is maintained by special
nondestructive evaluation inspection techniques in
lieu of testing, a pressure test for the rerated
condition is not required.