Presented by: Gary Scribner

Manager of Technical Services

Shanghai April 2016

The National Board of Boiler and Pressure Vessel Inspectors

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
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 – 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

The National Board of Boiler and Pressure Vessel Inspectors

4
 Term Definition Reference
Repair Work necessary to restore pressure-retaining Part 3, Section 9,
items to a safe and satisfactory operating Glossary of Terms
condition.

Alteration A change in the item from the original design Part 3, Section 9,
which affects the pressure containing Glossary of Terms
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.

The National Board of Boiler and Pressure Vessel Inspectors

5
 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.

The National Board of Boiler and Pressure Vessel Inspectors

6
 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.

The National Board of Boiler and Pressure Vessel Inspectors

7
 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.

The National Board of Boiler and Pressure Vessel Inspectors

8
 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.

The National Board of Boiler and Pressure Vessel Inspectors

9
 Organizations performing repairs or alterations shall be
accredited as described in Part 3 and NB-415,
Accreditation of Repair Organizations
“R”

NB-415

The National Board of Boiler and Pressure Vessel Inspectors

10
 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.

The National Board of Boiler and Pressure Vessel Inspectors

11
 “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.

The National Board of Boiler and Pressure Vessel Inspectors

12
The National Board of Boiler and Pressure Vessel Inspectors
13
 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.

The National Board of Boiler and Pressure Vessel Inspectors

14
 “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).

The National Board of Boiler and Pressure Vessel Inspectors

15
 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.
The National Board of Boiler and Pressure Vessel Inspectors
16
 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

The National Board of Boiler and Pressure Vessel Inspectors

17
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
.
The National Board of Boiler and Pressure Vessel Inspectors
18
 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.

The National Board of Boiler and Pressure Vessel Inspectors

19
 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).

The National Board of Boiler and Pressure Vessel Inspectors

20
 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 National Board of Boiler and Pressure Vessel Inspectors

21
◦ 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.

The National Board of Boiler and Pressure Vessel Inspectors

22
◦ 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.

The National Board of Boiler and Pressure Vessel Inspectors

23
 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.

The National Board of Boiler and Pressure Vessel Inspectors

24
 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.

The National Board of Boiler and Pressure Vessel Inspectors

25
 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)

The National Board of Boiler and Pressure Vessel Inspectors

26
27
 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.

The National Board of Boiler and Pressure Vessel Inspectors

28
 Routine Repairs are limited to
categories listed in NBIC Part 3,
3.3.2 e)

29
◦ 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.”

The National Board of Boiler and Pressure Vessel Inspectors

30
 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 National Board of Boiler and Pressure Vessel Inspectors

31
 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.

The National Board of Boiler and Pressure Vessel Inspectors

32
 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.

The National Board of Boiler and Pressure Vessel Inspectors

33
 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

The National Board of Boiler and Pressure Vessel Inspectors

34
 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 National Board of Boiler and Pressure Vessel Inspectors

35
 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.

The National Board of Boiler and Pressure Vessel Inspectors

36
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.

The National Board of Boiler and Pressure Vessel Inspectors

37
 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.

The National Board of Boiler and Pressure Vessel Inspectors

38
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.

The National Board of Boiler and Pressure Vessel Inspectors

39
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.

The National Board of Boiler and Pressure Vessel Inspectors

40
 Liquid Pressure Test

 Pneumatic Test

 Nondestructive Examination (NDE)

The National Board of Boiler and Pressure Vessel Inspectors

41
 Provides requirements for certification, stamping, and
documentation of repairs and alterations.
 Forms may be obtained from the National Board web site.

The National Board of Boiler and Pressure Vessel Inspectors

42
 Form R-1, Report of Repair Form R-4, Report Supplementary Sheet

The National Board of Boiler and Pressure Vessel Inspectors

43
 (Page 2)
 Form R-2, Report of Alteration

The National Board of Boiler and Pressure Vessel Inspectors

44
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 3 – 3.2.2)
 Manufacturer’s Data Report
 Certificates of Compliance

The National Board of Boiler and Pressure Vessel Inspectors

45
 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 pressure-
retaining item (upon request).

 Organization performing the

repairs is responsible for
distribution R Forms and
attachments.

The National Board of Boiler and Pressure Vessel Inspectors

46
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.

The National Board of Boiler and Pressure Vessel Inspectors

47
 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.

The National Board of Boiler and Pressure Vessel Inspectors

48
 www.nationalboard.org

Thank you!
The National Board of Boiler and Pressure Vessel Inspectors 49