COURSE OVERVIEW:

The meaning of pressure vessel repairs and alterations encompasses the engineering design and physical execution of modifications required to restore or change the functional capabilities of a vessel. This course focuses on the application of ASME PCC-2, the industry-standard code for the repair of pressure equipment after it has been placed in service. By moving beyond the original construction codes (ASME Section VIII), participants will learn the specialized techniques necessary to handle the unique stresses and material conditions of aged vessels while maintaining strict compliance with safety regulations.

The scope of the training includes a detailed evaluation of various repair methods, including welded patches, overlay, and the use of non-metallic composite systems for structural reinforcement. Participants will explore the critical distinction between a "Repair," which returns the vessel to its original state, and an "Alteration," which changes the design parameters such as pressure, temperature, or volume. The course provides a deep dive into the metallurgy of welding on existing equipment, focusing on the prevention of cracking and the management of residual stresses through heat treatment.

The coverage of the program is organized into twelve modules that guide the participant through the entire repair project lifecycle. Key topics include the calculation of required patch thickness, the design of nozzle replacements, and the use of "box-enclosures" for leak containment. The course also addresses the requirements for non-destructive testing (NDT) and pressure testing to validate the repair's integrity. The program concludes with a focus on documentation and the role of the Authorized Inspector (AI) in approving repair plans and final execution.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

• Distinguish between Repairs and Alterations as defined by the National Board.
• Apply the design and execution rules of ASME PCC-2 for vessel repairs.
• Design welded flush patches for shell and head remediation.
• Evaluate the use of fillet-welded patches and their limitations.
• Understand the requirements for weld build-up and corrosion overlay.
• Manage the risks of in-service welding and hot tapping on vessels.
• Determine when Post-Weld Heat Treatment (PWHT) is mandatory for repairs.
• Analyze the impact of nozzle replacements on vessel structural integrity.
• Select appropriate NDT methods to verify repair weld quality.
• Utilize mechanical clamps and leak enclosures as temporary fixes.
• Execute a vessel "Re-rating" assessment based on current condition.
• Document repair activities for the permanent vessel history file.

TARGET AUDIENCE:

This course is intended for Pressure Vessel Inspectors, Plant Engineers, Maintenance Managers, Welding Engineers, and Quality Assurance Professionals.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.