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NBIC NB-23 2017

Part 3 (Repairs & Alterations)
Orientation Program
www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 1
Gain
By completion of this module…..you will
1. Capture the concept of organization Part 3

2. Be able to visualize Owner, Inspector &
Contractors Roles in Repairs
3. Be familiar with Repairs & Alterations
4. Hint: Look into (17) on the sides : Revisions!!!
1
Learning outcome
1. Describe repair inspector duties and responsibilities

2. Understand the accreditation process and "R" Stamp program
3. Evaluate repair and alteration plans
4. Understand the requirements of a quality system
5. Explain welding fundamentals and processes
6. Recognize NDE requirements and methods
7. Understand material identification requirements
8. Verify calculations as related to a repair and/or alteration
9. Explain stamping requirements
10. Understand requirements for completing repair forms
Ref Codes
1. RCI-1, NB-263, Rules for Commissioned Inspectors

2. NBIC, Part 3, Repairs and Alterations
3. NB-415, Accreditation of Repair Organizations
4. ASME Section I, Power Boilers
5. ASME Section IV, Heating Boilers
6. ASME Section VIII, Div. 1, Pressure Vessels
7. ASME Section IX, Welding
8. ASME B31.1, Power Piping
To use only non-programmable calculator
2
Pass Criteria
1. Actively participate in classroom assignments,

2. Have a minimum attendance of 90%,
3. Complete the course evaluation survey, and
4. Achieve a passing score on the examination. 70%
Day 1
DAY 1
Session From To Title
08:30 AM 08:45 AM Introductory Remarks

1 08:45 AM 09:15 AM Overview and Objectives
2 09:15 AM 10:05 AM RCI-1, NB-263, Rules for Commissioned
Inspectors, Part 5, Duties of Repair Inspectors
3 10:15 AM 11:00 AM Accreditation
4 11:00 AM 12:30 PM Quality Systems with QC Manual
Workshop
12:30 PM 01:30 PM Lunch
5 01:30 PM 04:15 PM National Board Inspection Code, Part 3,
Repairs and Alterations
3
Day 2
08:30 AM 09:30 AM Homework and Quiz #1 with Review

6 09:30 AM 10:30 AM Fundamentals of Welding Processes
7 10:30 AM 12:30 PM ASME Section IX Welding
12:30 PM 01:30 PM Lunch
8 01:30 PM 03:00 PM Workshop: ASME Section IX Document

Review (WPS, PQR, and WPQ)
9 03:10 PM 04:15 AM Post-Weld Heat Treatment
Day 3

10 09:30 AM 10:20 AM Welding Fabrication Rules
11 10:30 AM 12:30 PM Non Destructive Examination
12:30 PM 01:30 PM Class Photo in Inspection Room; Lunch
12 01:30 PM 04:15 PM Alteration Plan and Calculations
04:15 PM 04:30 PM Exam Review
4
Day 4

13 09:00 AM 10:00 AM Workshop: Alteration Plan Welding
14 10:00 AM 11:30 AM Workshop: Completion of R Forms
11:30 AM 12:30 PM Lunch
12:30 PM 04:30 PM Final Examination (4 Hrs)
Inspector Role
Overall Idea
Technical Administrative
Pressure Retaining Items NBIC NB23
Boilers, Pr. Vessels

Piping, Valves
10
5
Four Parts (2017)
1. Installation
2. Inspection (In Service)
3. Repairs & Alterations
4. Pressure Relief Devices
11
Part 3
100/292 Pages [35%]

(1) Gen & Admin Requirements
Repairs & (2) Welding and Heat Treatment.

alterations (3) Requirements for Repairs and
Alterations
(4) Examination and Testing
Verify: make sure that
(something) is true, accurate, or (5) Certification/Documentation
justified. [Confirmation through and Stamping
objective Evidence that specified (6) Supplements (6)
requirements are fulfilled]
Section 7 to 11 info
2, 3, 4, 5
12
6
1.1 scope
Scope
Accreditation
Requirement & Guide line R, NR, VR Programs Requirements
Repairs & Alterations
13
Important Definitions
Repair — The work necessary to restore pressure-retaining items to a safe and

satisfactory operating condition. (Original Intended Design parameters)
Alteration — A change in the item described on the original Manufacturer’s

Data Report which affects the pressure containing capability of the pressure-
retaining item. Non physical changes such as an increase in the maximum
allowable working pressure (internal or external), increase in design
temperature, or a reduction in minimum temperature of a pressure-retaining
item shall be considered an alteration. (See NBIC Part 3, 3.4.4, Examples of
Alteration)
Re-rating (re-rate) — See alteration. Re-rate does not apply to PRDs
Water Head — The pressure adjustment that must be taken into account due to
the weight of test media (in this case, water) that is 0.433 psi/ft added
(subtracted) from the gage pressure for each foot the gage is below (above) the
point at which the pressure is to be measured.
14
7
1.2 Stds for PRIs
Original Std Repair std Alternative Approval /

Repair std Acceptance
ASME Ed X ASME Ed X ASME Current
Inspector &
Non ASME Ed X Non ASME Ed X ASME current
Jurisdiction
ASME sec I
Historical Boilers ASME sec I
current
Piping Std X Piping Std X Piping Std current
DOT
Transport Tanks x Transport Tanks x DOT
concurrence
15
1.3 Inspector
a) Inspection and certification shall be made by an Inspector holding a

valid commission with the appropriate endorsement issued by the
National Board and employed by an Authorized Inspection Agency
b) b) An Inspector employed by an Owner-User Inspection

Organization or a Federal Inspection Agency may authorize and
accept work only on pressure-retaining items owned or used by the
respective organization.
Each accredited Owner-User Inspection Organization’s quality program shall

have specific approval of the Jurisdiction as required.
16
8
Authorization & Acceptance Inspection
The Inspector’s authorization to perform a repair or alteration shall be obtained by the

repair organization prior to initiation of a repair or alteration to a pressure-retaining
item. The Inspector shall determine that the repair or alteration methods are acceptable.
Subject to acceptance of the Jurisdiction, the Inspector may give approval for routine
repairs prior to the start of work provided the Inspector ensures that the “R”
Certificate Holder has adequately addressed routine repairs in the quality program.
Authorization Acceptance
Inspector A Inspector A (preferred)
Inspector B (same organization)
Before signing the appropriate NBIC Report Form, the Inspector shall review the
drawings, ensure the repair or alteration was performed in accordance with the
accepted code
The Inspector shall verify the stamping or nameplate is correct & properly attached.
17
Accreditation Process.
NB-415, Accreditation of “R” Repair Organizations.
Establish
Prepare
Apply to QC Participate Get
Repair
NB program in Audit Certified
Demo
Manual
18
9
1.5 Quality System Requirements
1. Title Page 11.Welding, NDE and Heat Treatment

2. Contents Page 12.Examinations and Tests
3. Scope of Work 13.Calibration
4. Statement of Authority and 14.Acceptance and Inspection of
Responsibility Repair or Alteration
5. Manual Control 15.Inspections
6. Organization 16.Report of Repair or Alteration Form
7. Drawings, Design and 17.Exhibits
Specifications 18.Construction Code
8. Repair and Alteration Methods 19.Nonconforming Items
9. Materials 20.Records Retention
10.Method of Performing Work
19
2. Welding and Heat Treatment
Welding
Welder
WPS SWPS WPQ Records Welder ID
continuity
Expiry Revoke Renewal
20
10
2.5 Heat Treatment
Pre Heat Post Heat

Pre heat PWHT
Maintenance (Bake out)
21
Local PWHT
Heating Band (HB) shall consist of the SB distance plus 4 √(ܴ ∗ ‫)ݐ‬
The Soak Band (SB) shall extend tangentially and radially from the edge of
attachment weld area equally by a minimum distance t or 2 in. (50 mm),
whichever is less.
22
11
Alternative Welding Methods Without PWHT
Metho Toughness Pre heat / Inter

Material Limited to Process Others
d test Pass
Ceq ≤ 0.40
[P1 (G 1,3,3)] 300 F Electrode H4 or
GTAW, SMAW,
1 No [P3 (1, 2) exclude 175 F (P1) lower
GMAW, FCAW
Mn-Mo G2] 4” both side* Gas due point ≤ -60
F
Above + P4, P5A, Above with
PH 350 IP 450 * Bake out no if H4
2 Yes* P9A, P10A,B,C temper bead
Ref Part 3 NBIC electrode used*
P11A,B qualification
PH 350 IP 450 *
GTAW, SMAW, Corrosion – Harness
3 No P1, P3 Ref Part 3 NBIC
FCAW – WPS*
23
Alternative Welding Methods Without PWHT
Toughnes Pre heat /

Method Material Limited to Process Others
s test Inter Pass
GTAW, SMAW,
No & Corrosion – Harness
GMAW, FCAW 300 (P4)
4 Repair P4 G1,2 – P5A – WPS*
temper bead 400 (P5A)
weld
qualification
GTAW*, SMAW,
P1, P3, P4, P5A,
GMAW, FCAW
P9A, P10 (A,B,C) Dissimilar Metals
5 * temper bead -
P11 (A,B) to P8, Methods 2,3,4*
qualification
P(42,43,45)
D < 5NPS, t ≤ ½ in.

PH 300, IP
6 - P91 SMAW or GTAW Stringer Bead
550 Electrode B8 Gr
24
12
3 Repairs & Alterations
3.3 3.4
3. 1 Scope 3. 2 Gen
Repairs Alterations
(7) (5) (5)
25
3.2 General Requirements
3 R e pairs & Alte rations
3. 1 Scope 3. 2 Gen 3.3 R e pairs 3.4 Alte rations
Replacement Design Change of

Material Drawing Calculations Ref std
of parts Requirement service
26
13
3.3 Repairs
3.3 3.4
3. 1 Scope 3. 2 Gen
Repairs Alterations
Defect Routine Repair Repair Div. 2, 3

Repair Repair Examples Methods Vessels
9 sub
sections
27
3.4 Alterations
3. 1 3.3 3.4
3. 2 Gen
Scope Repairs Alterations
Based on
Examples of Div. 2, 3
Re Rating Allowable Encapsulation.
Alterations Vessels
Stress
Alteration Plan
28
14
Repair/Alteration Plan (Div.2)
3.3.5.1 The repair plan shall be reviewed and certified by an engineer
meeting the criteria of ASME Section VIII, Division 2 or 3, as
applicable, for an engineer signing and certifying a Manufacturer’s
Design Report. The review and certification shall be such as to
ensure the work involved in the repair is compatible with the User’s
Design Specification and the Manufacturer’s Design Report.
3.4.5.1 The alteration plan shall be reviewed and certified by an engineer meeting the
criteria of ASME Section VIII, Division 2 or 3, as applicable, for an engineer
signing and certifying a Manufacturer’s Design Report. The review and
certification shall be such as to ensure the work involved in the alteration is
compatible with the User’s design specification and the Manufacturer’s
Design Report.
Note: The engineer qualification criteria of the jurisdiction where the pressure
vessel is installed should be verified before selecting the certifying engineer.
Div. 2 Appendix 2-A (for UDS) & 2-B (Mfr. Design report)
29
4. Examination & Testing
4. Examination &
Testing
4.3
4.4 E&T for
4. 1 Scope 4. 2 NDE Encapsulatio
R&A
n.
E&T for E&T for

Repairs Alterations
30
15
5. Certification / Documentation & Stamping
5. 1 Scope
5. 2 Documentation
5.3 Distribution R1
5.4 Distribution R2
5. Certification &
5.5 Registration of Forms

Stamping
5.6 Registration Log
5.7 Stamping
5.8 Stamping (FRP Vessels)
5.9 Stamping (Yankee Dryer)
5.10 Alternate stamping FRP
5.11 Removal of Name Plate
5.12 Forms Completion
31
6. Supplements
1. Steam Locomotive Firetube Boiler Repairs

2. Historical Boilers
3. Repair and Alteration of Graphite Pressure Equipment
4. Repair and Alteration of Fiber-Reinforced Thermosetting Plastic
Pressure Equipment
5. General Requirements for Repairs and Alterations to Yankee Dryers
6. Repair, Alteration, and Modification of DOT Transport Tanks
7. Repair and Alterations of Pressure Vessels in Liquified Petroleum
Gas Service
8. Weld and Post Repair Inspection of Creep Strength Enhanced
Ferritic Steel Pressure Equipment
32
16
Sec 7 & 8
7 NBIC POLICY FOR METRICATION
Example 1: Using 1 in. = 25.4 mm;

12 in. = 304.8 mm (soft conversion)
Example 2: Using the above conversion, a hard conversion may

be 300 mm or 305 mm depending on the
degree of precision needed.
8 PREPARATION OF TECHNICAL INQUIRIES TO NB
Code Revisions or Additions
Code Interpretations
33
9 Glossary of Terms
Routine repairs are repairs for which the requirements for in-
process involvement by the Inspector and stamping by the “R”
Certificate Holder may be waived as determined appropriate by
the Jurisdiction and the Inspector. All other applicable requirements of
this code shall be met.
Prior to performing routine repairs, the “R” Certificate Holder should

determine that routine repairs are acceptable to the Jurisdiction
where the pressure-retaining item is installed
Jurisdiction is the power that a court of law or an official has to

carry out legal judgments or to enforce laws
34
17
10 Interpretations
35
11 Index (Important)
(1) Gen & Admin Requirements
(2) Welding and Heat Treatment.
(3) Requirements for Repairs and

Alterations
(4) Examination and Testing
(5) Certification/Documentation
and Stamping
(6) Supplements (6)
2,3,4,5
36
18
Re Call
3.3.2 ROUTINE REPAIRS

3.3.3 EXAMPLES OF REPAIRS
3.4.4 EXAMPLES OF ALTERATIONS
Changes in 2017 identified (17)
37
Alterations
3.4 Alterations
Based on Examples of Div. 2, 3

Re Rating Allowable Encapsulation.
Alterations Vessels
Stress
Alteration Plan
38
19
Re Rating
this code does not provide rules for de-rating boilers or

pressure vessels; however, when the MAWP and/or allowable
temperature of a boiler or pressure vessel is reduced, the
Jurisdiction where the object is installed should be contacted to
determine if specific procedures should be followed.
Reducing MAWP with the same design temperature,

considering the corroded condition !!!!
39
Re Rating
MAWP 300 PSI @ 650 F
Establishing a higher joint efficiency to re-rate a pressure- retaining

item is not permitted;
40
20
3.4.2 ALTERATIONS BASED ON ALLOWABLE
STRESS VALUES
For re-rating or re-calculating a new minimum wall thickness for a PRI

using a later edition of the original code of construction or selected
construction standard or code that permits use of higher allowable
material stress values than were used in the original construction, the
following requirements shall apply:
Year 1998 SA 516 Gr 70 Stress Value @200F 17500 PSI
MAWP 400 PSI @ 200F Dia 200 inch t (UG 27)= 2.318” (E=1, Full RT, Type 1 weld)
Now 2017 Stress Value @200F 20000 PSI
P based on (S 20 KSI) = 457 PSI
41
Conditions for use current stress values
1. The “R” Certificate Holder shall verify, by calculations
2. The pressure-retaining item shall not be used in lethal service;
3. The pressure-retaining item shall not be used in high-cycle operation or fatigue service
4. The pressure-retaining item shall have been constructed to the 1968 edition or later edition.
5. The pressure-retaining item shall be shown to comply with all relevant requirements of the
edition of the code, which permits the higher allowable stress values (e.g., reinforcement,
toughness, examination, pressure testing);
6. The pressure-retaining item shall have a satisfactory operating history and current inspection
of the pressure-retaining item shall verify the item exhibits no unrepaired damage
7. The re-rating shall be acceptable to the Inspector and, where required, the Jurisdiction;
8. All other requirements of Part 3, as applicable, and jurisdictional requirements shall be met;
9. Use of this paragraph shall be documented in the “Remarks” section of Form R-2.
42
21
Encapsulation
3.4.3 ENCAPSULATION
Encapsulation is a method used to maintain the pressure
retaining capability of pipe, nozzles, fittings and valves an
item (with the exception of fire tube boilers) by fabricating a
new pressure containing boundary over the item in the form
of a “welded leak box” as described by ASME PCC-2, Article
2.4.
43
Welded Leak Box
44
22
Exercise 006
Vessel Manufacturer’s SN: J809-21-2014
6 Cases (scenario) given for above

vessel modification proposal
Individual cases are separate (need not

be combined with other case)
45
23

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NBIC

NBIC NB-23 2017

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 1

By completion of this module…..you will

1. Capture the concept of organization Part 3

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 2

1. Describe repair inspector duties and responsibilities

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 3

1. RCI-1, NB-263, Rules for Commissioned Inspectors

To use only non-programmable calculator

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 4

1. Actively participate in classroom assignments,

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 5

08:30 AM 08:45 AM Introductory Remarks

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 6

Session From To Title

08:30 AM 09:30 AM Homework and Quiz #1 with Review

12:30 PM 01:30 PM Lunch

8 01:30 PM 03:00 PM Workshop: ASME Section IX Document

9 03:10 PM 04:15 AM Post-Weld Heat Treatment

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 7

Session From To Title

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 8

Session From To Title

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 9

Pressure Retaining Items NBIC NB23

Boilers, Pr. Vessels

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 10

2. Inspection (In Service)

3. Repairs & Alterations

4. Pressure Relief Devices

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 11

100/292 Pages [35%]

Repairs & (2) Welding and Heat Treatment.

Repairs & Alterations

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 13

Repair — The work necessary to restore pressure-retaining items to a safe and

Alteration — A change in the item described on the original Manufacturer’s

Re-rating (re-rate) — See alteration. Re-rate does not apply to PRDs

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 14

Original Std Repair std Alternative Approval /

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 15

a) Inspection and certification shall be made by an Inspector holding a

b) b) An Inspector employed by an Owner-User Inspection

Each accredited Owner-User Inspection Organization’s quality program shall

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 16

The Inspector’s authorization to perform a repair or alteration shall be obtained by the

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 17

NB-415, Accreditation of “R” Repair Organizations.

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 18

1. Title Page 11.Welding, NDE and Heat Treatment

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 19

2. Welding and Heat Treatment

Expiry Revoke Renewal

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 20

Pre Heat Post Heat

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 21

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 22

Metho Toughness Pre heat / Inter

www.astrongroup.com NB23 Part 3 (Repairs & Alterations) 23

Alternative Welding Methods Without PWHT

Toughnes Pre heat /