ASME PCC-2 Composite Pipe Repair using the Sylmasta Pipe Refurbishment System
Composite repair products from the Sylmasta Pipe Refurbishment System are tested and verified for making repairs conforming to ASME PCC-2, including Appendix 401-III Short Term Spool Survival and 402-III Validaton for Repair of Leaking Component.
Qualification for ASME PCC-2 enables Sylmasta products to be used in industries including oil and gas, chemical processing, power generation, water, wastewater and others where high pressure systems and hazardous pipe content are present.
As well as product qualification, Sylmasta have developed a calculator which helps determine the quantity of materials needed to make a composite pipe repair conforming to PCC-2 – underlining our expertise and commitment to clients working with high pressure pipework.
What is ASME PCC-2?
ASME PCC-2 is a standard developed by the American Society of Mechanical Engineers (ASME) which provides guidance for the repair of pressure-retaining equipment and piping after it has gone into service.
It covers a wide range of repair methods, such as welding, mechanical repairs and non-metallic composite repairs. The standard provides guidance on design, fabrication, examination and testing procedures for these repair methods.
Although ASME PCC-2 is non-mandatory and offers best practice rather than strict rules, end-users have greater confidence in the long-term performance and ability to withstand pressure of repair methods which conform to the standard.
ASME PCC-2 Appendix 401-III – Short Term Spool Survival
ASME PCC-2 Appendix 401-III – Short Term Spool Survival assesses the ability of a composite repair system to restore the integrity of a weakened pipeline carrying hazardous and non-hazardous fluid back to the strength of the original pipe.
Industrial Metal Epoxy Coating and SylWrap HD Pipe Repair Bandage have been certified as meeting this standard after rebuilding a pipe weakened by 86 percent to withstand over 309.6 bar pressure.
The qualification pressure test was carried out using calibrated and certified pressure gauges. The results were recorded on a data logger and independently witnessed and verified.
A defect was machined into a 170mm diameter ASTM A106 B Grade pipe spool. It reduced the wall thickness of the pipe from 7.1mm down to 1mm.
Before the repair, a flap wheel was used to clean the area back to bare metal and the pipe thoroughly cleaned. Industrial Metal was mixed and applied, filling the defect and rebuilding the pipe wall back towards original thickness.
The Sylmasta Pipe Refurbishment Calculator helped determine the size and number of SylWrap HD Bandages needed to reinforce the pipe for it to withstand the 309.6 bar pressure required to pass the test.
When pressure tested, the repair reached 310.29 bar before water began leaking through the edges – certifying Industrial Metal and SylWrap HD for ASME PCC-2 401-III repairs.
ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component
ASME PCC-2 Appendix 402-III – Validation for Repair of Leaking Component assesses the ability of a composite pipe repair system to seal leaking pipes, tanks and vessels containing non-hazardous fluids operating below 10 bar.
Superfast Aqua PW Epoxy Putty and SylWrap HD have been certified as meeting this standard after sealing a fully breached pipe, restoring its pressure-retaining capability and showing the repair would not degrade or be compromised over time under service conditions.
For the test, a 25mm diameter hole was cut into a 110mm diameter carbon steel pipe. The leak was sealed with Superfast Aqua PW. Before the putty had full cured, SylWrap HD was wrapped and smoothed over the top.
This helped force Superfast Aqua PW further into the hole for a fully effective seal. SylWrap HD set rock hard within minutes, curing to form a thickened, impact-resistant sleeve around the pipe.
To qualify for ASME PCC-2 Appendix 402-III, the repair had to withstand three separate pressure tests. Pressure was steadily increased through the pipe for 30 seconds until 30 bar was reached.
After 60 seconds of the pipe being pressurised at 30 bar, the repair was inspected for any visible leakage. With no leak or defect detected during any of the three pressure tests, repairs made using Superfast Aqua PW and SylWrap HD meet ASME PCC-2 Appendix 402-III standard.
The Sylmasta Pipe Refurbishment Calculator
The Sylmasta Pipe Refurbishment Calculator can be used to determine the products and quantities needed to make an ASME PCC-2 standard composite pipe repair.
Calculations can be made for leaks, surface profiling, protective coating and SylWrap composite wrapping by entering the data and design of a specific repair.
The calculator serves as an initial guide and judgement should be made on the exact repair based upon all conditions.
Also available on the Calculator is an ASME PCC-2 Repair System Quality Control Form. Filling in the form helps ensure all critical hold points are identified and the installation process is properly followed.
More information and assistance
If you would like more information about making ASME PCC-2 compliant repairs using the Sylmasta Pipe Refurbishment System or need help with a specific application, please contact Sylmasta via email, phone +44 (0)1444 831 459 or fill out the below form.
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