{"id":1068,"date":"2026-02-01T21:43:48","date_gmt":"2026-02-01T21:43:48","guid":{"rendered":"https:\/\/hydrocarbon.sbs\/?p=1068"},"modified":"2026-03-24T23:17:41","modified_gmt":"2026-03-24T23:17:41","slug":"composite-repair-of-equipment-and-the-practicalapplicability-of-asme-pcc-2","status":"publish","type":"post","link":"https:\/\/petrostreet.com\/main\/composite-repair-of-equipment-and-the-practicalapplicability-of-asme-pcc-2\/","title":{"rendered":"Composite Repair of Equipment and The Practical Applicability of ASME PCC-2"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">Unplanned outages or shutdowns can cost plant operators millions of dollars a day in lost production opportunities. Repair practices in hydrocarbon processing facilities have been evolving ever since these plants went into operation, especially those repairs that can be accomplished on-stream. Unplanned shutdowns can often be avoided by implementing in-situ repair techniques that are reliable, proven, and provide acceptable safety margins. <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">There was a time in the past when welding repairs were the only option to get pressurized or static equipment, including piping and piping components, back into service. As such, the industry has historically depended on welding as a means to repair equipment. Unfortunately, welding typically requires taking the equipment out of service to perform repairs. Furthermore, there are additional requirements related to safety such as hot work (making sure the area is free of flammable or other certain gases and vapors). <\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Now, with advancements in materials technology and the development of advanced analytical tools, modeling, simulation, and research, the hydrocarbon processing industry can take advantage of standardized alternative solutions to welding involving composite repairs. Composite repair approaches may, in the right cases, replace welding and its associated inherent safety risk due to the hot work involved.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img fetchpriority=\"high\" decoding=\"async\" width=\"931\" height=\"503\" src=\"https:\/\/petrostreet.com\/main\/wp-content\/uploads\/2026\/03\/Figure-1.png\" alt=\"\" class=\"wp-image-1986\"\/><\/figure>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\"><strong>Figure 1. Composite repair applied over a leak.<\/strong><\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"930\" height=\"662\" src=\"https:\/\/petrostreet.com\/main\/wp-content\/uploads\/2026\/03\/Figure-2.png\" alt=\"\" class=\"wp-image-1985\"\/><\/figure>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\"><strong>Figure 2. Composite repair applied on piping weld against internal<br>corrosion.<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Composite repair solutions have been tested and available in the market for quite a while. Composite repairs are one of the leading \u201ccold work\u201d repairs available as alternatives to welding repairs in terms of the relative ease of application and reduced safety risks.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Figure 3 illustrates a few examples of where composite repairs might be used:<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"921\" height=\"255\" src=\"https:\/\/petrostreet.com\/main\/wp-content\/uploads\/2026\/03\/Figure-3.png\" alt=\"\" class=\"wp-image-1984\"\/><\/figure>\n\n\n\n<p class=\"has-text-align-center wp-block-paragraph\"><strong>Figure 3. Composite repair; coverage of defects.<\/strong><\/p>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>Composite Repairs in Practice<\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Good baseline documentation is just as important for composite repairs as it is for welded repairs. Welding requirements are typically listed in a very clear manner by many leading codes and standards as well as jurisdictional and insurance authorities. These codes, standards, and sources spell out the practices and documentation information to be covered, such as welding method, welding procedure, consumables, welding operator, welding safety, or any other subject under welding. Welding codes and standards such as ASME BPVC Section IX are fairly comprehensive and detailed in scope.<br>Composite repairs can be done in accordance with the ASME PCC-2 document. The first component to address is whether an application is considered high risk or low risk. PCC-2 provides criteria for making this determination with information and guidance on materials, design, qualification of the intended repair via an identical sample, installation practices, and inspection. Using all of this information, a composite repair can be designed, qualified, installed, and QA\/QC tested. In most cases, this process is being implemented entirely by the contractor with little to no involvement by the owner\/operator. The current practice is that outside vendors provide these services for composite repairs while industry in-house resources still lack the knowledge and experience required to properly test and approve this kind of repair. When compared to welding, in-house resources do not have the required background, knowledge, and experience for qualifying an acceptable, effective composite repair. However, considering the practical applicability of ASME PCC-2, the author has found that it<br>is possible for in-house resources to fully implement a composite repair. Starting with a small team of design engineers, proficiency in designing a composite repair can be achieved. Next, workshop personnel source the raw materials and construct the composite model for qualification. Successful qualification to ASME PCC-2 then leads to performing the repair at the site.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">Conclusion<\/h3>\n\n\n\n<p class=\"wp-block-paragraph\">Looking at the spectrum of what composite repairs can cover, one can safely capitalize on, once an effective program is in place, the opportunities for accomplishing these types of remedies.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><br>Finally, as with any repair approach, it should be noted that there can be limitations for<br>composite repairs such as temperature. These limitations should be clearly understood and include both mechanical, materials, and chemical as well as other considerations.<br>The author estimates that, if the composite repair approach is implemented properly in place of welding repairs, approximately 70-80% of hot work at operating sites could be eliminated.<br>This practice would therefore reduce safety risks, as well as decrease the amount of time taken to evaluate hazards and perform preparatory site work associated with welding.<\/p>\n\n\n\n<h3 class=\"wp-block-heading\">References<\/h3>\n\n\n\n<ol class=\"wp-block-list\">\n<li>ASME BPVC, Boiler and Pressure Vessel Code, 2019.<\/li>\n\n\n\n<li>ASME PCC-2, Repair of Pressure Equipment and Piping, 2018.<\/li>\n<\/ol>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Unplanned outages or shutdowns can cost plant operators millions of dollars a day in lost production opportunities. Repair practices in [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":2191,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_uag_custom_page_level_css":"","_ppp_document_settings_meta":"{\"product_ids\":[{\"label\":\"Composite Repair of Equipment and The Practical Applicability of ASME PCC-2 - 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outages or shutdowns can cost plant operators millions of dollars a day in lost production opportunities. Repair practices in [&hellip;]","_links":{"self":[{"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/posts\/1068","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/comments?post=1068"}],"version-history":[{"count":4,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/posts\/1068\/revisions"}],"predecessor-version":[{"id":2027,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/posts\/1068\/revisions\/2027"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/media\/2191"}],"wp:attachment":[{"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/media?parent=1068"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/categories?post=1068"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/petrostreet.com\/main\/wp-json\/wp\/v2\/tags?post=1068"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}