Presented By:
CFM/VR-TESCO, LLC
Scott Smith – SVP & General Manager
Roy Button – Welding Engineer & Specialty
Welding (WDI) Division Manager
Our Presentation Focus
WHO ARE WE?
 Continental Field Machining (CFM) formed a valve
repair division in 1986 known as “VR-TESCO”.
 CFM/VR-TESCO is highly focused on disassembly,
inspection, repair, and reassembly of valves
throughout the Power Generation Sector.
 Specialized welding and machining equipment has
been developed to effectively complete difficult inline valve repairs.
 Personnel are given extensive training to perform
these activities.
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Our Presentation Focus
 Our presentation focus is on ASME Section 1 and
B31.1 Code valve repairs performed within the past
(2) two years.
 In this timeframe, CFM/VR-TESCO has performed
major welding and machining repairs on (46) forty-six
plus ASME Code large bore valves.
 The valve sizes have ranged between 12” to 24”.
 Valves from all the major OEM’s have been included
in these repairs.
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Our Presentation Focus
 (21) twenty-one of these valves are Code Boundary
valves, hence repairs are performed following
guidelines of ASME Section I and National Board
Inspection Code and Jurisdictional requirements.
 (25) twenty-five plus valves were part of the Boiler
external piping, hence repairs are performed
following guidelines of ASME B31.1.
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Original Manufacture of Valves
 Valves manufactured for use in Power Generation are
produced under the American National Standards as
outlined in ASME B16.34.
 This standard applies to new construction and covers
pressure-temperature ratings, dimensions,
tolerances, materials, NDE requirements, testing,
marking for cast, forged and fabricated valves with
flanged, threaded or welding ends.
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Original Manufacture of Valves
 It is the manufacturer’s responsibility to provide the
purchaser with documentation that details his
program compliance in the manufacturing of the
products.
 Requirements for manufacturing may be less
stringent than those required for repair of the
product.
 Listed are acceptance NDE criteria for new valves
manufactured.
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ASME B16.34 Acceptance Criteria
B16.34 - 11-2 Acceptance Standards for
Magnetic Particle Examination (MT)
11-2.1 Castings – Maximum acceptable
indications are as follows :
a. Linear indications
(1) 0.3” long for materials up to 0.5”
thick.
(2) 0.5” long for material 0.5” to 1.0”
thick.
(3) 0.7” long for material over 1.0” thick.
For linear indications, the indications must
be separated by a distance greater than
the length of an acceptable indication. A
linear is one with length in excess of 3 times
the width.
B16.34 - 11-2 Acceptance Standards for
Magnetic Particle Examination (MT)
11-2.2 Forgings and Rolled or Wrought
Material – Maximum acceptable indications
are as follows:
a. Linear indications
(1) 0.2” long for materials up to 0.5” thick.
(2) 0.4” long for materials over 0.5” – 1.0”
thick.
(3) .06” long for materials over 1.0” thick.
For linear indications, the indications must
be separated by a distance greater than
the length of an acceptable indication. A
linear indication is one with length in
excess of 3 times the width.
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ASME B16.34 Acceptance Criteria
B16.34 - 11-2 Acceptance Standards for
Magnetic Particle Examination (MT)
11-2.1 Castings – Continued
b. Rounded Indications
(1) 0.3” diameter for materials up to
0.5” thick.
(2) 0.5” diameter for materials over
0.5” thick.
Four or more rounded indications in a
line separated by 0.06” or less edge to
edge are unacceptable. Rounded
indications are those that are not
defined as linear indications.
B16.34 - 11-2 Acceptance Standards for
Magnetic Particle Examination (MT)
11-2.2 Forgings and Rolled or Wrought
Material – Continued
b. Rounded Indications
(1) 0.2” diameter for materials up to 0.5”
thick.
(2) 0.3” diameter for materials over 0.5”
thick.
Four or more rounded indications in a line
Separated by a 0.06” or less edge to edge are
Unacceptable. Rounded indications are those
that are not defined as linear indications.
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ASME B16.34 Acceptance Criteria
B16.34 - 111-2 Acceptance Standards for
Liquid Penetrant Examination (PT)
111-2.1 Castings – Maximum acceptable
indications are as follows:
a. Linear Indications
(1) 0.3” long for materials up to
0.5” thick.
(2) 0.5” long for materials over 0.5” to
1.0” thick.
(3) 0.7” long for materials 1.0” thick.
For linear indications, the indications
must be separated by a distance greater
than the length of an acceptable
indication. A linear indication is one with
length in excess of 3 times the width.
B16.34 - 111-2 Acceptance Standards for
Liquid Penetrant Examination (PT)
111-2.2 Forgings and Rolled or Wrought
Material - Maximum acceptable indications
are as follows:
a. Linear Indications
(1) 0.2” long for materials up to 0.5” thick or
less.
(2) 0.4” long for materials over 0.5” to 1.0”
thick.
(3) 0.6” long for materials over 1.0” thick.
For linear indications, the indications must be
separated by a distance greater than the
Length of an acceptable indication. A linear
indications is one with length in excess of 3
times the width.
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ASME B16.34 Acceptance Criteria
B16.34 - 111-2 Acceptance Standards for
Liquid Penetrant Examination (PT)
111-2.1 Castings – Continued
b. Rounded Indications
(1) 0.3” diameter for materials up to
0.5” thick.
(2) 0.5” diameter for materials over
0.5” thick.
Four or more rounded indications in
line separated by 0.06” or less edge to
edge are unacceptable. Rounded
indications are those that are not
defined as linear indications.
B16.34 - 111-2 Acceptance Standards for
Liquid Penetrant Examination (PT)
111-2.2 Forgings and Rolled or Wrought
Material - Continued
Rounded Indications
(1) 0.2” diameter for materials up to 0.5”
thick.
(2) 0.3” diameter for materials over 0.5”
thick.
Four or more rounded indications in a line
separated by 0.06” or less edge to edge are
unacceptable. Rounded indications are those
that are not defined as linear indications.
b.
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ASME Section I Repairs
 Repair requirements of a valve are usually confined to the
location of the valve in the boiler piping system of the power
plant.
 If the valve to be repaired is located in the piping system
which is considered part of the boiler proper or part of the
external boiler piping it is declared to be inside the Boiler
Code Boundary.
 Preamble to ASME Section I paragraphs 4, 5 & 7 provide the
detailed information defining Code Boundary’s.
 Repairs to piping and valves within the Code Boundary are
repaired using the requirements provided in ASME Section I,
National Board Inspection Code (NBIC) and the jurisdiction.
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ASME Section I Repairs
 To repair Section I Items a Quality Program & NBIC
“R” Stamp certification is required.
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Section I Valve Repairs
 CFM/VR-TESCO, LLC performed (21) twenty-one
“R” Stamp repairs in 2010-2012.
 Most of the repairs can be segregated in to 3 groups.
1. Valves requiring a seat or seats replaced.
2. Removal and rewelding of integral valve seats.
3. Repairs of cracks in the valve body or on guide ribs
or disc guides.
 Of the (21) twenty-one valves repaired (10) ten valves
required replacement of seat rings.
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Section I Valve Repairs
 All (10) valve bodies were SA217-C12A material.
 (10) Seats had cracks in partial penetration welds of
seat to body. Many of these welds had full 360o
cracks.
 (6) Seats had Hardface material missing from the seat
face.
 (1) Valve had 316 SS seats that were cracked 360o and
were replaced with A182-F91 material seats.
(4) Valves had seats that were manufactured from
A355-P22 (P5A) material and they were replaced like
for like.
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Section I Valve Repairs
SEAT RING REPLACEMENT
 All seat ring replacements were completed utilizing
the following guidelines:
 Minimum preheat 400oF.
 Welding process machine GTAW.
 WPS – 15E MN/GTAW-HT.
 .035” dia wire – ER90S-B9.
 Mn & Ni chemistry < 1.0.
 PWHT @ 1375oF – 2 hours soak time.
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Section I Valve Repairs
 Thermocouples and ceramic pads on ID seat area.
 Final NDE (PT) & (VT).
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Section I Valve Repairs
INTEGRAL SEAT REPAIR
 CFM/VR-TESCO, LLC repaired integral seats in
(11) Eleven valves from 2010 – 2012.
 Base metal of valve bodies were:
(2) A217-WC6
(9) A217-C12A
 All (11) valves had cracks in the seat area Hardface
going in to the base metal.
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Section I Valve Repairs
 (4) Four valves had major cracks in the upper and
lower 6oclock rib @ rib to body interface.
 (10) Ten valves had indications in the Stellite
Hardfacing on the guide ribs. This required removal
of the Stellite and undercutting of the base metal.
The repair required rewelding of the base metal and
Hardfacing.
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Section I Valve Repairs
INTEGRAL SEAT REPAIRS
CFM/VR-TESCO, LLC utilized the following guidelines
for Integral Seat Repairs.
1. All defects removed after removal of Stellite hard
facing material and approximately .080” of base
metal.
2. NDE (PT) inspection of all repair areas.
3. Sketch and dimensioning of all repair areas.
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Section I Valve Repairs
4. Preheat valve to 400oF minimum.
NOTE: 300oF for P4 material.
5. Weld excavated repair areas and Hardface under
cut areas with Er90S-B9.
NOTE: Er80S-B2 for P4 material.
6. Base metal area profiled and NDE with dry (MT)
on P15E material. Base material is kept at 100oF
minimum. No moisture allowed on as welded P15E
materials.
NOTE: PT or wet (MT) allowed on all other low alloy
materials.
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Section I Valve Repairs
7. Preheat back to 400oF.
NOTE: 300oF for P-4 base materials.
8. Apply a minimum of (2) layers of Stellite 21.
9. Cool valve to below 175oF and visually inspect
the welds.
10. PWHT minimum hold 2 hours @ 1375oF per heat
treat traveler.
NOTE: PWHT temp 1250oF for P-4 material.
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Section I Valve Repairs
11. Profile the seat and ribs to OEM specifications.
12. Final NDE, PT to ASME Section 1, VT to ASME B31.1
13. AI review of the weld data package and issuance of
R-1 Form and data plate as required.
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ASME B31.1 Valve Repairs
 CFM/VR-TESCO, LLC repaired (25) plus valves per
ASME B31.1 requirements in 2010-2012.
The majority of the valves were parallel slide gate
valves. (22) Valves required seat replacements.
 ASME B31.1 covers the external boiler piping as
defined for power boilers, high temperature, high
pressure boilers in which steam or vapor is
generated at a pressure of more than 15psig and
high temperature water is generated at pressure
exceeding 160psig and/or temperature of 250oF.
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ASME B31.1 Valve Repairs
 All welding or brazing of pipes or items shall be
performed by manufacturers or contractors who
perform repairs holding stamps for symbols
shown in Fig. PG-105.1 thru PG-105.3 of ASME
Section I of the ASME Boiler and Pressure Vessel
Code. (B31.1 Chapter 1 100.1.2).
 The installer of external boiler piping joined by
welding or brazing is required to have a Quality
Control system meeting, requirements of
Mandatory Appendix J of the ASME B31.1 Code.
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ASME B31.1 Valve Repairs
 For repairs of valves controlled by the
requirements of B31.1 the following are required
to be documented.
1. Removal of defect or reduce to acceptable
size as outlined in Chapter V 127.4.11.
2. NDE of the defect area by Magnetic
Particle (MT) or Liquid Penetrant (PT)
examination. NDE inspection acceptance
criteria per Chapter V – 136.4.3 for (MT) &
136.4.4 for (PT).
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ASME B31.1 Valve Repairs
3. Preheat of the base material as required
in Chapter V-131 “Welding Preheat”.
4. Welding shall be performed by use of
PQR’s, WPS’s & WPQ’s as outlined in
Chapter V-127.5.
5. PWHT of the repair as required by Chapter
V-132 “PWHT Requirements”.
6. Final NDE of the repair as required in
Chapter V-136.4 “Examination methods
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ASME B31.1 Valve Repairs
6. for Welds & Repairs”. ASME B31.1
Chapter V.
a. Visual Examination (VT) – 136.4.2
b. Magnetic Particle Examination
(MT) – 136.4.3
c. Liquid Penetrant Examination
(PT) – 136.4.4
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ASME B31.1 Valve Repairs
All examinations to be performed by
technicians certified to perform each nondestructive examination per ASME B31.1
Chapter V – 136.3.2 “Qualifications of
NDE personnel”.
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
360O CRACKED SEAL WELD
SEAT RING
FIGURE - 1
REPAIR
360o CRACKED SEAL WELD
SEAT RING
FIGURE - 2
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
SEAL WELDING OF SEAT RING
IN GATE VALVE
FIGURE - 3
THERMOCOUPLE PLACEMENT
FOR PRE-HEAT
REPAIR
SEAL WELDED SEAT RING
IN GATE VALVE
FIGURE - 4
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
6 O’CLOCK GUIDE RIB CRACKING
@ INTREGAL SEAT INTERFACE AND CRACKING 360 DEG. AROUND RIB
FIGURE - 5
FIGURE - 6
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
CRACKING IN INTREGAL SEAT AND GUIDE RIBS IN GLOBE VALVES
FIGURE - 8
FIGURE -7
CRACKS IN INTERGAL SEAT
CRACKS IN INTREGAL SEAT
CRACKS IN GUIDE RIB
CRACKS IN GUIDE RIBS
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
LAMINATION IN GUIDE RIBS
FIGURE - 9
LAMINATION IN GUIDE RIB
FIGURE - 10
LAMINATION GUIDE RIB
PIECES
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
WELDING INTREGAL SEAT
FIGURE - 11
GTAW MACHINE WELD OF INTREGAL SEAT
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REPAIRS – ASME SECTION 1 & B31.1
REPAIR
COMPLETED SEAT RING PARTIAL PENETRATION WELD
FIGURE - 12
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Recipe for Success
Successful repair of valves and valve components are a
Hallmark of CFM/VR-TESCO, LLC’s years of service. It
Takes a lot more than just welding and machining skills
to repair today’s valve deficiencies.
It starts with gathering all the information available
about the valve to be repaired. All the valve
component information from the OEM when the valve
was 1st purchased.
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Recipe for Success
The customer must supply the following information to
allow for the completion of work travelers and R-1 data
form if required.
 Unit Number
 Boiler Manufacturer
 Mfg Serial Number
 National Board Number
 Jurisdiction Number
 Year Built
36
Recipe for Success
 Original Code of Construction
 System and location of valve being worked
 Valve Drawing
 Valve Identification
 Valve Year of Manufacture
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Recipe for Success
Once all the pertinent information is gathered QA and
The Welding Department start the planning process:
 Initiate work traveler and weld data sheets.
 Identify WPS’s and Welder Performance
Qualifications.
 Create PWHT Traveler.
 Identify NDE requirements and notify NDE
subcontractor.
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Recipe for Success
 Issue filler material and supporting documentation
MTR/CMTR’s.
 Notify Authorized Inspector (If required).
 Present Data Package to Project Manager for review.
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Recipe for Success
CFM/VR-TESCO, LLC has specialized machining and
Welding equipment that is required to repair the
different types of valve repairs. Equipment is staged
and inspected before shipping to each project.
Personnel training on specialized equipment and valve
repairs.
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Recipe for Success
The recipe for success may seem simple, but care must
be taken on each step to insure the “best possible”
results for each valve repair.
CFM/VR-TESCO, LLC working with OEM’s and our
Customers have been “Teaming Together for Success”
for over 26 years.
41
Recipe for Success
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