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11.2 PCC-2 Core Welded Repairs: Articles 101, 201, 202, 211 & 212

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API 510 Pressure Vessel Inspector Exam

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1 Chapter 1: Introduction, Scope & Certification Requirements

1.1 Exam Structure, Administration & Study Strategy 1.2 API 510 Code Scope, Exclusions & Jurisdictional Boundaries 1.3 Roles, Responsibilities & Inspector Qualification

2 Chapter 2: Inspection Planning, Data Evaluation & Remaining Life

2.1 Corrosion Rates, Remaining Life & Corrosion Allowance Calculations 2.2 Inspection Intervals, On-Stream Inspection & Interval Deferrals 2.3 Condition Monitoring Locations (CMLs) & Data Analysis

3 Chapter 3: Vessel Evaluation, Corrosion Averaging & Fitness-for-Service

3.1 Corrosion Averaging & Minimum Thickness Evaluation 3.2 Pitting Evaluation & Corroded Area Limits 3.3 Fitness-for-Service (API 579-1) & Risk-Based Inspection (API 580)

4 Chapter 4: ASME Section VIII Div 1 Design & Thickness Calculations

4.1 Internal Pressure Design & Cylindrical Shell Calculations 4.2 Ellipsoidal & Hemispherical Head Calculations 4.3 Spherical Shells, Static Head & Vessel MAWP 4.4 Openings, Nozzle Reinforcement & External Pressure Basics

5 Chapter 5: ASME Section VIII Fabrication, Welds & Joint Efficiency

5.1 Weld Joint Categories (UW-3) & Joint Efficiencies (UW-12) 5.2 Radiographic Examination (UW-11, UW-51, UW-52) 5.3 Post-Weld Heat Treatment (PWHT) & Impact Testing (UCS-56, UCS-66)

6 Chapter 6: Welding Inspection & Metallurgy (API 577 & ASME Sec IX)

6.1 Welding Procedures (WPS/PQR) & Essential Variables 6.2 Welder Performance Qualification (WPQ) & Testing 6.3 Welding Processes, Metallurgy & Weld Discontinuities (API 577)

7 Chapter 7: Nondestructive Examination (ASME Section V)

7.1 Radiographic Examination Techniques & Image Quality Indicators (Article 2) 7.2 Ultrasonic Thickness Measurement (Article 23, SE-797) 7.3 ASME Section V Articles 1, 6 & 7: General Requirements, PT & MT

8 Chapter 8: Damage Mechanisms (API RP 571)

8.1 Atmospheric Corrosion & Corrosion Under Insulation 8.2 HTHA, High-Temperature H2/H2S Corrosion & Sulfidation 8.3 Amine, Caustic & Chloride Stress Corrosion Cracking 8.4 Wet H2S Damage, Brittle Fracture & Erosion-Corrosion 8.5 Boiler-Water, Steam-Condensate & Hydrochloric Acid Corrosion 8.6 Caustic Corrosion & Naphthenic Acid Corrosion

9 Chapter 9: Pressure Vessel Inspection Practices (API RP 572 & API RP 578)

9.1 Internal & External Vessel Inspection Practices (API 572) 9.2 Structural Components, Internal Trays, Linings & Skirts 9.3 Material Verification Programs & Positive Material Identification (API 578)

10 Chapter 10: Pressure-Relieving Devices (API RP 576)

10.1 PRD Types, Construction & Operating Principles 10.2 PRD Causes of Failure, Shop Testing & Overhaul 10.3 PRD Inspection Intervals, Records & Rupture Disks

11 Chapter 11: Repairs, Alterations, Rerating & Pressure Testing (API 510 & PCC-2)

11.1 Repair vs. Alteration Authorization, Execution & Methods 11.2 PCC-2 Core Welded Repairs: Articles 101, 201, 202, 211 & 212 11.3 PCC-2 Special Welding: Articles 209, 210, 215 & 216 11.4 PCC-2 Excavation, Flange, Exchanger & Test Articles 304, 305, 312, 501 & 502 11.5 Vessel Rerating Requirements & Engineering Calculations 11.6 Pressure Testing: Hydrostatic, Pneumatic & NDE in Lieu of Testing

11.2 PCC-2 Core Welded Repairs: Articles 101, 201, 202, 211 & 212

Key Takeaways Explain This Topic AI

Article 101 establishes PCC-2 scope, organization, and intent; it is the navigation starting point rather than a repair technique.

Article 201 governs butt-welded insert plates that replace damaged pressure-boundary material with a full-penetration welded insert.

Article 202 governs external weld buildup used to repair internal thinning; it does not govern fillet-welded lap patches.

Article 211 governs weld buildup, weld overlay, and clad restoration, including restoration of structural thickness or a corrosion-resistant layer.

Article 212 governs fillet-welded patches; patch design and lifecycle must be evaluated under API 510 and the applicable PCC-2 requirements.

Last updated: August 2026

PCC-2 Core Welded Repairs

The current API 510 effectivity sheet lists specific PCC-2 articles. Memorizing the correct article-to-method map prevents a common failure: selecting a plausible repair under the wrong design and examination rules.

1. Article 101 - scope, organization, and intent

Article 101 explains how PCC-2 is organized and how a repair article is used. A repair must have an applicable equipment and damage scope, a sound design basis, suitable materials, qualified personnel and procedures, installation controls, examination, testing when required, and records. PCC-2 does not override jurisdiction or API 510 authorization. The owner/user, pressure-vessel engineer, authorized inspector, and repair organization retain their defined responsibilities.

Before selecting an article, establish:

Equipment and construction code.

Damage mechanism, morphology, extent, and cause.

Current and future design conditions.

Remaining sound material and load path.

Whether the vessel can be removed from service.

Material and weldability, including PWHT and environmental-cracking concerns.

Required life, inspection access, leak consequence, and jurisdiction.

2. Article 201 - butt-welded insert plates

An insert repair removes damaged pressure-boundary material and installs sound plate with full-penetration butt welds. It is normally a permanent restoration when designed and executed correctly. The engineer defines insert material, thickness, shape, corner geometry, proximity to existing welds and attachments, forming, fit-up, joint design, PWHT, NDE, and testing.

The cutout should extend beyond damage into verified sound material. Smooth radiused geometry avoids sharp stress concentration. Material identity and forming history matter because an insert must be compatible with the vessel and service. The repair organization qualifies its WPS and welders under Section IX. The inspector verifies hold points, fit-up, root condition, completed weld examination, and records.

3. Article 202 - external weld buildup for internal thinning

Article 202 adds weld metal to the external surface to restore strength where thinning is on the internal surface. This is not an external lap-patch article. The engineer must show the remaining wall can safely support preparation and welding and that the completed deposit restores the required structural section under design conditions.

Critical issues include accurate mapping of internal loss, remaining ligament, weldability, heat input, hydrogen control, distortion, residual stress, service environment, deposit geometry, and ability to inspect the completed buildup. The repair does not remove the internal corrosion mechanism, so future corrosion allowance and monitoring remain essential.

4. Article 211 - weld buildup, overlay, and clad restoration

Article 211 covers related but distinct objectives:

  • Objective Function Main control
  • Structural weld buildup Restores pressure-boundary metal Required thickness and sound fusion

Weld overlay Adds a deposited layer for structural or surface function Deposit chemistry, dilution, and coverage

Clad restoration Reestablishes corrosion-resistant lining over base metal Chemistry, continuity, tie-in, and defect-free surface

A corrosion-resistant overlay is not automatically structural credit, and structural buildup is not automatically a corrosion barrier. The repair plan must state the function of each layer. PMI or chemistry verification, ferrite or hardness control when applicable, surface preparation, staged examination, and final thickness records may be required by the plan.

5. Article 212 - fillet-welded patches

A fillet-welded patch transfers pressure load through the patch and perimeter weld instead of replacing damaged plate with a butt-welded insert. It may be appropriate only within the article and API 510 limits after engineering evaluates damage, pressure, temperature, patch geometry, weld loading, crevice, leak path, service chemistry, fatigue, and required life.

Do not place a patch over an unevaluated crack-like flaw. Continued crack growth can extend beyond the patch. The design should avoid sharp corners and abrupt stiffness changes and provide examination and monitoring access. If a telltale or vent is specified, its status and safe routing must follow the approved design; do not improvise plugging or pressure testing.

6. Selection table

  • Condition Likely starting article Why
  • Damaged plate can be removed 201 Replaces damage with full-penetration insert
  • Internal thinning, sound remaining ligament, external access 202 External deposit restores structural section
  • Structural buildup or corrosion-resistant layer restoration 211 Controls deposit function and metallurgy
  • Engineered fillet-attached patch is justified 212 Governs patch load path and attachment
  • Exam traps

Article 202 is external weld buildup for internal thinning, not lap patches.

Article 212 is the listed fillet-welded patch article.

Repair authorization, engineering, jurisdiction, and construction-code requirements still apply.

Fixing wall thickness without controlling the active damage mechanism is incomplete.