Weld Repairs Archives - The Equity Engineering Group, Inc.

Local PWHT and Weld Residual Stress: A Case Study in Welding and PWHT Simulation

Jun 26, 2026

A local PWHT procedure that fully complies with WRC 452 does not guarantee the residual stress relief assumed in fitness-for-service assessments, and for equipment susceptible to environmental cracking, that gap can be the difference between a successful repair and a repeat failure. This case study presents a coupled welding and PWHT finite element simulation of a fractionator head repair, comparing local PWHT outcomes against furnace treatment and identifying ramp rate as the most powerful lever for improving stress relief.

New Guidance for the Design of Fillet-Welded Patches

Jun 26, 2026

The current ASME PCC-2 Article 212 guidance for fillet-welded patch repairs is known to be conservative, frequently driving patch plate thicknesses past the 1.5-inch threshold that triggers mandatory PWHT. This article presents Equity Engineering’s proposed T-min methodology, an FEA-validated alternative that eliminates unnecessary thickness penalties and reduces PWHT risk while remaining technically rigorous and grounded in ASME design-by-analysis principles.

Engineering 101: Run, Repair, or Replace? A Guide to Pressure Equipment Repair

Jun 26, 2026

Not every inspection finding requires physical repair, and not every repair that looks straightforward actually is. This article in our Engineering 101 series outlines the full pressure equipment repair process, from characterizing damage and identifying the governing codes to selecting the right method and closing out the work with proper documentation.

Dissimilar Metal Weld Repairs: Best Practices and Case Study

Nov 18, 2025

Dissimilar metal welds (DMWs) are often specified in process plants as an alternative to bolted mechanical joints and are successfully used in many corrosive and severe services. However, these welds can be subject to major weldability challenges and may lead to failures due to inherent material differences. In this article, the author examines these failure mechanisms, offers best practices for weld repairs and joint designs, and discusses a recent case study where laboratory analysis was used to identify the cause of a repeat DMW failure.

Advanced Analysis of Equipment Repairs and Alterations

Jul 30, 2024

Maintenance programs require a significant investment of time, energy, and money to keep facilities and equipment operating safely and reliably. Despite these efforts, there will always be a need for repairs, replacements, or alterations. In this article, the authors use a variety of case studies to discuss how advanced analysis techniques can support several post-construction activities. They offer insight into how to evaluate weld repair plans and post-weld heat treatments, validate rerate conditions, and ensure structural integrity.

Hot Tap Evaluations and Practical Guidance for In-Service Repair Welding

Nov 1, 2023

In-service welding as part of a maintenance program is a practical and economical way to address leak repairs or new nozzle installations; however, it does come with a few risks, including burn-through and hydrogen-induced cracking. In this article, Raj will discuss the risks involved with in-service welding, thermal analysis to quantify the risks, and practical in-service welding considerations to ensure safe and successful hot tap connections.

Leveraging EP-7-3-3 Series for Equipment Repairs

Nov 1, 2023

The need for post-construction equipment repairs and maintenance best practices has led to ASME PCC-1 and PCC-2 standards becoming valuable resources for many owner-operators, yet these standards inherently maintain a level of generality. In this article, Derek and Neal will explain how the Equity Engineering Practices (EEPs), specifically EP 7-3-3, address the gaps and provide the extra context, details, and guidance to provide more comprehensive solutions for post-construction equipment repairs.

Fundamentals of Design by Analysis

May 30, 2023

Combining design by analysis (DBA) methods with modern computational approaches provides critical engineering tools for evaluating the structural integrity of in-service equipment and new equipment designs. To know which DBA technique to employ, it is essential to understand all possible failure modes based on equipment operation and loading scenarios. In this article, Phillip offers a high-level overview of modern DBA techniques and procedures for providing protection against plastic collapse, local failure, buckling, and cyclic failure.

Turnarounds: Executing a Problem-Solving Team

May 25, 2021

A successful turnaround has five main stages: setting goals, project scoping, detailed planning, execution, and post-turnaround planning. This article focuses on the advantages of a problem-solving team to resolve equipment inspection discovery and efficiently minimize lost opportunity costs.

The Importance of Pre-Turnaround Reviews

May 25, 2021

A turnaround can cost hundreds of thousands or even millions of a dollars per day. In this article, you’ll learn how Risk-Based Inspection (RBI) helps to manage the costly impact of turnarounds through proper pre-planning to minimize the overall downtime.

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