ASME PCC-2 (Repair of Pressure Equipment) VIRTUAL TRAINING

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Upcoming Course

Code Start Date End Date Location Cost Instructor Register
PST0399-202202  12 Sep 2022  14 Sep 2022  VIRTUAL TRAINING   USD 2270  Mandar Mulay   Register

Past Course

Code Start Date End Date Location Cost Instructor Register
        Aaron A. Zick, Ph.D. 
PST0399-201701  02 Oct 2017  04 Oct 2017  Kuala Lumpur, Malaysia  SGD 2650  Mandar Mulay 
PST0399-201801  10 Dec 2018  12 Dec 2018  Kuala Lumpur, Malaysia  SGD 2750  Mandar Mulay 
PST0399-201901  02 Jul 2019  04 Jul 2019  Yogyakarta, Indonesia  USD 2295  Mandar Mulay 
PST0399-201902  14 Aug 2019  16 Aug 2019  Bandung, Indonesia  USD 2295  Mandar Mulay 
PST0399-201903  18 Sep 2019  20 Sep 2019  Kuala Lumpur, Malaysia  USD 2295  Mandar Mulay 
PST0399-202001  05 Oct 2020  07 Oct 2020  VIRTUAL TRAINING  USD 2065  Mandar Mulay 
PST0399-2021  30 Jun 2021  02 Jul 2021  VIRTUAL TRAINING  USD 2195  Mandar Mulay 
PST0399-202102  20 Dec 2021  22 Dec 2021  VIRTUAL TRAINING  USD 2195  Mandar Mulay 
PST0399-202201  08 Jun 2022  10 Jun 2022  VIRTUAL TRAINING  USD 2270  Mandar Mulay 

ASME PCC-2, being a relatively new standard and fairly popular, has proved to be useful worldwide for repair of pressure equipment and piping. Many large companies have adopted these procedures and incorporated them in their company specifications.

The intent behind this 3 day training program is to introduce this standard to all attendees and understand all the basic concepts and philosophy, as well as the various procedures for repair of pressure equipment and piping. We also will discuss the limitations and advantages/ disadvantages of all the procedures mentioned in the standard.

The correlation of this standard with other in-service codes and standards such as API-510/ 570/ 579/ 580 will also be understood and clarified to all attendees.

This course will not only be useful to maintenance engineers, but equally for all supporting disciplines such as design, operations and inspection engineers. It will help all engineers to collectively troubleshoot and resolve problems/ issues at site related to temporary/ permanent repairs of equipment and piping.

Day 1 :

  • Introduction and Overview of ASME PCC-2
  • Scope, Organization, and Intent
  • Applicability and limitations of repair methods covered by ASME PCC-2
  • Choosing correct repair technique for given defects
  • Detailed Repair methods and Inspection techniques
  • Welded Repairs
  • Butt-Welded Insert Plates in Pressure Components
  • Repair procedure and NDT of insert plate repair
  • Weld Overlay to Repair Internal Thinning
  • Pre-qualified repairs
  • Burst testing method
  • Welded Leak Box Repair
  • Fabrication of Welded box
  • Examination and testing

Day 2 :

  • Full Encirclement Steel Reinforcing Sleeves for Piping
  • Type A and Type B sleeves and their applicability
  • Weld Buildup, Weld Overlay, and Clad Restoration
  • Examination and Testing
  • Fillet Welded Patches
  • Alternatives to Postweld Heat Treatment
  • Alternatives to Traditional Welding Preheat
  • Threaded or Welded Plug Repairs
  • Flaw Excavation and Weld Repair
  • Mechanical Repairs (Non-welding repairs)
  • Mechanical Clamp Repair
  • Freeze Plugs
  • Damaged Threads in Tapped Holes

Day 3 :

  • Inspection and Repair of Shell and Tube Heat Exchangers
  • Inspection Tube count
  • Tube plugging
  • Mechanical Plug
  • Friction Plugs
  • Examination and Testing
  • Hot bolting
  • Half Bolting
  • Flange Repair and Conversion
  • Pipe Straightening or Alignment Bending
  • Pressure and Tightness Testing of Piping and Equipment
  • Pneumatic Testing-Do’s and Don’ts
  • Nondestructive Examination in Lieu of Pressure Testing for Repairs and Alterations
  • Relevance of ASME PCC-2 Standard with API 510 and API 570 Codes
  • 8 Nos of case studies/ exercise demonstrating use of every important topic from the standard. (relevant case study will be taken up after completion of the chapter daily)
  • Familiarize participants with the concepts and technical terms of the standard
  • Know the basic concepts of the standard and their design fundamentals
  • Troubleshoot to resolve various in-service issues.
  • Know the design philosophy of pressure parts
  • Understand the in-service problems in pressure equipment and piping
  • Learn the maintenance aspects in these equipment.
  • Get introduced to all the repair techniques.(temporary and permanent)
  • Discover the fabrication requirements, assembly and welding requirements.
  • NDT and testing procedures for repaired equipment and piping

The course is designed for, but not limited to maintenance engineers, and design, operations and inspection professionals who are involved in equipment such as pressure vessels, heat exchangers, process columns, drums, piping, etc.

  • Design Engineers / Managers
  • Mechanical Engineers / Managers
  • Maintenance Engineers / Managers
  • QAQC Engineers / Managers
  • Inspection Engineers / Managers
  • Reliability Engineers / Managers

Aaron A. Zick, Ph.D.

Founder and President


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.


Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).


Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.



A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).