Ab 539 Engineered Composite Systems For Pressure Equipment Alterations

the pressure equipment safety authority
Engineered Composite Systems for

Pressure Equipment Alterations
AB-539
Edition 1, Revision 1 - Issued 2023-02-24

Engineered Composite Systems
for Pressure Equipment Alteration
Table of Contents
FOREWORD ................................................................................................................... iv
1.0 INTRODUCTION .................................................................................................. 1
2.0 DEFINITIONS ....................................................................................................... 2
3.0 REFERENCE PUBLICATIONS ............................................................................ 5
4.0 SCOPE AND REQUIREMENTS FOR ECSs ........................................................ 6
4.1 Responsibilities .......................................................................................... 6
4.1.1 Owner-user ..................................................................................... 6
4.1.2 Engineered Composite System Supplier ........................................ 6
4.1.3 Engineered Composite System Designer ....................................... 6
4.1.4 Engineered Composite System Installer Organization ................... 6
4.1.5 ABSA .............................................................................................. 7
4.2 Applicability ................................................................................................ 7
4.3 Limitations.................................................................................................. 8
4.4 Exclusions.................................................................................................. 8
4.5 Registration Requirements ........................................................................ 8
4.6 Alteration Reporting Requirements ............................................................ 9
5.0 ENGINEERED COMPOSITE SYSTEM ................................................................ 9
5.1 Engineered Composite System ................................................................. 9
5.1.1 Substrate ........................................................................................ 9
5.1.2 Surface Preparation ........................................................................ 9
5.1.3 Reinforcing Fibers ........................................................................ 10
5.1.4 Polymer Matrix .............................................................................. 10
5.1.5 Quality Assurance ........................................................................ 11
5.2 Engineered Composite System Material Qualification by Supplier .......... 11
5.2.1 Substrate and Surface Preparation .............................................. 12
5.2.2 Qualification Testing Requirements for ECSs Used on Type A
Defects..................................................................................................... 12
5.2.3 Qualification Requirements for ECSs used on Type B Defects .... 14
5.3 Engineered Composite System Qualification Report ............................... 15
5.3.1 Qualification Report– ECS Elements ............................................ 15
5.3.2 Qualification Report – Laminate (for ECSs used on Type A
Defects) ................................................................................................... 15
5.3.3 Cure Data – Laminate................................................................... 16
5.3.4 Qualification Report – Filler .......................................................... 16
5.3.5 Qualification Report – Primer (if relevant) ..................................... 16
5.3.6 Qualification Report – Adhesion ................................................... 16
5.3.7 Qualification Report – Short Term Pipe Spool Survival Test ........ 17
5.3.8 Qualification Report – Energy Release Rates (for ECSs used on
Type B Defects) ....................................................................................... 17
5.4 Short Term Pipe Spool Survival Test ....................................................... 17
5.4.1 Method.......................................................................................... 17
5.4.2 Test Report ................................................................................... 19
5.5 Qualification for use of ECS’ on Type B Defects on Other Substrates or
using Other Methods of Surface Preparation ........................................... 19
Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page i

for Pressure Equipment Alterations
5.5.1 Test Report ................................................................................... 20

5.6 Qualification Requirements for Other Components ................................. 20
5.7 Requalification ......................................................................................... 21
5.7.1 Requalification Tests for Type A Defects ...................................... 22
5.7.2 Requalification Tests for Type B Defects ...................................... 22
5.8 Installation of Engineered Composite Systems ........................................ 22
5.8.1 General Requirements.................................................................. 22
5.8.2 Responsibilities............................................................................. 22
5.8.3 Installation Instructions ................................................................. 23
5.8.4 Additional Requirements............................................................... 23
6.0 DESIGN METHODOLOGY................................................................................. 24
6.1 Owner-user Requirements ....................................................................... 24
6.1.1 Integrity Assessment .................................................................... 24
6.1.2 Risk Assessment .......................................................................... 24
6.1.3 Maintenance and Monitoring ........................................................ 24
6.1.4 Removal of Engineered Composite Systems ............................... 25
6.1.5 Record Keeping Requirements for ECS ....................................... 25
6.1.6 User Design Specification (UDS) .................................................. 25
6.2 Design Basis ............................................................................................ 26
6.3 Environmental Compatibility .................................................................... 26
6.4 Design Temperature Effects .................................................................... 26
6.5 Cure Requirements .................................................................................. 27
6.5.1 Designs for Type A Defects .......................................................... 27
6.5.2 Designs for Type B Defects .......................................................... 27
6.6 Design Based on Substrate Load Sharing ............................................... 28
6.7 Design Based on Laminate Allowable Strains (Defect Type A) ............... 28
6.8 Design Based on Allowable Stresses Determined by Performance Testing
(Defect Type A) ........................................................................................ 29
6.9 Design of ECSs for Through Wall Defects (Defect Type B) ..................... 29
6.10 Axial Extent of Repair .............................................................................. 29
7.0 COMPETENCIES OF INSTALLERS AND INSPECTORS ................................. 30
7.1 Requirements and Responsibilities of Installer Organizations ................. 30
7.1.1 Training......................................................................................... 30
7.1.2 Qualification .................................................................................. 30
7.1.3 Training Records .......................................................................... 30
7.1.4 Documented Evidence and Maintenance of Competency ............ 31
7.2 Requirements and Responsibilities of Owner-users ................................ 31
7.2.1 Training......................................................................................... 31
7.2.2 Training Records .......................................................................... 31
8.0 EXAMINATION AND TESTING .......................................................................... 32
8.1 Pre-installation ......................................................................................... 32
8.2 In-process ................................................................................................ 34
8.3 Post-installation ....................................................................................... 34
9.0 QUALITY MANAGEMENT SYSTEM REQUIREMENTS .................................... 36
9.1 ECS Suppliers ......................................................................................... 36
9.2 ECS Installer Organization....................................................................... 36
9.3 Owner-users ............................................................................................ 37
Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page ii

A.0 ANNEX A (NORMATIVE) – Applicability ............................................................ 38

A.1 Pressure Piping Systems ................................................................ 38
A.1.1 ASME B31.1 – Power Piping........................................................ 38
A.1.2 ASME B31.3 – Process Piping ..................................................... 38
A.1.3 ASME B31.5 – Refrigeration Piping ............................................. 39
A.1.4 ASME B31.9 – Building Services Piping ...................................... 39
A.1.5 CSA Z662 – Steam Distribution Pipelines .................................... 39
A.2 Boilers ...................................................................................................... 39
A.3 Pressure Vessels, Thermal Liquid Heating Systems, and Fired-Heater
Pressure Coils ......................................................................................... 39
B.0 ANNEX B (INFORMATIVE) – REGISTRATION REQUIREMENTS ................... 40
B.1 ECS Procedure Specification (ECSPS) Registration ............................... 40
B.2 Alteration procedure registration .............................................................. 41
B.3 ECS Alteration Report – Inspection and Certification .............................. 41
B.4 Typical ECS Process Flow Diagram ........................................................ 43
C.0 ANNEX C (INFORMATIVE) – SAMPLE FORM .................................................. 44
D.0 ANNEX D (INFORMATIVE) – ECSPS AND PQRs............................................. 47
D.1 ECS Procedure Specification................................................................... 47
D.2 ECS Procedure Qualification Record (PQR)............................................ 48
E.0 ANNEX E (INFORMATIVE) – DESIGN CONSIDERATION FOR PRESSURE
CONTAINMENT ............................................................................................................ 49
E.1 Recommendations for Model and Defect Size Selection ......................... 49
E.1.1 Scenario 1 - Leaks in Plain Pipe .............................................................. 49
E.1.2 Scenario 2. Leaks on Girth Welds .......................................................... 52
E.1.3 Scenario 3. Leak on Seam Weld ............................................................ 53
E.1.4 Scenario 4. Tees ..................................................................................... 54
E.2 Final Comments ....................................................................................... 56
10.0 REVISION LOG .................................................................................................. 57
Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page iii

FOREWORD
As provided for under Section 40 of the Pressure Equipment Safety Regulation, the
Administrator in the pressure equipment discipline has established that ABSA document
AB-539 “Engineered Composite Systems for Pressure Equipment Alterations”
provides guidelines and specifies requirements that must be met for registration of
alteration designs and procedures that include engineered composite systems.
The next reaffirmation of this document is scheduled for 2024.
Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page iv

1.0 INTRODUCTION
This document was developed to establish the requirements for the use of engineered
composite systems in the post-construction alteration activities of pressure equipment.
Use of an engineered composite system may be considered, if there is a valid technical
and safety justification, to provide for the safe and continued operation of pressure
equipment that is not compliant with the original registered design until the equipment
can be repaired, altered, or replaced. The pressure equipment owner-user is
responsible for determining if the use of an engineered composite system is appropriate
and if the installation and use can be safely performed.
This document assumes that an integrity and defect assessment has already been
performed and a decision has been made to consider use of an engineered composite
system. This document does not establish guidelines or requirements for pressure
equipment integrity assessments, or defect assessments.
This document does not provide all the necessary information required to perform a
pressure equipment alteration using an engineered composite system. It is the
responsibility of the owner-user, in conjunction with any other organization responsible
for the design, manufacturing, or installation of engineered composite systems, to
ensure that all of the necessary engineering, installation, and safety requirements are
addressed for any given installation.
ASME PCC-2 Part 4 Article 401, and ISO 24817 are standards defining the
requirements for the external application of engineered composite systems to damaged
pressure equipment. Information from these publications, and other relevant good
engineering practices, has therefore been referenced in the applicable sections of this
document to provide guidance on the qualification, design, installation, testing,
inspection, and removal of engineered composite systems.
This requirements document was developed through consultation with the public, plant
owner-users, engineered composite system suppliers, installer organizations, the
Technical Safety Authority of Saskatchewan, and other stakeholders; their input has
been invaluable in compiling this document. The scope, recommended use and
limitations established by this document reflect common and practical use of ECS for
alteration of pressure equipment. With intent of further consultations, available relevant
information, acquired knowledge and experience, the scope, recommended use and
limitations may be modified in future editions of this document.
This requirements document will be reviewed periodically to ensure that it is aligned

with current industry practices. We would welcome any suggestions you have to
improve this document. Please provide your comments to:
Ljupco (Lou) Petrusevski

Manager, Design Survey
petrusevski@absa.ca
Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 1 of 57

2.0 DEFINITIONS
For the purpose of this document, the following definitions apply:
Certified testing organization – a testing organization that is certified or accredited to

ISO/IEC 17025 or other nationally or internationally recognized accreditation that is
acceptable to ABSA and the owner-user
Note: Examples of some acceptable accreditation bodies that provide accreditation for testing programs
includes but is not limited to: The Standards Council of Canada (SCC), American Society for Testing and
Materials, the U.S. Department of Defense, American Association for Laboratory Accreditation, National
Aerospace and Defense Contractors Accreditation Program (NADCAP)
Composite – a thermoset polymer resin that is reinforced by fibers
Composite system – a system comprised of multiple elements such as the substrate

material, substrate surface preparation methods, composite materials (laminate, fibers,
and resin), filler material, adhesive, composition methods, sealing, coating, etc.
Cure (curing) – the setting of a thermosetting resin by an irreversible chemical reaction
Cure schedule – a time-temperature profile qualified to generate a specified glass

transition temperature or heat distortion temperature of the resin
Design lifetime – the maximum application lifetime of the laminate
Engineered composite systems (ECS) – a composite system which has been

designed and applied under a specified, controlled process so that under the design
conditions, there is a high degree of confidence that the repair will maintain its integrity
over the design lifetime
Engineered composite system designer – a company or a person that designs and

certifies the design of the engineered composite system
Engineered composite system installer organization – a company or an owner-user

that installs the engineered composite system
Engineered composite system procedure qualification record (ECSPQR) - a record

of variables recorded during the qualification of the ECS using test specimens
Engineered composite system procedure specification (ECSPS) – a written

document providing direction to the person applying the ECS
Engineered composite system supplier – a company that supplies the engineered

composite system materials and installation instructions
Filler material – material used to repair external surface imperfections prior to the
application of the composite / laminate

Glass transition temperature – the temperature at which a resin undergoes a marked

change in physical properties
Heat distortion temperature – the temperature at which a standard bar of the resin
polymer deflects by a specified amount under a given load
Installation Instructions – instructions provided by the ECS supplier in the method

statement for each ECS application. Installation instructions include details such as:
acceptable environmental conditions during ECS application, material storage, surface
preparation, resin system mixing, laminate lay-up for the component geometry, laminate
consolidation procedure (fiber wetting), cure schedule, key hold points, and batch
testing reports of the qualified ECS materials.
Note: Installation instructions are used as input for the ECS procedure specification.
Installer– a person who is qualified to apply an engineered composite system
Integrity assessment – an examination of an item of pressure equipment, related

processes and documentation to determine its conformity to the requirements
established by ABSA
Laminate – the part of the ECS that is the composite.
Note: Composites are composed of discrete lamina or layers which are wrapped or stacked,
one on top of the other. This stacked construction is the laminate. Common alternate terms
used in industry include: repair laminate, and composite material.
Method statement – describes the main procedures carried out prior to and during
ECS applications that are generic in nature for a particular ECS and include the
following information: Health and safety, quality assurance, installation procedure and
environmental information
Owner – a lessee, a person in charge, a person who has care and control and a person
who holds out that the person has the powers and authority of ownership or who for the
time being exercises the powers and authority of ownership
Owner-user – an owner that has implemented a quality management system,

recognized by ABSA, to manage the integrity of pressure equipment
Ply – a single wrap or layer (lamina) of a laminate
Post cure – additional elevated temperature applied after resin has hardened to ensure
the required glass transition temperature is achieved

Pressure equipment – a boiler, a fired-heater pressure coil, a thermal liquid heating

system and other equipment designed to contain expansible fluid under pressure,
including, but not limited to, pressure vessels, pressure piping systems, and fittings, as
defined in the regulations
Resin – all of the components that make up the matrix portion of a composite
Risk assessment – a comprehensive and systematic process of evaluating the

potential risks to people, environment, and property that may be a result of operating
pressure equipment
Note: In the context of this document, the wording in the above definition” result of operating pressure
equipment “includes risks related to performing activities for the use of an ECS, while the pressure
equipment is in operation.
Substrate – the surface on which the ECS installation is carried out.
Type A Defect – a defect within the substrate, not through-wall and not expected to
become through-wall within the design lifetime of the ECS
Type B Defect – a through-wall defect or a defect within the substrate where at the end
of service life the remaining wall thickness is less than 1 mm
User Design Specification (UDS) – a document created by the owner-user containing

sufficient detail to provide a complete basis for the design and installation of an ECS for
pressure equipment alterations.
Work Pack – describes the job specific procedures related directly to the procedures
carried out prior to and during ECS application and include the following information:
Scope of work, health and safety, risk assessment, ECS details, Installer qualification
level and specific installation instructions

3.0 REFERENCE PUBLICATIONS
The following publications have been referenced in this document in a way that some or
all of their content is used as a requirement of this document. Only the referenced
editions listed apply.
The organizations that are involved in the use of ECS shall have access to these
referenced standards, in order to use this AB-539 document.
ISO 24817:2017(E) – Petroleum, petrochemical and natural gas industries – Composite

repairs for pipework – Qualification and design, installation, testing, and inspection
ASME PCC-2-2018 – Repair of pressure equipment and piping – Part 4: Nonmetallic

and bonded repairs – Article 401 – Nonmetallic composite repair systems: High-risk
applications
ISO 8501 – 1:2007 Preparation of steel substrates before application of paints and
related products — Visual assessment of surface cleanliness — Part 1: Rust grades
and preparation grades of uncoated steel substrates and of steel substrates after overall
removal of previous coatings
SSPC-SP 10/NACE No. 2, Near-White Blast Cleaning -The Society for Protective
Coatings (SSPC); National Association of Corrosion Engineers (NACE); The
Association for Materials Protection and Performance (AMPP)
SSPC-SP2, Hand Tool Cleaning-The Society for Protective Coatings (SSPC); The
SSPC-SP 3, Power Tool Cleaning-The Society for Protective Coatings (SSPC); The
SP 11, Bare Metal Power Tool Cleaning-The Society for Protective Coatings (SSPC);
The Association for Materials Protection and Performance (AMPP) Association
SSPC-SP 15, Commercial Grade Power Tool Cleaning-The Society for Protective
Coatings (SSPC); The Association for Materials Protection and Performance (AMPP)

4.0 SCOPE AND REQUIREMENTS FOR ECSs
The scope of this document is to provide a systematic approach outlining the

requirements and recommendations for the procedure qualification, design, installation,
testing, inspection, and registration of engineered composite systems (ECSs) for
pressure equipment alterations.
The requirements of this document shall be satisfied by anyone planning to design,

register, and install an ECS on pressure equipment. ECSs are applied to restore the
structural integrity of a pressure component that has been degraded or damaged by
service-induced deterioration mechanisms or external mechanical damage.
The use of ECSs on pressure equipment may introduce new risks which may further
damage pressure equipment and cause the pressure equipment to fail. Some examples
of the new risks include, but are not limited to, new damage mechanisms initiated under
the composite material, and development of operating and residual stresses due to
constrained differential expansion. It is the owner-user’s responsibility to assess and
address all applicable risks and the impact of damage mechanisms, failure modes, and
the addition of operating and residual stresses when an ECS is used.
4.1 Responsibilities
4.1.1 Owner-user
Owner-users shall develop, implement, and maintain all documents,

processes, and procedures used to perform or contract the design,
manufacturing, installation, and use of an ECS within the scope of their
quality management system (AQP-8000 series PEIMS / IMS).
4.1.2 Engineered Composite System Supplier
ECS suppliers shall develop, implement, and maintain all documents,

processes, and procedures used for the manufacturing and specification
of ECS materials within the scope of their quality management system.
4.1.3 Engineered Composite System Designer
ECS designers shall ensure that the design of the ECS conforms with all
owner-user design specifications, shall have adequate training and shall
be deemed competent by the pressure equipment owner-user, in the
design, application, inspection, and re-evaluation of ECSs.
4.1.4 Engineered Composite System Installer Organization
ECS installer organizations shall ensure that the ECS is installed to the
satisfaction and acceptance of the owner-user, and conforms to the
registered alteration procedure. The ECS installer organization shall have

personnel that are qualified in the application, installation, examination,

testing, and repair of ECSs.
4.1.5 ABSA
ABSA shall review ECS designs and procedures for pressure equipment
alterations. This is intended to ensure, within reasonable bounds, that the
relevant technical requirements are documented and addressed by the
owner-user and its representatives, and that all administrative
requirements are met for the purpose of ECSPS and alteration procedure
registration, installation and maintenance.
4.2 Applicability
ECSs may be used as a temporary means of restoring the structural integrity of

pressure equipment identified in Table 4.1. The application of an ECS is limited
to installation on pressure equipment designed for the below listed conditions:
- Design Pressure (Note 1) ≤ 3500 kPag (500 psig)

- Design Temperature ≤ 250°C (482°F)
- Minimum Design Temperature ≥ -50°C (-58°F)
Refer to Annex A for complete applicability details for each general pressure
equipment category.
Notes:
1) Design pressure refers to the pressure equipment maximum allowable working
pressure (MAWP) registered with ABSA in accordance with PESR Section 19(1)(-v).
Table 4.1 – Applicability of General Pressure Equipment Categories

Pressure Equipment Category(1)
Material of Construction Pressure
Pressure Boilers
(Substrate) Piping
Vessels and BEP
Systems
Metallic Y N N
Non-metallic N N N
Y – Permitted as defined in Annex A
N – Not Permitted
Notes:
1) Refer to Annex A for complete applicability details
2) This table does not apply to ECS maintenance activities. Refer to Section 6.1.3 of this
document for maintenance and monitoring requirements. It is intended that the maintenance
and monitoring procedures will include the post-installation examination and testing
recommendation provided in Table 8.3 of this document.

4.3 Limitations
ECSs shall only be considered for installation on pressure equipment managed

by owner-users who hold a Certificate of Authorization Permit, that includes
performing or contracting the design, manufacturing, and installation of ECSs
within the scope of their quality management system (AQP-8000 series PEIMS /
IMS).
ECSs shall not be considered for use in the following applications:
a) Pressure equipment in public occupancy service

b) Pressure relief devices, or flanged joints connecting a pressure relief
device
c) Complex fittings, such as valves, filters, miniature pressure vessels, or
other appurtenances installed in a piping system
d) New construction of pressure equipment
e) For the purpose of re-rating (i.e. up-rating of in-service pressure
equipment)
f) Pressure equipment operating under a fitness-for-service assessment
g) Areas of pressure equipment that may interact with engineered
pressure enclosures (EPEs)
h) Areas of pressure equipment that may interact with hot taps
4.4 Exclusions
The following types of composite systems do not meet the requirements of this
document:
a) Any pre-fabricated / pre-cured components or laminates made using

composite materials, such as composite sleeves, split composite sleeve
systems, etc.
b) Generic type composite wraps that are not engineered for a specific
installation
4.5 Registration Requirements
A person that is planning to install an ECS on pressure equipment shall ensure

the following is registered with ABSA prior to commencement of the alteration:
a) ECS procedure specification (ECSPS); and

b) Application-specific alteration procedure
Refer to Annex B for detailed requirements for ECSPS and alteration procedure
registration.

4.6 Alteration Reporting Requirements
After the ECS installation is complete, the alteration of the affected pressure
equipment shall be inspected, verified and certified on an alteration data report
acceptable to ABSA.
Refer to Annex B for detailed alteration report requirements.
5.0 ENGINEERED COMPOSITE SYSTEM
5.1 Engineered Composite System
The ECS is a combination of the following elements and procedures:
- Substrate (base metal surface)

- Method of surface preparation
- Load transfer material (filler material)
- Primer layer adhesive (an adhesive used in some systems to bond
the composite laminate to the substrate)
- Composite material (laminate, fibers, and resin)
- Application method (sealing, coating, and other elements as needed)
- Curing protocol
Limitations on the elements allowed for the ECSs are specified in this section.
5.1.1 Substrate
The substrates shall be:
a) Metallic substrate materials covered in the applicable codes of

construction listed in Annex A of this document. Metallic substrate
materials include, for example, carbon steel, stainless steels,
duplex and super duplex stainless steels, aluminum, and titanium.
Qualification testing completed on one representative alloy for each

substrate group shall be considered as applicable to all alloys within that
group. For example, testing on 316L stainless steel will be applicable to all
other austenitic grades of stainless steel, but not to duplex or super duplex
alloys.
5.1.2 Surface Preparation
One of the following surface preparation methods shall be used:
a) Abrasive blast cleaning to SA 2½ (SSPC-SP10, NACE No. 2)

with non-metallic grit only, such as olivine sand, garnet, iron
furnace slag, copper refinery slag, nickel refinery slag,

aluminum silicate slags, and fused aluminum oxide. The

abrasive media used in qualification testing shall be defined in
the test reports. Blasting media that leaves a residue on the
surface after blasting, such as walnut blasting, shall not be used
unless the qualification testing was completed with such media.
b) Power tool cleaning to ST-3 (SSPC SP3, SP11 and SP15). The
tools and method used in qualification testing shall be defined in
the test reports.
c) This document is only applicable to preparation of surfaces

using hand tools (ST-2 or SSPC-SP2) if the qualification testing
is completed on samples representative of impaired pipe that
has been in service (i.e. not if tested on as-new pipe). The
condition of the pipe at time of preparation, tools and method
used in qualification testing shall be defined in the test reports.
It is intended that the methods used for ECSPS qualification testing be

replicated for preparation on site and that no other methods shall be used
as alternatives to those qualification tested.
Note: The above-referenced cleaning specifications are as provided by the following

surface preparation standards: Preparation of steel substrates before application of
paints and related products (ISO 8501), and those published by The Society for
Protective Coatings (SSPC), National Association of Corrosion Engineers (NACE) and
Association for Materials Protection and Performance (AMPP).
5.1.3 Reinforcing Fibers
The reinforcing fibers shall be the following continuous fibers in woven or

stitched fabric form:
a) Glass fiber (E-glass, S-glass or ECR-glass fiber, or equivalent)

b) Aramid fiber
c) Carbon fibers
An ECS that uses carbon fiber (or other electrically conductive

components) shall include a method to provide electrical isolation of the
fiber from the host substrate in order to prevent bimetallic (galvanic)
corrosion. The isolation layer must be considered as part of the ECS and
included during the qualification testing.
5.1.4 Polymer Matrix
The polymer matrix shall be one of the following thermoset polymers:
a) Polyester resins
b) Vinyl ester resins

c) Epoxy resins (Bisphenol A, F or novolac systems)

d) Water-cured polyurethane resins
Thermoplastic resins (polymers) shall not be used in the polymer matrix of

the ECS.
5.1.5 Quality Assurance
a) The manufacturers producing the ECS materials shall have an

ISO 9001 quality management system, or equivalent, in place
that provides controls for consistent and repeatable production
quality.
b) ECS materials supplied shall be issued with relevant batch
numbers and expiration dates.
c) The quality program shall include batch testing of the qualified
ECS materials and include as a minimum:
- Tensile properties of the reinforcing fibers

- Physical properties of the fabrics, i.e. fabric mass per unit
area
- Glass transition temperature of the polymer matrix
- Cure characteristics of the polymer matrix (such as gel
time)
- Compression strength of the filler material
d) Test results shall be retained or be retrievable by the ECS

supplier and be traceable by batch number.
- Test results shall be traceable to both the fiber testing

and fiber production.
e) The frequency of sampling and ECS material testing shall be

specified in the ECS supplier’s QMS.
5.2 Engineered Composite System Material Qualification by Supplier
Qualification of the ECS shall be completed in accordance with Table 5.2.2.1

through Table 5.2.3.1 of this document.
- All ECS components listed in Section 5.1 of this document shall be

tested to determine the mechanical properties and thermal
performance.
- Materials performance and test data shall be measured by a certified
testing organization.
- ECS qualification data shall be measured for a representative member
of each family of substrate materials (e.g., carbon steel, low- and

high-alloy steel, stainless steel, aluminum, etc.) for which use of the
ECS is desired.
- The same cure schedule shall be used for all test samples and
specified in the qualification record/report.
Note:
a) ECS supplier qualifies the ECS.
b) ECS supplier develops installation instructions for the use of the ECS.
c) ECS installer develops engineered composite system procedure
specification (ECSPS) based on those instructions.
d) ECS installer qualifies the ECSPS.
5.2.1 Substrate and Surface Preparation
a) The specific method of surface preparation of a specific

substrate group, as described in section 5.1 of this document,
shall be an integral part of the ECS and its qualification.
b) Qualification data are not transferable between different
substrate groups or different methods of surface preparation.
c) Any change in the surface preparation method or substrate
group requires requalification of the ECS (see section 5.2.3 of
this document).
d) The surface roughness achieved on the samples used to
measure the lap shear strength, 𝜏, and the energy release rate,
𝛾, shall be recorded and quoted in the qualification report.
5.2.2 Qualification Testing Requirements for ECSs Used on Type A

Defects
Table 5.2.2.1 Qualification Requirements for the Laminate
Property Symbol Test Method Notes

ISO 527 or Report cure schedule and test
Tensile strength in the axial direction sa
ASTM D3039 temperature
Tensile strength in the circumferential ISO 527 or Report cure schedule and test
sc
direction ASTM D3039 temperature
Report cure schedule and test
fa
Tensile strain to failure in the axial ISO 527 or
temperature
direction ASTM D3039
Minimum value must be >1%
fc
Tensile strain to failure in the ISO 527 or
temperature
circumferential direction ASTM D3039
Minimum value must be >1%
ISO 527 or Report cure schedule and test
Tensile modulus in the axial direction Ea
ASTM D3039 temperature
Tensile modulus in the circumferential ISO 527 or Report cure schedule and test
Ec
direction ASTM D3039 temperature
Layer (ply) thickness tlayer - Derive from tensile test samples
Load in the circumferential
ISO 527 or
Poisson’s ratio ca ASTM D3039
direction, reaction in the axial
direction

V-notched beam
shear test (ASTM
Shear modulus G D5379) or V-
temperature
notched rail shear
test (ASTM D7078)
EN 59, ISO 868,
Barcol or Shore D Hardness ASTM D2583, or
temperature
ASTM D2240
ISO 11359-2, ASTM
a
Thermal expansion coefficient in axial
E831, or ASTM
direction
D696
ISO 11359-2, ASTM
c
Thermal expansion coefficient in E831, or ASTM
circumferential direction D696
Report cure schedule associated

with measured value and the pre-
ISO 11357-2, ASTM measurement heating cycle used
Glass transition temperature Tg E1640, or for the test
ASTMD6604 Measure for all relevant
components (including primers,
resins, fillers, and coatings)
Table 5.2.2.2 Qualification Requirements for the Interface Adhesion

Strength

Follow general guidance of
standards; metal adherents may
be used provided sample of
composite included between the
plates

EN 1465 or ASTM Minimum value of 5,000 kPa (725
Lap shear strength
D3165 psi)
Report surface preparation
procedure, roughness achieved,
and substrate used
temperature
Must be ≥ 0.3.
Lap shear strength after immersion in Report surface preparation
LT
EN 1465 or ASTM procedure and substrate used
water at a minimum temperature of
D3165 Report cure schedule and test
40°C for 1,000 hours
temperature
Report roughness achieved
Must be ≥ 0.3
Lap shear strength after conditioning Report surface preparation
HT
EN 1465 or ASTM
at the elevated design temperature for procedure and substrate used
D3165
1,000 hours Report conditioning temperature
Report roughness achieved
ISO 11357-2, ASTM
Where a primer is used, glass with measured value, and the pre-
Tg E1640, or ASTM
transition temperature measurement heating cycle used
D6604
for the test

Table 5.2.2.3 Qualification Requirements for Fillers

Compressive modulus of filler ASTM D695 or ISO

material 604
ASTM D695 or ISO
Compression strength of filler material 
604
ISO 11357-2, ASTM
with measured value, and the pre-
Glass transition temperature of filler  E1640, or ASTM
measurement heating cycle used
D6604
for the test
Table 5.2.2.4 Qualification Requirements for ECSs Used on Type A

Defects

Short-term pipe spool survival test  See section 5.4 Laminate must not fail
5.2.3 Qualification Requirements for ECSs Used on Type B Defects
Table 5.2.3.1 Qualification Requirements for ECSs Used on Type B

Defects
Property Symbol Test Method Notes

procedure, roughness achieved
Energy release rate, circular defects LCL ISO 24817, Annex D and substrate used
temperature
Energy release rate, slot defects
procedure, roughness achieved
w
See Annex E of this
and substrate used
Test results will be provided for document
consideration and review
temperature
ISO 24817, Annex
F: “Measurement of Report surface preparation
Impact survival test 
Impact procedure and substrate used
Performance”
Qualification requirements for
procedure, roughness achieved,
additional substrate groups or
 Section 5.5 and substrate used
additional methods of surface
preparation
temperature

5.3 Engineered Composite System Qualification Report
The data recorded in accordance with the requirements in Section 5.2 of this
document shall be presented using a format equivalent to that shown in this
section.
5.3.1 Qualification Report– ECS Elements
ECS Supplier Name: [Add ECS supplier company name]

ECS Name: [Add ECS product name]
Polymer system: [Add trade name for polymer system]

[Specify fiber type, fiber orientation, fiber count[BG1] in
Fabric details: each orientation, mass per unit area of fabric, weave
type, and trade name]
Filler reference: [Add trade name for polymer system]
Other (e.g. primer): [Add trade names]
Surface preparation methods and

[Confirm surface preparation procedure used for
substrates qualified (state combinations
preparation of samples for lap shear tests]
tested):
Cure schedule: [Specify cure schedule used for test samples]

Maximum service temperature for Type [Maximum service temperatures (taken from standard
A defects and cure requirement: Tg-offset)]
Maximum service temperature for Type [Maximum service temperatures (taken from standard
B defects and cure requirement: Tg-offset)]
Component test completed
[Yes / No]
(See section 5.6 of this document)
5.3.2 Qualification Report – Laminate (for ECSs used on Type A

Defects)
Test Report
Property Detail Symbol Value Units
Reference
Test temperature Ttest °C / °F
Tensile strength Circumferential sc MPa / ksi
Tensile strain to failure Circumferential fc %
Tensile modulus Circumferential Ec GPa / ksi
Tensile strength Axial sa MPa / ksi
Tensile strain to failure Axial fa %
Tensile modulus Axial Ea GPa / ksi
Ply thickness tlayer mm / in
Poisson's ratio Circumferential ca 
In-plane shear modulus Circumferential G GPa / ksi
µin / in / °F
Coefficient of thermal
expansion
Circumferential c or mm /
mm /°C

µin / in / F
Coefficient of thermal
expansion
Axial a or mm /
mm / °C
Shore D hardness  
Barcol hardness  
5.3.3 Cure Data – Laminate
Cure
Cure Time
Property Symbol Temperature Value Units
(hours)
(°C)
Tg °C / °F
Glass transition
temperature
5.3.4 Qualification Report – Filler
Test Report
Reference
Compressive modulus Filler GPa / ksi
Compression strength Filler GPa / ksi
Glass transition Detail cure
Filler °C / °F
temperature schedule
5.3.5 Qualification Report – Primer (if relevant)
Test Report
Reference
Glass transition Detail cure
Primer °C / °F
temperature schedule
5.3.6 Qualification Report – Adhesion
Surface preparation and substrate details (list

substrate, preparation method, roughness values
measured and cure temperature and time before
testing
Lap shear (ambient) 
Conditioning Water at a
temperature / minimum of  °C / °F
environment 40°C / (104°F)
Air at
elevated
Conditioning
design
temperature /  °C / °F
temperature
environment
of ___°C /
(___°F)

5.3.7 Qualification Report – Short Term Pipe Spool Survival Test
Detail Test Report Reference Value Units

Percent wall loss qualified (%): %
Cure temperature and time before testing °C / °F
Test temperature °C / °F
Test pressure kPag / psig
5.3.8 Qualification Report – Energy Release Rates (For ECSs Used

on Type B Defects)
Substrate tested
Surface preparation method tested
Surface roughness measured
Number of layers used to measure LCL
Cure time and temperature before testing
Test temperature °C / °F
Property Symbol Test Report Reference Value Units
Energy release rate LCL J/m
2
List additional substrate/surface preparation combinations tested in separate tables.

Impact Test
Substrate tested
Surface preparation method tested
Surface roughness measured
Number of layers used to measure LCL
Number of layers used for impact test
Property Test Report Reference Value Units
Cure time and temperature before testing Hours °C/°F
Test temperature °C/°F
Energy Release rate calculated LCL
Confirm energy release rate is ≥ LCL 
5.4 Short Term Pipe Spool Survival Test
This section establishes and describes the test method to be used for
demonstration that an ECS is suitable for application on a type A defect. The
purpose of this test is to confirm the ECS has acceptable inter-laminar shear and
bond strength. It demonstrates the structural integrity of an ECS up to the yield
level of the original pipe.
5.4.1 Method
a) The following qualification test shall be completed using a steel

pipe of at least 100 mm (4 in.) outside diameter, and minimum
length of 6 times the outside diameter in addition to the length of
the installed laminate.

b) The steel pipe shall have a minimum specified yield strength of

235 MPa (35,000 psi), e.g., ASTM A106 Grade B or
international equivalent.
c) The ECS supplier may select the depth of the defect to be
tested, i.e., percentage of wall loss.
d) The ECS shall be qualified only for defect depths up to this
chosen depth [see (c)].
e) A defect shall be machined in the pipe to a depth equivalent to
the wall loss for which the ECS is being qualified.
- The defect shall have a length, l, of a minimum of one-half of
the outside pipe diameter along the axial direction of the pipe
spool, and a width, w, of one-fourth of the outside pipe
diameter around the hoop direction of the pipe spool.
- A radius, or a taper may be machined outside the edge of
the defect, the radius, or the taper needs to be sized to
provide sufficient transition from the defect to the pipe
surface, but the dimensions of machined (transition) area
shall not exceed 2l nor 2w, as shown in Figure 5.4.1.1 of this
document.
- To avoid stress concentrations, the interior and exterior
corners should be machined with a radius.
- The edge of the laminate shall be at least 3 times the pipe
diameter away from the ends of the pipe spool.
f) The test pressure of the spool, Pf, shall be determined by
calculation using:
2𝑡𝑠𝑠𝑎
𝑃𝑓 =
𝐷
Where:
D – is the outside diameter of pipe
t – is the wall thickness of undamaged spool
ssa – is the yield strength obtained by a tensile test or from a
mill certificate of spool pipe
g) A laminate shall be applied over the defect in the test spool and
shall survive a test to the pressure Pf.
h) The thickness of the laminate expressed in terms of number of
layers shall be calculated using the equation below, where ts is
the remaining wall thickness of the pipe spool at the defect and
sc is the characteristic tensile strength of the ECS in the hoop
direction and tlayer is a layer (ply) thickness.
1 𝑃𝑓 𝐷
𝑛𝑙𝑎𝑦𝑒𝑟𝑠 = ⌈ ( − 𝑠𝑠𝑎 𝑡𝑠 )⌉
𝑡𝑙𝑎𝑦𝑒𝑟 𝑠𝑐ℎ 2
i) sch is defined as the mean strength in the hoop direction and is

the characteristic tensile strength, sc, minus two standard
deviations.

j) The altered spool shall be pressurized to Pf, and the minimum

time to reach Pf shall be 30 s.
k) Qualification requires the altered pipe to survive loading to Pf
and show no visual signs of degradation when inspected in
accordance with ISO 24817:2017 Table 16.
2l
Defect
D l w
2w
Machined area (including taper)
Figure 5.4.1.1 – Schematic of defect to be used for short-term burst test, where l > D/2
and w > D/4
5.4.2 Test Report
A report shall be prepared giving the test conditions, depth of wall loss for
which the ECS has been qualified, details of the ECS, the pressure test
result and the maximum wall thickness that can be altered using an ECS.
5.5 Qualification for Use of ECSs on Type B Defects on Other Substrates

or Using Other Methods of Surface Preparation
Where an ECS has been fully qualified for one substrate and method of surface
preparation, this simplified qualification procedure may be used for other
combinations.
Only three tests are required to be completed. The three tests should be identical
to three of the nine tests in terms of laminate thickness and defect size used in
the full qualification test program. mean,substrate2 shall be the mean value of the
three tests completed.
The value of  for this combination of substrate and surface preparation,

LCL,substrate2, is given by:
𝛾𝑚𝑒𝑎𝑛,𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒2
𝛾𝐿𝐶𝐿,𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒2 = 𝛾𝐿𝐶𝐿,𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒1
𝛾𝑚𝑒𝑎𝑛,𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒1

5.5.1 Test Report
A report shall be prepared giving the test conditions (including test

temperature) and details of the ECS including the materials of
construction, surface preparation technique, substrate, surface roughness
measured, cure schedule, the individual data points, and the calculation of
the value of LCL,substrate2.
5.6 Qualification Requirements for Other Components
Additional testing is required to confirm the ECS procedure specification is

applicable to components with more complicated geometry. The qualification test
shall therefore be repeated for each unique fabric style provided by an ECS
supplier. Fabric style shall be defined in terms of:
- Fiber orientations
- Fiber content in each orientation
- Total fabric mass per unit area
One test shall be considered applicable to all ECS polymers that use the same
application method. For example, it only needs to be completed using a low
temperature ECS variant where both low and high temperature systems are
offered, provided both systems have been fully qualified separately otherwise,
and both systems have the same form (e.g. both are liquid epoxies). The tests
must be repeated where the ECSs utilize different polymers, for example:
- Repeat for both epoxy and polyurethane systems even if they use the
same reinforcement fabric styles
- Repeat where the form of the polymer changes between ECSs (e.g. for
liquid epoxy systems and pre-impregnated epoxy systems even if they
use the same reinforcement fabric styles)
A single pressure test shall be completed on an equal tee of either 4 NPS or 6

NPS diameter. A through-wall defect shall be created as shown in Figure 5.6.2.
The defect shall be either 20 mm (0.8”) or 25 mm (1”) in size. The defect may be
simulated by placing a circular polymeric release film of the appropriate diameter
over a smaller diameter hole prior to application of the laminate. The holes shall
not be filled or sealed by any means (mechanical or chemical) prior to application
of the laminate.

Figure 5.6.2 – Schematic of Component Test Pipe
A laminate of twice the thickness used in the qualification tests in section 5.2.3 of
this document shall be applied to the tee with overlaps satisfying requirements of
ISO 24817:2017, equation (18). The cure time and temperature shall be
equivalent to that used for the tests in section 5.2.3 of this document.
Internal pressure shall be applied and the value at which the laminate begins to
leak shall be recorded. The test will only be considered valid if the failure takes
the form of delamination of the laminate from the substrate, followed by leaking
for the edge of the laminate. Results shall be discarded if failure results through
weeping through the laminate or yielding of the substrate. In this event, a new
test shall be completed using a larger hole size.
The pressure at which the leak is recorded shall be equal to or greater than the
pressure predicted for the thickness of laminate used in the qualification tests in
section 5.5 of this document using ISO 24817:2017 equation (12), with factors fT2
and fleak set to 1 and the value of LCL derived in section 5.2.3 of this document.
5.7 Requalification
If a change or modification to the laminate materials is made, then the testing

specified in 5.7.1 and 5.7.2 of this document shall be completed.
If the modified ECS is found to be of lower performance than the original system,
then it shall be treated as a new system and validated according to section 5.2 of
this document.
If the modified ECS is found to be of higher performance than the original

system, then it may be treated as a new system and validated according to
section 5.2, or the qualification data from the original ECS may be used.

5.7.1 Requalification Tests for Type A Defects
Requalification tests shall include the testing specified in Table 5.2.2.1 and
Table 5.2.2.2 of this document.
5.7.2 Requalification Tests for Type B Defects
Requalification tests shall include the testing specified in Table 5.2.2.1,

Table 5.2.2.2 and Table 5.2.3.1 of this document. Only three pressure
tests are required and results shall be compared with γLCL of the original
ECS as set out in section 5.5 of this document.
5.8 Installation of Engineered Composite Systems
5.8.1 General Requirements
a) The installation of an ECS shall meet the requirements of ISO

24817:2017 Section 8 and Annex J, and any additional
requirements or limitations defined within this document.
b) ECS installer organizations shall have a documented installation
procedure that ensures the successful and repeatable alteration
of pressure equipment utilizing the ECS.
c) The ECS supplier shall provide full installation instructions.
d) Personnel involved in the installation of an ECS shall be trained
and qualified according to Section 7 of this document.
5.8.2 Responsibilities
Responsibilities shall be defined and assigned within the work pack and
accepted by all parties involved. In addition to the responsibilities defined
in the work pack:
a) The owner-user is responsible for acceptance of the following

prior to using the ECS:
i. ECS installation procedures

ii. Method statement and work pack
iii. Inspection and test plan (ITP)
iv. Acceptance and sign-off of ECS alteration report
b) The inspector is responsible for all verifications as defined within

the inspection and test plan (ITP) and Section 8 of this
document.

5.8.3 Installation Instructions
The installation instructions shall meet the requirements referenced under

section 5.8.1(a) of this document. The installation instructions shall be the
same as those used in the ECS qualification. The installation instructions
shall be incorporated into the installation procedures.
5.8.4 Additional Requirements
In addition to the requirements referenced under the section 5.8.1(a) of

this document, any additional requirements specified herein, or project
specific requirements specified by the owner-user or parties involved in
the installation process shall be defined within the ECS installer
organization’s work pack. The additional requirements shall not affect, or
overrule, the requirements of the installation instructions used in the ECS
qualification. In the event of conflict the ECS supplier shall be consulted.
As a minimum the additional requirements shall include the following:
a) Requirement for the ECS installer organization to hold a quality

management system certificate of authorization permit covering
the applicable scope of work
b) Addition of a section to the ECS installer organization’s QMS to
cover the scope of work related to engineered composite
systems
c) Ensuring competencies of personnel for installation are in
accordance with Section 7 of this document
d) Development of the alteration ITP
e) Responsibility for providing risk assessment information
including hazards for the alteration location and environmental
conditions
f) Responsibility for providing heating and hoarding to facilitate the
installation of laminate
g) Ensuring the completion of the alteration to the requirements of
the registered alteration procedure
h) Providing product specific instructions for use and application;
instructions shall match those used in the ECSPS and may
include unique or one-off application guidelines
i) Specify the time between the surface preparation and first
coating application based on site conditions; the time shall be as
short as possible and shall not exceed the lesser of the
maximum time specified within the installation procedure (if
specified) or the maximum time specified per ISO 24817:2017
Annex J

6.0 DESIGN METHODOLOGY
ECS design requirements shall be determined by applying the methods given in ISO
24817:2017 Section 7.5, implemented as described here. All requirements of ISO
24817 Section 7.5 not specifically mentioned here shall be applied as written in the
standard.
6.1 Owner-User Requirements
The owner-user has the ultimate responsibility for all pressure equipment within
their care and control. The owner-user is required to determine that the ECS is
suitable for intended application and service conditions, and that the ECS
provides for an equivalent standard of safety to the altered pressure equipment.
In addition, the owner-user shall ensure that the use of ECS and the subject
equipment is managed safely and meets or exceeds all technical, safety, and
regulatory requirements. The owner-user shall have implemented an effective
quality management system (AQP-8000 series PEIMS / IMS) that meets and
conforms to the requirements defined in Section 9 of this document.
6.1.1 Integrity Assessment
The owner-user shall perform an integrity assessment of the damaged

equipment and perform a preliminary root cause analysis and document
the results per the owner-user’s quality management system (AQP-8000
series PEIMS / IMS) and management of change procedure.
6.1.2 Risk Assessment
The owner-user shall perform a risk assessment, and accept the risks
related to installation and maintenance of an ECS. The owner-user may
seek input from the ECS supplier (where required) as per ISO 24817:2017
Section 7.1.
6.1.3 Maintenance and Monitoring
The ECS and the subject pressure equipment shall be maintained and
monitored to ensure the continued safe operation until a permanent repair,
alteration, or replacement can be made and the ECS safely removed. A
description of the methods of maintenance and monitoring that will be
used while the ECS is installed shall also be established. The frequency of
maintenance and monitoring shall consider the type of ECS, accessibility,
process fluid, service conditions, and the risk assessment results. ECS
suppliers shall provide recommendations to the owner-user for
maintenance and monitoring of the ECS that shall be considered by the
owner-user and implemented into the owner-user’s maintenance and
monitoring plan.

6.1.4 Removal of Engineered Composite Systems
The owner-user shall specify a date when the ECS will be removed and
the pressure equipment permanently repaired, altered, or replaced (i.e.
shall specify the design lifetime of the ECS).
At the end of the design lifetime, the owner-user shall:

a) Remove the ECS and permanently repair, alter, or replace the
pressure equipment; or
b) Re-evaluate the ECS design to determine if the design lifetime can
be extended. If the ECS design lifetime can be extended, the
owner-user shall:
i. Compile all supporting records and assessments used to
revalidate the ECS design lifetime,
ii. Define and document inspection and monitoring
requirements to support the extended design lifetime, and
iii. Complete and file a new AB-323, Alteration Report for
Installation of ECSs as per the owner-user quality
management system (AQP-8000 series PEIMS / IMS).
6.1.5 Record Keeping Requirements for ECS
The owner-user shall keep all pertinent information regarding each ECS
until the ECS is removed and the pressure equipment is repaired, altered,
or replaced. The records of each ECS shall be available for ABSA audits.
In addition, each record shall include:
a) Risk assessment
b) Technical justification
c) Detailed design records
d) Root cause analysis
e) Installation procedure (including QA records)
f) Maintenance and monitoring records
g) Re-evaluation records
h) Removal confirmation date by the owner-user
i) Certificate of alteration
j) Any other pertinent information as may be needed to establish
evidence of safe installation and operation of the ECS and
associated equipment
6.1.6 User Design Specification (UDS)
The owner-user shall supply to the ECS designer UDS stamped by a

Professional Engineer. The UDS shall include data required by ISO
24817-2017 Section 7.4, ISO 24817-2017 Annex A, details of the service
environment where the ECS is to be applied, and any other details that
must be considered in the ECS design.

6.2 Design Conditions
The pressure equipment design conditions, as registered with ABSA, shall be

used for design of the ECS. In addition, the ECS shall be designed to sustain
conditions at the minimum test pressure registered with ABSA plus adequate
margin, regardless of any pressure test exemption provided for in Table 8.3 of
this document. The maximum permitted test pressure (i.e. minimum required test
pressure plus allowable margin) considered shall be clearly documented to
ensure the pressure is not exceeded during testing.
6.3 Environmental Compatibility
This section is intended to supplement ISO 24817:2017 Section 7.5.2.
Where the environment is strongly acidic (pH < 3.5), strongly alkaline (pH > 11),
highly saline, or is a strong solvent, e.g. methanol, glycol, benzene and toluene in
concentration greater than 25%; and the repair will be exposed to the line
contents (type B defects only), the ECS supplier shall provide written evidence to
demonstrate the basis on which they have determined the compatibility with the
ECS. This may include:
a) Testing (in which case the test details including test method, environment,
temperature, exposure times, and properties followed must be specified)
b) Experience (in which case successful experience must be documented
including environment, temperature, and time in service)
c) Expert opinion (in which case the basis for the decision should be
documented)
6.4 Design Temperature Effects
The requirements of ISO 24817:2017 shall be complied with as follows:
a) Tg shall be taken as the value quoted in qualification testing

b) fT2 in Table 8 shall be calculated as follows:
𝑓𝑇2 = 0.0000625[𝑇𝑚 − 𝑇𝑑 + (𝑇𝑡𝑒𝑠𝑡 − 𝑇𝑎𝑚𝑏 )]2 + 0.00125[𝑇𝑚 − 𝑇𝑑 + (𝑇𝑡𝑒𝑠𝑡 − 𝑇𝑎𝑚𝑏 )] + 0.7

6.5 Cure Requirements
The post-cure heating requirements for the ECS shall be specified in the output
of the ECS design assessment and be part of the ECSPS. Post-cure heating
requirements are defined below:
6.5.1 Designs for Type A Defects
The minimum cure used in ISO 24817:2017 Annex C qualification testing

shall be applied to all ECSs unless the ECS supplier specifies a higher
temperature post-cure is required.
6.5.2 Designs for Type B Defects
The laminate shall be heated in line with a post-cure cycle verified during
qualification testing to achieve a glass transition temperature of at least
20°C above the operating temperature if:
a) the line is out of service when the ECS is applied, and

b) the pressure equipment operating temperature is ≥ 30°C above the
installation temperature.
Where no verified heating cycle is available then the laminate shall be

heated to at least the operating temperature of the pressure equipment
and held there for at least four hours unless the ECS supplier specifies a
higher temperature or longer hold are required.
If the ECS design temperature is ≥ 30°C above the operating temperature

then the laminate shall be cured in line with a post-cure cycle verified
during qualification testing to achieve a glass transition temperature of at
least 20°C above the design temperature.
Where no verified cycle is available then the laminate shall be heated to at

least the design temperature of the line and held there for at least four
hours unless the ECS supplier specifies a higher temperature or longer
hold is required.
Post-cure heating shall not be attempted on pressure equipment that is in

service.

Is the line going to be

No post-cure required.
out of service when No
Allow to cure on line.
the repair is applied?
Yes No
Is the repair operating Is the repair design

temperature °C temperature 30°C
No
above the installation above the operating
temperature temperature
Yes Yes
Is the repair design Post-cure to glass

temperature 30°C transition temperature
above the operating >20°C above the design
temperature temperature by following
a post-cure cycle verified
No
Yes
during qualification
testing.
Post-cure to glass
If no cycle is available
transition temperature
then heat to the design
>20°C above the
temperature and hold for
operating temperature
at least 4 hours unless
by following a post-cure
the Repair System
cycle verified during
Supplier specifies a
qualification testing.
higher temperature or
If no cycle is available
longer hold are required
then heat to the
operating temperature
and hold for at least 4
hours unless the Repair
System Supplier specifies
a higher temperature or
longer hold are required
6.6 Design Based on Substrate Load Sharing
ISO 24817:2017 Equations 1, 2, 5, and 6 shall not be used.
6.7 Design Based on Laminate Allowable Strains (Defect Type A)
All ECSs must be supported by calculations using ISO 24817:2017 equations 3,

4, 8, and 9.
Calculated laminate thicknesses shall be < D/12 for pipes of 6” outside diameter
or greater.

Calculated laminate thicknesses shall be < D/6 for pipes below 6” outside
diameter.
The value of T in equation 10 shall be calculated as the difference between the

temperature at which the laminate first hardens and the design temperature. If
the laminate is applied at ambient temperatures and hardens before being post-
cured, then the ambient temperature shall be used as the lower value.
6.8 Design Based on Allowable Stresses Determined by Performance

Testing (Defect Type A)
ISO 24817:2017 Section 7.5.6 shall not be used.
6.9 Design of ECSs for Through-Wall Defects (Defect Type B)
Refer to Annex E of this document for guidance on the design for type B
through-wall defects.
6.10 Axial Extent of Repair
The laminate shall extend beyond the defect by at least the maximum of 50 mm
and the amount determined using ISO 24817:2017, equation 18.
The overlap shall also comply with the considerations in equation 19 when ECSs
have been designed using ISO 24817:2017, equation 12.

7.0 COMPETENCIES OF INSTALLERS AND INSPECTORS
This section provides guidance on the training, qualification, and competency

certification of installers and inspectors of ECSs. This section is intended to supplement
ISO 24814 Annex I.
Owner-user and installer organizations shall establish and document the competency
requirements for all personnel involved with the installation and inspection of ECSs. The
competency requirements shall consider elements such as qualifications, experience,
and skill in assessing and certifying the competency of those who install and inspect
ECSs.
7.1 Requirements and Responsibilities of Installer Organizations
Installer organizations shall have verifiable processes and procedures for

training, qualification, and certification of all personnel involved in the installation
of ECSs. Competency process and procedures, as a minimum, shall address the
following elements:
7.1.1 Training
a) The installer organization is responsible for the training of all

personnel involved in the application of ECSs as per the
manufacturer’s instruction.
b) Qualified trainers shall be used to train installers and other
supervisors.
c) Competency shall be established, and the minimum training
requirements of ISO 24814 Annex I shall apply.
7.1.2 Qualification
a) The installer organization shall have a qualification

procedure / process for each specific installation technique and
ECS.
b) This qualification process shall be documented and available to
the owner-user for review.
7.1.3 Training Records
a) The installer organization shall keep a verifiable training record

for all personnel that perform ECS installations.
b) The training records shall be kept in accordance with the
installer organization’s QMS.

7.1.4 Documented Evidence and Maintenance of Competency
a) The ECS installer organization shall have a complete record of

competency for all personnel that perform ECS installations.
b) Each record, at a minimum, should include certifications,
training, and a record of completed installations.
c) The record shall be reviewed in accordance with the timeline
specified in the installer organization’s quality management
system.
d) The record shall be available to the owner-user for review and
acceptance.
e) The ECS installer organization shall revalidate the competency
of the installation personnel that have not been actively involved
in ECS applications for 12 months or longer.
7.2 Requirements and Responsibilities of Owner-Users
Owner-user organizations shall have verifiable processes and procedures for

training, qualification, and certification of all employed personnel involved in the
installation of ECSs. Owner-user organizations shall also have processes and
procedures to verify the training and competency of all personnel contracted to
perform ECS installations and inspections. Competency process and procedures,
as a minimum, should address the following elements:
7.2.1 Training
a) The owner-user is responsible for the training of inspectors in

the application and inspection of ECSs.
b) The inspector at a minimum shall have training and certification
for in-service pressure equipment inspection.
c) The inspector shall complete basic training in the application of
engineered composite systems.
7.2.2 Training Records
a) Training records shall be kept in accordance with the owner-

user’s quality management system (AQP-8000 series PEIMS /
IMS).

8.0 EXAMINATION AND TESTING
This section provides guidance on the pre-installation, in-process, and post-installation

examination and testing requirements for ECSs. This section is intended to supplement
ISO-24817-2017 Section 9.
The owner-user is responsible for assuring that the overall quality control, detailed
examinations, tests, and retention of records associated with alterations using ECSs are
performed. All records shall be retained for the duration of the installed life of the ECS.
The owner-user may designate specific examination and testing activities to responsible
parties. The responsible parties for each criterion identified below shall be identified on
an inspection and test plan acceptable to both the owner-user and installer organization
prior to commencing the alteration.
8.1 Pre-Installation
Table 8.1 of this document provides recommendations on the minimum

pre-installation activities that should be performed on the substrate and laminate
prior to installation.

Table 8.1 – Pre-Installation Examination and Testing Recommendations
Section Criteria Allowable Limits Method

A baseline inspection shall be conducted as As per owner-
Baseline
per the owner-user documentation user
Inspection
requirements requirements
Design In accordance with the ECS design and
Visual
Conditions1 registered ECSPS
In accordance with the ECS design and
Wall Thickness UT, RT
registered ECSPS
Surface In accordance with the ECS design and Calibrated
Temperature registered ECSPS instrument
Visual
comparison
(Prior to ECS Application)
with ISO
Surface In accordance with the ECS design and
8501-1 or
cleanliness registered ECSPS
equivalent
Substrate
SSPC or NACE
standards
Visual, replica
Surface tape with
In accordance with the ECS design and
preparation and micrometer,
registered ECSPS
anchor profile digital surface
micrometer
Defect nature and dimensions are within the
Defect limits of the ECS design, registered ECSPS, Visual, UT, RT
and installer competency
Free of protruding sharp edges and in
Geometry accordance with the ECS design and Visual
registered ECSPS
Confirm that any leak sealing device used
has stopped the leak;confirm size of leak
Leaking defect Visual
sealing device is within defect size
considered in design of ECS
Packaging / Sealed, clear labels with batch number and
Visual
Materials
Containers expiry (within date)

ECS
Fabric No fabric defects2 Visual

Epoxies No crystallization Visual
Notes:
1. Design conditions include material, design pressure, design temperature, MDMT.
2. Fabric defects include creases, stretched fibers, tearing, discoloration, changes in
pattern, changes in color, changes in weave across the material area, and other visible
manufacturing defects or physical damage.

8.2 In-Process
Table 8.2 of this document provides recommendations on the minimum activities

that should be performed on the substrate and laminate during installation.
In-process activities include curing time.
Table 8.2 – In-Process Examination and Testing Recommendations

Ensure above the greater of the minimum
Ambient
Environmental
allowable temperature for mixing epoxies as Calibrated

Conditions
Temperature &
specified by the Manufacturer and the instrument
Humidity
atmospheric dew point temperature.
Area is shielded from adverse weather
Weather
conditions, including moisture for the Visual
Conditions
duration of the installation.
In accordance with the ECS design, the
Surface Calibrated
registered ECSPS, and at least 3°C above
Temperature instrument
Substrate
the dew point.

Free of protruding sharp edges and in
Geometry accordance with the ECS design, registered Visual
ECSPS, and installer competency.
Leaking Defect Zero leakage during application of ECRS Visual
Laminate
Application Visual
In accordance with the ECS design.
of ECS1
Surface
Resin-
Layer
Rich
Surface & Ambient In accordance with ECS design, curing Calibrated

Temperature schedule, and registered ECSPS instrument
Notes:
1. Application of ECSs includes installation technique, mixing ratio, laminate length, layer
count, fabric orientation, pits, wrinkles, dry spots, foreign matter, and polymer color.
8.3 Post-Installation
Table 8.3 of this document provides recommendations on the minimum post-

installation activities that should be performed on the surface of the installed ECS
and the interface or bond between the substrate and the installed ECS.

Table 8.3 – Post-Installation Examination and Testing Recommendations
Internal Corrosion In accordance with the ECS design RT

(Under ECS)
Substrate
A baseline inspection shall be conducted as Per owner-

Baseline
per the owner-user documentation user
Inspection
requirements requirements
No leakage and/or growth exceeding the
Defect growth RT, PA, PAC
design defect size
Visual, Tap
Substrate
Delamination /
and ECS
Between
None allowed Test, RT, PA,

Bond
Edge Lifting
PAC
External Corrosion None allowed Visual
Verify axial extent, taper length, and
Geometry laminate thickness are as per the ECS Visual
design
Pressure In accordance with code of construction and Per code of
Laminate
Test2 the ECS design construction

Corrosion Verify that adequate corrosion protection is
Visual
protection reinstated as per the ECS design
Damage Verify that adequate protection is present to
Visual
Protection prevent damage of the installed ECS
Identification of Verify that adequate markings are present
Visual
alteration location to identify the alteration area
Surface
Reference Table 16 of ISO 24817-2017 Visual
Surface Layer
Defects1
Resin Rich
(Cured)
Fabric In accordance with the ECS design and

IR device
Orientation registered ECSPS
Shore D
In accordance with material specifications,
Surface Hardness Hardness
ECS design, and registered ECSPS
Testing

Notes:
1. Surface defects include pits, wrinkles, dry spots, foreign matter, polymer color, impact
damage, etc.
2. Pressure testing is required except as exempted below.
The owner-user may waive the pressure test when the ECS is installed on live
pressure equipment. In order to waive the pressure test, the owner-user shall ensure
that the following additional requirements are met:
a. The owner-user shall perform a risk assessment to assess and accept the risks
related to waiving of the pressure test.
b. A service test shall be performed after installation of the ECS utilizing process
fluid in accordance with owner-user specification for not less than 10 minutes.
c. Additional daily monitoring shall be performed during the first two weeks of
service.
9.0 QUALITY MANAGEMENT SYSTEM REQUIREMENTS
Organizations involved with the design, manufacturing, installation, and use of an

engineered composite system shall maintain a quality management system that will
establish that all of the requirements of the applicable regulations, codes, and standards
will be met.
9.1 ECS Suppliers
The owner-user and the ECS installer organization shall be satisfied that the
ECS Supplier has implemented an effective quality management system (ISO
9001 or equivalent).
The ECS supplier’s quality management system shall include appropriate

controls of the composite system manufacturing process to ensure quality. The
quality management system shall address the manner in which the organization
controls the entire composite system manufacturing process, including but not
limited to, the control of design (i.e. development of material specifications),
material selection, procurement, manufacturing, inspection, final product testing,
traceability, certification, and marking with the batch/lot number and production
date. The ECS supplier’s QMS shall also include processes and procedures to
address the requirements of Section 5.1.5 of this document.
9.2 ECS Installer Organization
ECS installer organizations shall hold an Alberta quality management system

certificate of authorization permit, the scope of which includes the work to be
carried out.

The quality management system shall include appropriate controls of the

composite system installation process to ensure quality. The quality management
system shall address the manner in which the organization controls the entire
composite system installation process, including but not limited to the control of
design, material selection, procurement, composite system procedure
qualification, installation, inspection, testing, marking, certification, and
qualification of all personnel involved in the installation of composite systems as
per the requirements of Section 7.1 of this document.
9.3 Owner-Users
Owner-users who perform or contract the design, manufacturing, and installation

of composite systems shall hold an Alberta quality management system
(AQP-8000 series PEIMS / IMS) certificate of authorization permit, including
written processes and procedures for the control of design, material selection,
procurement, installation, inspection, testing, marking, certification, post-
installation integrity management, and removal of composite systems, and
qualification of all personnel involved in the installation of composite systems as
per the requirements of Section 7.2 of this document.

A.0 ANNEX A (NORMATIVE) – Applicability
This document is applicable to a variety of components and defects. The following

sections summarize the types of defects that can be temporarily altered using ECSs for
each pressure equipment category.
A.1 Pressure Piping Systems
A.1.1 ASME B31.1 – Power Piping
Pressure piping systems designed and constructed for ASME B31.1

power piping and boiler external piping applications shall not be altered
using ECSs.
ASME B31.1 non-boiler external piping may be altered using ECSs on a

case-by-case basis when accepted by ABSA.
A.1.2 ASME B31.3 – Process Piping

process piping applications may be altered using ECSs. The scope of
ECS alterations are limited to the defects and fluid services permitted in
the Table A.1.
Table A.1 – ASME B31.3 Defect Applicability for Metallic Substrates
Fluid Service (Per ASME B31.3)

(P>3500 kPag & T>250°C)
(P≤3500 kPag & T≤250°C)
Temperature
Category ‘D’
Category
Pressure
Elevated
Normal
Normal
Type of Defect
Purity
High
High
‘M’
(Note 1)
General wall thinning Y Y N N N N N

Local wall thinning Y Y N N N N N
Pitting Y Y N N N N N
Gouges / dents N N N N N N N
Blisters Y Y N N N N N
Laminations Y Y N N N N N
Circumferential cracks N N N N N N N
Longitudinal cracks N N N N N N N
Through-wall penetration (Note 2) Y N N N N N N
Y - Permitted / N - Non-permitted

Notes:
1) The defect size permitted for temporary alteration using an ECS shall be established
during design of the ECS.
2) Leaks resulting from through-wall penetrations shall be stopped before application of
the ECS.
A.1.3 ASME B31.5 – Refrigeration Piping

refrigeration piping applications may be altered using ECSs on a
A.1.4 ASME B31.9 – Building Services Piping

building services piping applications may be altered using ECSs on a
A.1.5 CSA Z662 – Steam Distribution Pipelines
Use of ECSs on piping systems designed and constructed for CSA Z662
steam distribution pipeline applications, as defined by AER Directive 077,
is not within the scope of this document.
A.2 Boilers
Boilers and boiler external piping shall not be altered using ECSs.
A.3 Pressure Vessels, Thermal Liquid Heating Systems, and Fired-Heater

Pressure Coils
Pressure Vessels, thermal liquid heating systems, and fired-heater pressure coils
shall not be altered using ECSs.

B.0 ANNEX B (INFORMATIVE) – REGISTRATION REQUIREMENTS
Registration of an ECS is achieved through a two step process:
- ECS procedure specification (ECSPS) registration; and

- Registration of an application-specific alteration procedure (i.e. design and
installation procedure)
Both registrations shall be obtained prior to starting any physical work. A submitter of an
ECSPS is responsible to communicate to the owner-user any applicable conditions
and/or limitations of the procedure registration.
For complex designs, an Alberta safety codes officer may require the involvement of a
Professional Engineer in accordance with applicable provincial legislation.
Refer to Figure B.4 of this document for guidance on the typical ECS workflow process
and responsibilities associated with ECS activities.
B.1 ECS Procedure Specification (ECSPS) Registration
ECSPSs shall be submitted to the ABSA for review and registration. The
information to register this type of procedure includes the following:
a) The engineered composite system procedure specification (ECSPS):
The contents of the ECSPS shall meet the requirements of this document
and describe all variables for each ECS. These variables shall align with
the ECS qualification, design requirements in Sections 5.0 and 6.0 of this
document. The information required to be in the ECSPS may be in any
format, written or tabular, to fit the needs of each organization, as long as
every variable is included or referenced.
b) Supporting procedure qualification records (ECSPQRs) covering the

full range of the ECSPS:
The contents of the ECSPS shall meet the requirements of this document
and document all variables for each test coupon. All variables, if recorded,
shall be the actual variables (including ranges) as determined from the
test coupons. If variables are not monitored during installation on the test
coupon, they shall not be recorded. It is not intended that the full range of
a given range of variables to be used in production be used during
qualification, unless required due to a specific variable or based on
direction from the ECS supplier. The information required to be in the
ECSPQR may be in any format to fit the needs of each organization, as
long as every variable is included. Also the type of tests, number of tests,
and test results shall be listed in the ECSPQR.

c) Installation instructions provided by the ECS supplier:
The installation instructions shall include batch testing reports of the

qualified ECS materials in accordance with Section 5.1.5 of this document.
d) Any other information requested by ABSA to survey the ECSPS and

determine whether it is suitable for registration.
B.2 Alteration procedure registration
The purpose of the alteration procedure registration is to confirm that the owner-
user has completed the necessary steps to install an ECS safely. The information
to register an ECS alteration procedure includes the following:
a) Owner-user’s name
b) Plant location and address
c) Code of construction, including the relevant edition which the pressure
equipment is compliant with
d) ECS installation location
- For piping, the line number and copies of the registered line list,
P&ID, and isometric drawing showing the installation location
e) The design pressure and temperature
f) Details on the damage mechanism and size / type of defect
g) Details of the ECS design, dimensions, and installation requirements
h) Material specifications
i) ECS procedure specification number
j) Inspection and testing details
k) Design calculations, including the design life of the composite laminate
l) A report of physical tests conducted for the purpose of establishing the
working pressure of the altered pressure equipment (if applicable)
m) Risk assessment summary, including the root cause
n) Maintenance and monitoring details, including for emergency mitigation
o) Timeline for the permanent repair, alteration, or replacement of the
pressure equipment
Any other information that is necessary to determine if the ECS is suitable for
registration.
B.3 ECS Alteration Report – Inspection and Certification
ABSA Form AB-323: Alteration Report for Installation of Engineered Composite

Systems, shall be used to document and certify each alteration using an ECS in
Alberta. A sample AB-323 can be found in Figure C.1, Annex C of this document.
A fillable version of this form is available on ABSA’s website at www.absa.ca.

The installer organization is responsible for completing the ECS alteration report
and ensuring that the report:
a) Is certified by the installer organization

b) Is certified by an in-service inspector that is certified by the ABSA
c) Contains an owner-user’s statement, signed by an official, or designate, of
the owner-user having responsibility over the integrity and regulatory
compliance of the altered pressure equipment. The owner-user’s signature
provides for the:
- Acceptance of the installed ECS and all risks associated with its
use in the alteration to ensure safe operation of the subject
pressure equipment
- Certification that the ECS installation details have been reviewed
and found to comply with the user’s design specification and
registered alteration procedure design

B.4 Typical ECS Process Flow Diagram
Figure B.4 – Typical ECS Process Flow Diagram

C.0 ANNEX C (INFORMATIVE) – SAMPLE FORM
The following sample form is provided in this Annex:
Figure C.1 – Alteration Report for Installation of Engineered Composite Systems

ALTERATION REPORT
FOR INSTALLATION OF ENGINEERED COMPOSITE SYSTEMS AB-323 2021-03
(Name and Address)

Alteration
Organization Alteration Org. Job No.: Provincial Quality Prog. Expiry Date:
No.:
(Name and Address)
Owner
Provincial Quality Prog. No.: Expiry Date:
(Address)
Location of Installation
Pressure Piping
Provincial Piping Design Registration No. Composite System Design Responsibility
Owner Alteration Organization
Engineered Composite System Procedure Specification
Provincial Registration No. Engineered Composite System Procedure Specification No.(s) Used
Contractor:
Provincial Registration No. Engineered Composite System Procedure Specification No.(s) Used
Owner:
Construction Code
Construction Code:
Lines
Min and Max Min and Max
Drawing & Rev. Fluid (air / Des. Press. C.A Original Pipe NPS &
Des. Temp. Oper. Temp. Pipe Mat’l Spec & Grade Pipe Coating (existing) NDE
No., and Line No. steam / etc.) (kPa) (mm) Schedule
(°C) (°C)
Description of Defect Area

Type of Defect:
Nature of Defect:
Size of defect at time of installation (Area / Depth):
Max size of defect per registered alteration procedure (Area / Depth):
Cause of defect (Corrosion / Erosion):
Description of Work Performed

Document No. of the registered alteration procedure: Registration Letter Date:
Surface Roughness / Anchor Profile Specification: Time from completion of surface preparation to application of 1 st layer:
Ply or Layer Thickness (mm): Layer and reinforcement orientation:
Number of layers installed: Installed laminate thickness (mm):
Installed laminate length (mm): Installed taper length (mm):
Minimum Temperature During Curing (°C): Maximum Temperature During Curing (°C):
Curing Time (hrs): Post cure barcol or shore harness measurement:
Laminate design lifetime:
Description of Environmental Conditions During Installation

Minimum Substrate Temperature (°C): Maximum Substrate Temperature (°C):
Minimum Ambient Temperature (°C): Maximum Ambient Temperature (°C):
Pipe pressure during installation (kPag): Pipe contents during installation:
Humidity (%): External Environment:

ALTERATION REPORT
FOR INSTALLATION OF ENGINEERED COMPOSITE SYSTEMS AB-323 2021-03
Non-Destructive Examination (Specify type and extent)
Pressure Test
Test Pressure (kPag): Test Type (i.e. Code, service leak, etc.): Test Medium:
Remarks
Certificate of Compliance
I certify that the statements made in this Report are correct and that all design, material, construction and workmanship on this alteration conform to the requirements of the
Provincial Regulations.
Alteration Organization Name: Quality Program Reg’n No.: Program Expiry Date:
Authorized Representative:
Name Signature Date
Date work was completed

Certificate of Inspection
I have inspected the alterations described in this report. To the best of my knowledge, this work has been done in accordance with the Provincial Regulations.
Authorized Inspector or Certified In-Service Inspector:
Name* Signature Date
*Include inspector’s National Board commission number and/or provincial certificate number.
Owner’s Statement
As an official, or designate, of the Owner, having responsibility for the integrity and regulatory compliance of the pressure equipment, I accept use of the installed engineered
composite system and all risks associated with its use in this alteration to ensure safe operation of the subject pressure equipment.
I also certify that I have reviewed the details of the ECS installation and confirm that it complies with the User’s Design Specification and registered design specific to this
alteration.
Official, or designate, of the Owner:
Name* Function / Title Signature Date
Report Received by Authorized Inspector:
Name* Signature Date
*Include inspector’s National Board commission number and/or provincial certificate number.

D.0 ANNEX D (INFORMATIVE) – ECSPS AND PQRs
This annex provides guidance on the minimum information to be documented in each

engineered composite procedure specification.
D.1 ECS Procedure Specification
The ECS procedure specification (ECSPS) is a written document providing

direction to the person applying the ECS.
The ECS procedure specification used by the organization having responsibility

for operational control of the ECS process (i.e. ECS installer organization) shall
have been qualified by that organization. ECS procedure specifications address
the conditions (including ranges, if any) under which the application of the ECS
must be performed.
The ECS procedure specification, at a minimum, shall demonstrate that the ECS
meets the requirements of this document, and contains the following information:
a) Name of the organization responsible for the ECSPS

b) Name, signature, and date of the organization’s employee approving
the ECSPS
c) ECSPS name / number, revision, and date
d) The applicable construction code(s) where the ECSPS will be used
e) Substrate geometry (i.e. straight piping, tee, elbow, etc.)
f) Supporting procedure qualification record numbers
g) Design and environmental condition data:
i. Maximum design pressure and temperature
ii. Minimum design temperature
iii. Minimum / maximum substrate temperature during installation
iv. Minimum / maximum ambient temperature during installation
v. Humidity range (percentage)
vi. Other external environmental restrictions
h) Substrate data:
i. P-no. and group no. or material specification (i.e. type, grade,
UNS number)
ii. Geometry limits (i.e. minimum and maximum diameter)
iii. Defect types
i) Laminate data:
i. Manufacturer’s name and specification for each raw material
(i.e. fiber, fabric, resin)
ii. Ply or layer thickness
iii. Layer and reinforcement orientation
iv. Minimum / maximum number of layers
v. Mechanical property ranges:

- Circumferential direction (tensile modulus, strain to failure,

tensile strength, Poisson’s ratio, thermal expansion
coefficient)
- Longitudinal direction (tensile modulus, strain to failure,
tensile strength, thermal expansion coefficient)
- Shear modulus
- Barcol or Shore hardness (of cured laminate)
- Glass transition temperature or heat distortion
temperature for each cure temperature / time combination
- Peak exothermic temperature measured for the glass
transition temperature sample
- Impact performance
j) Substrate surface preparation technique:
i. Surface roughness / anchor profile specification
ii. Surface preparation method and medium used
iii. Time from completion of surface preparation to application of
first layer
iv. Short-term lap strength
v. Long-term lap strength
k) Curing data:
i. Minimum / maximum curing temperature
ii. Minimum / maximum curing time
l) Any other information that is necessary to determine if the ECSPS is
suitable for registration.
D.2 ECS Procedure Qualification Record (PQR)
The PQR is a record of variables recorded during the qualification of the ECS by
the ECS installer organization, using test coupons. It also contains the test
results of the tested specimens by the ECS supplier. Recorded variables for each
PQR normally fall within a small range of the actual variables covered by the
ECSPS.
The ECS PQR, at a minimum, shall demonstrate that the test coupon installation
meets the requirements of this document as derived from the PQR test coupons,
and contain the information required by Sections 5.2, 5.3, 5.4, 5.5, 5.6, and 5.7 of
this document.

E.0 ANNEX E (INFORMATIVE) – DESIGN CONSIDERATIONS FOR PRESSURE

CONTAINMENT
ISO 24817 and ASME PCC-2 include four calculation methods that can be used to
reliably assess the leak-sealing pressure limits of a repair. This annex explains the
assumptions and limitations of the models and gives guidance on how to select and
apply them accordingly.
E.1 Recommendations for Model and Defect Size Selection
The objective of the following graphics is to give a guide on how to select the
most appropriate model provided by the standards for common applications.
Guidance is also given on selecting a relevant defect size to use in the
calculations to ensure the predicted repair performance will match that achieved
in practice. The following text refers to equation numbers in ISO 24817:2017 and
uses SI units only for clarity.
It is recommended that the size of defect used in ISO 24817:2017 formulas (12)
to (15) should be at least 15mm. Defect sizes below 15 mm may be considered if
supported by engineering, and analyses acceptable to ABSA are provided.
Defect sizes below 10 mm shall not be used.
The energy release rate value used with ISO 24817:2017 equation 14 shall be
the lower of the value derived in qualification testing and 200 J/m2 unless
supported by engineering, and analyses acceptable to ABSA are provided.
E.1.1 Scenario 1 – Leaks in Plain Pipe
Local area of corrosion size, dcor, with a single

perforation (hole), size h.
If the damage was caused by internal

corrosion then the size of the perforation is
clearly defined, although it will continue to
grow over time. The predicted size of h at ‘end
of repair life’ must be used for the calculations.

If the entire area around the pin hole can be

fully prepared by the qualified method then the
repair thickness can be calculated using
equation 12 of ISO 24817:2017.
d should be considered in increments of 5 mm.
If the corroded area is filled with epoxy putty

then the extent of putty must be taken as the
defect size, d = dcor.
If the hole is localised with good metal

surrounding it then it is reasonable to assume
d = h.
If the defect area cannot be prepared (perhaps

due to the thin wall, for example) then the
defect size should be set to the size of the
area unprepared, d = dcor.
Equally, if the area of corrosion is deep and

the perforation is in the center then the repair
will only be bonded around the full extent of
the defect and the size of defect modelled
should be d = dcor.
If the entire area around the defect cannot be

prepared then this must be modelled using
ISO 24817:2017 equations 13 and 14 (the
lower thickness calculated can be used) of ISO
24817:2017, even though the perforation is
very small. The repair is only bonding to well-
prepared pipe in the areas shown, creating a
slot defect with width w.
Model using equations 13 and 14 of ISO

24817:2017.
Set w as the width of pipe unprepared.

If a stop-gap is applied over a small perforation

then the defect must be modelled using
equations 13 and 14 (the lower thickness
calculated can be used) of ISO 24817:2017,
with the slot width, w, being taken as the size
of the stop-gap, even though the perforation is
very small.
Model using equations 13 and 14 of ISO

24817:2017.
Set w large enough to cover the stop gap and

all fairing.
Where there are multiple perforations close to

each other then the defect size should be
selected to encompass all perforations and
may be assessed using equation 12 of ISO
24817:2017.
Defects may be treated as individual defects

provided they are surrounded by fully-
prepared, sound metal and are spaced by
more than 4d.
Model using equation 12 of ISO 24817:2017.
Set d as the diameter of a sufficiently large

circle to enclose all perforations (if interacting)
– do not use the side of a square for this value.

E.1.2 Scenario 2 – Leaks on Girth Welds
This scenario constitutes a pin hole on a girth

weld.
DO NOT use equation 12 of ISO 24817:2017.
Use equations 13 and 14 of ISO 24817:2017,

taking the smallest repair thickness.
Selection of the size w to use should include

an allowance for fairing and stop gaps.
ISO 24817 mandates a minimum value of w of

15 mm but it is considered unlikely that this will
be sufficient from a practical view point. It is
recommended that 25 mm is also checked to
gauge how close to the limits a repair might
be. If the required thickness increases to an
unacceptable level then a composite may not
be a reliable solution.

E.1.3 Scenario 3 – Leak on Seam Weld
This scenario constitutes a pin hole on a

longitudinal or helical seam weld.
DO NOT use equation 12 of ISO 24817:2017.
Use equation 15 of ISO 24817:2017.

an allowance for fairing.
Full surface preparation around the defect is

required.
Ideally, the weld bead in the termination length

should be ground flush to remove leak paths
along which pressure can track and
accumulate.
If a stop gap is applied that extends 360°

around the pipe circumference, then equations
13 and 14 of ISO 24817:2017 should be
considered instead.

E.1.4 Scenario 4 – Tees
This scenario constitutes a hole on a tee, and

several methods should be considered
depending on the location of the hole. For a
hole on the flank of a tee, the appropriate
defect selection will depend on the extent of
surface preparation that can be completed.
If full preparation is possible then:

1. If the hole is on plain metal then use
equation 12 of ISO 24817:2017.
2. If the hole is on a weld then use
equations 13 and 14 of ISO
24817:2017.
Base calculations on the diameter of the pipe
on which the defect is located (header or
branch as appropriate).
Include the geometrical stress concentration

factor for the tee (2) in the final repair
thicknesses proposed (both for Type A and
Type B assessments) as mandated by ISO
24817, if the hole is within the overlap distance
from the opening on the header.

If full preparation is only possible away from

the defects (due to thin wall) then design as a
slot using equations 13 and 14 of ISO
24817:2017, taking the smallest repair
thickness. Base calculations on the diameter of
the header.

an allowance for fairing, stop gaps, and the
lengths where surface preparation is not
completed.
The geometry of the tee will not affect the Type

B assessment (because the tee geometry is
remote from the crack growth) but should be
included in the Type A assessment (because
the repair will need to carry all loads around
the tee).
For a hole in the crotch of a tee, in weld metal,

the appropriate defect selection will depend on
the extent of surface preparation that can be
completed.
If surface preparation cannot be completed at

the defect then consider using equations 13
and 14 of ISO 24817:2017, taking the smallest
repair thickness. Base calculations on the
diameter of the header.

an allowance for fairing, stop gaps, and the
lengths where surface preparation is not
completed.
The geometry of the tee will not affect the Type

B assessment (because the tee geometry is
remote from the crack growth) but should be
included in the Type A assessment (because
the repair will need to carry all loads around
the tee).

If extensive surface preparation is possible

then it is not clear which model most closely
reflects how the pressure will load the repair
interface. The models are based on de-
bonding on a flat plate or around the
circumference of a pipe and so none of the
methods closely reflect the scenario here.
Assessment using equation 14 of ISO
24817:2017 based on the larger diameter of
the header is the most conservative approach
but will limit cases for which the repairs can be
used.
Alternatively, a reliable prediction of

performance for de-bonding on the header can
be made using equation 12 of ISO
24817:2017, with d = db, the branch diameter.
The thickness required using equations 13 and
14 of ISO 24817:2017 for the branch should be
considered in addition, and the greatest
thickness of all assessments selected.
Include the geometrical stress concentration

factor for the tee (2) in the final repair
thicknesses proposed (both for Type A and
Type B assessments) as mandated by ISO
24817 if the hole is within the overlap distance
from the intersection.
E.2 Final Comments
The approaches and concepts described above can be applied to other

geometries where damage is commonly found. For example, defects at trunnions
can be considered in the same manner as tees.
If there is any doubt about how the pressure will load the repair interface then
assessing performance using equation 14 of ISO 24817:2017 (with a relevant
value of energy release rate) will generally give a lower bound to expected
behavior.

10.0 REVISION LOG
Edition # Revision # Date Description

1st Edition issued 2021-03-18
1 1 2023-02-24 Minor Editorial Revision

Ab 539 Engineered Composite Systems For Pressure Equipment Alterations

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the pressure equipment safety authority

Engineered Composite Systems for

Edition 1, Revision 1 - Issued 2023-02-24

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page i

5.5.1 Test Report ................................................................................... 20

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page ii

A.0 ANNEX A (NORMATIVE) – Applicability ............................................................ 38

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page iii

The next reaffirmation of this document is scheduled for 2024.

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page iv

This requirements document will be reviewed periodically to ensure that it is aligned

Ljupco (Lou) Petrusevski

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 1 of 57

For the purpose of this document, the following definitions apply:

Certified testing organization – a testing organization that is certified or accredited to

Composite – a thermoset polymer resin that is reinforced by fibers

Composite system – a system comprised of multiple elements such as the substrate

Cure (curing) – the setting of a thermosetting resin by an irreversible chemical reaction

Cure schedule – a time-temperature profile qualified to generate a specified glass

Design lifetime – the maximum application lifetime of the laminate

Engineered composite systems (ECS) – a composite system which has been

Engineered composite system designer – a company or a person that designs and

Engineered composite system installer organization – a company or an owner-user

Engineered composite system procedure qualification record (ECSPQR) - a record

Engineered composite system procedure specification (ECSPS) – a written

Engineered composite system supplier – a company that supplies the engineered

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 2 of 57

Glass transition temperature – the temperature at which a resin undergoes a marked

Installation Instructions – instructions provided by the ECS supplier in the method

Installer– a person who is qualified to apply an engineered composite system

Integrity assessment – an examination of an item of pressure equipment, related

Laminate – the part of the ECS that is the composite.

Owner-user – an owner that has implemented a quality management system,

Ply – a single wrap or layer (lamina) of a laminate

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 3 of 57

Pressure equipment – a boiler, a fired-heater pressure coil, a thermal liquid heating

Risk assessment – a comprehensive and systematic process of evaluating the

Substrate – the surface on which the ECS installation is carried out.

User Design Specification (UDS) – a document created by the owner-user containing

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 4 of 57

3.0 REFERENCE PUBLICATIONS

ISO 24817:2017(E) – Petroleum, petrochemical and natural gas industries – Composite

ASME PCC-2-2018 – Repair of pressure equipment and piping – Part 4: Nonmetallic

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 5 of 57

4.0 SCOPE AND REQUIREMENTS FOR ECSs

The scope of this document is to provide a systematic approach outlining the

The requirements of this document shall be satisfied by anyone planning to design,

Owner-users shall develop, implement, and maintain all documents,

4.1.2 Engineered Composite System Supplier

ECS suppliers shall develop, implement, and maintain all documents,

4.1.3 Engineered Composite System Designer

4.1.4 Engineered Composite System Installer Organization

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 6 of 57

personnel that are qualified in the application, installation, examination,

ECSs may be used as a temporary means of restoring the structural integrity of

- Design Pressure (Note 1) ≤ 3500 kPag (500 psig)

Table 4.1 – Applicability of General Pressure Equipment Categories

Issued: 2023-02-24 AB-539 Edition 1, Revision 1 Page 7 of 57

ECSs shall only be considered for installation on pressure equipment managed