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VOLUME - II

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STUDY OF CODES AND STANDARDS

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1. ASME SEC. VIII Drv.1 Pressure Vessel code

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2. API 510 Pressure Vesse! Inspection code

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3. API RP 572 Recommended

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Practice

4. API RP 576 Pressure Reliving Devices

5. ASME Sec. IX Welding Qualification Code

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'W
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API -. 510 COURSE NOTES

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VOLUME - I I

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STUDY OF

ASME See, VIrI

Div, 1

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STUDY OF ASME See. VIII Div. 1

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CONTENTS

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1.

AS~1E BOILER & PRESSURE VESSEL CODES

2.

INTRODUCTION TO ASME SECTION VIII DIV.

3.

MATERIAL OVERVIEW

4.

DESIGN

OF PRESSURE VESSEL

5.

FABRICATION

REQUIREMENTS

>

6.

INSPECTION

7.

NDE OF PRESSURE VESSELS

8.

CODE STAMPING AND REPORTS

9.

TOPICS FROM ASME SEe. VIII ON. 1 FOR

& TESTING

NUMERICAL QUESTIONS IN API-SI0

EXAM

1.

ASME BOILER & PRESSURE VESSEL CODES

11 INTRODUCTION

ASME Codes give stipulations and guidelines for !he design,

materials, manufacture and testing of pressure vessels. These
are issued by the American Society of Mechanical Engineers,
New York. The codes were first issued in 1915. Since then,
many changes have been made and new sections added to the
code as need arose. It is a LIVE code and is revised and
updated periodically. It keeps pace with time and is responsive
to its users.

2) CODE SYSTEM
In its present from the ASME Code System is a follows:
Section I
Section
Part
Part
Part
Part

" Power Boilers.

II
A
B
C
D

Material specifications.
Ferrous materials,
Non Ferrous Materials
Welding rods, electrodes, filler metals.
Material properties.

Section 111
Nuclear Power Plant Components.
Section IV

Heating Boilers.

Section V
Non destructive

Examinations.

Section V/
Care and operation of Heating Boilers.
Section V/I
Rules for care of Power Boilers
SecUo" VII/

Division 1 - Pressure Vessels

Division 2 Alternative Ru!es ( Pr Vessel)
Division 3 Rules fer constructive of High
Pressure Vessels
\fl'e/ding and Brazing Qualifications
r--'~)er glass reinforced Plastic Prc:s::;urc
\ '.':;sols

, ,':S for in
I'

service; IfIspectlon

:iCI ;Jlan( COlflrOllcnts

,,'

r011Cli::21

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3)

ISSUE

FREQUENCY

ASME

Issues complelely

new edilion

of all Sections

three years on 1" of .July of the year 01 issue.

-.;

was issued on : 1sl July 2001. Addenda

issued on 1sl July every year.

Latest

aftor

edition

to the latest edition

are

2001 Edition with 2001 Add. _ 1sl July 2001 .

st

. 2002 Addenda

- 1 July2002 .... (A 02)

2003 Addenda

1sl July 2003 ..... (A03)

A fully revised edition incorpOraling

issued on 1sl July 2004.

4) APPLICABILl1Y

all above addenda

The editions and addenda become applicable

would

be

after six months

from date of issue. Thus, for 1" Jan. 2004 to 31 Jan,200A,

Ihe

construclion
of Pressure Vessels shall be as per 2001 edition
1
and 200 +2002 addenda. However, for old C<Jntracls s pi IIing
OVer beyond

1" Jan 2004, the applicable

edition and addenda

which were valid at the date 'of signing contract

of contract.

5)

CODE

INTERPRETATION:

to

are valid till end

ASME issue Wrilten replies know as "Interpretations"

the inquiries

concerning

technical

aspects

of the code These

are issued twice in a year (July and December)

and are sent to

"Edition - SubsCribers" as up-date service.

6)

CODE

CASES
Boiler and Pressure
consider
same

Vessels

propOsed additions

lime iI may formulate

eXlsl"'9

requlrenlenls

bOOks "is

These

Committee

meets

regulany

and reVISions to Ihe Code. At the

Code cases
are

to clanly

Published

PubliShed along with ne".' editions

arc .. "IOnlallcally Sent '0 subscnbers

eeJ/tlon IS PUb/IS/led

as

, Intenl'

() E S lAMe'

llle".,

Sfelnllh

C "cllfiel

I,'

of

'epIC1' fill ",,' "'",..

""If

"""

at Ion

of

COde.Case

and Supplemenls

of Code case book iiIl new

o
7) C

to

10 US2 S 12 "'.0S

IS granled

"\''1 Ib',1 'yp'ca I Code S,;)hols

by /. S M [

a," U. u/ ~ "'e

---------n
(

Mani.Jfacturei".s 1;::lcilXties
. and organization
representative
authorization.

of

inspection

agency

and

are subj,ected to joint

ASME

Designee

review

before

by

granting

The ASME Codes have attained legal status in most of the American States, who have
adopted them and made them mandatory Codes of practices in tfle interest of safety.
All the boilers and pressure vessels

niade to ASME Code Section I (power bailers),

Section VIII Div. 1 & 2 (unfired pressure vessels)

and Section III (nuclear vessels) .

need to be fabricated by approved Works who hold code stamps in recognition of their
operating quality system. These equipments are inspected and certified by qualified
ASME Authorized Inspectors.
SALIENT FEATURES OF ASME CODES

Every ASME COde starts with specifying the scope of the code in terms of capacity,
size and pressure and other limitations if any. It 31so deals with and the battery limits
and the areas of code jurisdictions.

The Codes categorize and classify acceptable grades for materials of construction,

for

specific applications covered by the codes. The codes also idei1tify and categorize
various methods of construction I fabrication.

The codes specify the required N.DT. and other inspections. They also specify the
accept I reject criteria

What

is most important about the ASME Code is that is covers

manufacturing

activity

a vast field of

without sermonizing. They are user friendly. and keep pace with

changing technologies

No wonder - the Users and the Manufactures wond over have

adopted the ASME codes whole heatedly There are more boiler 2;ld pressure vesse:s
built under ASME codes than those ur1der all other codes taf-:entogether
The participants

are advised to refer the actual code clauses and extract If1formatlon

from ti,e latest codes applicable

(c, refer to tile

ASME code is even evoivllig docUm2!lt and one h2s

lalr;st Zlppllcable edltloll

I JrIcjr;rS(a:liJll)(JtllC COc!I:.

;lr1(~s/1OulcJIIUI

Dc

and addenda
referred to as

nlese

notes Will help

tile "COlle " It

self

III

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2.

INTRODUCTION TO ASME SECTION Viii Diy. 1

.J
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Scope

of the Code;

ASME Section

VII Div. 1 ;

199J!:

.,)
Definition

;J

of a pressure

vessel as per Code:

Containers for containment of pressure (external or intemat), obtained from an

;,

external source, or by application of heat (through direct or indirect Source), or

,
;,

by combination thereof. ASME Sec. Vtll Oiv 1 covers mandatory requirements

specific

prohibitions,

and non - mandatory

gUidance for pressure

vessel

materials, design, fabrication, examination, inspection, testing and certification.

:>

""Scope

)(

; xclusions

Following pressure vessels are

Div.1

)
)

I.

those covered

not inciuded in the purview of ASME Sec.vl/l

by other sections.

)
II.

Pressure containers whiCh are integral parts (or components) of rotating

machinery.

III.

IV

Piping System beyond battery limits

Pipe fitlings, valves, pipe components and other accessories,

beyond

battery limits.

v.

Vessels with incident loading of external or internal operating pressure not

exceeding

15 psi

(No lirnitations

on size).

VI.

Vessels having inside diameter or width/heighUcross section diagonal not

exceeding 6" (No limitations on length or pressure)
VII

Vessels

for pressures

exceeding

Vessels

for Human OCCupancy

3000 psi.

VIII

~:

Un;" 'oct Sleam 80d,,,s (W"11 press","

['i':: ;);)rators & 1-i'22t f:::XC!1dilCj8/S

Unfircci (Prucess

e." '''ed

I" eke:

i~c.Jt generated)
.,rj

rehef devices as per ASME See II

steam boilers.

sto;] m fe: IIr'S """,

peket pressure s 50 p.si ond be low

...
_..__. __
....__
.. __
...
_..

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Battery Lir:!lJ!:~

(a)

F~r externai :.;onnections

~
I.

Welding

II.

Threaded joints for screwed

III.

First Flange face for bolted connections

IV.

Sealing surface for proprietary

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(b)
(c)
(d)

;)

ends, for welded

external connection
connections

connections

Weldment of pressure part to non-pressure part.

Manhole and handhole covers - fOr vessel openings.
Sealing surfaces for instruments, gauges, etc.

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Responsibilities:
I.

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ii.

Manufacturer's:
(a)

Compliance of all requirements

(ie. Vendors)

of Code by himself, and by all others

(b)
(c)
(d)

Providing proper certification of materials and construction.

Providing applicable design calculations.
Establishing a mandatory Quality System.

Inspector's:

(a)
(b)
(c)
(d)
(e)

Monitoring quality control.

Verification of design calculations.
Conducting specified inspections.
Code stamping.
Certification.

l)
:>

Code

Composition:

:)

The code content is organised in 3 sub-sections

i)
Sub-section A - General Requirements

ii)
Iii)
IV)
v)

General

)(

)
)
)
)

Sub-section B - Requirements
Sub-section C - Requirements
Mandatory Appendices
Non-Mandatory
Appendices

and two Appendices

as follows:-

pertaining to methods of fabrication

pertaining toclasses
of materials

Requirements:

Desiqn
The User shall assure
vessel.

will be suitable

penar'mance,

retention

hiniself

that the design.

for Intended
of satisfactory

(jetC:'flOratlon during t:le vessel's

service,

matprial

with respect

mechanical

Illtended

and constn.ictioll

properties,

service life

/.1.,

to s8fety,

of the
intended

and protected

relatively

from

111gh"factor

of

j-~

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-.,

--"-

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safety" (previously 4, prQ~ently 3.:5) is ddQr.:.~(.;

;.::' :.a'-l.ecare of the incidental

material abuse: during construction and serviCE:.

>
)

General Principle:
.

A vessel may be manufactured by any process which shall not unduly impair the
inherent material properties or jeopardize tl1e safe, reliable and optimum
performance of the vessel.

Methods of fabrication: requirements are Getailed in subsection B

UW
for welded vessels
UF
for forged vessels
UB
for brazed vessels
ULW for layered construction
[Alternative Rules]
ReqUirements based on materials:

Requirements based on materials adopte-J and other specifications are referred

to in the following clauses of

subsection C of the ASME Code Section VIII

Divn.1. The stress values have been tabulated in the Part '0' of Section II.
UCS
UH.~
UNF
UCL

for
for
for
for

Carbon and low alloy stecis

high alloy (stainless) steels
non-ferrous materials
clad materials

UHT for high tensile, heat treated Ferritic Steels (such as Q & T)
UCI & UCO - for Cast Iron & Cast Ductile Iron Steels.
UL T
for low temperature appliC3tion using materiais of
higher
permissible stress values

MATERIAL OVERVIEW

3.

COMMON ASTM SrECS. FOR C.S. PLATES

Sr
No

Plate
Spec.

Composition %
C

')

(max)

P
(max)

S
(max)

A36

0.26

0.04

A283Grc

0.24

A285Grc

A515Gr60
Gr70

A516Gr60
Gr70

Remarks:

(
l

Si

En~~. properties
Mn

T.S.

Y.S.

Elog

(x1000
psi)

(x1000
psi)

0/0

0.05

58 - 80

36

20

0.04

0.05

55 - 65

30

25

0.28

0.035

0.045

0.90'
(max)

55 - 75

30

28

0.24

0.035

0.04

0.15 0.30

0.90'
(max)

60 - 80

32

25

0.31

0.035

0.04

0.15 0.30

0.90'
(max)

70 - 90

38

21

0.21

0.035

0.04

0.15 0.30

0.8 1.25

fiO - 80

32

25

0.27

0.035

0.04

0.15 0.30

0.8 -

70 - 90

38

21

1.25

Structural

Quality

Plates

& Shapes.

Structural

Steel for Bending

,..,
/

Plates

may be ordered

I Forming

(Low & Med

as rolled or norm

T. S )

(P V plates, Low & Med. T. S)

Plates >= 2" thk Must be normalized

for < 2" purchaser's
(P V plates, High & Med Temp service)

option

f'lates >= 15" ttlk Must be normailled

for < 1 5" purchaser's
V plates, Moderate & Low Temp service)

. ',)ptlonal

If present,

not to excecc1 spcclflerJ

Illaximum

option

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SELECTION OF CARBON & ALLOY STEELS

SERVICE TEMPERATURE

BASED ON

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STEEL TYPE
~

SPECIFICA TIONS

i;)
MODERATE

1.

TEMP.

C - Steels

SA 285 grC (3/4 in. thk max)

0
0

SA 516 All Grades

.ELEVATED

:"

2.

3.

C - 1/2 Mo

SA 204 gr 8, C

C - 5/4 Mn - 1/2 Mo

4.

1/2 Cr - 1/2 Mo

SA 302 gr 8
SA 387 gr 2
1000 (max)

,,
,
,

5.

1Cr - 1/2 Mo

SA 387 gr 12
1100 (max)

6.

5/4 Cr-

1/2 Mo - Si

SA 387 gr 11
1150 (max)

7.

9/4 Cr - 1 Mo

,,

SA 387 gr 22
1200 (max)

LOW TEMP
8.

C - Steel (F. G.)

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9.

,
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~

5/4 Ni Steels

10

7/2 Ni Steels

~RYOGENIC
11

SA 516 A.II Grades

(Impact tested)
SA 203 gr A or 8

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~

875 (max)
875 (max)

775 (max)

TEMP

600 (max)

SA 515 All Grades

TYPICAL TEMP.
LIMIT (DEG. F)

SA 203 gr C or 0

( -50 )

( -90 )

( -150 )

TEMP

9 Nr Steel

SA 353
( -320 )

:'c;s:cnilrc

SS
S/\ 240 Type 304.3041,347

( -425 )

.,

ill
'"

.,

MA TERIAL REQUIREMENTS:

...
1/

"-

..

GENERAL:
1.

Material

subject

to stress due to pressure

of ttle specifications

(i.e. pressure

given in ASME Code Section

are permitted

in the applicable

Specifications

parts) shall conform

to one

II, ,md shall be limited to those that

Part (such as UCS,UNF,UHT

etc.) of the subsection

C.

rI

..
rI

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,
',"I

Permitted

Rods

for Plates, Forqinqs,

and Bars are covered

and SB for nonferrous

"

\Nith

,(

Manufacturer,

material

Certified

complied

3.

ilot

identified

permitted

issued

by

by a suffix SA for ferrous

Materials

Steel

all requirements

material
Properties

where

certificate

or not recognized

are to be identified

I Raw

I Product

Material

of the Specification

and grade are

as required by the relevant

markings

specifications.

markings

is not available,

can be ascertained

or is certified

Sect. VIII Div I, may bs accepted

out on representative

allowable

as

to a Specification

sample/s

provide'd

and satisfy

In such cases Vessel or part manufacturer

to the Specification

specifications

identification

by ASME

I tests are carried

The maximum

Code

needs to re-certify

and grade, based on the findings.

stress

and grades

values

for different

are stipulated

service

in ASME

temperatures
Code

Section

for these
II Part D _

of Materials.

Permitted

Section

respectively.

with identification

materials,

but material

analyses

the material

5.

Fasteners,

specification.

appr'oved

Certificates

with, before correlating

authentic,

check

Test

These are designated

materials

and verified whether

"Partially"

being

Mill

Pipes & Tubes,

in the ASME Code Section II Part A (for ferTous materials)

& Part 8 (for non- ferrous materials).

materials,

Castinas,

Specifications

II Pari C

These

for Weldinq

specifications

S:::.:\ or SFl3 for sUltat)le classification

G. Preforned

or Prefabricated

ConsumaQles

are give:l

are covered

a designation

by ASME

number

Code

with a suffi\:

and grading

Pressure

Paris when made

by otttcr

litcHI tile=:pressure

:0

Form

U2. with .For welding

containers

or packages,

be accepted

7.

query

or tagging

jf done as per the app.licable Consumable

for pr.vessels

Requirements

(Section

are discussed

one should refer to applicable

General
Material

a)

tht: marking

may

viii

Div.1 stipulations)

here for understanding

purpose

only. For specific

code book and addenda.

Requirements
types

Compatible

Product

welding Consumables

( ASME Section

Plates
Castings
Forgings

d)
e)

Pipes & Tubes

(SA 106/312) (SA 179/213)
I=asteners
(SA 193/194/307)

f)

(SA 515/516/240/285)
(SA 216/351/217/352)
(SA 181/105/182 etc.)

Bars & Shapes (Sections)

Max. Allowable
MASVs

at

specification

Stress Values

various

I;:, sed

provlderj
Ofl

SA 36/283/479

(MASVs):

service

temperatures

for

each

acceptable

material

are given in ASME Section 11- Part D.

f~or vessels designed

Deg F is used

IS

II Part C )

Forms and Typical Specifications

a)
b)
c)

"lith

Specification,

Steel & Low Alloy Steels with max. 0.35% Camon

High alloy steels ( stainless steels and alloys)
Non ferrous (AI, Cu, Ni, Cu Ni, Ni Cu etc.)

b)
c)
d)

TillS

of the materials,

in lieu of Certified Test report.

Materials

General

con~urnabl"f.,

to operate

at low temperature,

over and above tile thicknesses

service experience

V(~ss('1 dimensions

All design

in corroded

generally

calculated

calculations

the MASV at 100

for pressure

are required

vessels,

to be made

condition

,,

,
,

Use of Structural Steels for pre$su,-e parts (Typica!ly. SA 36/ SA 283 )

a)

b)

Limitations:
i)

not pennitted for lethal service

ii)

should not be used for unfired steam boilers

iii)

Design temperature only (-) 20 Deg.F. to (+) 650 Deg.F.

iv)

for thicknesses below 5/8" (160101) only

Testinq:
Each plate to check test for chemistry and physical properties.
( Tensile strength, Y.S., % Elongation and severe Bend test as per SA-6
requirements ).

a.Check Tests for materials used for pressure parts

(
a)

Check test allowed only in the case of partial identification:

b)

Check test requirements :Each piece is tested for chemical

properties. Acceptance

composition

& mechanical

criteria as per pemlitted specification

for

which the material is being qualified.

Cast, forqed, rolled and die-formed pressure parts:
These shall be made from materials of permitted specifications;
meeUor be suitable for design conditions of completed vessel.

and should

NOT [RT/PT/MT]

and Heat treatment (Nonn/SR) as applicable must be conducted prior to its

release for attachment to the pressure vessel. Partial data report (form U2)

needs to be issued for such components.

in ev:dence of code compliance.

f\rUJlundertolerance
a)

Plates with 0.01 inch or 6% under tolerance (whichever is smaller) may be

used for full desigr. ~ressure,
However If material specification

allows greater under tolerance

(eg

3mm for a 10mm thick plate), then ordered thickness for the matenal

SllOlilcJ

IlC

suffiCiently <:]reater'

'J
I.

b)

::or pipe or tube

-6j"der~tl by'its nominal Well thickness, the manufacturing

under tolerance shall be taken into account. For S.S & M.S. pipes, th0.
manufacturing

under tolerance is -12.5%. For M.S. tubes,

it is zero

(tolerance +20/-0). For S.S. tubes. The tolerance Iimit~ are given in a
separate chart.

9.

a)

MATERIALS FOR LOW TEMPERATURE SERVICES:

Carbon and low alloy steels : Impact test requirements with respect
minimum design metal temperature in service are explained

in

to

UCS-66

of ASME VIIl-1 See Fig. UCS-66 and UCS-66.1 for Carbon Steel and low
alloy steel materials and weldments of comparable chemistry.
b)

!JNF 65 : Non ferrous materials have marked resistance to lowering

In

impact values at subzero temperatures. As such no impact tests required

upto:

c)

i)

Wrought aluminium :alloys

-4250eg.F.

(-254 Oeg. C)

ii)

Copper and copper alloys } :

Nickel & Ni alloys
}

-3250eg.F.

(-198 Oeg. C)

iii)

Titanium and zirconium

- 75 Oeg.F.

(-60 Oeg. C)

UHA 51 : Austenitic Stainless Steels too exhibit notch toughness

cryogenic temperatures.

- For Types 304,304L,316,316L&347,

upto -425 Oeg.F.(-254

at

Oeg. C)

impact tests are waived.

- For Ferritic Stainless/High

Alloy Steels like Types 409,410,430,

impact tests are required at any service temperature

etc,

below -20

Deg F (-29 deg C)

I :)

--'-'---"'-'---'

'---

__

4. DESIGN OF PRESSURE VESSEL

A.

BASIC REQUIREMENTS:

1)

Minimum thicknesses of shell and heads:i)

ii)

After rolling and forming - in

allowance

qeneral

1.6mm

(1/16")

(a)

above not applicable to UHT materials & PHE Plates

(b)

for unfired steam boilers: 6.4mm (1/4") + corr. allow.

corrosion

(c)
for compressed air service: 2.4mm(3/32") + corr. allow.
Mill under tolerance
a)

Plates with 0.01 inch or 6% under tolerance (whichever is smaller)

may be used for full design pressure, instead of at the given design
thickness ordered.

However if material specification allows greater under tolerance

(e.g. 0.3mm

for, a 1Omm'thick plate), then ordered thickness for

the material should be sufficiently greater.

b)

For pipe or tube - ordered by its nominal wall thickness,

the

manufacturing under tolerance shall be taken into account. For S.S& MS. pipes, the manufacturing under tolerance is -12.5%. For
M.S. tubes, it is zero (tolerance +20/-0). For S.S. tubes it is given in
separate charts.

2)

Quality factor for Castinqs

A quality factor of 80% is multipled to allowable stress values for castings when
computing design thicknesses.

3)

Shapes covered by the Code:

For Vessels of cylindrical and spherical shapes, ASME Code Section VIII Div.1
provides design rules in the general sub-section [Part UG] For vessel ends,
hemispherical, ellipsoidal, and torispherical shapes are preferred over flat ends
For transitions, loriconical
Other

s!lapes

arc

or conical shapeS are preferred (in that order)

corlsidered

unconventionClI and condltioflS

construct/orl :lflcj safe operation are set forih in Clause U-2

(g)

for design,

__

4)

COjrn~i.':.!ll':~'"'\:=E~c.~-:
The

US(;:"

shall specify corrosion allowance tor vessels subject to thinning by

corrosion, erosion or mechan:cal abrasion - to be provided for the desired life of

the vessel, by a suitable increase in the thickness of the matenal over that
detennined by the design formulae.
5)

Tell Tale Holes:

Tell Tale holes are used to provide some positive indication when the thickness
has been reduced to a dangerous degree. Tell Tale holes of 1/"(6" to 3/16"
diameter and to a depth of not less than 80% of the thickness of the seamless
shell, are provided
expected.

on the Opposite surface to that where deterioration

is

In clad or lined vessels, through-thickness tell tale holes of 1/16" to 3/16" dia are
provided, and are also used for leak tightness of welds attaching linings to the
parent metal.
For lethal service vessels, tell tale holes are prohibited.
Note: Vent holes are made for lug attachment pads, bearing pads etc. to allow
welding gases to escape. Test holes made for example on reinforcing pads,
6)

have internal threads for fitting nipples for air tests, and also act as Vent holes. ,
Openinqs for Drain:
Vessels subject to corrosion shall be provided with a suitable draiil opening at
the lowest point practicable

7)

in the vessel; or_a pipe may be used extending

inward from any other location to within 1/4" of the lowest paint.
Lininqs:
Corrosioil resistant or abrasion resistant linings, whether or not attached to the
wal! of the vessel shall not be Considered as contributing to the strength of the
vessel wall.

8)

Exception: Vessels designed to Part UCL of the Code

Desian Temperature of V~
:
i)

Maximum Temperature is the rT:eanmetal telnperature-through

eXpected

II)

th:cKness-

under operating conditions.

ivilnimum DeSign Temperature

is the lowest temperature exr:::cted in

9)

Desiqn'Loadinqs :
i)

Internal or ExtArnal Design Pressure.

ii)

IJead Weight of the Vessel: Weight of the vessel and normal contents of
the vessel

undAr operating

or test conditions

[including

additional

pressure due to additionarwei~Jht due to static head of liquids].

iii)

Super imposed static reactions - from weight of attached equipment [such

as motors, machinery, other vessels, piping, linings, insulation].

iv)

Loading due to attachment of internals, vessel supports, lugs, rings, skirts,

saddles and legs.

iii)
Loadings due to cyclic
variations or

and dynamic

reactions

owing

to pressure

iv)
temperature variations, or from equipment mounted on the vessel
mechanical loadings.

v)

"

vi)

and

Wind,snow,and seismic reactions,where applicable.

Impact loadings due to fluid shock.'

viii)
Loadings due to temperature gradients and differentiai them1al expansion.
10)

Maximum Allowable Stress Values:

a) These are the maximum unit stress permitted in a given material used in the /
construction of the vessel as per the Code.
In ASME Code Section VIII Div.1,

the maximum allowable stress values for

temperatures of minus 20 Deg.F.to 650 Deg.F., [and in particular for 100 Deg.F.
] are generally equivalent to Ultimate Tensile Strength divided

by a factor of

safety of 3.5 (approx). or t\vo-third of yield str~ngth whichever is lower, refer

ASME Section 11-0

11 )

Thickness of shells under internal pressure:

A cylindrical shell is Subject to, a circumferential stress along its longitudinal

seams, and a longitudinal stress along its circumferential seams. The incidental
CirCumferential stresses are almost t\vice as much as the longitudinal stresses in
any given v~ssel.

Tnercfore we need to calculate only the thickness required to

sustain the Circumferential stress, along the longitudinal seams, for tile given
deSign conditions [design pressure Jnd design temperature]

Ttle formula is valid

when P does not exceed 1/25SE and thicKness does not exceed one-half of the
inside radius.
a)

For cylindrical shells: (Using inside dimensions)

t, inches =
where - 'f

P x Ri / (SE - 0.6P) or

P = SEt I (Ril + 0.6t)

is the corroded min. thickness of shell, inches

'Ri' is the inside radius of the shell, inches (corroded)

'Ro' is the outside radius of shell, inches (corroded)
'P'

is the design pressure in psig

oS' is the maximum allowable stress value in tension, psi

.E' is the Joint Efficiency [Refer to Table UW-12 ]
Di

is Inside diameter of shell (corroded)

Do is Outside diameter of shell

b)

Alternate Formula for cylindrical sh.ells : (Using outside dimensions)

t, =

c)

P x Ro I (SE + OAP) or P = 2SEt I (Ro - OAt)

For spherical shells: (Inside dimensions)

t, =

P x Ri / (2SE - 0.2P) or P = 2SEt / (Ri + 0.2t)

[ Limitations:
d)

thickness shall not exceed 0.356R

P shall not exceed 0.665 SE ]

Alternate formula for spherical shells: (Outside dimensions)

t, inches

P x Ro / (2SE + O.8P) or P-= 2SEt / (Ro _ 0.8t)

Spherical shell formulas are valid when thickness does not exceed
I .

O.356R, or P does not exceed 0.665 SE.

12)

Thickness of shells and tubes under external pressure:

Cylindrical shells, tubes and spherical shells under external pressure are subject
to buckling loads, either owing to internal vacuum and extern a! almospheric
V'?Ssllre, or owing to a differential pressure acting externally.
S,;C!l vessels need stiffening supporis, and the unsupported span between the
r

c,'ffc:l ;rs

(I),

deCij0:S tlie vessel

tllickness

Ti,e I\ppenciix-')

of ti,e Code

", /

pmvid0.s V~n::'.",:....::;:ui:: ~liV;;1g 'la!Lit, (f Do !t, piolted agai:l':it I . Do, '{{here' Do'
is the outer diameter of tt;e v~$seLiRefer UG-28
13)

or ASME

Section VIII Oiv.1 J

Thickness of FORMED HEADS with Pressure on Concave Side

The

required

thickness

at the thinnest point

after forming of ellipsoidal,

torispherical & hemispherical heads under pressure on the concave side shall be
computed by under noted formulae:
a)

For Ellipsoidal Heads: ( 2 : 1 type)

t, == P x Oi / (2SE - 0.2P)
Alternately.
t

==

or P == 2SEt / (Do + 0.2t)

Poo / (2SE + 1.8P) or P == 2SEt/ (0 _1.8t)

A good approximation of 2 : 1 Ellipsoidal head is one with knuckle radius

of 0.17oi and spherical radius of 0.90oL\
b)

For Torispherical Heads: (when r == 0.06 xL)

t,

==

0.885 x P x L / (SE - 0.1 P) or P == SEt! (0.885L + 0.1t)

- Alternate Formula for Torispherical Dished Ends (when r> 0.006L)

t,

==

P x L x M / (2SE - O.2P) or P == SEt / (LM + O.2t)

where L
M

==

==

inside spherical crown radius

1/4

x [3
.r

Limitations

+ (L /
==

r ) 1/2

is the inside knuckle radius in inches.

Knuckle radius shall nol be less than 6% of inside crown radius [ Ri ],

nor less than three times knuckle thickness.

c)
14)

For Hemispherical Heads:

Ri shall be less than Do.

The formula Hemispherical shell can be adopted

,LQintEfficiencies
Joint

Efficiency

'E' referred to above are chaned out in T2ble UW-12 as

:opplicable to weld jOints completed by an arc or' gas welding process. Joint
efficiency

depends on Ihe Iype of joint and on Ihe degree of radiography

-2Xamlnatlon of the jOint. Table UV"'~2 of ASME Code See. Viii Div. 1 details
!Olnl deSCriPtion, IIOlilations, JOint categories and degree 01 rOdiography
::examination for each type number [Type 1 to Type 6 ) of the \','eld seam. Fig
.':'/V3

S110\'/S

weld

jOint

locations of Categories A, G, C & D

-----.- ....--_ .. _h __ ._. ._._....~

15)

Formed Heac.s, Pressure on Convex Side,

The

required

tori spherical
thicknesses
a)

thickness

at the thinnest

or hermispherical

heads

point after
shall be

forming

greater

of

of ellipsoidal,
the

following

The thickness as computed for heads with pressure on the concave side
as given in (13) above, and,

b)

16)

Thickness as computed by the procedure given in UG-28 and Mandatory

Appendix-5 for Heads.

Minimum Thickness of Unstayed Flat Heads and Covers:

t,

x [ CP I SE ]

112

= a factor depending upon the method of attachment

o = Inside diameter of shell inches.

where C

'(
)

The above

attachments.
incorporated.

)
)

formula is applicable

17)

Extra moments

to both welded

applied to the cover

of the flat head

and bolted
by bolting,

methods

of

are to be

Openinqs in Pressure Vessels:

a)

Shape of the openings:

Openings in cylindrical and conical portions of"

vessels, or in formed heads, shall preferably be circular, elliptical or

>

obround. Openings of other shapes shall be provided with a suitable

radius at all comers.
b)

Size of the openinqs : Properiy reinforced openings, in cylindrical shells of

diameter of upto 60 inches, shall not exceed half the vessel diameter, and
in any case not over 20 inches. For vessel diameter of over 60 inches, the
openings

shall not exceed 1/3rd the vessel diameter and in no case

eXceed 40 inches. For larger openings, supplemental rules apply.

18)

~nforcement
a)

of Openirlqs :

Beinfo~ent

required f~in!:]sifls!lell~_<JJeads

The principle is that material removed shal! be equal to material added.

T/lis

IS

achieved by providmg doubling plate either outside or inside the

._.

The limitatior.s am, on the .out6:- diameter of the doubling plate,; which
shall not be greater than twice the size of the fini:;hed 9pening, and its
thickness

shall not be greater than the provided thickness

of the

shelllhead.

Credit is given to corroded size of the nozzle neck of the opening, fillet
welds provided inside and outside, and at the outer edge of the reinforcing
pad, to the additional thickness available in the shell and the nozzle neck,
and to 2 1/2 times the thickness of the nozzle neck protruding outside

"

rI

..

"-

and/or inside the shell.

b)

Reinforcement waived for sinqle openinQs, in the case of,.

finished opening size 3 112" diameter in shell or head of thickness

3/8" or less;

~(

finished opening size 2 3/8" diameter in shell or head of thickness

,,
,

over 3/8";
Threaded studded or expanded connectio.ns where hole cut in the
shell or head is f!Ot more than 2 3/8" diameter.

c)

Openinq may be located throuqh a welded circumferential

seam ioints,

provided the weld is fully radiographed for a length equal to three times

the diameter of the opening with the center of the hole at mid-length.
Openings ( without added reinforcement

J in a shell plate, shall not

be placed near the edge of the weld in the main joint, closer than
1/2 inch, for plates 1 1/2 inch thick or less.
d)

Reinforcement of Multiple Openinqs:

::

Combined reinforcement can be provided for multiple openings, provided

the minimum distance between centers of any of these two
1 1/3rd times their

openings

is

average diameter and the area of reinforcement

between any two openings is atleast equal to 50% of the total required fo,
the two openings.

When the distance between the centers of any two openlllgs is less thall
; i 13rd

times their average diameter, then no credit for reinforcement

a:lowed for materials between these openings, and supplemental

ne,,":cJ to be applied

is

rules

):)

e)

Reinforcement for OpeninQs if Flat Hea~

So far as the opening in a flat head does not exceed one half of the

i)

~
~

flat head diameter (or the shortest span),it shall have a total cross

sectional
where,

area of reinforcement not less than that given by 'A',

A = 0.5 x d x t;

& t

;,
j

= nominal thickf)~ss of the vessel wall

For larger openings, higher value of C (in 16 above) and increased

thickness of flat heads shall be provided.

,,

finished Qiqmeter of the circular opening

In olher words, the fial head may be required to be thicker by the amount
of reinforcement required.

;:)

19)

Nozzle Neck Thickness:

'(
Wall thickness of a nozzle neck shall not be less than, the GREATER of the
following (a) or (b) :_

,
~

a)

thickness computed for applicable design,mnrlitions

formulae, plus corrosion allowance,

t=PRi/SE-O.6P,OR

.as

per the

t= PRO/SE+O.4p

b)

the smallest of the following:

(i)

calculated thickness (plus corrosion allowance) of the vessel or

head on which nozzle is located with E :: 1.0.

(ii)
20)

Insp~n

the minimum thickness of the standard wall pipe (Schedule 40 of

ANSI 8 36.10) plus corrosion allowance.
OpeninQs :

All pres su, e vessels for use with compressed

G ir,

and Ihose subject to internal

ca'Tosion, erosion or meChanical abrasion are reqUIred to be prov'ded \<;th

SUitable manhole, handhole, or other inspection openings ror examination and

Cleaning

Inspection

a)

are waived.

fo, vessels upto 36" II), if lell-tale hales a'e provided at a spaCing of one
"Ole

-.?'~----'.'--'---~--

openings

pe, ten square feet or a rraclion II'", eof of inrerna' veSsel s ",face

~_

..

-.

--.- ..

-.--.-.-

~
~

>'t.)
a/2a, with a minimun: 01 ~';'-ii'l,~ifr..nnly SP<lc(;.J holes. This excejJtion is not
for compressed air vess'els.

~
~
l~

,.;>
~
~

21 )

b)

for shell side of fixed tube heataxchangers;

c)

other exceptions are detailed in ~G-46 C, 0 & E.

d)

for sizes of mandatory inspection openings: see UG-46F.

Permissible Out-Of Roundness for Shells and Formed Heads:

.;>
;)

a)

b)

,,(
)

For internal pressure,

(Oi Max - Oi Min) divided by Oi Nom = 1% Max.
For external pressure, Refer Fig.UG-80.1 : Max. plus/minus deviation' e',
from true circular form, shall be between 0.020 t to 1.0 t, as plotted on the

:>
:>

c)

curves with Do / t on Y axis a,nctu Do on X axis, where L = design length.

Heads: out of profile + 1 1/40/ _ 5/8 0
for Hemispherical Head, use L=0.50 in the ratio UOo.

Welded Joint Efficiency Values (UW -12)

)
)
)
)

Type of joint and radiography

Efficiency allowed
percent

1) Double-welded butt joints (Type 1)

Fully radiographed
Spot-radiographed
No radiograph

100

85
70

2) Single-welded butt joints

(backing st;-ip left in place) (Type 2)
Fully radiographed
Spot-radiographed
No radi8gr2ph
3) Slr1gle-welded butt jOints (Type 3)

90
80
65

b .__
._
~
~
~

5.

FABRICATION REQUIREMENTS

1. GENERAL (UW - 26)

(a) The rules in the following paragraphs apply specifically to the fabrication of
pressure vessels and vessel parts that are fabricated by welding. These shall
be used in conjunction with the general requirements for Fabrication

in

Subsection

In

A, and with

the specific

requirements

for

Fabrication

Subsection C that pertain to the class of material used.

(b) Each Manufacturer or parts Manufacturer shall be responsible for the quality
of the welding done by his organization. He shall conduct tests not only of the
welding procedure to determine its sUitability to ensure welds 'Nhich will meet
the required

tests, but also of the welders and welding

operators

to

determine their ability to apply the procedure properiy.

~
.
(c) No production welding shall be undertaken until after the welding procedures
which are to be used ,have been qualified. Only welders and welding
operators who are qualified in accordance with Section IX shan be used in
Production.
(d) Welders not in the employ of the Manufacturer (Certificate of Authorizatr;~
Holders)

may

be used to fabricate

pressure

vessels

constructed

in

accordance with this Division, provided all the following conditions are met.

(1)

All COde construction shall be the responsibility of the Manufacturer.

(2)

All welciing shall be performed in accordance with the Manufacturer's

welding

procedure

specifications

vvhich have been qualified

by the

Manufacturer in accordance with the requirements of Section IX.

(3)

4
( )

All welders shall be qualified by the Manufacturer in aCQxdance with the

requirements of Section IX.
The Manuf8cturer's Quality Controi Sysiern shall include as a minimum:
(0)

a reqlcirement for complete and exclusive administrative and technical

supervision of all welders by the Manufacturer;

(I))

evidence of the Manufacturer's authority to assign and remove welders

at his discretio:l without involvc:rnr:nt of

211y

other or!C3ni?3!i n,:

r

73

.
~

'->
')..l
~

'->

(c)

a requirement for Assignment of Welder Identification sy1!111bQts:

(d)

evidence that this pro~ram has been accepted by the Manufacturer's

,.~

Authorized Inspection Agency which provides the inspection service.

(5)

"~

The Manufacturer shall be responsible for Code compliance of the vessel

..,)

or part, including Code Symbol stamping and providing Data Report

Forms propeny executed and countersigned by the Inspector.

;;.)

;;,

2. QUALIFICATION OF WELDING PROCEDURE (UW-28)

::;

(a)

;;J

;:,

Each procedure of welding that is to be followed in construction shall be

recorded in detail by the manufacturer.

(b)

The procedure used in welding pressure parts and in joining load-carrying

nonpressure parts, such as all permanent or temporary clips and lugs, to

pressure palis shall be qualified in accordance with Section IX.

,r

,,

(c)

have essentially no load~carrying function (such as extended heat transfer

surfaces, insulation support pins, etc.), to pressure parts shall meet the

:>

following requirements.
(1) When the welding process is manual, machine, or semiautomatic, procedufE~/

:>
)

The 'procedure used in welding non pressure-bearing attachments which

qualification is required in accordance with Section IX.

(2) When

the

accordance

is any

automatic

(d)

welding

process

with a Welding Procedure Specification

Section IX as far as applicable),

required .

l(

welding

performed

in

(in compliance with

procedure qualification

testing is not

Welding of all tes~ coupons shall be conducted by the Manufacturer.

Testing of all test coupons shall be the responsibility of the Manufacturer.
Qualification of

welding procedure by one Manufacturer shall not qualify

that procedure by one Manufacturer except as provided in QW - 201 of

Section IX

IC"

3. FORMING SHELL SECTIONS AND HEADS:

Thr: following

Carbon

C)

Vessel

provisions

shall apply in addition

to the general

rules for fanning

UG-79,-

and low alloy steel plates shall not be formed cold by blows.

~
~

shell sections,

heads, and other pressure

:')

alloy steel plates fabricated

the resulting

and any of the following

extreme

boundary

parts of carbon

and low

by cold forming shall be heat treated subsquently

fiber elongation
conditions

is more than 5% fonn the as-rolled

when

condition

exist.

~
~
~

~C

(1) The vessel

will contain

(2) The material

requires

(3) The thickness

, (4) The reduction

either liquid or gaseous

(see UW-2).

impact testing.

of the part before cold fonning exceeds

by cold forming from the as-rolled

(5) The temperature

lethal substances

of the material

5/8 in. (16 mm).

thickness

is more than 10%.

during forming is in the range of 2500F to 9000F (

121C to 482C).

'~

~
The extreme

fiber elongation

shall be detennined

by the following fonnulas

~
For double curvature

(for example,

heads),

% extreme fiber elongation

(75t1R) (1 - Rtr)

~
for single curvature

(for example,

cylinders),

% extreme fiber elongation

.~

= 50

tlR) ( 1 - Rtr)

Wtiere.

'~
T = plate thickness,

i~

Rr = final center line radius in.

i~

.,

J~

in.

R = original
VVhen 'lesser

center line radius (equals infinity for flat plate), in

shell sections,

heads, or other pressure

boundary

alloj' steel plate are cold formed by other than the Manufacturer

'~

,"'

rCOurr8d cerLlfication

for tll8 pari sllalllndlcate

paris of canJon or low

of the vessel,

wllCther or not the pari

tldS

the

been heat

J"

"j

'3
')
'.

;~

(~

4. GENERAL PRECAUTiUj\lS IN FABRICATION

I.

Structural discontinuities

should be avoided. Square comers

of pads

should be fOunded off before fitment and welding . Unweldeci faces offlame cut edges should be ground smooth and sharp edges ground
round.
ii.

Welding of minor items direct to structural and pressure parts should be

avoided. Use of intermediate I doubling pad is preferred.

III.
IV.

Toes and brackets and ends of stiffeners should land on stiffened plating
Fillet welds should be carried around attachments to avoid points of
stress concentration.

v.

Weld sequence

should

be planned

before

hand. Welding

should

progress towards free edges all the time to avoid shrinkage stresses.
VI.

Back step welding, s~<ipwelding, low heat input, minimum weld deposits
will prevent deformation and local bulking.

VII.

Shrinkage allowance for main seam should be provided for at the fitup
stage, in order to obtain final dimensions within tolerance limits.

viii.

Avoid all kinds of metallurgical and mechanical notches.

Tests
/

Structures are subjected to direct or compressive

proof load to check their

buckling strength. Pressure vessels are subjected to tensile loading by means of

a test pressure. Ability to withstand such loading is the proof of their integrity.
Equipments

under test should be adequately

should be c31ibrated and

national standards.

supported.

P(essure

gauges

verified for accuracy, with a "master" traceable to

5. CRITICAL AREAS IN WELDING FABRICATION

1.

Climatic Conditions for Weldino

hio welding of any kind shall be done beloVi base metal temperature of 0 deg F.
Between 0 dcg F and 32 dcg F, pretleating to 60 deg F - i.e warm to hand, is
recommended prior to vicldlilq

Further, wht=:nsurfaces are wet or covered with ice, or when snow is falling on
the surfaces to be welded, or during periods of high wind, no welding should b..:~
done unless welders and the wort<are properly protected and covered.

2.

Cuttinq, Fittinq and Aliqnment

Gas cut edges for welding should be smooth, uniform, free of loose scale, slag,
oil, paint\ etc. prior to welding. Preferably they should be ground down to bright
metal and slightly preheated.
Welding edges of plates should be aligned and retained stress-fr~

in position

during welding operation, by using tack welds, clamps, etc. Tack welds should
be examined visually for defects, which if found shouJd be removed.

ALIGNMENT TOLERANCES (Table UW-33)

Section Thickness, in..

Upto 1/2, inc!.

8,C&D

1/4 t

1/4 t

Over 1/2 to 3/4 inc!.

1/8 in.

1/~ t

Over 3/4 to 1 1/2 inc!.

1/8 in.

3fi 6 in

Over 1 1/2 to 2, inc!.

1/8 in.

1/8 t

Lesser of

Lesser of

1/16t or 3/8"

1/8t or 3/4"

Over 2

NOTE:

: Joint categories A

/'

Offsets within allowable tolerance shall be given a minimum of 1:3 taper

transition, if necessary, by adding additional weld metal.

(
3.

Finish of the Lonqitudinal and Circumferential Seams:

Butt welded joints shall have complete penetration and full fusion. Seams shall
be free from coarse ripples, grooves, overlaps, abrupt ridges and valleys,
undercut or underflush.
Weld ,-einforcement on each face of the weld shall not exceed the following:

i
-!

Maximum Reinforcement, in.

C.Seam in pipe & tubing

Mat'I Nom.Thk,in

3/32
1/8

Less than 3/32

3/32 to 3/16, incl.
Over 3/16 to 1/2,incl
Over 112 to 1, incl.
Over 1 to 2, incl.
Over 2 to 3, incl.
Over 3 to 4, incl.
Over 4 to 5, incl.
Over 5

5/32
3/16

114
1/4
1/4
1/4
5/16

Other Welds
1/32
1116
3/32
3/32
1/8
5/32
7/32
1/4
5/\6

(
4.

Fillet Welds:
Fillet welds shall have adequ'ate penetration into the base metal at the root and
side Viall of the weld joint. Reduction of the base metal thickness at the fillet weld
toe is not permitted.

1_

Distortion Control:
/'
One has to keep a close eye on distortion of the weldments, as many times, a
good and sound weld with all NOT cleared in first go leaves the product rejected
from distortion point of view.

6_
(,

Control of weldinq -- a Special Process

In short, there is a vast difference in Quality Control of Welding fabrication
inspection

and other inspection

activities. In welding fabrication,

systematic

monitoring of activities from material procurement to packing and delivery stage

has to be ensured by Q_ C_personnel to achieve the results_

6_ VVELD REPAIRS
Vessel or parts of vessel which are to be weld repaired may need to be postweld heel
treated after the repairs have been made, if it is the design or service requirement
fOI-mal Repail Procedure needs to be written down, with step by step instructions
precautions

_.:..,
d,:J

Including non destl-uctlve examination, as applicable, cleail~, delineate:-J

This Weld Repair Procedure ShOUld b'e approved' by the Customer I User and -the
Authorized Inspector (AI), ana recorded on Data Report. For Carbon Steeis, "cosmetic ",_
or minor surface restorations after removal of tack-welds etc. are not viewed seriously. __
But conducting MT of affected area is in order. For Low Alloy steels MT after cosmetic
repairs is a must.

For Carbon and Low Alloy Steels, weld repairs are pennitted provided relevant WPS I
PQR I WPQR are established, and subject

tq obtaining

permission of ultimate User and

AI.

A Typical Repair procedure for CS and LAS :

1.

Remove defect completely by trepanning (boat shaped groove)

2.

Magnetic Particle Inspection (MT) of the area, to ensure that defect is completely
removed.

3.
4.

Preheat the area to 150 Deg C, and maintain the temperature during weld repair.
Build up the area employing appropriate WPS and Welder, and using large
(5mm dia) low hydrogen type electrodes with routine precautions
interpass cleaning.

such. as

5.
Upon filling up the groove fully, weld over one more run, known as temper bead,
to grain refine the undenying layers.
2.

Maintain postheat of about 250 Deg C, for about an hour (by using asbestos
blankets etc), and cool down slowly.
7.
Dress down the temper bead, and carry out MT to ensure there are no surface
defects.
8.

9.

Apply NOT (RT or UT as required by Design, Service or Repair Procedure).

Post Weld Heat-treat as per requirement.

Notes: A Repairs to Castings and Forgings of pressure vessels would be govemed by

applicable Material SpeCifications and Parts UCI & UF, of the Code's subsection
8 Repairs to stainless steel will iilvolve trepanning, dye chec~:, low heal input in
welding,

complete

filling up with compatible

electrodes/

filler wires,

using

optimally low currents

Final NDT \'.'Quld be PT (dye checL;) and RT where

applicable

all, only solution annealing, with Clien:'s concurTence

PWHT - if

a(

'I

i-~

---------====~-_.-..
.
..
...
"
D
~

Surface

L>

Weld Metal Build Up

Deposits of weld metal are applied to the surface of base metal for the purpose:

b
~
~

a.

Restoration of base metal thickness for strength consideration;

or

b.

modifying the configuration of weld joints in order to provide tapered transitions

as follows:

I.

Butt weld procedure qualification is required as per ASME Section IX for

the thickness of weld deposited.

~
".

All weld metal build up must be examined over the full surface of the
deposit by either MT or PT to acceptance criteria App. 6 & 8 respectively.

l)

:
)

DC
1)
i)
j)

l)
l)

When such surface weld metal build up is used in welded joints, which require full or
spot radiographic examination, the weld metal build up also shall be included in the
examination.
7. POSlWELD HEAT TREATMENT

All welds in the Pressure Vessels or Pressure Vessel parts '-=:u're

to be given a

Pastweld Heat Treatment at a soaking temperature not less th2:-: :~,a~specified in under
noted

Tables,when

the nominal

thickness

[as defined bei:;w] of the weldment"

including carTosion allowance, exceeds the limits given in these Tabies ..

i)
)

Table UCS-56 tor carbon and low ailoy steels

l)

UHA-32 for high alloy steels

>

UHT -56 tor territic steels with enhanced tensile properties

),

,,(,
~

and

UNF-56 for specific non-ferrous materials

The 2bo\'e Tables specify the minir,1Umnominal thicknesses above which the postweld

t
~

heat :re2tment is mandatory. These Tables also specify holding (soaking) temperatures
and nOicjlllg times for different thicknesses and different tj';J8S
Into::' h!:.:nlbers & Group Nos by the Code

or

materials classified

)
)
)
)

>
)

)
)

~
)

f~Oi
tilIC-,S

',0,:1)' llsed

materials given beIIJ'.'.',PWIIT !lccomcs 111211-::::,01\

above nominal

flW/l(:O!1ceJ

below

For carbon steels, nominal t~ickness above 31.i'5mm

For low alloy steels ot grades 1 Cr 1/2 Mo, 2 1/2 (.r.-1 Mo etc., at nomin~l_
thickness above 16mm, and for grades such as 5 Cr. 1/2 Mo and 9 Cr. 1 Mo.
PWHT is required for all thicknesses.

For austenitic stainless

nor prohibited.

For non-ferrous

steels [Type 304,316, etc.] PWHT is neither required

materials,

PWHT is normally not necessary nor desirable,

except for alloys like CDA-954, Zirconium grace R60705 alloy N08800, etc.
For UHT materials (territic steels with enhanced tensile properties], PWHT is
required tor all thicknesses.

TABLE UCS - 56
POSTI'JELD HEAT TREA Trv,ENT REQUIREMENTS FOR CARBON AND
LOW ALLOY STEERLS

I Normal
I

Material

Minimum Holding Time at Normal Temperature

For Nominal Thickness [See UW - 40(f)]

Holding
Temperature,
OF, Minimum

Up to 2 in
Over 2 in to 5 ir
1 hrlin., 15. 2 hr plus
15
min minimum
mln for each
additional inch
lover 2 in
None
None

P - No. 1
11100
Gr. Nos. 1, 2,
3
Gr. NO.4

NA

'"

Over 5 in
2 hr plus 15
min for each
additional inch
over 2 in
-~~one

NOTES:

(1)

When it is impractical to postv.'eld heat treat at the temperature specifi~d in this

Table,

it

IS

permissible

to carry out the postv,teld heat treatment

temperature for longer periOds of time in accordance

(.

Post\'/eld ilcat treatmcnt

(e')

for welcjed Joints over

IS

Wltll

at lowe,

T;Jble UCS _ 5G 1

rnanciatory under the following condltlollS .

1 1/)

III

flOrninal tllickness

- I

(b) for welded joints over 1 1/4 in nominal thickness through 1 1/2 in nominal.
thickness unless preheat is applied at a minimum temperature of 2000 F during
welding.

(c) for welded joints of all thickness if required by UW _ 2, except postweld heat
treatment is not mandatory under the conditions specified below:

for groove welds not over 1/2 in size and fillet welds with a throat not over 1/2 in
that attach nozzle connections that have a finished inside diameter not greater
than 2 in.

Nominal

thickness

is defined in clause No. UW-40(f) of ASME Code Section Viii

Div.1. For pressure vessels or parts thereof, it is the greatest weld thickness of the
equipment or part of the equipment which has not been previously post weld heat
treated.

Thus, the nominal thicknesses in the following cases are:

1.

In a full penetration weld joining materials of same thickness, it is a total depth of

the weld, exclusive of any permitted weld reinforcement.

2.

In groove welds, norn;nal thickness is the depth of the groove

3.

In a groove and fillet type of weldment, nominal thickness is the depth of the
groove, or the throat thickness of the fillet, whichever is greater.

In a fillet weld, nominal thickness is Its throat dimension.

!n stud welds, nom. thickness is the diameter of the stud.

6.

When parts of unequal thicknesses

thickness is,

are Joined together,

then the nomin2!

thinner of the adjacent parts butt welded.

the thickness of the shell in a corner joint
th~ de~th of actual \,/cldment acros~ the nozz:e neck, includlrlg througll the
r"ernforcement pa(j
" tl18 thickness of tile n~nl.le fleck

butt welded to a Weld Neck FIClnge

Q-..--.~
~

\)

\)
lW

W
~

Operation

Of PWHT

The PWHT can be r:-presented as a time and temperature cycle, recordf'd on a chart.
The heating and cooling rates as well as the soaking temperature and its holding time
are important, and are specified in the Tables above.

-..)
~

PWHT

should be performed preferably by heating the equipment as a whole in an

enclosed

furnace. The equipment may be heated in more than one heat in a furnace,

;)

with an ovenap of atlas 5 feet of the heated sections of the vessel shall be provided. At

:)

the same time, the portion outside the furnace shall be shielded in such a manner that

temperature gradients are not harmful.

:)

Local postweld heat treatment , for example, of a heavy section, or a circumferential

seam individually, may also be done in more than two or three heats, provided the

from likely harmful temperature gradients. In such cases, the heated band on either

side of the locally heat treated area shall be atleast twice the thickness of the shell.

r>

For carbon

'J(

~
)

heating is done uniformly and the portion outside the heated band is suitably protected

Deg.C.per

and low alloy st-2-2!s, the maximum heating rate is specified

as 200

hour per inch ~~::~-~ss.

...~i!e the maximum cooling rate allowed, after the

soaking period, is 278 Deg.C

C-2~

hour per inch thickness.

The maximum loading and unloading temperatures should preferably be 300 Deg.C., to

avoid thermal shock, though a temperature upto 400 Deg.C. is allowed by the Code.

The minimum holding temperature,

or what is known as the soaking temperature,

varies for different types of materials, designated by ~p Numbers in ASME Code. For

~(

carbon steels the minimum soaking temperature is 593 Deg C. For low alloy steels the

soaking temperatures ranges from 630 to 720 Deg C, depending upon the content of Cr
& Mo

The spatial variation in holding temperature

during soaking period in a furnace or

heating chamber, should not be more than 30 degrees betwepn the highest and lowest
temperature, throughout the portion of the equipment being heated. The Code however
allo\\'s a difference of upto 83 Deg C

p----. -..'-'--"-

b
\

During

controlled,

.)

~:'~atl"lg ::;nd ho:r!in~; periods

t~18

as to avoid

reducing

prevent

Benefits

atmospheres

excessive

the

oxidation

are recommended.

direct flame impingement

fumace

atmosphere

of the vessel
Bumer

~hOLiid bE: ~~)

ski'n surface.

locations

should

Neutral

or

be designed

to

on vessel surface.

of PWHT

i)
~

1.

;)

Stress Relief:

Relieving of locked

up stresses in weldments, dispersal of peaks &

valleys of stress levels homogeneously in a welded structure, and affording

dimensional stability.

it a

)
)
)
)

2.

Tempering: Softening hard zones, such as at HAl and in cold formed components

3.

Providing

escape route 10 nascent Hvdroaen entrapped

in welds, thus preclUding

possibility of underbead cracking. All of the above assure a safe and reliable welded
equipment.

~
~

Summary

All carbon-and

Ihickness

of Postweld

Heat Treatment

lOW-alloy steel seams

eXceeds

Some materials

Requirement

must be postweld

1 1/4 in or 1 1/2 in if preheated

must be postwe!d heat-treated

Vessels

Unfired steam bailers

containing

lethal substances

at lower thickness.

must be postweld

High-alloy

heat-treated:

(oP more than 50 psig)

For welder vessels the details of PWHT

describe in fOllOWing table of the code.
and low-alloy

if nominal

to 200' F before welding.

Carbon-steel
vessels for service at lowered temperature
treated unless exempted from impact test.

earbon-

heat-treated

steel vessels

must be posrNeid

temperature

ueS-56,

and hOlding

UCS-66,

UeS-67,

Al;oWdble

working

time

heat'

are

UeS-79,

UeS85

steel vessels

UHA-32
3. PRESSURE

TESTING

A) HYdrostatic
Tesl

mUsl

OF VESSELS:

Test

be al leasl

1 3 limes

Ihe maximum

multiplied by the lov;est ratio of the stress value for the test temperature
for the design ternperature

pressure
to that

rw'
~

t"

[\)

If the allowable sircs$ at design lerr.i)erature is less than the allowable stress at

\i
\)

test temperature the hydros;tatic test pressure must be increased proportionally.

\)

Test pro = 1.3 x MAWPX

'"

Allow.stress at test temp.

AlIow.stress at design temp.

\)

Inspection must be made at a pressure not less than Test pr.divided by 1.3.

\)

Corrosion

allowance

may be considered

in calculating

test pressure.

The

maximum allowable working pressure may be assumed to be the same as the

~.

-3
~

.>
:

design pressure when calculations are not made to determine the maximum
allowable working pressure.
Max.lnspection temp. = 120 dec F,.

Test gauge range limit = 1.5X Test Pr:

= 4X Test Pro

3(
~

:)

:)
:)
)

Min. Test temp.= MDMT+30 deg.F

B) Pneumatic

,.

(Minimum)
( Maximum)

Tests

Pneumatic test may be used instead of hydrostatic test when:

Vessels are so designed dndsupported

thai they cannot safely by filled with

water.and Vessels for service in which traces of testing liquid cannot be tolerated
Prior to Pneumatic test, Testing of attachment wells asper WU-50 must be
performed

)
)

Test pressure

must not be less Ihan 1.1 limes maxImum allowable working

pressure multiple by the ratio of stress value S for test temperature oi vessel to
~
)
)

"

the stress value S for design temperature.

Min. Test temp.= MDMT +30 deg.F

The pressure in the vessel shall be gradually increased to not more than onehalf of the test pressure. Thereafter, the test pressure shall be increased in steps
of approximately one-tenth of the test pressure until the required test pressure
has been reached Then the piSsure shall be reduced to a value equ21t09/1 0 of
the test pressure and held for a sufficient time to permit inspection of the vessel.
Leakage is not allowed at the time 0; the required visual inspectioil.
Test

gaug9 range limil = 1 5X Test Pr.

= 4X Test Pr

(MillimUill)
( Maximum)

,r
),)

L)

6. INSPECTION & TESlH~G

b
~

From Inspector's Viewpoint, following are the major areas of concern during

manufacture of pr. Vessels.

~
~

A. MATERIAL INSPECTION:

~
~

>
~
~

(
t

1. Materials for Pressure .parts and Non.pressure .parts ... ( UG-4 a,b )
2. Scrutiny of Mill-Certificates-compliance

with specification,

co-relate material with certificate

Identification marks,

( UG-93 a)

3. Additional requirements: Impact test results, PWHT etc ..... ( UG-84,85 )

4. Mill Under-tolerance for plates

( UG-16. c)

5. Tolerances on bought-out heads

(UG-81. a,d)

B. FABRICATION

INSPECTION:

1. Tracability of plate mari<ings/transfer of mari<ing

2. Shell forming, out of roundness

'" __

3. Taper transition, Skirt length of Heads

( UG-8G 2 ,2\
( UW-9 c: fig.UW-13.1 d,I,m,n,o )

4. Scrutiny ofWPS/PQR documents

__

5. \fVelder Qualifications/Re-qualification

of contract welders, caliing and witness

the tests

( UW-26 J,b; UW-28d)

( UW-26c; UW-29 c,d,e; UW- 48 b)

6. Conditions not suitable for welding

7. Alignment tolerances

( UG-n.::: )

8. Weld reinforcement.

( UG-30)

( UW-33)
( WU-35)

9. \'\'eld - penetration, welder identification

10 ?\,\'~T requirements
11 1'!DTofPr.Vessels

( UG-37 a.f)

( UW --40 a2, UCS-56)

(UW-2a,c;

UW-11a-1 t05);UW-11b;UW-57,

UG-93d3; UW-50, UW 51, UW-52 App.4,6,8,12)

12 Pressure testing .....
13 ':':-OJ'2 Stamping.(
1<1 R'2 :)(:<1sand reten tion

( UG-99, UG-100, UG-102 , UW50 for Pneumatic test)

UG-11 G, UG-118 )
( UG- PO )

1.
A.

NDE OF PRESSUR~ VESSELS

SELECTION OF NOT TECHNIQUE W.R. T. WELDING DISCONTINUITY

Applicable

NOT methods I Welding Discontinuities

Discontinuities
Porosity
Slag Inclusion
Incomplete fusion
Incomplete Penetration
Undercut
Overiap
Cracks
Laminations

Applicable

RT

UT

-J
-J

-J

NA

NA

MT

..J"

.b

NA
NA
NA

\'
-J
.
.
\'
\'

-J
-J

NOT

PT

Methods

vr
-Ja

NA
NA
NA

-J

.0

.0

-J

-J

..J"

-J3.C

-Ja
-Ja.c

-Jb.c

Note 1 :
a.
Surface
b.
c.

ET

-J

NA

Surface and slightly subsurface

Weld preparation or edge of base metal
Applicable method
.

. -J

Marginal applicability depending on othertactors such as material thic"ness,

Discontinuity size, orientation and location

~2:
c

Le2 ; testing can reveal only through and through leaks.

Applica~le

NOT methods for Weld joint types

Joints

Butt.
Corner

UT

PT

-J

MT

VI

\1

-J
-J

\'

ET

-J

\1

-J

.
.

-~

Lap

Note

NOT-Methods

RT

\'
I

------;;~

-\1

-J-

'J-~APPlicable

-J
\i

l
I

\'
\'
Y

method

Marginal applicability depending

DisContinuity

--

size,

orientation

I.cc~i-;testrflg C21l reveal Oflly tilrougil

all

other factors such as malerial thickness,

and location

anl~ UiiOUgh leJks

',-'

::I

,
B. CODE REQUIREMENTS OF NDE-jASf\..1E: Sec. VIii Div.1)
1 RADIOGRAPHY REQUIREMENT:
a) Full Radiography
Conditions for which full radiography is specified are the following:

1) All but welds in the shell and heads of vessels

used to contain

lethal

substances must be fully radiographed.

2) If the plate or vessel wall thickness at the weld joint exceeds the thickness
given in table UCS-57, UNF - 57, and UHA - 33, then full radiography

is

required. (e.g. P. No.1, gr 1,2, 3 require full radiography - UCS 57)

3) Butt welds unfired steam boilers with a design pressure exceeding 50 psi.
4) All butt welds in nozzles for vessels 1) & 3) above. In others, category Band
C welds upto NPS 10 and upto 1 1/8 in. thk. do not required radiography.
5) All category A and B welds shall be Type no.(1) or Type no.(2) and shall be
radiographed accordingly.(UW - 12)
6) Category Band

C welds (excluding those in nozzles in 4 above) which

intersect the Category A welds shall be at least spot radiographed.

7) Weld metal build up ( 1 : 3 taper) to be radiographed

same as joint itself.

b) Spot Radiography
1)

Butt welded joints Type (1) or (2) of Table UW - 12 if design efficiency is

selected for spot radiography.

2)

If spot radiography

is specified fOL entire vessel then radiographic

examination is not required of category Band C butt welds in nozzles less

than NPS 10 or 1 1/8 in. thick.

C) No Radiography
No radiography is required if vessel is designed for external pressure or
dosign efficiency (Table UW - 12) is selected for no raciography.

_ UL ;RASONV~: ExAMINATION:
lJarasonic examination may be substituted""' for radiography

for the final

closure seam of a pressure vessel. (UW-11 a7)

3. MAGNETIC PARTICLE EXAMINATIONS:

1. When a pressure part is to be welded to a flat plate thicker than 1/2 in (13
mm) to form a comer joint (fig. UW 13.2). Then MP examination is required on
weld joint preparation prior to welding and also after welding. (few exceptions
described in UG - 93).
2. If vessel is to be Pneumatically Pressure tested.

All welds around openings

and all attachment welds with throat dimension exceeding 6mm ( 0.25 inch)

4, LIQUID PENETRANT EXAMINATIONS:

In case of non-magnetic materials LPE can be substituted for MPE for

above examinations.

C. NOT ACCEPTANCE CRITERIA:

iliaanetic Particle Examination

r MT 1 -

Mandatory Appendix 6

.-

Magnetic Particle Examination shall be performed in accordance with the written

procedure

certified

by the

Manufacturer

to

be

in accordance

with

the

requirements of T-150 of ASME Section-V.

1.1

NDE Personnel:
a.

Shall have a vision, with correction if necessary,

Jaeger Type

to enable reading

NO.2 Standard Chart at a distance of not less than

a
12

inches; and shall be capable of distinguishing and differentiating contrast

between colours used. This requirement shall be checked annually.
b
12

Shall be competent and duly certified in MT techniques

.l;valuation of Indications:
Indications will be revealed by retention of magnetic particles in the orientation of
the possible defects

All such indications are not necessarily imperfections

11O,'IO\ler.Since excessive surface rougtincss, magnetic permeability variations

- l suctl as at the edg~ of na.;l! ~ije(;t :wnec-.\

indications.

(;iC.

:'la~'also riI.~du(;(.;sia:ilar

An indication is the evidence of a mechanical imperfection. Indications which

have dimensions greater than 1/16th of an inch are considered "relevant".
a)

A linear indication is one having a length greater than three times the
width.

b)

A rounded indication is one of circular or elliptical shape with a length

equal to, or less than three times its width.

c)

Any questionable or doubtful indications shall be re-examined to

determine whether or not they are relevant.

Acceptance Standards

1.3

These acceptance standards shall apply unless other more restrictive standards
are specified for specific materials or applications within this Division.
All surfaces shall be free of :

a)
b)
c)

relevant linear indications;

relevant rounded indications greater than 3/16 inch;
four or more relevant rounded indications in a line separated by
1/16

d)

An

inch or less, edge to edge.

indication

of

an

imperfection

may

be

larger

than

the

imperfection that causes it; however, the size of the indication

IS

the basis for acceptance evaluation.

2.

Liquid Penetrant Examination

r PT 1- Mandatory

Appendix 8

Liquid Penetrant Examination shall be performed in accordance with the written

procedure certified by the Manufacturer
requirements of T-150 of ASME Section-V.

2 1

@E
-Cl.

to be in accordance

with

the

Personnel:
Shall have a VISion, with correction if necessary, to enable reading a
Jaeger Type

NO.2 Standard Chart at a distance of not less than 12

IIlChes; and shall be capable of distinguis[ling and differentiating contrast

betwee;~ colours Used. This requirement shall be checked annually.
i)

2 2

SI1311 be competent and duly certified in PT techniques

l~.\l9~13tloll_QLLndic_~o_~

-.-A" indic<:li,"' is

II I.

---- ---

eviden G ot a med:2nical imperfection. Only indica tion wluch

J.dve dimensions grealer Ihan 1/161h ot an inch shall be considered "relevant":

aj

A linear indication is one havieg a length greater than three times the
width.

b)

- A rounded indication is one ot circular or elliptical shape with a length

equal to, or less than three times its width.

,(

Any. questionable

cj

or doubtful

"

indications

shall be re-examined

10

determine whether or not they are relevant

Acceptance Standar~
.

2.3

These acceptance slandards shall apply unless other more restrictive standards
are specified for specific matenals or applications within this Division.
AI/ surfaces shall be free of :

.a)

relevant linear indications;

b)

relevant roun'ded indications greater than 3/16 inch;

cj

four or more relevanl rounded indicalions in a line separaled by 1/16 inch

qr less, edge to edge.

d)

An indication of an imperfeCtion may be larger Ihan the imperfection that

causes it; however, the size of the indication is the basis for acceptance
evaluation .

.-

3.

1lJtrasonic Examination of Welds

Ultrasonic

Examination

r UTJ - Mandatory

shall be Rertormed in accordance

procedure certified by the Manufaclurer 10 be

requirements ofT-150 of ASME Section-V. _
}
3.1
'r

(
32

~mpetence

Appendix 12
wilh Ihe written

in accordance

with

Ihe

of NDE Personnel

. UT Examination Personnel shall be qualified and certified in accordance with

Employers written practice, as per SNT- TC-1A.
~ance

- Rejection Standards

These Siandards shall apply unless other standards are specified for specific
applications within this Division.
Imperfections which oroduco a response greater ::,3n 20% of the reference level
shall be investigate"

to Ihe extent that the opera to. can determine ihe shape,

'''em"y .and lO'3Iio.- of all such i,nperlections, rind evaillale Ihem in terms of the
acceptance slanda~-:;s given in (a) and (b) below-

1;1

I \

Indication's charactedzeu as cr:'lckz.;~ck of fusion or ii1cornp!ete peii8lmii011

(a)

i:.\re

unacceptable regardless o.flength.

Jb)

Other imperfections are unacceptable if ~e indications exceed the

referenc~.Jevel amplitude and have lengths which exceed:
114inch for t upto 3/4 inch;
1/3 t for t from 3/4 in. to 2 1/4 in;

"-

3/4 in. for t over 2 1/4 in;

,

where

,-

is the

reinforcement.

thickness

of the

weld

excluding

any

allowable

For a butt weld joining two members having different

,
I

thicknesses at the weld, t is the thinner of these two thicknesses. if a full

penetration weld includes a fillet weld, the thickr:!ess of the throat of the
fillet shall be included in t.
3:3 Report of ultrasonic examination, including Record of repaired areas and results of
re-examination.

duly verified by the Inspector, shall be retained by the Manufacturer

and incorporated in the Manufacturer's Data Report [ MDR ].

4.

RADIOGRAPHIC

EXAMINATION - CLAUSES UW-51 & UW-52

All welded joints subject to radiography shall be examined in accordance with

,

Article 2 of ASME Section V.

4.1

. NDE Personnel:
RT Examination Personnel shalt be qualified and certified in accordance with
Employer's written practice, as per SNT-TC-1A.

4.2
,

Evaluation of Radioqraphs:
100% Radioqraphy-:
,
The requirements of ASME Section V Article 2 Clause T-280 are used as

guide Final acceptance of radiographs shall be based on the ability to see the
prescribed penetrameter image and the prescribed hole. or the designated wire
of a wire penetrameter.
Indications

shown

impe.fections
Cr

Itena

on

tile

radiographs

of welds

and

characterized

as

are unacceptable under tile following conditions or acceptance

and the repairs are

re-radiographed and evaluated to the same

acceptance criteria.
f\cc_eptCJnc~C:.rl!eri<3.
.. Tile following imperiections are unacceptable

---.-

--

Any" indicClticn charac~~f!::::'::';~as a crack or zone {if incomplete' fllSi,)n ur'

penetration;

Any other elongated i~dication on the radiograph which "has I~ngth

greater than:

1/4 inch for t upto 3/4 inch;

1/3 t for t from 3/4 in. to 2 1/4 in;

3/4 in. for t over 2 1/4 in;

where t

= the thickness

of the weld excluding any allowable reinforcement. For

the thinner of these two thicknesses. If a full penetration weld includes a fillet

weld, the thickness of the throat of the fillet shall be included in t.

Any group of aligned indications that have an aggregate length greater than 't'

a butt weld joining two members having different thicknesses at the weld,

,
,
,
).

in a length of 12t, except when

the distance

or

is

between the successive

imperfections exceeds 6L, where L is the length of the longest imperfection in

the group;

Rounded indications in excess of that specified by the acceptance standards

given in Appendix 4 of ASME Code Sec.vlll Div 1.

4.3

Evaluation of Spot Radiowaphy:

UW-52 of ASME VIII _ 1.

Spot Examination of welds by radiography shall be made in accordance with

Article 2 of ASME Section V. Minimum length of spot radiograph shall be 6
inches (150mml.

p;-cceptance Criteria: : For Spot Radioqraphy

I.

Welds in which, indications

are characterized

as cracks or zones of

incomplete fusion or penetration shall be unacceptable.

II.

Welds in which indications are characterized as slag inclusions or cavities

shall be unacceptable if the length of ani such indication is greater than
2/3t where 't' is the thickness
reinforcement.

of the weld excluding any allowable

For a butt weld joining two members having different thicknesses at the
weld, 't' is the thinner of the two thicknesses. If a full penetration weld
includes 3 fillet weld, the thickness of the throat of the fillet shall be
included in .t'

_---~-_

......

..

_-~.

-----

_h __

------ ..---.

I,',

jr S8\'cr(-~;,

-..

---.. -

ir:,;ic.?,tionswitllin the above iimitations eXist in line, :j"ie 'J-:~lds

shall j"'e judged acceptabieif

the sum of the longest dimens~ons of a:/

such indications is not more than '1' in a lengtt of '61' [or Proportionately
for r9diographs shorter than '61'], ana if the longest indications considered
are separated by atleast 3L, of acceptable

weld metal where L is the

length of the longest indication. '

"The maximum length of acceptable

indications

shall be 3/4 in.

Any

indication shorter than 1/4 in. shall be acceptable for any plate thickness.
"

IV.

Rounded indications are not a factor in the acceptability of welds not

required to be fully radiographed.

Evaluation and Retests in the case of Spot RadioQfaphy:

When a spot radiograph is acceptable in accordance with the above criteria,
the entire weld line represented by this spot radiograph is acceptable.

(
When a spot radiograph discloses an indication unacceptable to above criteria,
then 1'1.'0 additional spots shall be marked by the Inspector, in the weld line
represented by the original sp~t radiograph, but away from the spot. If both the
spots, meet acceptance criteria, and then the defect disclosed in the original
spot is repaired and radiographed to acceptable criteria, then the entire weld
line is considered acceptable. However, if either of the two additional spots"does not comply with the acceptance criteria, the entire represented weld line
shall be" rejected; and either removed or repair-welded and fully radiographed
to acceptance criteria.
'I

..-- ....-.--.-

I,

8.

CODE STAMPING AND REPORTS

GE~.NERAL : The -marking and certification of all pressure vessels built under this
Division shalf comply with the requirements of the following paragraphs,

The units used in Manufacturer's Data Reports, Manufacturer's Certificates of

Compliance (UG-120), and in or stamping pressure vessels shall be either:
(1) U.S. Customary units (ft-Ib) exclusively; or
(2) Both U.S. Customary units and metric, in which case the U.S. Customary units
shall be the standard, and the metric units shall be shown parenthetically.

Required

Marking:

(a) Each pressure vessel shall be marked with the following:

(1) (a) the official Code U Symbol shown in Fig. UG-116 sketch (a) on vessels
inspected in accordance with the requirements in UG-90 through UG-97 (when
inspected by a user's Inspector as provided in UG-91, the word USER shall be
marked above the Code Symbol); or
(b) ,the official UM Symbol shown in Fig. UG-116 sketch (b) on vessels constructed in
accordance with the provision in U-1 0).
(2) name of the Manufacturer

preceded by the words "certified by";

(3) maximum allowable working pressure -------- psi at

OF.
'.
I
0'
,37
(4) minimum deSign mela temperature -------------- F ---~h------pSI
'I

(5) Manufacturer's serial number;

('6) Year built.

(b) (1) The type of construction used for the vessel shall be indicated directly under the
Code Symbol by applying the appropriate letter(s) as follows: vessesls having
Category A, 8, or C joints (except nozzles or for example, Arc welded

~W.

(c) When a vessel is intended for special service and the special requirements [ UG120 (d)], the appropriate lettering shall be applied as i;.;:ed below:
Lethal Service

Unfired Steam Boiler

UB

Direct Firing

DF.

(rl) When a vessel has been radiographed in accordance with UW-11, rrla;king shalt be

applied undp.r-the Code Symbol as follows:

, (1) '''RT 1."-Vessel fully radiographed
(2) "RT 2" when the complete vessel satisfies the requirements of UW-11 (a)(5) and
r

when the spot radiography requirements of UW-11 (a)(5)(b) have been applied; or
.

'

(3) "RT 3" when the vessel satisfies the spot radiography requirements of UW-11 (b); or
.(4) "RT 4" when only part of the 'complete vessel has satisfied the radiographic
requirements of UW-11 (a) or where none of the markings "RT 1", "RT 2", or "RT 3"
are applicable.
(e) (1)The letters HI shall be applied under the Code Symbol when the complete
.
-.
vessel has been postweld heat treated as provided in UW-1 O.
(2)The letter PHT shall be applied under the Code Symbol when only part of the
complete vessel has been postweld heat treated as provided in UW-1 O.

(f)( 1) Except as provided in below, the Code Symbol shall be applied after the
hydrostatic test or pneumatic test.
(2) The Code Symbol may be preapplied to a nameplate. The nameplate may be
attached to the vessel after the final fabrication and examination sequence but
before the hydrostatic tests or pneumatic test provided the procedure for sequence
of stamping is described in the Manufacturer's accepted Quality Control System.

,.-

(h) Parts of vessels for which Partial Data Reports are required in UG-120 (c) shall.~e
'I

marked by the parts Manufacturer with the following:

(1) the official Code Symbol shown in Fig. UG-116 sketch (a), above the word "PART";
(2) name of the Manufacturer of the part of the pressure vessel preceded by the words
"certified by";

(3) the Manufacturer's serial number.

Thisrequirement

does not apply to such items as handhole covers, mandllole covers

and their accessories.

(g) F~emovable pressure parts shall be permanently marked in a manner to identify
them with the vessel or cllamber of which they form a part. This does not apply to
n12nllo!e covers, handllole covers, and tlleir accessory paris

CHAPTER

SUMMARY OF TOPICS FROM ASME SEC. VIII DIV. 1 FOR

NUMERICAL QUESTIONS IN API-510

1)

EXAM.

Joint Efficiencies calculations:

(A)

Weld categories (UW-3):

A, 8, C, 0

(8)

Type of Radiography ( UW-11) :

RT - 1: Full Radiography: Full length, radiography of all but welds
(except NPS ~10 or t n ~ 1Yen)

RT - 2: Full Radiography: Cat - A: Full length radiography

Cat - 8: Spot RT per [UW - 11 (a) 5 (b)]
RT - 3:

Spot radiography as per UW-11 (b ).

RT - 4:

No radiography ( None of RT-1, RT-2, RT-3)

(C)

Joint Efficiency (E) for Welded shells or heads, from Table UW-12.

(0)

Joint Efficiency (E) for seamless Heads & Vessels sections

E = 1.0.
E

UW-11 ( c )

(E)

= 0.85,

If Spot RT of Cat-B joint is done as per (UW _ 11 (a) 5 (b)]

If Spot RT of Cat-B joint is not done as per (UW _ 11 (a) 5 (b)]

Joint Efficiency (E) for Pipes and Tubes ( Seamless and Welded):
1. Treat pipes and tubes as Seamless parts ( i.e. like 0 above)
2. Take allowable stress for that product from the stress tables (which
actually give SE values directly for pipes and tubes)

NOTE:

To understand how to C/100SC correct E: values for seamless / welded / radiographed

vessel components aneJdlSllee! heads, refer Fig L-1.4 -2 &3 from App.-L of Code

:.~) Static head Calculations:

1)

2)

StatiG-Head conversion:

1 ft

0.433 psi'

1 mtr

0.1 bar

Part MAWP : It is the Maximum Pressure permissible for a vessel Part. 1l is

calculated using the code formula and considering available
thickness (excl. C.A.) and allowa~le stress at design temperature.

Part

MAWP

SEt

I (R + 0.6t)

(
3)

VesseIMAWP:

It is the Maximum Pressure permissible at top of vessel when

Vessel is in normal operating position. It is lowest value of all
Part MAWPs . adjusted for static head. ( UG-98 a)

4) Hydrostatic head at any point at a depth 'h' ft from top

0.433 X h

5) Max. pressure acting at any point = Vessel MAWP + Static head

6) Max. pressure acting at any point can not exceed Vessel part MAWP,

7) Safe Vessel MAWP may be recalculated by:

Vessel MAWP

= Part MAWP

0.433 X (static head in ft.)

8) nepth dished heads: ( UG-32 f, UG-32 d )

,
Hemisp. Head = /2 + skirt length (if any)
2.1 Cllip
VVllere

= /4 +

IJ::: 10. of Head

skirt length.

3)

Internal Pressure calculations:

I) Tilicknes'i

of shells under internal'pressure

a) For cylindricaLshelis :
Thk ( t)

P x R I (SE - 0.6P) or P

where - t
R
P
S
E

b)

I (Ri + 0.6t)

is the corroded min. thickness of shell, inches

is the inside radius of the shell,inches (corroded)
is the'design pressure in psig
is the maximum allowable stress value in tension, psi
is the Joint Efficiency [Refer to Table UW-12 ]
is Inside diameter of shell (corroded)

For spherical shells:

t, = P x Ri I (2SE - 0.2P) or P = 2SEt I (Ri + 0.2t)

II} Thickness

= SEt

a)

of formed heads:

Ellipsoidal Heads: ( 2 : 1 type)

t, = P x 0 I (2SE - 0.2P)

or

P = 2SEt I (0 + 0.2t)

A good approximation of 2 : 1 Ellipsoidal head is one with knuckle radius

of 0.170 and spherical radius of 0.90.
b)

TorisphericalHeads:
t,

= 0.885

x P x L I (SE - 0.1 P) or P = SEt / (0.885L + 0.1t)

Inside Knuckle radius= 6% of inside crown radius L, nor less than three
Times knuckle thickness. Ri shall be less than Do.
c)

Hemispherical Heads:

(
t, =

P x R / (2SE - 0.2P) or P = 2SEt / (R + O.2t)

d) .

Flat Heads and Covers (Un stayed)

t,

0 x [ CP / SE ]

1/2

,
where C = a factor derJcnding upon the method of attachment of the flat head
D

Inside diameter of shell inches

4) Pressure t~sting calculations:

'HYDROSTAT',C TEST

Test shall be conducted at test pressure given by:

Test pc = 1,3 x MAWPX

Allow.stress at test temp.

Allow.stress at design temp,

Test shall be after completion of fabrication work; but before painting

Inspection must be made at a pressure not less than : Test pressure /1.3

Code does not specify upper limit but permanent deformation shall be avoided

The MAWP may be assumed to be same as the design pressure

calculations are not made to determine the MAWP

eo

Any non-hazardous liquid may be used at test temp below its Melting Point

Min.Test temp

Inspection should be performed at temperature not exceeding 120 deg.F .

Test gauge range

MDMT + 30

when

F (170 C) when low temp operation is specified

1.5 to 4 times test pressure

PNEUMATIC TESTS

Pneumatic test is used instead of hydro test when:

1. Vessels are so designed and supported that they cannot be safely filled with water
2.

Vessels in service in which traces of testing liquid cannot be tolerated and cannot
be easily dried

, Test pressure must not be less than 1.1 times MAWP multiple
value

for the test temperature of vessel te th8 stress va'~8

FOllowing safety precautions shall be observed.

by the ratio of stress

fc, design temperature.

1) /, ~I \'>'el-:1:-;<:;rr..:und ~I~,:ni'lg:;
exceeding

~mm ( 0.25 incn

&nd ail attachment

weids

shall be MT or P1Ltested

with

throat

dimensivn

prior to applying

Pneumatic

, pressure

2). The pressure

pressure
3). Thereafter,

in ,the vessel shall be gradually

the test pressure

the test pressure

4). Then the pressure

sufficient

shall be increased

until the required

test pressure

shall be reduced

time to permit inspection

time of the required

increased

in steps of approx.

of the test

one-tenth

of

has been reached

to test pressure
of the vessel.

up to one-half

/1.1 , and held for a

Leakage

is not allowed

at the

visual inspection

5). Test temp shall exceed MDMT by 30 F (17C)

(
6). Pro Gauge

range

1.5 to 4 times test pressure

5) Impact- testing Exercises:

/

A)

UCS-66:

MDMT - Thickness

combination

falls on or above the relevant

curve.

Impa"ct test is not required (Exact values in Table 66)

B)

UG-20 (f) : Impact test exempt if,

1. P No 1, gr. No~ 1 and 2
a.
b.

Materials
Materials

2.

Hydrostatic

3.

Design

A thickness < 0.5 inch

B, C, D thickness ~ 1.0 inch

test performed

temp

as required

= -20 F to 650

OF

4 . No cyclic or thermal shock loading

C)

UCS-G8 (c) . If PWHT is performed

'Nhen it is not design

of 10 OF (17C)

exemption

in impact

testing

requirement,

temp may be given

reduction
to minimum

-~~--------------------~-

6\, Reinforcement

of Nozzles:

1., Principle of Reinforcement

Additional area required

2. Notations:

= Area removed = d x tr = Ar

(All refer to corroded conditions)

t, tr

= Shell thickness provided, required respectively

tn, tm

=
=

a, b

Nozzle thickness provided, required respectively

Fillet weld sizes: nozzle to pad, pad to shell respectively
...,

3. Limits of reinforcement:
a)

Parallel to vessel wall on either side of opening 'axis

= dia (d) opening in corroded condition or

= d/2 + t + tn
Use larger value
b)

Normal to vessel wall

='2 1/2 t or
= 21/2 tn + te

use smaller value

( te = Thickness of reinforcement element)

4. Areas available
A 1) Inshell

= d (t - tr)
= 2 (t + tn)(t - tr) - Use larger value

A2) In Nozzle

= 2.5 t (tn-trn)
= 2.5 tn (tn-trn) '" ..... Use smaller value

(
5 Pad area required
Ap = Ar - [ A 1 + A2

6. Heinforcement wai\'ed for sinqle openinqs, in the case of,

,

Fi'lished opening size 3;1;." diameter in shell or head of thickness %" or less;

Finished opening size 2 'le" diameter in shell or head of thickness over %";

')Z

~(

-{

-..>
~

7) A.tb.;;chrnentwelds for nozzles:

~
~
~

, Nozzle construction shall be conforming to one of the code accepted t}lpe (UW _ 16)

NOTATiONS:
Radius

((

= 1/8 in. (3.2 mm)

= minimum inside
~I

minimum blend radius

corner radius, the lesser of

or y.; in.

53

(!)f

COURSE

f\JOTES .

VOLUME - I I

STUDY OF

API 510R
, INSPECTION CODE

/
I
'I

OBJECTIVE OF API- 510 CERIFICATIQN

The objectfve of API-510 certification
accreditation

program

IS

to provide a system of

of inspector who possess adequate level of specialised knowledge and

skill to draw up and execute quality systems and inspection programs so as to

provide high level of integrity and improve management control for safe operation of
the Pressure
methods

Vessels.

procedure

It is intended to create awareness towards establishing

for inspection on the basis round technical considerations

promoting self-regulatiofJ.and

improve levels of safety.

API-510 standard is based on the accumulated knowledge and experience of

owners, operators, manufacturers, and repairers of Process equipments. The object

of this publication is to provide guidance in the inspection, repair, alteration, and

reconstruction

of Pressure Vessels used in the petroleum and chemical industries.

The rules given in this standard are minimum requirements.

Each edition,
beginning
revision,

reVISion, or addenda

with the date of issuance shown on the cover page for that edition,
or addenda.

becomes

to this API standard may be used

effective

Each edition,

revision, or addenda to this API standard

six months after the date of issuance for equipment that

is

certified as being rerated, reconstructed, reconstructed, relocated, repaired, modified

(altered),

inspected,

and tested per this standard.

between the date of issuance of the edition , revision

date, tile purchaser

During the six-month

time

or addenda and the effective

and manufacturer shall specify to which edition, revision,

or

addenda the equipment is to be rated, reconstructed, relocated, repaired, modified

(altered), inspected, and tested.

It shall be remembered that if any federal, state, or municipai regulation with

may conflict which this ArJl standard then the regulations
starin: :Id

shall prevail over API

j)

'.

.CHAPTER
..
Pressure Vessel Inspection Code
Maintenance
1.

Inspection, Rating, Repair, and Alteration

Scope

1.

This

inspection

alteration,

code covers

the maintenance

inspection,

repair,

and re-rating procedures for pressure vessels used by the

.petroleum and chemical process industries.

2.

This inspection code applies to vessels constructed in accordance with

the APlIASME
Liquids

and

recognized
other

Code for Unfired Pressure

Vessels

Gases, Section VIII of the ASME

for Petroleum

Code,

and other

pressure vessel codes ; to nonstandard vessels ; and to

vessels

constructed

non-code

or approved

as jurisdictional

special.

3.

This inspection

code

IS

only applicable to vessels that have been

placed in service.
4.

Hie

following

are excluded from the' specific

requirements

of this

inspection code

a.

Pressure

vessels

jurisdictional

on movable

structures

covered

by otrler

regulations

All classes of containers listed for exemption from construction

In the scope of Section VIII, Division 1, of the ASME Code.

')
{"

.,

Pressure vessels that do /lot exceed tne following vOlump.s and

pressures:

1.

Five cubic feet (0.14 cubic meters) in volume and 250

pounds per square inch (1723.1 kilopascales)
pressure.

design

2.
One and a half cubic feet (0.042 cubic meters) in volume
and 600 pounds per square inch (4136.9 kilopascales)
...,
design pressure.

CHAPTER 2
References
I

The most recent editions of the following standards, codes, and specifications are
cited in this inspection code.
\
1:

API

'I

II
I

RP 572

Inspection of Pressure Vessels

RP 574

Inspection of Piping, Tubing, Valves, and Fittings.

,RP 576

Inspection of Pressure- Relieving Devices

r,.
Guide for Inspection of Refinery Equipment, Chapter II,
" Conditions Causing Deterioration or Failures"

/'

Boiler and Pressure Vessel Code, Section V, Section VI, Section VII, Section
VIII, Section IX, and Section IX.

National Board

.National Board Inspection Code.

_\

"CHAP'fER 3
Definitions

For the purposes of this standard, the following definitions apply.

Alteration

A physical

change in any component or a re-rating that has design

implications that affect the pressure-<:ontaining capability of pressure vessel beyond

the scope of the items described in existing data reports.

The following should not

be considered

alterations, any comparable or duplicate replacement, the addition of

any reinforced

nozzle less than or equal to the size of existing reinforced nozzles,

and the addition of nozzles not requiring reinforcement.

ASME Code

: Abbreviation

and shortened title for the ASME Boiler and Pressure

Vessel Code. This abbreviated title includes the addenda and Code cases of the
ASME Boiler and Pressure Vessel Code.

Authorized

Pressure

Vessel

tnspector

An employee

of an authorized

inspection agency who is qualified and certified to perform inspections under this
inspection code.

Authorized

Inspection

Agency:

Anyone of the following

a ..

The inspection organization of the jurisdiction in which the pressure vessel is

used

b.

The inspeclion

organization

of an insurance

company

thai is licensed

registered to write and actually does write pressure vessel insurance.

or

c.

Th8 inspection organization of an owner

maintains. an. inspection organiz~tion

~Iessure \ ve~sel who

vj" u~;::,( 'Jf

for his equipment

only and not for

vessels intended for sale or ,resale.

d.

An independent organization or individual that is under contract to and under

the direction of an owner-user and that is recognized
prohibited
owner-

by the jurisdiction

user's

inspection'

in which the pressure

program

shall

provide

ddor otherwise

vessel is used.
the controls

not
The

that

are

necessary when contract inspectors are used.

Construction

Code

: The code or standard to which a vessel was originally built,

such as API/ASME, API, or State Special/non-ASME.

Inspection

code

Jurisdiction

: Shortened title for API 510 used in this publication.

A legally constituted government administration

that may adopt

rules relating to pressure vessels.

Maximum

allowable

working

pressure

: The maximum gauge pressure permitte.d'

at the top of a pressure vessel in its operating position for a designated temperature.
This pressure
thickness

is based on calculations

using the minimum (for average

for all critical vessel elements,

exclusive

of thickness

pitted)

designated

for

corrosion and loadings other than pressure.

Minimum

allowable

a vessel.

shell thickness

: The thickness required for each element of

The minimum allowable shell thickness is based on calculations

that

consider temperature, pressure, and all loadings.

On-stream
pressure

vessel

procedures
may

flCl(

inspection

The inspectiOl1 used to establish

for continued

operation

Non destructive

the suitauility
examination

of a
(NDE)

are used to establish the suitability of the vessel, and the vessel mayor

he In operation vvhilc the inspection

IS

being camed

OIJt

Because a vess<c:!

m;~y t.'::;

:Jperatir,m whi;c an on-strealJl inspection is being carried out, an on-stream

!:1

inspection

means essentially that the vessel is not entered for internal in:>pection.
,

Pressure

vessel

THis dpressure

: A container qesigned to'withstand internal or external pressure.

may be imposed by an external source, by the application of heat

from a direct or indirect source, or by any combination thereof.

Pressure

vessel

acceptable

to the owner-user

engineering

disciplines

characteristics

engineer

Shall be one or more persons or organizations

who are knowledgeable

associated

with

evaluating

and experienced
mechanical

and

in the
material

which affect the integrity and reliability of pressure vessels.

pressure

vessel

engineer,

regarded

as a composite

by consulting

with appmpriate

The

specialists, should

be

of all entities needed to properly assess the technical

requirements.

Quality

assurance

determine

All planned, systematic, and preventative actions required to

if materials,

equipment, or services will meet specified requirements

so

that equipment will perform satisfactorily in service.

Repair

: The work necessary to restore a vessel to a condition suitable for safe

operation

at the design conditions.

pressure,

the requirements

addition

or replacement

If any repair changes the design temperature or

for re-rating

shall be satisfied.

A repair can be the

of pressure or non-pressure -parts that do not change the

rating of the vessel.

Repair organization
a.

: Anyone

of the following

The holder of a valid ASME Certificate of Authorization that authorizes the

use of an appropriate ASf\~r::Code symbol stamp.

0n ovmer
WI

or user of pressure vessels who repairs his or her own equipment

2cco;dance

with this inspection code

'-j

c.

A contractor whose qualificatiofl.s are- acceptab!.~ io the prE:::sure-vessel

owner or user and who makes repairs in accordance with this inspection
\

code ..

d.

\ An individual or organization that is authorized by the legal jurisdiction.

Re-rating

: A change in either the temperature ratings or the maximum allowable

working pressure rating of a vessel, or a change in both. The maximum allowable

working temperature and pressure of a vessel may be increased or deceased
because of a re-rating, and sometimes a re-rating requires a combination of
changes. Re-rating below original design conditions is a permissible way to provide
for corrosion.
(

When a re-rating is conducted in whi~h the maximum allowable

working pressure or temperature is increased or the minimum temperature is

decreased so that additional mechanical tests are required, it shall be considered an
alteration.

Examiner

: A person who assists the API authorized pressure vessel inspector by

performing specific NDE on pressure vessels but does not evaluate the results of /
those examinations in accordance with API 510.

(
*********

CHAPTER 4
Owner - User Inspection Organization
4.1

GENERAL

An owner or user of pressure vessels who controls the frequency

inspectiol}s

of the

of the pressure vessels or the maintenance of them is responsible

for the functions of an authorized inspection agency.

4.3

OWNER - USER ORGANIZATION

An owner - user organization

implementing,

RESPONS~81L1T1ES

is responsible for developing

documenting,

executing, and assessing pressure vessel inspection systems

and inspection procedures that will meet the requirements of this inspection
code.

These

systems

and procedures

will

be contained

In a quality

assurance inspection manual and shall include the following.

a.

Organization

and reports of structure for inspection personnel.

b.

Documentation

and maintenance of inspectioll_and quality assurance

procedures.

(
c.

Documentation

d.

Corrective action for inspection and test results.

c.

Intemal audits for compliance with the quality assurance inspection manual.

--~-~-"-----_

_-------

..

and reports of inspection and test results.

~
~

-"--'---'-"'-'--'-'

_A,

.._._

... _

._

. _

... _

f.

~eview and approval of drawings, dE7si::~tn

:..:.a~";L:lation$,
and sjjecifications
repairs, ?lterations

for

and ratings.

g.

Assurance

that all jurisdictional

repairs, alterations,

requirements

for pressure vessel inspection,

and rerating are continuously

met.

~
~

h.

Reports to the authorized pressure vessel inspector any process changes

that could affect pressure vessel integrity.

;
I.

Training

requirements

techniques,

for inspection

and technical knowledge

personnel

regarding

inspection

tools,

base.

,
,

J.

Controls

necessary

so that only qualified

welders

and procedures

are used

for all repairs and alterations.

k.

Controls
personnel

I.

Controls

necessary

so that. only qualified

nondestructive

examination

(NOE)

and procedures are utilized.

necessary

so that only materials

conforming

to the applicable

section of the ASME Code are utilized for repairs and alternations.

m.

Controls necessary so that all inspection measurement

are properly maintained

{
I..

n.

Controls

necessary

organizations

and test equipment

and calibrated.

so that

the work

of contract

meet the same inspection

requirements

inspection

or

repair

as the owner - user

organization.

o.

Internal

auditing

relieving

devices.

requirements

for the quality

control

system

,or pressure

.~.4

API AUHOr-<:~SED
PRESSU~E VESSEL INSPECTOR DUTY

.When inspections, repairs, or alterations are being conducted or pressure

vessels, an API authoriz(::dpressure vessel inspection shall be responsible to

the owner - user for determining that the requirements of API 510 on

inspection, examination, and testing are met, and shall be directly involved in

the inspection activities. The API authorized pressure vessel inspector may

be assisted in performing visual inspections by other properly trained and

qualified individuals who mayor Illgy not be certified vessel inspectors.

'.

**********

l'

-'.
i

CHAPTEFI 5

INSPECTION PRACTICES
'5.1

Preparatory

work

Safety precautions are important in pressure vessel inspection because of the

limited access to and t~e confined spaces of pressure vessels.
Safety and Health Administration

( OSHA)

regulations

Occupational

pertaining to confined

spaces and any other OSHA safety rules should be reviewed and followed
where applicable .
.

,f

\.
For an internal inspection,
p08itive

the vessel should be isolated by blinds or other

methods from all Sources of liquids, gases, or vapours.

The vessel

should be drained, purged, cleaned and ventilated and gas tested before it is
entered.

Where

required,

protective

equipment

should

be worn that will

protect the eyes, lungs, and other parts of the body from specific hazards that.
may exist in the vessel.

5.2

MOdes of deterioration

Contaminants

cause

in fluids handled in pressure ve..ssels may react with metals and

corrosion.

particularly

and failure

Stress

reversals

in parts of equipment

at points of high secondary

stress.

Of stresses

are common,
are high and

reve.-::;als are frequent, failure of parts may OCcur because of fatigue.

failures

in pressure

pressure

chang~s.

of expansions

------.---

-----~

vessels

Fatigue

may Occur because of cyclic temperature

ana

Locations where metals with different thermal coefficients

are welded together may be susceptible

to thermal fatigue.

,
Oeterior~tion

or creep may o.ccur

above

for 'which

those

temperatures,

and

permanently

Since

chemical

metals

may cause failures,

If excessive temperatures

stress concentration.
property

it is ( esigned.

such distortion

is ~ubjected

if equipment

changes

weaken equipment.

in

to temperatures

weaken

particularly

at points

are encountered,

metals

may

take

Creep is dep(mdent

at higher
of

structural-

place

that

may

on time temperature,

and stress, so the actual or estimated levels of these quantities shall be used
in any evaluations.

At subfreezing

temperatures,

water and some chemicals

handled in pressure

vessels may freeze and cause failure.

(
At ambient temperatures,
Susceptible
brittle

to brittle failure.

fracture

transition
required

carbon, low-alloy,

of steels

temperature
hydrostatic

A number of failures

that. were

test pressure;

or overload)

Although

excessive

operating

evaluated,

the potential

pneumatic

testing

loadings

below

of equipment

than

stress level

(the

their
of the

have

first hydrO

temperature

because

or the addition
Special attention

of re-hydro

of any other

of

shall

be

testing

or

additional

should be given to low-

2 X Cr-1 Mo ) because they may be prone to temper

[ Temper

embrittlement

Other ;orms of deterioration,

carburization,

however,

to

for a brittle failure because

is a loss

of ductility

toughness due to postweld heat treatment or high-temperature

7000 F ) (3700 C) ]

attack

below

20 percent

fractures,

the transition

for a brittle failure

shall also be evaluated.

embrittiement,

most brittle

the potential

have been attributed

to temperatures

greater

of a particular

conditions

alloy steels ( especially

exposed

and to pressures

OCcurred on the first application

test

and other ferritic steels may be

such as stress corrosion

graphitization,

and erosion,

:'12)'

and

notch

service (above

cracking,

hydrogen

also OCcur under

special circumstances.

These forms of deterioration

are more fully discussed

in Chapter If of the API Guide for Inspection for Refinery Equipmc:'nt.

5.3

CORROSION-RATE

DETERMINA TfON

For a new vessel or for a vessel for which service

conditions

changed, one of the following methods shall be employed

are being

to determine

the

vessel's probable corrosion rate. The remaining wall thickness at the time of
the next inspection can be estimated from this rate.

A corrosion rate may be calculated from data collected

.(

by the owner or user

on vessels providing the same or similar service .

If data on vessels providing the same or similar service are not available,
corrosion

rate may be estimated

from the owner's

or user's experience

from published data on vessels providing comparable

If the probable corrosion rate cannot be determined

above,

on-stream

hours of service
nondestructive
Subsequent

determinations

thickness

determinations

corrosion

measurements

by either item a or item'b

monitoring
of

or

service.

shall be made after approximately

by using suitable

the

devices

vessel

shall be made afier appropriate

or

1000

or actual
system.

intervals until the

corrosion rate is established.

If it is determined

that an inaccurate

corrosion

rate has been assumed,

the

rate to be used for the next period shall be increased or may be decreased

to

agree with the actual rate.

5.4

MAXIMUM ALLOWABLE WORKING PRESSURE DETERMINATION

The maximum allowable working pressure for the continued
vessel shall be based on computations

.<.

that are determiW;d

;1

.c

use of a pressure
using the latest

edition ,of 'the ASME Code or the r.onstruction code to which the vessel
built.

The

computations

resulting
shall

maximum

allowable

working

Vva~'

pressure -from these

not be greater than the original

maximum allowable

working pressure unless a rerating is performed in accordance with 7.3

5.5

INSPECTION OF PARTS

The following inspections are not all inclusive for every vessel, but they do
include

the features that are common to most vessels and that are most

important.

("

Authorized pressure vessel inspectors must supplement this list

with any additional

involved.

a.

items necessary

for the particular

vessel or ve'ssels

Examine the surfaces of shells and heads carefully for possible cracks,
blisters, -bulges, and other

signs of deterioration.

Pay particular

attention to the skirt and to support- attachment and k'luckle. regions of

the heads.

If evidence of distortion is found,

it may be necessary to

make a detailed check of the actual contours or principal dimensions of

the vessel and to compare those contour s and dimensions with the
original design details.
b.

Examine

welded

joints

and the. adj~cent

service induced cracks or other defects.

heat-affected

zones

for

On riveted vessels, examine

rivet head, butt strap, plate, and caulked edge conditions.

If rivet-

shank corrosion is suspected, hammer testing or spot radiography

at

an angle to the shank axis may be useful.

Examine the surfdces of all manways. nozzles, and oth9r openings for
distoriion. cracks, and other defects, paying particular attention to tile
'.\felding used to attach the parts and their reinforcements.

Normally,

'.veep holes in reinforcing plates should remain open to provide visual

, c

.\ J

/'

~vid8Iil.:e

(Ii

:a:Jkage as we!! as to prevent pressure built-up irf the

cavity. Examine ,accessible flange faGes for distortion_and determine

the condition of gasket-seating surfacE::s.

API Recommended Practice 574 can provide more information on the

inspection of piping, valves, and fittings associated with pressure
vessels.

API

Recommended

Practice

information on pressure vessel inspection.

1 ('

tU

572 can

provide

more

'(

CHAPTER 7
Repairs, Alterations, and Re-rating of Pressure Vessels
7.1

GENERAL

This section covers repairs and alterations to pressure

The requirements

that must be met before pressure

are also covered

in this section.

performed,

the applicable

vessels by welding.

vessels can be rerated

VJhen repairs or alterations

requirements

of the ASME

which the vessels were built, or other specific pressure

have to be

Code, the codes

to

vessel rating codes

shall be followed.

7.1.1

Authorization

All repair and alteration work must be authorized

pressure

vessel

organization.

inspector

Authorization

by the authorized

before the work

is started

for alterations

to pressure

by a repair ....
vessels

that

comply with Section VIII, Divisions 1 and 2, of the ASME Code and for
repairs to pressure vessels that comply with Section VIII, Division 2 of
the ASME code may not be given until a pressure
experienced
alterations
7.1.2

vessel engineer

in pressure vessel design has been consulted

about the

and repairs and has approved them.

Approval
The authorized

pressure vessel inspector

shall approve

all specified

repair and aiteration work after an inspection

of the work has proven

the work to be satisfactory

witnessed.

pressure

and any required

. 1'1u/

I.l

, '
/'

test has been

7.1.3

Defect Repairs

A crack in a welded joint and a defect in a plate may be'repaired

preparing

by

a U- or V- shaped groove tQJhe full depth and length of the

crack and then filling the groove with weld metal.

Corroded
deposit.

areas, as defined ~y 5.7 may be restored with weld metal

The nondestructive

for the extent of restoration

examination

and inspection

being performed

appropriate

shall be specified

in the

repair procedure.

7.2

WELDING

All repair and alteration welding shall be in accordance

requirements

7.2.1

with the applicable

of the ASME c<;:>de,except as permitted in 7.2.11.

Procedures

and Qualifications

The repair organization

procedures

shall use qualified welders and welding

qualified in accordance with applicable

requirements

of

Section IX of the ASME Code.

7.2.2

Qualification

Records

The repair organization

procedures

and its welding performance

shall be available

code

qualifications.

These records

to the inspector prior to tre start of welding.

repair organization's
performance

shall maintain records of its qualified welding

qualified welding procedures

qualifications

The

and welding

shall be in accord with the appropriate

7.2,3

Heat Treatment - Preheating

'For alterations or repairs of vessels initially postweld heat treated

as a

code ,requirement and constructed of P-1 and P-3 steels listed in the
ASME Code, preheating to not I~ss than 3000 F ( 150 F ) maya be
considered as an alternative

to post weld heat treatment.

The use of

this minimum preheat alternative is to be restricted to preheating

those

steels that meet the ~xemption criteria found in UCS-56 (f) (1) through
(4) of Section VIII. Division 1, of the ASME Code.
weld exceeds

the maximum

thickness

exempt

If the depth of the

fr,om postweld

heat

treatment, the repair weld or alternation shall be postweld heat treated

in accordance with the applicable requirements

of the ASME Code.

Vessels constructed of other steels that initially required postweld

treatment

shall normally

be postweld heat treated

heat

if alternations

or

repairs involving strength welding are performed.

7.2.4

Temper Bead Welding

For weld repairs of vessels originally postweld heat treated as a code

requirement

and constructed

Code, a temper

of P-1 and P-3 steels listed in the ASME

bead welding

postweld heat treatment.

may be used

of 350F ( 175C)

interpass temperature

of

is to be

must be met.

The weld area shall be preheated and maintained

temperature

in lieu

If a temper bead welding technique

used, the following requirements

a,

technique

during welding,

shall be 450F ( 230C ),

,
t

.'.

[\

"

'

at minimum

The maxirnum

b.

.The initial alay~r of weld metal shall be deposited over the entire
area with X inch ( 3 milimeter ) maximum diameter electrodes~~ ...
Approximately one-half

the thickness

of this layer

shall

be

removed by grinding before subsequent layers are deposited.

Subsequent layers ah" be deposited with 5/12 inch ( 4 milimeter
) maximum

diameter

electrodes

in

a manner

to

ensure

tempering of the prior beads and their heat affected cones.

final

temper

bead

reinforcement

layer

shall

be

The

removed

substantially' flush with the surface of the base material or the

previous weld layer.

c.

Heat input shall be controlled within a specified range of welding

current and voltage.

d.

The weld area shall be maintained at a temperature of 500F 2:

50F ( 260C 2: 28C) for a minimum of 2 hours after completion
of the weld repair.

e.

The repair

welding

shall be witnessed

by the authorized

pressure vessel inspector.

f.

The weld metal shall be deposited by the manual shielded metal

arc process using low hydrogen electrodes.

The maximum

bead width shall be four times the electrode core diameter.

g.

The use of the temper bead welding technique is to be restricted

to temper bead welding those steels that meet the postweld
heat treatment

exemption

criteria

lhrough (4) of Section VIII, Division

fOUGd in UCS-56
1, of the ASME Code.

(f)

(1)

If the

depth of the repair exceeds the maximum thickness exempt

from local postweld heat treatment, the repair weld shall

('"

/
j.J

"

~
':

~)

be

postweld

heat treated

requirements

In

accordance

with

the

applicable

of the ASME Code.

7.2.5 Local Postweld Heat Treatment

Local postweld heat treatment ( PWHT ) may be substituted

degree

banding

on local repairs on all materials,

following precautions

a.

The application
pressure

b.

engineers

that the

are met

is reviewed, and a procedure

vessel

engineering

are taken and requirements

provided

for 360

experienced

is developed

in the

by

appropriate

specialities.

The suitability of the procedure is evaluated.

In evaluating

and

developing

procedures,

the

overall

locat, postweld

and local

heat

treatment

strains and distortions

resulting

from

heating of a local restrained area of the pressure vessel

the
shell/

shall be considered.

c.

A preheat of 300F ( 150C) or higher, as specified by specific

welding procedures,

d.

is maintained during welding.

The required local postweld heat treatment temperature

maintained

shall be

for a distance of net less than two times the base

metal thickness measured from the weld.

e.

Heat shall be applied to any nozzle or any attachment within the

local postweld heat treatment 3rea.

-r.ts

Repairs to Stainless Steel Weld Overlay and Cladding

The repair procedure(s) to restore removed, corroded, or missing clad or overlay

areas shall be reviewed and endorsed prior to implementation

by the pressure

vessel
, engineer and authorized by the inspector.

Consideration

shall be given to factors which may augment the repair sequence

such as stress level, P number of base material, service environment, possible

previously dissolved hydrogen, type of lining, deterioration of base metal properties
(

by

temper

pressurization

embrittfement

of

chromium-molybdenum

alloys

),

minImum

temperatures, and a need for future periodic examination.

For equipment which is in hydrogen service at an elevated temperature or which

has exposed base metal areas open to corrosion which could result in a significant
- atomic

hydrogen

migration

in the base metal, the repair must additionally

considered by the pressure vessel engineer for factors affecting the following
a.

Outgassing metal.

b.

Hardening of base metal due to welding, grinding, or arc gouging.

c.

Preheat and interpass temperature control.

d.
Postweld
properties.

heat

treatment

to reduce hardness

and restore

be

mechanical

After COoling to ambient temperatures, the repair shall be inspected by the liquid
penetrant method, according to ASME Code, Section VI/I, Division 1, Appendix 8.

For vessels constructed with P-3, P4, or P-5 base materials, the base metal in the
area of reoair should be examined for cracking by the ultrasonic examination
accordance

with ASME

Code, Section V. Article

5, paragraph

T-543.

in

This

Inspection-Is most appropriately accomplished following a delay of at least 24 hours

'() ,)
:

-I-.:

afte, completed; repairs for equipcuent in hydrogen service and for chromiummolybdenum all~ys that could be affected by delayed cracking.

7.2.7 Design

Butt joints shall have complete penetration and fusion.

when repairing them is likely to be inadequate.

Parts should be .replaced

Part replacements shaH be

fabricated according to the applicable requirements of the code. New connections

may be installed on vessels as long as the design, location, and method of
attachment comply with the applicable requirements of the appropriate code.

Temporary repairs may remain in place for a longer period of time only if evaluated,
approved, and documented by the pressure vessel engineer and the authorized API
pressure vessel inspector.

Filet welded patches may be applied to the internal or

external surfaces of shells, heads, the headers as long as, in the judgment of the
authorized pressure vessel inspector, either of the following is true :
/'

a.

The fillet welded patches provide design safety equivalent to reinforced

openings designed according to the applicable section of the ASME Code.

b.

The fillet welded patches are designed to abs<?,rbthe membrane strain of the

parts so that in accordance with the rules of the applicable section of the ASME
Code, the following result :

"
1.
The allowable membrane stress is not exceeded in the vessel parts or the
patches.

/..
T!;e sirainCi in t~e patches does not result In fillet weld stresses that exceed
allowable stresses for such welds.

23

"

-Overlay patches shall have rounded corners. Flush (insert) patches shall also have
rounded corners, and they shed be installed with full penetration butt joints.

7.2.8 Material

The material used in making repairs or alterations shall conform to the applicable
section of the ASME Code. Carbon or alloy steel with a carbon content over 0.35
percent shall be not be welded.

7.2.9 Inspection
/

Acceptance criteria for a welded repair or alteration should include nondestructive

examination techniques that are in accordance with the applicable sections of the
applicable

vessel

code.

Where use of these nondestructive

examination

techniques is not possible or praGtical, alternative nondestructive examination

methods may be used.

7.2.10

Testing

After repairs are completed, a pressure test shall be applied if the authorized
pressure vessel

inspector believes that one is necessary.

A pressure test is

normally required after an alternation. Subject to the approval of the jurisdiction,

,

'.

appropriate nondestructive examinations shall be required where a pressure test is

not performed.

Substituting nondestructive examination procedures for pressure

test after an alteration may be done only after a pressure vessel engineer
experienced in pressure vessel design and the authorized
inspector have been consulted.

7.2.11

'~

.J.~

..)

Filler Metal

pressure vessel

.......
The filler

metal used for weld repairs should have minimum specified

tensile

strength equal to or greater than the minimum specified tensile strength of the base
metal.

If a filler metal is used that has a minimum specified tensile strength lower

than the minimum specified tensile strength of the base metal.

In addition,

the

fbllowing shall be met :

a.

The repair thickness shall not be more than 50 percent of the required base

metal thickness, excluding corrosion allowance.

b.

The thickness of the repair weld shall be increased by a ratio of minimum

specified

tensile strength of the base metal and minimum specified tensile ,of the

filler metal used for the repair.

c.

The increased thickness of the repair shall have rounded corners and shall be

blended into the base metal using a 3 to 1 taper.

d.

The repair shall be made with a minimum of two passes.

7.3

RERATING

'Rerating a pressure vessei by changing its temp~rature ratings or its maximum

allowable working pressure may be done only after all of the following requirements

have been met

a.

Calculations

engineer

from either the manufacturer or an owner user pressure vessel

experienced

in pressure vessel design, fabrication,

or inspection

shall

justify rerating

b.

A rerating

constructio:i

--,,#

shall be established in accordance with the requirements

of the

code to which the press:.Jre vessel was built or by computations that

--.:....-.---

-"'

--_.-

-.-.-- ..

.:...aredetermined using the ~ppropl:jate formulas in the latest edition of the ASME
Code. '

c.

Curre'nt inspection records verify that the pr-essure vessel is satisfactory for

the proposed service conditions and that the corrosion allowance provided is
appropriate.

d.

The pressure vessel has at some time been pressure tested in accordance

..

with the new service conditions, or the vess~J integrity is maintained by special
nondestructive evaluation inspection techniques in lieu of testing.

e.
The pressure vessel inspection and rerating is acceptable to the authorized
pressure vessel inspector.

The pressure vessel rerating will be considered complete when the authorized
pressure vessel inspector oversees the attachment of an additional nameplate or
additional stamping that carries the following information
Rerated by

-----------------------Maximum Allowable Working Pressure -

~:
, .. A,

Date

.Psi at

FO

~re

determined using the appropriate formulas in the latest edition of the ASME

Code ..

c.

Current inspection records verify that the pr-essure vessel is satisfactory for

the proposed service conditions and that the corrosion allowance provided is
appropriate.

d.

The pressure vessel has at some time been pressure tested in accordance

with the new service conditions, or the vesseJintegrity is maintained by special

nondestructive evaluation inspection techniques in lieu of testing.

e.

The pressure vessel inspection and rerating is acceptable to the authorized

pressure vessel inspector.

The pressure vessel rerating will be considered complete when the authorized
pressure vessel inspector oversees the attachment of an additional nameplate or
additional stamping that carries the following information :

Rerated by

-----------------------Maximum Allowable Working Pressure

,.
'..

Date

26
-:)

:)
,)

,''',

.psi at

FO

API - 510

COURSE' NOTES

VOLUME

- I I

=:.:...

================--"'"

STUDY OF

API

,-'\

..

-J
~-:)

.....
~~
.,i J

I-'L

___

RP. 572

--.0

~'~s;'~~i:""",",~~r>'
' '"
llIr

-=-

=-.;..,.;.;....
==---="'-=---''----=----

' ';;;.

API - RP 572
INSPECT/ON

OF PRESSURE VESSELS

1. Scope

This RP pcovides sUPPorting infOnnation fo, inspection of p'essu'e

vesseis. The

inspection 'equicements a'e cOve'ed in API 510 code while RP 572 gives pcactical
guide lines fo meet fhese ,equi,ements Wilh emphasis on safely.
It includes

fOl/owing:

Types of presSure vessels

Construction

Standards

Maintenance

inspection

Reasons for inspection

Cause of Deterioration

Frequency and time of inspection

Methods of inspection and limits

Methods of repair

Records and reports

2. Types of PresSure Vessels

COde.
A PCessuceveSSelis

a Conlaine' Ihat falls wilhin the scope of Section VIII of the ASME

I! " LUil! as Pe, va,ious slipulations and "quicements of section VIII code",
fllethods

of constructions,

Pressure

vessels are horizontal type and vertical type.

Based au Iype of sUppon ie.

Saddfe

supponed, Skin SUppolfed, ',u9 SuPPO".d

VeSSels can be sPhelic31 0' cylindrical wilh vacious Shapes of d"'''d

---.

cegacds

materials of constrUctions.

-._- ---.- ..----.

--

ends

----------~-----._---- --------- -. --------

'1

---.. --------

--~",":'r~,,
__ ----"'-------

__

-~--i

~T'~
~'-T"~

:'!. Co.lsrruction

",' T'~
,,,
r~

~, I"~

f'r~

I :>

C:.]

t'.

Other national or international

codes are periodically

construction

materials become available.

5. Reason

5.1
(
"

5.3

revised as the designs of PVs improve and as new

to the requirements

under which it was designed

it should be maintained

according

to the requirements

under which it was

for inspection

General: To determine the physical condition of the vessel and to determine

the

Safety: Periodic scheduled inspections

emergency

or unsafe operation

Continuity:

Periodic inspection

can reveal conditions

can lead to a well-planned

that might result in

maintenance

program

leading to a safe, reliable plant.

t: I .;l

5.4

c]~
e. I ~
( I~

Reliability:

External inspections

made during equipment

operation

may reveal

important information without requiring the equipment

to be opened.

Defects

of parts, undue vibration,

such as leaks, cracks,

improper installation

unusual noises and another evidence

(.j ~

of malfunctioning

may be found

,;J

e..:.;>

If this

e> J .::>

6. Causes

61

is analyzed

and correctiYe

steps

are taken,

the overall

of Deterioration

General
the

~ .. j .~

Deterioration

environment.

electrochemical

~ ..~
~'

information

reliability of operations will improve.

~,l.~

el::>

is possible
The

on all vessel surfaces

Deterioration

may

either due to content

be

mechanical,

or

chemical,

in nature.

.~

~ ..

~> .~

5.2

Corloslon

Corrosion

is the prime cause of deterioration

internal

ccrrodents

in refineries

.~

C;. " .~

COrll[)n'.lficJS.

:, .-.
I'''~

;)

..I

I'\.~

,~

'.J

in a pressure

vessel

Cllili may occur on any pari of the vessel

Tile :110st common

~~

'-.

authority.

type, rate, and causes of deterioration.

5.2

t. ];l

"-c.

to the jurisdiction

Inspection

Construction

If re-rated,

I:~

(:

code as acceptable

re-rated.

c..r~

c'l ~
~'I..~

and constructed.

,-. 1 ~
t.

ASME Sepi')n VIII, Div. 1, Div. 2

PV should be maintained according

'", I'~
,. I .,;)
I ,:)

4. Maintenance

~'r'~
f-'r~

C-

Standards

are sulfur

and chloride

External

corrosion,

conditions

6.3

Erosion:

especially

under

insulc-l!0';,

var~es with

':ltmospheric

and increases with ~umidity.

Erosion is reduction

of thickness due to impingement

of solid particles

in liquid streams or liquid particles in gaseous streams.

Corrosion

6.4

and erosion combine to increase rates of deterioration.

Metallurgical

and Physical

Changes:

which may cause micro-structural

conditions

or metallurgical

to service

conditions

changes due to temperature

(Heating and Cooling) or Chemical changes in the metal.

Examples

of these

changes

attract, carbide precipitation,

6.5

PVs are exposed

are graphitization,
intergranular

Mechanical

Forces:

temperature

changes, Vibration,

high-temperature

hydrogen

corrosion.

PVs may fail due to excessive

abnormal

pressure

Thermal

shock,

Cyclic

surges and external

loads

etc. leading to structural failure.

6.6

Faulty Material: PVs may fail due to faulty material usea (Material mix-up) during
fabrication

stage.

Laminations

may not be revealed

initially, but may propagate

conditions.

Which may open up after corrosion

has occurred

during

service

leading to rapid

failure or leaks.

6.7

Faulty Fabrication:

Faulty fabrication includes poor welding, improper heat treatment, fabrication

with dimensions

The

use

of

penetration,

outside the tolerances allowed by the ASME code .

improper

welding

techniques

lack of fusion, and cracking,

may

undercutting,

result

in

incomplete

slag inclusion

in the

welds.
Improper heat treatment may either leave high residual stresses (too low HT
temp)

or damage

due to excessively

high

Sudden cooling after HT because brittleness

..

..

Poor

fabrication

permitted

Imp,oper
:"lj

111

can cause

period.

and cracks .

tolerances

outside

of the range

by the ASME code, which can lead to stress concentrations

subsequent
o

techniques

HT temp or soaking

and

failure.

installation
tile case

of Ifllernals

may result

of a pressure

surge,

1_-;q~J:;)(1;z.;rlt

')

.J

III

the blockage

the displacement

of passages,
of the internal

!fT:proper fiiting or tigiltening

,
'
the case of threaded joints.

7. Frequency

& Time of Inspection

7.1

Governing

Factors

The frequency

Frequency

of flanged ()f thread may result in leaks and in

of inspection

with which a pressure vessels should be inspected depends on several

factors.

The most important

factors

is the rate of deterioration

and the remaining

corrosion

allowance.

API 510 gives rules for the frequency and extent of inspection

Additional

inspection

may be required based on insuration or legal requirements

of tl18

jurisdiction.

7.2

Opportunities

Inspections

for Inspection

during the following opportunities

When vessels,

process

are possible:

towers, exchangers

are removed from services

to clean

trays, tube bundles, and the like.

a

When a vessel or an exchanger

scheduled

b.

External

is removed from service at other than the

time.
inspections

may be made while a vessel

or an exchanger

is in

service.

These inspections

should cover the condition of foundation, supports, insulation,

ladders,

etc.

platforms,

The existence
internally

7.3

Inspection

Scheduling

,'~
..
4

:?
"j

of abnormally

high metal temperatures

or hot spots

on

units can also be detected.

Schedule

of sllutciowns

th2 collaboration
jurisdiction

and location

insulated

paint,

for maintenance

of process,

maintenance,

or inspections

is usually arranged

through

and inspection groups or as mandated

by a

8.0 METHODS

OF INSPECTIOl'J & !-IMITS

8..1 Safety precautions

Safety precautions

must be taken before entering a vessel.

The vessel should be isolated from all sources of liquids, gases, or vapors,

using

blind or blind flanges

The vessel should be drained, purged, cleaned and gas tested before it is entered.

Before inspection starts, all persons working around should be informed about the
personnel

working in the v~ssel.

As a precaution

8.2 Preparatory

the manway- covers are moved from

near manway.

10'?9tion.

Work

The tools needed for vessel inspection, and personnel safety should be checked
availability

8.3 Ladders,

8.3.

inspection

and Walkways

of pressure

on platforms

could

vessels

stairways,

,.;-

to or bearing on the vessel.

cause

corrosion

due

to water

accumulation

and Supports

for vessels are almost always constructed

Some settling is expected in any foundation.

settlement

should start with ladders,

dead weight might have caused buckling of vessel walls.

Foundations

Foundations

Platforms

or walkways connected

Depressions
Excessive

safety signs should be in stalled prior to in vessels

Stairways,

The external
platforms,

for

and working condition.

Any necessary

Usually a safety guard is stationed

should be corrected

of concrete.

However, if it is excessive

or uneven,

before serious damage occurs.

Records

of settlement should be maintained on vessels known to be settling.

Anchor

Bolts

DistO:ll011 of anchor

bolts

may indicate

expa'1Slon margin in expansion

the

serious

slot.

foundation

settlement.

Check

for

G{~':l~r<:'teSupports
TIle op::.ning between concrete supports and a vessel shell or head should be sealed .
to prevent water from sealed to prevel)t water from seeping between the supports and
the vessel.

Steel Supports
Steel supports (Skirt, Leg) should be inspected for corrosion, distortion and cracking.
The inside surface of a skirt sheet is often subject to attack by condensed
especi311y when the temperature

in the endosed

moisture,

area is less approximately

1000F

(40C)
The fire proofings on support beams and skirt should be inspected.
Very light taps with a hammer will disclose lack of bond between concrete fireproofing
and tile protected steel.
if moisture

can get behind the fireproofing,

fireproofing

to bulge.

the steel may corrode and cause

the

The bulge in the fireproofing would indicate the corrosion.

8.4 Nozzles
If any setting of the vessel has occurred, nozzles and adjacent shell area should b~
inspected

for distortion and cracking.

Flange faces may be checked with a flange square for distortion

Nozzles

should .be internally inspected

cracking

and

The grooves of ring joint flanges should be checked for cracks due to excessive

bolt

distol1ion

when possibie for corrosion,

The inspection can be visual with a scraper and a flashlight.

tigtltening.
8.5 Grounding

Grounding
IS

Connections

connections should be visually examined to see that good electrical contact

maintained.

These

connections

electncity
Resistance

provide a path for the harmless discharge

into the ground.

to ground

should

f=(eco[llrl1'2nded resistance

~.

~.:)

J ~

..

;?
~

'...
.J

of lightning or static

not

exceed

the

accepted

values

in

the

is 5 ohms or less, however maximum resistance

area.
is not

8.6 Protective

Coatings

and ln~lll<l~ion

Rust spots, blisters, and film lifting are the types of paint failures usually found.
Visual examination
If in doubt,
insulation

few samples

of bulging or bucking

8.8 Internal

can be determined

can be found and

by measuring

the changes

in

Profiles are made by taking

Inspection

Preparation

interiors

shall

high-pressure

be cleaned

by power wire

brushing,

abrasive-grit

blasting,

water blasting.
is to review the previous available records of the

inspection.

It steam is injected into a vessel, corrosion

opposite

of the

from a line parallel to the vessel wall.

The first step in an internal inspection

vessel

Small distortions

or by making profiles of the vessel wall.

measurements

grinding,

the condition

Metal Surfaces

circumferences

Vessel

determine

by placing a straight edge against the shell of the vessel.

The extent

Surface

to beller

and bulges will nonnally be quite evident.

measured

may be removed

and the metal wall under it.

8.7 External

Buckles

of insulation is nonnally sufficient to determine its condition.

and erosion

may occur at places directly

the steam inlet.

Bottom heads and pockets that can collect condensate

In any type of vessel, corrosion

8.9 Detailed

are also likely to be corroded.

may occur where dissimilar

metals are in close contact.

Inspection

A del2ilec! !C]spectic:l shoukJ start at end of the vessel and war'" tc'.vard the other end .
.4. systematic

Items

procedure

should be followed to avoid overlooking

obscure but important

All ,)arts of !lie vessel shouid be inspected for C'Jrrosion, erosion, hydrogen blistt"ring,
deformation, cracking, and laminations. A c3reful record should bp. made of the types
and locations of all detr:rioration found.

Thickness measurements should be taken at those locations that show the most
deterioration. When deterioration appears to be widespread, enough readings should
be taken to assure an accurate determination of the remaining thickness. When
deterioration is slight, one thickness measurement on each head and each shell sheet
may be sufficient on small vessels, but more measurements should be taken on large
vessels. Ultrasonic instruments can be used to obtain the necessary measurements.

Pitting corrosion can Usually be found by scratching sUspected areas with a pointed
scraper.

When extensive and deep pitting or grooving is found, and depth

measurements are Wanted, the areas may have to be abrasive blasted. The depths of
pits or grooves can be measured with a depth gauge, a pit gauge. or (in the case of
large pits or wide grooves) a straightedge and a steel rule. A depth can be estimated
by extending the lead of a mechanical pencil as a depth gauge. Depressions or.
poCkets that can hold sludge or water should be scraped clean and carefully examined,
for evidence of corroion.

A hammer can be used to inspect for thin areas of vessel shells, nozzles, and parts.
Naturally, experience is needed before the hammer can be used effectively.

When

'teiking the 'he", nozzle. oe p,rt, 'n experienced in'pectoe can often find thin 'pots by

listening to the resulting Soc;ndand by noting the feel of the hammer as it strikes.

When ceacks ace sU'pocled 0' found. Iheie oxtent c'n be checked with dye-Pen"canl.

Magnetic-particle (wet or dry). or ultrasonic Shear-wave inspection methods. To use

any of these methods effectively. the suspected areas must be prepared by abrasive
blasting, grinding. or other methods acceptable to the inspector. Figure 30 shows a
cr.'3ckIn a shell weld.

'J, olded
','.?t

seams in ""el

shells should be closely checked wh'n Iho seNic,

is amin,

I1YO'ogen sulfide (H2S). caustic ammonia cycliC high temperature. or another

seN,,,

,oat

moy peomole cencks In odd,"oo welds in vO"ols Conslo"'ed

01 l1igl1-

sl:"erl;:J;~ ~::,-.-;!<, (.LI);:; 7D,JOi1 r-:;i ter>slle) or

coarse grain steels should b8 ched:ed.

Welds

in vessels c'.>ns:n..:dr:-dof low-chrome materials and in high-temperature

should

receive careful inspection.

welded

seams. The wet fluorescent

service

In all cases, cracks may occur in or adjacent

magnetic-particle

to the

technique

should be considered

examined

for internal corrosion.

the best means of locating surface indications.

Nozzles

connected

The wall thickness

some cases.
These

to the vessel should be visually

of nozzles can

a record of inside diameter measurements

measurements

or with

scissor-type.

calipers.

When the piping

is

can be obtained by calipering around the

In this way, any eccentric corrosion of the nozzle will be revealed.

inspection

shell areas are inspected.

supports

internal

of internal equipment

This may be very difficult in some large vessels.

for trays. baffles,

equipment

should be made when adjacent

screens, grids.

piping, intemal

stiffeners,

to be any metal loss, the thickness

against

(he original

thickness.

thickness

instruments

ultrasonic

The general
sUliaces

and other

should be inspected carefully. Most of this inspection will be visual.

Light tapping with a hammer can be used as a check for soundness.

condition

of the support

Transfer

If there

"
appears

should be measured and checked

or direct-reading

calipers,

micrometers,

or

can be used for these measurements.

of trays and related equipment

should be noted. Sheii and tray

in contact with tray packing should be examined for possible loss of metal by

corrosion.

The condition

the vessel

but will affect the efficiency and continuity

Inspection

will be required for such equipment. If measurements

be obtained

appreciable
vessel

of trays and related equipment

with calipers or ultrasonic

The performance

or

In

of nozzles may be desirable.

inside diameter

actual nozzle wall thicknesses

In most instances,

The

instruments.

can be made with a pair of internal. spring-type transfer calipers

direct-reading,

disconnected,
flange.

best be obtained with ultrasonic

will not affect the strength

of operation.

of

Normally only visual

are required. they can

instruments.

of some trays dependS on the amount of leakage. If tray leakage

then efficiency

is lost, and the withdrawal

may be almost impossible

Therefore,

is

of side streams from \tie tower

tray leakage

should be minimized

The proC(~Ss design will usually speCify ti,e amount of leakage that cali be toleraled

Tests

for leakage

overflow

may be made by filling the tray with water

weir and observing

leaks can be located by observing

of the tray during the te~t. If difficulty

is encountered

in determining

plug the weep or drain holes in the low sections

Because

piping

connections.
determine
thinness

should

be" thoroughly

inspected

the underside
the location

visually,

its condition.

The sound,

especially

the feel, and any indentation

metal loss is indicated,

will indicate

any

the remaining

wall

may be measured.

of vessels such as catalytic reactors are very complicated.

an illustration

of this internal equipment.

although

measurements
(although

some scraping,
and corrosion

Inspection

of this equipment

picking, and tapping

rate calculations

Figure 31 is

may be mostly

may be necessary.

may be required

Thickness

in some

areas,"

operating efficiency rather than strength is the most important consideration.

Erosion

usually differs in appearance

Figure

22 shows erosion and corrosion.

from corrosion.

Figure 21 shows erosion

Erosion is characterized

by a smooth,

appearance;

marked absence of the erosion product; and f\\etalloss,

to a clearly

marked

local area. On the other hand.

smooth

or bright. See 6.2 for more detailed information

detailed

information

for erosion.
exchanger

corroded

bright

usually confined

areas

on corrosion

and

are not often

and 6.3 for more

on erosion.

The shells of exchangers

next 10 bundle baffles and inlet impingement

Turbu!ence

neal the impingement

plates should be

plate and increased

velocity

bundle baffles sometimes cause erosion of the adjacent shell areas

ErOSion or corrosion
regularly

at threaded

inspector is a quick way to

'The internals

around

of

of the tray prior to the test.

Hammer testing of the pipe by an experienced

or cracking in the pipe. If excessive

thickness

checked

the

of their design, ballast and valve-type trays cannot be checked for leakage.

All internal

visual,

of the

the time it takes for all of the water to leak through

gasket surfaces of the tray. Excessive

leaks,

to the height

at the baffles of exctlangers

spaced rings when a flashlight

Somet.imes a lack of scale will indicate

will often show' up as a series

beam is directed

tillS

type of erosion.

10

of

parallel to the shell surface.

Erosion occurs not only in exchangers but in any vessel that has wear plates, baffles.
or impingement plates. In catalytic reactors and regenerators, the catalyst anc' air
distribution facilities are especially susceptible to erosion and should be examined
closely for this type of attack.

Areas directly above or below the liquid level in vessels containing acidic corrodents
are s'ubject to hydrogen blistering. Blisters are most 6asily found by visual examination.
A flashlight beam directed across the metal surface will sometimes reveal blisters; the
shadows created by the bliste!s can be obseNed. When many small blisters occur,
they can often be found by running fingers over the metal surface. The

metal

thickness of large blisters should be measured so the remaining effective wall

thickness can be determined. Usually this can be done with an ultrasonic thickness

instrument or by drilling a hole at the highest point of the blister and measuring the
thickness with a hook scale. If an ultrasonic thickness instrument is used, the blister
size must allow a transducer to be placed on it for an ultrasonic test (UT) reading.
Also, if the blister is near a weld, a, UT reading may be difficult because of the weld
roughness. Figures 32 and 33 illustrate hydrogen blistering.
/

Both the shell and the heads of a vessel should be inspected for deformation. Normally
the shell is more likely to suffer deformation than the heads. However, some older
vessels have heads formed with a small knuckle radius, which
{

'-

may be seriously

deformed. Unless dimensions of head parts, such as the crown radius or the knuckle

,~

1---'

radius, are already on record, these dimensions should be taken and recorded at the

t:' ~

time of the first inspection. If deformation is suspected or indicated later. these

'=-

t.: ~
p. .
'- :>
~.,

'-

~.

".:>

'-.

....,

~.
f4..

',.

,..-.

fo- ...

~~

i
I

Excessive deformation of the shell by either bulging or

collapsing can usually be

detected visually from the outside of the vessel, unless it is externally insulated. Out-

ofroundness or bulging may he evaluated by measuring the inside diameter of the

vessel at the cross section of r.laximum deformation and comparing ii with the inside

diameter at tile cross section of minimum deformation

::J

.l
~.~

Excllanger s!lells Sllould be checked closely for any defomlation, particulariy after

~.')

repcl1rs or .1!tera~ions OutofrOlllldlless caused by welding can make inst31lation of

..

.. "....

"'~

....

eo,

measurements should be repeated and compared with the original values.

t
~~.

.~

('"
.. c~.'-".~ ...

..

"

_:~
~,::.,~

b-,~

tuIJ0 ~~i'l,--:!esextremely difficult, and extractions after dif!lc~i: iljsldllations can b~ neariy

h,~

impossible.

~":Y-,~

If the out-of-roundness occurs at intervals throughout the length of the vessel,

D>'1~

~~'!"
f'v" "
.....

measurements should be taken at each interval to compare with the original shell
dimensions or measurements. In this case. the center wire method or the plumb line

~"'I~

(or optical plummet) method can be used to measure the deformation. In the center

~r~

wire method, a steel wire is positioned on the centertine of the vessel and stretched

~,.

,.;,)

taut. If no manways or nozzles exist in the .centers of the heads, a plumb line or an

~:'7

('.,;)

optical plummet may be used. When the deformation is restricted to one side of the

(:

r~

vessel, it may be more convenient to measure offsets from a wire stretched parallel

''--" ;'-'
...
(;

I,;)

i~

C;:~

and adjacent to the wall rather than along the vessel axis (as in the method shown in
Figure 28, but with the brackets and wire inside the shell instead of out side). In

C ~
C :;)

horizontal vessels, some special method may be required to hold the wire in position.
The wire furnishes a reference line from which to measure the deformation. Sufficient
measurements can be taken at intervals along the wire to permit drawing a profile view
of the vessel wall. Local deformation can sometimes be measured by placing a straight

c' ::;)

edge parallel to the vessel axis against the vessel wall and using a steel rule to

C ~

measure the extent of bulging. The best method of locating suspected deformations is

C
t,

,;J

to direct a flashlight beam parallel to the surface. Shadows will appear in depressiorls

,:;)

and on the unlighted side of intern;:;1bulges.

t ......
I ,...,I

A careful inspection should be made for evidence of cracking. A strong light and a

C:

m2gnifying glass will be helpful when doing this work visually. If cracking is suspected

t
t
t

I ....,1

t I~

. I ~
~. I ::l
~'-I.~
[

':>

~.I ~
t:'

investigation must be used. The most sensitive method of locating surface cracking is
tile wet fluorescent magnetic-particle method. Other valuable methods are the dry
magnetic-particle, dye-Penetrant, ultrasonic, and radiographic methods.

t- I ~

~- I

or any evidence of cracking is found using visual means, a more thorough method of

t,

Ves~els containing amines (absorbers, accumulators, coalescers, condensers, coolers,

contactors,

extractors, filter vessels, flash drums. knockout drelms. reactivators,

reboilers, reclaimers, regenerator's scrubbers, separators. settlers,) skimmers, sour

gas drums, stills, strippers, surge tanks, treating towers, and treated fuel gas drums)
are subject to cracks in their welds and the Ileat-affected zones of the welds.

~"I .~
~~ II '"".
.
..1

(1\

'-

u-",

,-""1.

"'\

r"'.

i- ..

'-

f'
-

i
_.I.

~
~
-:.,
.I

Wet fluorescent

magnetic-partide
cracks

detecting

surface

inspection

method. See API Publication 945 for more detailed

on boilers

should

deaerator

cracking.

recommended

and

tesiing is a Jery sensitive

discontinuities

and

is

the

have their welds and heat-affected

Wet

fluorescent

in- S;1ection method

primary

magnetic-particle

recommended

information.

zones

Deaerators

checked

testing

of

is

for possible
the

primary

inspection method.

Supports

are almost always welded to the shell. The

point of attachment

should

be

examined

closely for cracking. A-good light and a scraper will usually be sufficient

for

this examination.

The attachment
checked

points of baffles to exchanger

closely

magnifying

for cracks.

glass. a scraper,

have an appearance
cracks

Usually,

visual

inspection

and a brush is sufficient.

and heads should also be

with

the aid of a light,

Laminations

in vessel

plates

similar to cracks, but they run at a slant to the plate surface, while

run at right angles to the surface.

inserted,

channels

If open sufficiently

for a thin feeler to be

the angle of the lamination can be observed.

If a lamination

is suspected

approximately
lamination

but not open enough for a feeler to be inserted,

200 deg F (75deg C) with a torch will usually

to lip upward. In many cases, an ultrasonic

trace the lamination.

heating

to

cause the edge of the

flaw detector

(Note all figure nos. Referred in above discussion

may be used to
refer to figure

nos. of API 572)

8.10

Limits

of Thickness

The limits of corrosion

that may be tolerated

must be known,

the two most' important

factors of this problem are the following:

-- The retiring thickness of tile part considered
-- Tile rate oi de(eri'Jration
Due to several

variables.

such as size. shape material

and method of construction.

Etc , API 510 does not specify any retirement thickness.

Wilen

COITosion or erosion

comparing

cOllsecutive

is ~)resent. tile rate of metal

inSpeCllJ:1 records

'J

.j

loss can be obtained

by

Someti,;-;es a graph to show this information is dral'tn and is kept with the vessel
records.
When the limit to safe thickness is approached or reached, decisive action is
necessary
Different parts of a vessel may have different retiring thickness
Most vessels are built with some thickness in vessel walls and heads over that
required. e.g.

a.

Excess thickness deliberately added in the design as a corrosion allowance.

Excess thickness as a result of using a nominal plate thickness rather the exact,

smaller value calculated

b.

Excess thickness as a result of setting minimum plate thickness of

construction purposes.

(
c.

In some cases, the excess thickness of the shell or head plates is used by the
designer as nozzle reinforcement.

(
"\

API - 510

COURSE NOTES

VOLUME

- I I

~}.~~,;)
1"--.. 0.,_

",~"'";J

.:>
e,':::.:>
e,_L .

~
--::~-,~
~,. I

,
\

STUDY OF

_c :,:,

/GIn

'- ,:::::' ::>

,~::'

~.''~

~
~ ... -. ~
~'-;~
~,"~,.~

~l,_

1.......

~il
~l,

"'..""

"

,~

:~
.~

API RP. 576a

~ ~
~.-'
~
~'

'~

.
~

b~

API - RP 576

.;;~.~

~ ..... ~
~~

"

INSPECTION OF PRESSURE-RELIEVING DEVICES

..

..~
~~
~~..~
~.~

1. Scope

...-. ....

~.~

C.~
,""

This recommended practice describes automatic pressure

used in the Oil and petrochemical industries.

relieving devices

COmmonly

This publication
control valves.

in tanks, fusible

plugs, and

~-~

~: ...~
~.-

e..

.-;>

does not cover weak seams or sections

This publication does not COver training requirements

inspection and repair of pressure relieving devices.

e....;)

e;;J

2. Reasons

for mechanics

involved

in the

For Inspection

t::... i"",
'- '- r""
p"
"

Pressure-relieving
devices are installed on process equipments to release
pressure due to upset operations, extemal fires & other hazards.

'- I'"

e ~.;)

A properiy designed, and installed pressure-relieving device that is maintained in good

condition is essential to the safety of personnel and the protection of the equipment.

e' ,~
~"; ,;)

To determine

e ;)

:>
-~

~l

device.

freq~ency.

3. Type of pressure-relieving

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the condition of the pressure-relieving

To e'.'aluate inspection

('. ::>
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(.

excess

devices

A pressure relief valve is an automatic pressure-relieving

device that under excessive
static upstream p~essure opens and allows the product to flow until normal pressure
has been restored.

(
fuJ[ety Valve

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A safety valve is a spring-loaded pressure-relieving

device that is popped open by
enough static pressure and kinetic energy of the gas or vapor to overcome the spring
force on the disk as it is lifted, to provide full opening and allow minimal overpressure.
The closing pressure will be less than the set pressure and will be reached after th-=blow down phase is completed.
Safety valves are used on steam boiler drums and super-heaters
used for general air and steam sel'Jlces in a refinery

They may also be

Safety valves should not be used where the esc3pe of fluid around blowing valves is
not desl~ahle

Relief Valve:
A relief valve is a spring-loaded pressure-relieving device for liquid service that begins
to open when the inlet pressure reaches set pressure, overcomes the spring force, and
begins to lift the disk off the seat and that continues to open as inlet pressure and the
lift of the disk increase. The closing pressure is less that that of the set pressure and
will be reached after the blow down phase is completed.
Relief valves are normally used for incompressible fluids.
Safety Relief Valve:
A safety relief valve is a spring-loaded pressure relief valve that acts as a safety valve
when used in gas or vapor service and as a relief valve when used in liquid service
A safety relief valve opens fully before the over-pressure reaches a valve 10 percent
greater than its set pressure in a compressible medium .or 25 percent greater than its
set pressure in an incompressible medium

Balanced Safety Relief Valve

A balanced safety relief valve is a safety relief valve that incorporates a pressurebalancing bellows, piston, or both to minimize the effects of back pressure on its
operational characteristics.
Balanced SRVs are normally used in refinery process industries that handle
flammable, hot. or toxic fluids, which may pass through a dosed discharge system-Or
be released through the valve at a safe, remote point.
Rupture Disk Device
A rupture disk is a thin diaphragm normally held bet\'1een specially designed flanges
that relieves pressure from a vessel or system by rupturing at a predetermined
pressure ..
Rapture disks are available in ':arious metals, polymers, plastics and coated metals.

Nonmetallic disks, such as those of impervious graphite, are flat. Some bulged metal
disks are designed for installation with the concave side towards the source of
pressure This places the disk material in tension.

4. Causes Of Improper Performance

4 1CarrosioQ
Corrosion IS ti,e baSIC cause of pitted or broken valve paris, deposits of corrosive
reSidue tllat interfere with tile operation of the moving parts, or a general deterioration
of ti,e material of the relieving device.

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There are many causes of damaged valve seats:

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4~2 DamaQed SeatinQ Surfaces

a~ Corrosion

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b~ Foreign particles that get into the valve inlet and pass through the valve when it
opens, such as mill scale, welding spatter slag, corrosive deposits, coke, or dirt.

c~ Leakage past the seating surfaces of a valve after it has been installed. This
leakage contributes to seat damage by causing erosion (wire drawing) or
corrosion of the seating surface~

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The first is a weakening of the spring, which causes a reduction

possibility of premature opening.

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of the spring,

which

causes

Improper SettinQ and Adjustment:

Plugging and Sticking:

5. Frequency

and Time Inspection

5.1

Frequency

products

can

(
Inspection

To ensure proper performance, 2 definite time interval between inspections

established for every pressure relieving device on operating equipment.

should be

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.~

breakage)

In petrochemical
service, process solids such as c9ke or solidified
sometimes plug various parts of the valve and connected piping.

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e
e
e
e

(complete

in set pressure and the

Improper setting of a pressure relief valve is usually due to carelessness

by or
inadequate training of maintenance personnel.
Valve malfunction may also be due to sticking of disc or disc holder in the guide. This
may be due to corrosion and galling.
Galling may be due to valve chatter or flutter caused by improper piping at valve inlet
or outlet or by over sizing at valve.

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The second is a total failure

uncontrolled valve opening
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Failed spring:

Spring failure occurs in two forms~

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of valve seat or valve disc.

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Depending
another

on operating

experiences,

tllis interval may vary from one installation

to

In API 510 ;;,'" subsection on pressure-relieving

deVices e~,tablishes a maximum
Interval between inspections
of 5 years. or 10 years depending on valves are
employed III c:;'!Osive 0' non-corrosive service.

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5.2 Shop Test Block

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After a pressure re:ief valve is removed from service, it is usually taken to the shop for
inspection and repair.

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An important phase of maintenance is testing to determine

tigl,tness of the valve "as received" and after its ovemaul.

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Bottled nitrogen may be used instead, especially for high-pressure

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Most test blocks are designed to test pressure relief valves with air because it is a safe
and readily available medium.

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The air test is generally used to test safety, relief, and safety
pressure and valve tightness.

relief valves

for set

5.4 TestinQ with Water

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Test blocks may include facilities that test relief valves with water. Water in safe and
inexpensive.

Cr~

The Air-system test block includes a compressor or other source of high-pressure air, a
supply reservoir, a test drum or surge tank pressure gauge and other instrumentation.

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valves.

5.3 Testinq with Air

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and

Most test blocks have facilities for testing with either air or water to simulate, as closely
as possible, the media handled by safety and relief valves, respectively.

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the set pressure

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The water-system test block includes a positive displacement
other instrumentation.

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pump. piping valves

and,

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6. Inspection,

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3.

If valve opens at set pressure, it is O.K. functionally. If valve opening pressure

is tligher than set pressure, give it a second test, on second test if it opens at
set pressure means it was stuck on first occasion probably due to deposits.
If
the valve opens at lower than set pressure. The spring has become weak.

Af1er tile :est pop, valve is visually inspected and checked for evidence of
pitling, roughening, corrosion or breakage of springs, evidence of deposits of
foreign material or corrosion products, condition of inleVoutiet nozzles and
(~viderlCe of deposits, t)lockades etc. Body wall U,ickness measurement.

:;

l)rsl11,Jilliing & reassembly of valve.

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to shop

When the valve is first received in shop it should be placed on test stand and
pressurized to determine its "as received" relieving pressure (pop pressure).

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it is transported

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& Setting

After a pressure relief valve is removed from service,

for inspection testing and resetting ..

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Testing

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. AIle, per-pressure. clip.ck &. initial visual inspection, valvG sh:'l" be

-:areful/y dismantled for through ovemauling.

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After cleening, the parts should be checked for wear and corrosion.

Seating sUrfaces
on the disc and nozzles should be inspected
roughness
and damage.

Seat lapping
flatness blocks)
shall be checked with optical flats or other suitable devices.
(e.g.

Spring shall be checked for cracking or deformation.

Worn out or damaged parts shall be replaced or reconditioned

Seating surfaces shall be machined and lapped.

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The valve shall be then reassembled according to manufacturer's

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Spring shall be adjusted to pop at desired pressure

Setting of valve to set pressure: After the valve has been reconditioned and
reassembled,
should be adjusted for the last time to ensure the valve will pop
at
the requiredits
setspring
pressure.

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If a new
pee"u'e I, eequleed, the manufaclueer,
must
not 'el
be exceeded.

limit, fa, adju"ment

of Ihe 'pring

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After
the valve
has been adjusted, it should be Popped at least once to prove
the accuracy
of setting
the setting.

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The....devlallon
of Ihe
for
set pro
== 70pop
psi. pce"u,e

fcom Ihe 'et p'e;,u,e

'hould '101 exceed,

2 P"

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Fo, p,e"uee
max
set pr '= 'ellef
10% valve,
of WP. that Complywith Sec!;on VIII,Divi,'on 1, of Ihe ASME code,

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setting
When Ihe pee"u'e

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" te'ted

with wale" It 'hould be ,al'ed

"OW'y to the cequi,eo

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The discharge should be observed for evidence of leakage, or the test gauge should

be observ8d of a momentary drop in pressure

Attalnmc:nl
water
from

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0: the set pressure IS

111-2
valve discharge

usually indicated be a small continuous stream of

TI:2 C,:<::,;',;..I; ',' .~t ",,~)ichthe valve releas{::sshnuld n~wnnli1 the ~;);(,ra"';~s ::'Jied 2'Jove
bsf'J~e the "~!Vl~;:; approved for service.
Checking of Valve fur tightn:)ss: Once the valve is set to pop at its set pressure, it
should be checked for leakage.
On the test block, it can be tested for tightness by increasing the pressure on the valve
to 90 percent of the set pressure and observing the discharge side of the valve for
evidence of leakage.
7. Records

&

Reports

The need to keep records: For each pressure-relieving device in service, a complete
permanent record should be kept.
The record of each device should include its specification data and a continuously
accumulating history of inspection and test results.
Historical records (service records) showing dates and results of inspections are
necessary for the follow-up or control phase of the pressure-relieving device program.
They enable periodic reviews to determine whether the planned test internals for a
device are being realized. They also provide performance data that helps evaluate the
suitability of the device for its particular service.
It is especiaily important that the re,cords offer a practical and realistic basis for
establishing and maintaining safe and ;economical inspection intervals for the device.

API - 510 COURSE NOTES

VOLUME

-II

STUDY OF

ASME Sec.- IX

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ASME SEC. iX. -- - WELDING QUALIFICATIONS

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CHAPTER - 1

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ESTABLISHING WPS.

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ASME Section

IX relates to qualification of welders, welding operators,

brazing operators and the procedures that they employ in welding and brazing .

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It is divided into parts, part OW gives requirements for welding and part OS contains
requirements

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for brazing. For the purpose of this course we shall deal only with part

OW.

WPS & PQR

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The purpose

of welding procedure specificaticn

(WPS) and procedure

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of providing the required properties for its intended application.

records (POR) is to determine that the weldment proposed for construction

el:)

t.\.

WPS

is intended

essential

to provide direction

for the welder and lists the variables,

qualification
establishes

that welder or welding

operator .performing

test is skilled workm:Jfl so that welding

Part OW is divided into 4 31iicles

Welding gereral requirements

Art'cle II

Welding procedure Qualifications

Article III

Wcld:;1(j cer,ormance ~ualificalions

ej:)I"'"

-'"'<.

("nlcle IV

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procedure

procedure

qualification

sound metal or the welding operator is able to operate welding equipment properly.

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the welding

test

The purpose of performance qualification is to determine if the welder is able to deposit

Article I

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both

the properties of weldment and not the skill of the welder.

t,\.1 ':>

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is capable

and non essential and the acceptable ranges of these variables when using

It is presumed

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qualification

the WPS.

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brazers and

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G~fo .c we pr8<::eed Ie, ~IS ;;, ~ ~ understand

various test position

in grc'~'<

V-.'~.I~I~;In

plates, grool/e welds in pipes and fille: weld in plates etc. (Ref. Figure 461.3, 4 & 5)
In general,

1G or 1F is called flat positions

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2G or 2F is called horizontal and circumferential

~.:',:)

3G or 3F is called vertical position &

4G or 4F is called overhead position
Position

5G is only in welds in pipes. It is a position when pipe axis is held horizontal

and circumferential

seam is welded without rotating.

In a way it is combination

of 1G,

3G & 4G.
Position

6G is also for the pipes when pipe axis is at 45 deg. to horizontal

circumferential

seam

is welded

without

rotating

the pipe.

plate and

It is combination

of all

positions.
(Refer

Fig. 461.1) is the diagram defining the position for groove welds depending

the inclination

on

of the axis of the weld and the angle of rotation of the face of the weld.

(
There is similar (Refer fig. 461.2)
(Refer

fig

specimen
a,b,c,d,e,f

451.1)
required

gives
for

giving position for fillet welds.

the thickness
procedure

limits and the type and number

qualification

of groove

and

(Refer

of the test
fig.

463.1)

shows the method of the taking the test specimen.

In case of weld between dissimilar materials where it is difficult to carry out bending
that weld is at the center of convex position, transverse

longitudinal
(Refer

fig

by

bends and the fig. look like (Refer fig. 463.1. c)

451.3 & 4514)

similar except
section)

that instead

Give the test required to fillet test and (fig462.4)

of bend there is macro examination

(Refer fig 452 1) gives performance

specimen

bends are replaced

so

required

qualification

a,d ( it is

of 2 sections

of %

limits and type and number of the test

table (fig) gives the diameter limits. It is wortn noting that one, two

or more welde~s can be qualified

on just one test coupon.

Each may be using even

dlffen~nt processes
(Refer
welds

fig

46:::: B & C) gives ti,e requirements

:5 ~

:.i gives pcriormance

qualification

for performance

qualification

pOSition and diameter

limits

of fillet

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WeldinQ Vdriables :

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Article

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various

..

welding

processes

"~

variables

....,:,

variables

for performance

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Essential

variables

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the mechanical

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~.

showing

and non essential

in P-number,

variables

for procedure

properties

are those welding variables

properties

of weldment

e,

supplementary
qualification:

essential

and

essential

whose change will affect

of the weldment

(ex. Change

filler metal, electrode type, preheat post heat etc.)

procedure

I:>
;:>
en ::>
e. ::>

for procedures

(other than notch-toughness)

Supplementary

t.
t.

variables,

are those welding variables

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I
t. r~

essential

qualification.

(,_

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It also gives tables for-

(IV) gives data about various types of weldii'lg variables.

essential

variables

for procedure

are those

whose change

welding

variables

for

will after the notch toughness

(ex. Uphill or down hill vertical welding,

heat input, preheat

or

PWHT)

Non essential

variables

for performance

affect the mechanical properties

gauging or cleaning etc,)

are those welding

of weldment

variables

(ex. Joint

design,

which will not

method

of back

i~

e. :>

e. [~

Essential

variables

for perfor'mance

are those welding

variables

which will affect the

ability of welder to deposit sound weld (e.g, position, deletion of backing F-number

etc.

c. I ~

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Change

~l:>

Before we ptoceed let us first understand

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All those

materials

composition

are divided

the term P-number

into various

Pial"

divided

carbon

Lmder

and

t:

into groups depending

steels

st:lHlless

Vi-mOUS

CSi,

Cr-Mn

steel as P8 matenal

A-number and F-number,

depending

on their nominal

on their nominal composition

;\'l1umbers

arp' groupeo

Ferrous weldirlg

all Wr,!<jHl(.j '~Iectr()(jes

;lild

vje/dlllg

rods are groUi)2(j

.~

"

as P-1

consumable

based on thelf weld metal chemical

.)

performance,

on the type of refinement

& C-Mn-Si

~:'

('~

P-numbers

2S

/ min. specified

UTS etc. OW-422 gives the full details

3c stel11tlc

t'

as well

and further .divided into groups depending

and further

e ~

(~

in process is essential variable for procedure

materials

are classified

composition
1'1

and

dlffererlt

(table 442)
F-Ilumber

depending

on their (J.,VVS ;Iassificallon

composition

(table 432)

which is based on tyoe 01

IlL;):

and chemical

Now let us have look on some essential variables tables.

OW 253 WPS- SMAW
OW 353 WPO- SMAW
The following

tables are to be referred frequently for worKing with ASME Section

and hence one has to understand

them (how to) in right context

Refer

ASME Section

1.

Refer Fig. QW 461.3

Groove Welds in Test Position

2.

Refer Fig QW 461.4

Fillet welds in Plates Test Positions.

3.

Refer Fig. QW 461.5

Fillet Welds in Pipe Test Positions

4.

Refer fig. QW 462.2

5.

(a, b, c, d & e)

6.

Refer fig QW 463.1

IX.

Method of Taking out the Test Specimen

(Performance Qualification
Method of Taking out the Test Specimen

(a, b, c, d,e & f)

7.

Refer Table QW 451

8.

Refer Table QW 452

9.

Refer Table QW 461.9

10.

Refer Table QW 461.1

Qualification)
Procedure Qualification

Thickness

Limits and

Test Specimens.
Performance Qualification

and Test

Specimens.
Performance Qualification
diameter limits.

Acceptance

Criteria

QW 153 Tensiun Test

QW

4
5.

Test Jig dimensions

Procedure

1.

IX

Qualification

163 Bend Test

QW 183 Micro Exar,lination

Procedure Specimens

QW 18<1 MICro Examination

Performance

QW 191 Radiographic

Examin2tion

Specimens

Position and

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CHAPTER - 2

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WPS/PQR - TESTS, ACCEPTANCE AND RECORDS

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Weldinq Procedure Qualification

The purpose of procedure qualification testing is to demonstrate

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and

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methods

joint

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mechanical

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weld

specification

Evaluation of overall preparation, welding, testing and end results.

Approval (if the result are favorable)

Preparation

specimens

of Procedure Qualification Sample joints

production

>"

."

assemblies

results

will

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t I ~~
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~~

in the middle. The size, type,

of materia!

used as well as the welding details are governed

specifications

to be welded

in

for testing.

by the particular

that are to be qualified.

The test results for a procedure qualification sample weld,

.l~

I "-'
I

joint

Evaluation of Lest Results

preparation

L~

have a representative

and the number, type, and size 0 specimens to be removed

procedure

6.QJ)J.Qv91

usually

are related to the type and thickness

The matenals
welding

"".'"'

and

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e, ..

\.

application

Testing of representative

and thickness

.{~

e:-. I

~,

the

-. I
e' I

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meet

produce

Preparation and welding of suitable samples

Test

~.

e..'L

that

will in fact

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..

properties

procedure specification

materials

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e' I

in a

the

There are four steps in the Qualification of weldinq procedure:

e;_I_~

prescribed

that

requirements.

--'r

\'/elding and testing, should now be

:2

analyzed

by the responsible

with the records of joint

made available

;or review

parties to determine

whether

These
the test

details and results meet the requirements of the applicable spec;fic3:lons

fU'"

quallf'Cilil""

i)l.1..alificatlg[l Tests and Procedure Specifictigns

,:12

II1spectlon

agency

or customer

test

results,

and

ti10

',si;;

prOductl();~ .-.,:irjl,lq

IS

(Jone

must

the procedure

appro,.-e

the

speClk:atlons

procedure
before any

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~rh~
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.

~,

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Qualifica,!or.

is accomplished

when" the required

approval

has been

!;;...~

available

to show that the joints were indeed satisfactory.

.;-....;)

witness

the welding

~....~

factual

knowledge

c: ,:)

production

c ~

At

~r

obtained.

However.

tests have

authentic

been completed

documentary

and

evidEnce must be

,.. .

'h

any

and testing of all specimens.

of procedure

details that

As an inspector, you should

if possible.

will

because

be helpful

you will

gain

in later inspections

of

welds.
time,

procedure

an ASME

Authorized

if he is not satisfied

Inspector

can

call

for re-qualification

of a

with the data presented.

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Code Qualification

Requirements

AWS

Welding

Structural

Code, in paragraph

qualifying

those welding

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paragraph

51 of that code,

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contract

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requirements.

qualify

a welding

procedures

must be qualified for other reasons,

such

as

that must be tested

to

given

C,' ...l_~

The

ASME

e...J ~

procedures.

e..J~
e:. I.~

Qualifications

t:' ..~
t. '~

requirements

to. ~

ASME

Section

~.j: ..~

25392,

states

~,

f~

~-

and

"in accordance

IX

Pressure

Vessel

IX is the basic

All sections

Code

Section

It is titled
require

IX"

in

Ilion

Nuclear

Components

"The welding procedure

IX of this Code".

Simiial ;y, NG-25392

for

Paragraph

refers to NG4000

t .~

quallfl,;:,!ro;1

of welding

e~- .~

28 requllcs

l)f'azlng procedures

~ ..
'- ..

~
~

~.

addition

about

Welding

welding

procedures

Power

welding

and Brazing

procedures
to

to be

supplemental

Piants, paragraph

.. shall be qualified

/\SI\:1::-:'3",:',:;)n VIII. Division I. on Pressure Vessels.

~
~

is authoritative

document.

of the ASME
with

Code

e .~
'-'"

5.10. The test results required

of each specific section.

4000 and Section

Section

in paragraph

5.12.

Boiler and Pressure Vessel Code

qualified

for
of

The type and number of specimens

are

the requirements
status

ASME

Section

forth

the prequalified

e~' ~
e" : ~

Boiler

sets

which do not meet

or which

procedure

are given in paragraph

5.5

in accordance

NB-

with NB-

NC-253~ 2 refers to NC-4000

and

and IX
paragra;)ll

In accordarlce

"'/llI,

'~N 28,

requires

tile

See: ')n IX Paragraph

US

to be Similarly qualified

" , -:5
,) I .
I_~

n .I1~>t.~~3..t~''''.I'>'-'''_1I';4j\~':~i~;",~i~Dl.fl!i~_r)_.~.~'''''''"''

__

~'''_'

------.-----

Other

;)roce,dures

Seals,

are no exception,

specification.

The

completely

stlall

be

as N8-436i

or Installer

the

shall be qualified

as

shall prepare

qualified as a new procedure

requirements
a

on Specially

for

listed below

hard surfacing

new procedure

and

D8signed

a procedure
and stlall

be

are changed,"
states.

'The

shall be completely

re-

when any of the changes listed in NB-4382 are made."

NC-4321

Code is well summarized

and so forth-entitled

manufacturer

organization

III, such

Manufacturer

on

ASME

Each

"Eacll

procedure

NB-4381.2

procedure

The

Seclion

re-qualified when any of the essential variables

Paragraph

qualified

in ASME

and/or

in a series of identical paragraphs

"Procedure

Installer

Specifications

is responsible

and shall establish the procedure

NB-4321.

and Qualifications,"

for the welding

and conduct

done

by his

the tests required by this

Article and by Section IX of this Code.

Chanqes

in a Qualified Procedure

If a fabricator
make

a change

qualifying
listed
For

who has qualified

in that procedure,

tests. Re-qualification

in the governing
example,.

treatment
addition

a welding procedure
may

at some

be necessary

is necessary when anyone

later

to conduct

date to ,

additional

of the essential

variables

standard or code is changed.

one such variable

has a profound

is the heat treatment

effect on most welds,

to a welding procedure when

essential

it

desires

that follows

Its omission

welding.

Heat

(when called for) or its

not called for would be a change in an important

variable. requiring requalification

of the procedure.

!'-Jote

The

most

Important

re-qualiflcation
weidel

and

conSlcJered
pages

factors are usually

is necessary,

Much

welding operator

classed

the same

qualifications.

essential and generally require

f~emernt)er,
to

reference
detcnl1l!le

Sl10uld
whetller

as essential variables;
situation

exists

The variables
re-quallficatlon

always be
the magnitude

made

if cllanged,

in connection

with

that are most frequently

are sho\'m

to

in the foiivwing

the governing

of a given change

code or

requires

re-

~."
"""I;t

CHAPTER - 3

~.~

~l
~

WELDING CONSUMABLES

~,~
~.~

~'-J

A Brief Introduction:

~'3

~,~

ASME
..

~,

welding

e3
e3
e:3
e:,3

e:.~
~,:3
e.,....,.

Section

II Part

covers

and brazing comprising

grouped

classification

of Welding Rods, Electrodes

consumables

are

Specifications.

referred to as SFA Number.

into

Each SFA No. covers consumables

for compatibility

and properties

number

of

of consumables

for

and Filler metals, These

sub-sections,

in

of overall similar characteristics,

other

grouped

with same group of parent metals. For example, electrodes

words,

together

for carbon

("l&

~~"---

'-.~~

steel are grouped in SFA 5.1

Periodical

Assessment,

& Certification

Approvals

,c~

,-,~

~.

.......;)

Each

SFA

specification

manufacturing

stipulates

methods,

requirements

required

tests

&

for chemical

test

methods,

composition
acceptance

limits,'
criteria,

.'"

,- .. ;;J
c.,;)

ciasSlflcation,
oenodical

marking,

assessment,

packaging,
approvals

intended

use of the consumables,

and rules

for

and certification

e'~
e"~

Some

E'~"~
C ~

Sam::: of the commonly used SFA Nos. are listed below:

t.

<3

Common

conDlete

Specifications
the list is not exhaustive.

For

iist refer to Section II-C.

l
~

t:.' ,~
C .
~
i

t:Li~

t-' '~
tiLL ~

t ,::>
~~l.

~:' ~

~,

.~

t, ~
,II.,

~~

SF A 5.1 Coverec carbon steel arc welding electrodes

SFA 5.4 Covered corrosion resisting cllromium and chromium-nickel

electrodes

SFA 5.5 Low Alloy steel cov~red arc welding electrodes

SFA 5.5 Co,'rosion resis:ing chromiulI\
SF A ;),17 Carbon steel electrodes
SFA;)

and chromiulll

nickel stee: bare filler wire

and fluxes for submerQ;:d

18 Car()on steel filler metals for gas shielded arc

SFA 5 20 Carbon steel electrodes

arc welding ( SAW)

\'.'21011I9

(GTAW / GMAW

for flux-cored arc w8Id:'19 ( FCAW)

S r A 5.23 Lo\'.' /-\lloy steel elc<:trodes 8- Ilu ~es for S;\\N

..,.....-~.))

~)J
SFi:, 5.21) Low alloy steel filier meldls for ga~; shif:,ded arc welding (GTAW I GMAW)

~~
~ ~

SFA 5.2~ Low Alloy sleel electrodes for Flux-cored

...

arc welding ( rCAW

~'~

...

AWS Classification

~-~

American

,-))
~

in an alfa-numeric

of Consumables

Welding Society has evolved a system of identifying classes of consumables

code, which is commonly referred to as AWS class. An explanation

of what this classification

~.~~

signifies is given below for typical four common examples:

C~.~

C-~

1. Classification

of covered Electrodes for SMAW

e~

(Shielded

~<)

AWS - E - XX - YY - G

Metal Arc - also known as Manual Me~al Arc):

e,g AWS E-7018

~~,:)

or, AWS E 801882

~--~

e__
:
a

E ..

Coated electrode

XX

. Minimum tensile strength in ksi

'-:..~:)

YY

e..,~

Coating Type & chemistry

Alloy addition, if any

e ~
t'" .;)

2. Classification

e,~

AWS - ER - XX -S - yy

of GTAW I GMAW I PAW Bare Wire Rod

e.g AWS ER-70-S-G2

e_;~

:j
i

ER ..

Bare Rod I electrode

C ;)

XX ... Minimum tensile strength in ksi

"-r

S ..

,,,_I.,
!~

e;~
t

yy

Solid

.. Specific chemical composition

.~

e~~
e.,~
t ::>

F.

(I ..
~

1st X

t:' '~

2nd X

CO:1oitlon of Heatlreatlilenl

t .~

3rcj X

11l1:J2ct slrengtt1

e:. ~

r-:

Electrode

..

3. Classification

of SAW Wire and Flux for Carbon Steel

AWS - F - XXX - E - yyY

Flux
Tensile strength in 10,000 psig

~" '.=>

t.

J _:~

..,

e ~

VMe

r"~

'3.
~;
YYY

~~.

(:.--~(

Ciassificatior. of

carbon steei wire, e.g. EL8, EM12r-, or EH14;,

(:.--~
~--~I

4. Classification of SAW Wire & Flux for Alloy Steel

I--:'-~i

AWS - F - XXX - E C- YYY N- ZM

h~

~._~\
;:-,

~\

Flux

1st X

Tensile strength in 10,000 psig

2nd X

Condition of Heattreatment ..

C:.: _~(

as welded

C ;).

Post heat

C,;".~

3rd X

lmpact strength

~-~

Electrode wire

C~_ .::) ,
t.:'__~ i

Composite electrode

yyy

Classification of alloy steel wire

For special purpose

ZM

Chemical composition of weld metal

t._~,

e..'.:.:'~

t.

0
.. ~

"

Classification of Parent Materials and Weldinq

po' ....
'-- ,::) ':

t-' -:t i

Consumables

C ~

In developing ASME Section IX, each welding process that was included in the

c~.~\

Section, was reviewed with regard to those parameters, called VARIABLES, which

C .~

have significant effect upon welding operations and fabricator's ability to qualify

t: ~
.
~,

Welding

i ""'"

"'c,
\.......

r'J,

I'.

L~
J ,

'-

1 ,..,
I..J,

..,

~.:.-..

and for ease of remembering, following main Essential Variables should be considered

t '~

in propos!ng Jny Welding PlOcedure Specification:

e~
'~

e '~

II

C"

re-qualification of a Procedure with a new set of Essential Variables. Broadly speaking,

variables in the case of low temperature operation.

Data". Change in an Essential Variable of an established Welding Procedure requires

e.: '.~

II;

e- .. ~
e-. I
f\> I .~

__
i~

__

Welding Process, eg SMAW, GTAW, SAW etc.

Parent Material, material specifications categorized into P Nos.
Material Thickness

I .~

10

.-::~I .AI
'. i .-

'~

as

Essential Variables are given in comprehensive details in the chapter called "Welding

~~:.; .

Procedures and Welders' performance. Variables are categorized

Essential, Non-essential and Supplementary (for .assurance of notch toughness)

~J r ...
fi'.

as per ASME Code Section IX

'...1

,,-",I ....

~~~'~i~~~-.'l]jli!l

_'JlL~!IIIIIIlIUjjH"_JdV-l

r:5
~
~

iv. Welding Consumable, categorized into F No. & A No.

~""

v. Maintenance of Preheat, Interpass & Post heat

;:,..~

vi. Post Weld Heat Treatment and finally, the supplementary essential requirement of,

t:,~

vii. Impact Testing to assure notch toughness properties. Assignment of P Numbers

~"~

To rationally reduce the number of Welding Procedure required to be qualified, base

G'l,J

materials have assigned P Numbers, essentially based on comparable material

~.:.....,
characteristics, such as chemical composition, mechaniCal properties and weldability.

~3

~.

""'

(Refer Q\I\I-442)

..

,~

,
,,'
...

'~"-3

,r

Assignment of F Numbers

~'"

~
~

..

Numbers ( Refer Q\I\I-432), essentially on the basis of their usability characteristics,

which fundamentally determine the ability of the Welders to make satisfactory welds,

C:~3
~-\

with a given filler metal. This grouping also reduces the number of welding procedures

"---.,..."

'....

...

+'14

~':: i .
r ...

~>::t1-..#
"'"
i

fA.. ..

,-'-;3
I

!"'"

tI'u.

r..l

i"
e:::.;:J
1"'-

: Electrodes and welding rods have been grouped into F

and performances which required to be qualified, where it can be logically done.

Assignment of A Numbers :\I\Ield Metal compositions have been classified and

grouped
into A Numbers. essentially on the basis of their weldability characteristics, as reflected
by the nominal chemical composition obtained from their actual weld metal analyses.

"',. r~
I

t:. ;~

f,autiQI"@!YNote

e:.',

These

t:L~

qualification

e:~[,
CJ.,

t:

i.,
r

assignments

do not imply that base materials and filler materials

be

indiscriminately substituted for a base metal or a filler metal which was used in the
test, without consideration of compatibility . from the standpoint of

metallurgical properties, postweld heat treatment, design, mechanical properties and

service r2quirements.

t.' ~
t, ~

~.

~.~
~ ...

~'

~
~ ...

~
~

~.

e<. ~
~

1"\, ..

..,

:,::" I ...,
.\,! ~

11

"-"\I~
1J_!l.I~-.-.''!t~.;~iI'IIt:~'llj,Jl:?t:"'''~~~~~~d_~_~;_"ItiaJilMf.~,~~_

~.-."'~~

CHAPTER 4

Guidelines for Review of WPS, PQR and WPQS.

An inspector has to review the WPS, PQR and WPQ documents to ensure that they
meet the ,A,SMEsect IX requirements. A checklist shall be used to verify that the WPS
is properly completed and is addressing all the requirements of ASME Sect IX and
construction code. It is also necessary to verify that PQR has been completed to meet
all the ASME sect IX requirements (induding test results as per acceptance criteria)

The important part here is also to verify that values of essential variables recorded on

. >"

''---3

the POR properly support the specified range of WPS

C':~

~:3
~\::~3 .

e::3

Checklist for Review of WPS (SMAW Process)

Refer OW 250 for variahies.

e::.~

(Supplementary variables not needed)

~'~~

t.':~
t:'

1)

I.,--r~

C":~

See identification block showing WPS no.

.,Rev

and

POR no.

There is signature of the viewer at the end.

C:::-,l~

~.J.",,\
I,..~.... ~

. Also at the end the reviewer shall give his comments.

2)

OW 402 gives joint details. OW 403 is indicating Base metals for example if a

e:,_J~

POR is having base metal thk, 25.4mnl the WPS supported by it can be from

tA.':!~

48mm to 5.8mm. So if these variables are written in OW 403.8 properly in WPS

and POR column then the column at qualification shall indicate OK which

t~L~
(.> ..

L~

~:,r:~
t~L~

~-~

3)

confirms that the variable is within the requirements and addressed properly.
OW 404 is for filler metals

4)

OW 405 is for positions

5)

QW 406 is for preheat

QI/V 407 is for Pill/ST

~::~,.~

t!~
~:.l

ow
o

4C; IS for electncal charactenstlCs

OW ,~. ~; IS for technique

.
~

~>"'~
~..
j '~

~.L ~
eLL ~

e- I '~
:..' I _~

.
,

I ,:)

f-.>.I

'

12

9)

Additionally OW

1j()1

says "A.change in process is an essential variable."'! I)i~

has to be verified here and documc'ilted.

10)

QW 202.~, 3,4 are mentioned for reminder to the verifier.

11)

This is reminder for OW 200.4 combination of processes.

12)

This is reminder for reviewer for bend and tension test as per QW 451.1

13)

This is reminder for OW 404.5. The basis for assigning A numbers.

14)

This is reminder for OW 170- Notch toughness - if required by construction

code.

15)

This is to remind if there are any contracts /company/other

16)

requirements to be addressed (OW201)

1 :5