Professional Documents
Culture Documents
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VOLUME - II
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Practice
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VOLUME - I I
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STUDY OF
Div, 1
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CONTENTS
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1.
2.
3.
MATERIAL OVERVIEW
4.
DESIGN
OF PRESSURE VESSEL
5.
FABRICATION
REQUIREMENTS
>
6.
INSPECTION
7.
8.
9.
& TESTING
EXAM
1.
11 INTRODUCTION
2) CODE SYSTEM
In its present from the ASME Code System is a follows:
Section I
Section
Part
Part
Part
Part
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/
, ,':S for in
I'
service; IfIspectlon
,,'
r011Cli::21
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3)
ISSUE
FREQUENCY
ASME
Issues complelely
new edilion
of all Sections
-.;
Latest
aftor
edition
are
. 2002 Addenda
2003 Addenda
4) APPLICABILl1Y
would
be
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
5)
CODE
INTERPRETATION:
to
the inquiries
concerning
technical
aspects
CODE
CASES
Boiler and Pressure
consider
same
Vessels
propOsed additions
eXlsl"'9
requlrenlenls
bOOks "is
These
Committee
meets
regulany
to clanly
Published
as
, Intenl'
() E S lAMe'
llle".,
Sfelnllh
C "cllfiel
I,'
of
""If
"""
at Ion
of
COde.Case
and Supplemenls
o
7) C
to
10 US2 S 12 "'.0S
IS granled
by /. S M [
a," U. u/ ~ "'e
---------n
(
Mani.Jfacturei".s 1;::lcilXties
. and organization
representative
authorization.
of
inspection
agency
and
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
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
manufacturing
activity
a vast field of
without sermonizing. They are user friendly. and keep pace with
changing technologies
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
I JrIcjr;rS(a:liJll)(JtllC COc!I:.
;lr1(~s/1OulcJIIUI
Dc
and addenda
referred to as
nlese
self
III
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2.
.J
..'>
Scope
of the Code;
ASME Section
VII Div. 1 ;
199J!:
.,)
Definition
;J
of a pressure
;,
,
;,
prohibitions,
vessel
:>
""Scope
)(
; xclusions
)
)
I.
those covered
by other sections.
)
II.
III.
IV
beyond
battery limits.
v.
15 psi
(No lirnitations
on size).
VI.
Vessels
for pressures
exceeding
Vessels
3000 psi.
VIII
~:
Unfircci (Prucess
e." '''ed
I" eke:
i~c.Jt generated)
.,rj
steam boilers.
...
_..__. __
....__
.. __
...
_..
b
~
Battery Lir:!lJ!:~
(a)
~
I.
Welding
II.
III.
IV.
~
~
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(b)
(c)
(d)
;)
external connection
connections
connections
;)
~
Responsibilities:
I.
:>
;)
;) (
o
:>
ii.
Manufacturer's:
(a)
(b)
(c)
(d)
Inspector's:
(a)
(b)
(c)
(d)
(e)
l)
:>
Code
Composition:
:)
ii)
Iii)
IV)
v)
General
)(
)
)
)
)
Sub-section B - Requirements
Sub-section C - Requirements
Mandatory Appendices
Non-Mandatory
Appendices
as follows:-
Requirements:
Desiqn
The User shall assure
vessel.
will be suitable
penar'mance,
retention
hiniself
for Intended
of satisfactory
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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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.
Divn.1. The stress values have been tabulated in the Part '0' of Section II.
UCS
UH.~
UNF
UCL
for
for
for
for
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.
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
,..,
/
Plates
may be ordered
I Forming
as rolled or norm
T. S )
option
. ',)ptlonal
If present,
Illaximum
option
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BASED ON
~
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STEEL TYPE
~
SPECIFICA TIONS
i;)
MODERATE
1.
TEMP.
C - Steels
0
0
.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.
~
~
9.
,
~
~
5/4 Ni Steels
10
7/2 Ni Steels
~RYOGENIC
11
~
~
875 (max)
875 (max)
775 (max)
TEMP
600 (max)
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
of ttle specifications
(i.e. pressure
are permitted
in the applicable
Specifications
to one
C.
rI
..
rI
~
,
',"I
Permitted
Rods
"
\Nith
,(
Manufacturer,
material
Certified
complied
3.
ilot
identified
permitted
issued
by
Materials
Steel
all requirements
material
Properties
where
certificate
or not recognized
are to be identified
I Raw
I Product
Material
of the Specification
markings
specifications.
markings
is not available,
can be ascertained
or is certified
out on representative
allowable
as
to a Specification
sample/s
provide'd
and satisfy
to the Specification
specifications
identification
by ASME
The maximum
Code
needs to re-certify
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
authentic,
check
Test
materials
"Partially"
being
Mill
Castinas,
Specifications
II Pari C
These
for Weldinq
specifications
G. Preforned
or Prefabricated
ConsumaQles
are give:l
are covered
a designation
by ASME
number
Code
with a suffi\:
and grading
Pressure
by otttcr
litcHI tile=:pressure
:0
Form
containers
or packages,
be accepted
7.
query
or tagging
for pr.vessels
Requirements
(Section
are discussed
a)
tht: marking
may
viii
Div.1 stipulations)
purpose
Requirements
types
Compatible
Product
welding Consumables
( ASME Section
Plates
Castings
Forgings
d)
e)
f)
(SA 515/516/240/285)
(SA 216/351/217/352)
(SA 181/105/182 etc.)
Max. Allowable
MASVs
at
specification
Stress Values
various
I;:, sed
provlderj
Ofl
SA 36/283/479
(MASVs):
service
temperatures
for
each
acceptable
material
IS
II Part C )
a)
b)
c)
"lith
Specification,
b)
c)
d)
TillS
of the materials,
Materials
General
con~urnabl"f.,
to operate
at low temperature,
service experience
V(~ss('1 dimensions
All design
in corroded
generally
calculated
calculations
for pressure
are required
vessels,
to be made
condition
,,
,
,
b)
Limitations:
i)
ii)
iii)
iv)
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)
b)
composition
& mechanical
for
and should
NOT [RT/PT/MT]
f\rUJlundertolerance
a)
(eg
3mm for a 10mm thick plate), then ordered thickness for the matenal
SllOlilcJ
IlC
suffiCiently <:]reater'
'J
I.
b)
under tolerance shall be taken into account. For S.S & M.S. pipes, th0.
manufacturing
it is zero
(tolerance +20/-0). For S.S. tubes. The tolerance Iimit~ are given in a
separate chart.
9.
a)
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)
In
c)
i)
-4250eg.F.
(-254 Oeg. C)
ii)
-3250eg.F.
(-198 Oeg. C)
iii)
- 75 Oeg.F.
(-60 Oeg. C)
at
Oeg. C)
etc,
below -20
I :)
--'-'---"'-'---'
'---
__
BASIC REQUIREMENTS:
1)
ii)
qeneral
1.6mm
(1/16")
(a)
(b)
corrosion
(c)
for compressed air service: 2.4mm(3/32") + corr. allow.
Mill under tolerance
a)
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)
3)
s!lapes
arc
corlsidered
(g)
for design,
__
4)
COjrn~i.':.!ll':~'"'\:=E~c.~-:
The
US(;:"
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)
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)
II)
th:cKness-
9)
Desiqn'Loadinqs :
i)
ii)
IJead Weight of the Vessel: Weight of the vessel and normal contents of
the vessel
undAr operating
or test conditions
[including
additional
iv)
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
viii)
Loadings due to temperature gradients and differentiai them1al expansion.
10)
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
11 )
sustain the Circumferential stress, along the longitudinal seams, for tile given
deSign conditions [design pressure Jnd design temperature]
when P does not exceed 1/25SE and thicKness does not exceed one-half of the
inside radius.
a)
P x Ri / (SE - 0.6P) or
b)
c)
[ Limitations:
d)
Spherical shell formulas are valid when thickness does not exceed
I .
12)
c,'ffc:l ;rs
(I),
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
required
thickness
torispherical & hemispherical heads under pressure on the concave side shall be
computed by under noted formulae:
a)
==
==
==
where L
M
==
==
x [3
.r
Limitations
+ (L /
==
r ) 1/2
c)
14)
,LQintEfficiencies
Joint
Efficiency
:opplicable to weld jOints completed by an arc or' gas welding process. Joint
efficiency
-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
15)
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)
x [ CP I SE ]
112
where C
'(
)
The above
attachments.
incorporated.
)
)
formula is applicable
17)
Extra moments
to both welded
and bolted
by bolting,
methods
of
are to be
a)
>
~nforcement
a)
of Openirlqs :
Beinfo~ent
required f~in!:]sifls!lell~_<JJeads
IS
._.
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
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
..
"-
3/8" or less;
~(
,,
,
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)
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
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)
::
openings
is
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
is
rules
):)
e)
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,
& t
;,
j
,,
In olher words, the fial head may be required to be thicker by the amount
of reinforcement required.
;:)
19)
'(
Wall thickness of a nozzle neck shall not be less than, the GREATER of the
following (a) or (b) :_
,
~
a)
t=PRi/SE-O.6P,OR
.as
per the
t= PRO/SE+O.4p
b)
(ii)
20)
Insp~n
G ir,
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)
c)
d)
.;>
;)
a)
b)
,,(
)
:>
:>
c)
)
)
)
)
Efficiency allowed
percent
Fully radiographed
Spot-radiographed
No radiograph
100
85
70
90
80
65
b .__
._
~
~
~
5.
FABRICATION REQUIREMENTS
(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
operators
to
may
be used to fabricate
pressure
vessels
constructed
in
accordance with this Division, provided all the following conditions are met.
(1)
(2)
procedure
specifications
by the
4
( )
(I))
211y
73
.
~
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(c)
(d)
,.~
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;;.)
;;,
::;
(a)
;;J
;:,
(b)
,r
,,
(c)
:>
following requirements.
(1) When the welding process is manual, machine, or semiautomatic, procedufE~/
:>
)
the
accordance
is any
automatic
(d)
welding
process
l(
welding
performed
in
procedure qualification
testing is not
IC"
Carbon
C)
Vessel
provisions
to the general
UG-79,-
and low alloy steel plates shall not be formed cold by blows.
~
~
shell sections,
:')
the resulting
extreme
boundary
parts of carbon
and low
fiber elongation
conditions
when
condition
exist.
~
~
~
~C
will contain
requires
(see UW-2).
impact testing.
lethal substances
of the material
thickness
121C to 482C).
'~
~
The extreme
fiber elongation
shall be detennined
~
For double curvature
(for example,
heads),
(75t1R) (1 - Rtr)
~
for single curvature
(for example,
cylinders),
.~
= 50
tlR) ( 1 - Rtr)
Wtiere.
'~
T = plate thickness,
i~
i~
.,
J~
in.
R = original
VVhen 'lesser
shell sections,
boundary
alloj' steel plate are cold formed by other than the Manufacturer
'~
,"'
rCOurr8d cerLlfication
tldS
the
been heat
J"
"j
'3
')
'.
;~
(~
Structural discontinuities
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.
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.
Tests
/
supported.
P(essure
gauges
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.
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.
8,C&D
1/4 t
1/4 t
1/8 in.
1/~ t
1/8 in.
3fi 6 in
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
/'
(
3.
i
-!
Mat'I Nom.Thk,in
3/32
1/8
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_
(,
systematic
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
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
AI.
1.
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.
complete
electrodes/
filler wires,
using
applicable
PWHT - if
a(
'I
i-~
---------====~-_.-..
.
..
...
"
D
~
Surface
L>
Deposits of weld metal are applied to the surface of base metal for the purpose:
b
~
~
a.
or
b.
I.
~
".
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
to be given a
Pastweld Heat Treatment at a soaking temperature not less th2:-: :~,a~specified in under
noted
Tables,when
the nominal
thickness
i)
)
l)
>
),
,,(,
~
and
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
flW/l(:O!1ceJ
below
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 non-ferrous
materials,
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
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)
it
IS
permissible
IS
Wltll
at lowe,
T;Jble UCS _ 5G 1
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
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.
2.
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.
6.
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
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
:)
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
as 200
C-2~
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.
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
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,
.)
t~18
as to avoid
reducing
prevent
Benefits
atmospheres
excessive
the
oxidation
are recommended.
fumace
atmosphere
of the vessel
Bumer
ski'n surface.
locations
should
Neutral
or
be designed
to
on vessel surface.
of PWHT
i)
~
1.
;)
Stress Relief:
Relieving of locked
it a
)
)
)
)
2.
Tempering: Softening hard zones, such as at HAl and in cold formed components
3.
Providing
possibility of underbead cracking. All of the above assure a safe and reliable welded
equipment.
~
~
Summary
All carbon-and
Ihickness
of Postweld
Heat Treatment
eXceeds
Some materials
Requirement
must be postweld
Vessels
containing
lethal substances
at lower thickness.
must be postweld
High-alloy
heat-treated:
if nominal
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
\)
\)
'"
\)
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
~.
-3
~
.>
:
design pressure when calculations are not made to determine the maximum
allowable working pressure.
Max.lnspection temp. = 120 dec F,.
3(
~
:)
:)
:)
)
B) Pneumatic
,.
(Minimum)
( Maximum)
Tests
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
pressure multiple by the ratio of stress value S for test temperature oi vessel to
~
)
)
"
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
(MillimUill)
( Maximum)
,r
),)
L)
b
~
From Inspector's Viewpoint, following are the major areas of concern during
~
~
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,
Identification marks,
( UG-93 a)
( UG-16. c)
(UG-81. a,d)
B. FABRICATION
INSPECTION:
'" __
( UG-8G 2 ,2\
( UW-9 c: fig.UW-13.1 d,I,m,n,o )
__
5. \fVelder Qualifications/Re-qualification
the tests
( UG-n.::: )
8. Weld reinforcement.
( UG-30)
( UW-33)
( WU-35)
( UG-37 a.f)
UW-11a-1 t05);UW-11b;UW-57,
1.
A.
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
. -J
~2:
c
Applica~le
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
DisContinuity
--
size,
orientation
all
and location
',-'
::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:
used to contain
lethal
is
b) Spot Radiography
1)
2)
If spot radiography
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
and all attachment welds with throat dimension exceeding 6mm ( 0.25 inch)
above examinations.
r MT 1 -
Mandatory Appendix 6
.-
certified
by the
Manufacturer
to
be
in accordance
with
the
NDE Personnel:
a.
to enable reading
a
12
.l;valuation of Indications:
Indications will be revealed by retention of magnetic particles in the orientation of
the possible defects
(;iC.
:'la~'also riI.~du(;(.;sia:ilar
A linear indication is one having a length greater than three times the
width.
b)
c)
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)
d)
An
of
an
imperfection
may
be
larger
than
the
IS
r PT 1- Mandatory
Appendix 8
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
2 2
l~.\l9~13tloll_QLLndic_~o_~
-.-A" indic<:li,"' is
II I.
---- ---
A linear indication is one havieg a length greater than three times the
width.
b)
,(
Any. questionable
cj
or doubtful
"
indications
shall be re-examined
10
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)
b)
cj
d)
.-
3.
Examination
r UTJ - Mandatory
(
32
~mpetence
Appendix 12
wilh Ihe written
in accordance
with
Ihe
of NDE Personnel
- 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 \
(a)
i:.\re
"-
where
,-
is the
reinforcement.
thickness
of the
weld
excluding
any
allowable
,
I
4.
RADIOGRAPHIC
. 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
acceptance criteria.
f\cc_eptCJnc~C:.rl!eri<3.
.. Tile following imperiections are unacceptable
---.-
--
penetration;
greater than:
= the thickness
the thinner of these two thicknesses. If a full penetration weld includes a fillet
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,
,
,
,
).
the distance
or
is
4.3
are characterized
as cracks or zones of
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(-~;,
-..
---.. -
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
indications
Any
indication shorter than 1/4 in. shall be acceptable for any plate thickness.
"
IV.
(
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.
GE~.NERAL : The -marking and certification of all pressure vessels built under this
Division shalf comply with the requirements of the following paragraphs,
Required
Marking:
(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
(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
UB
Direct Firing
DF.
(rl) When a vessel has been radiographed in accordance with UW-11, rrla;king shalt be
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
(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";
CHAPTER
1)
EXAM.
A, 8, C, 0
(8)
RT - 4:
(C)
Joint Efficiency (E) for Welded shells or heads, from Table UW-12.
(0)
UW-11 ( c )
(E)
= 0.85,
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:
1)
2)
StatiG-Head conversion:
1 ft
0.433 psi'
1 mtr
0.1 bar
Part
MAWP
SEt
I (R + 0.6t)
(
3)
VesseIMAWP:
0.433 X h
6) Max. pressure acting at any point can not exceed Vessel part MAWP,
= Part MAWP
,
Hemisp. Head = /2 + skirt length (if any)
2.1 Cllip
VVllere
= /4 +
skirt length.
3)
I) Tilicknes'i
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)
II} Thickness
= SEt
a)
of formed heads:
or
P = 2SEt I (0 + 0.2t)
TorisphericalHeads:
t,
= 0.885
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, =
d) .
t,
0 x [ CP / SE ]
1/2
,
where C = a factor derJcnding upon the method of attachment of the flat head
D
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
eo
Any non-hazardous liquid may be used at test temp below its Melting Point
Min.Test temp
MDMT + 30
when
PNEUMATIC TESTS
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
1) /, ~I \'>'el-:1:-;<:;rr..:und ~I~,:ni'lg:;
exceeding
weids
shall be MT or P1Ltested
with
throat
dimensivn
prior to applying
Pneumatic
, pressure
shall be increased
test pressure
shall be reduced
increased
in steps of approx.
of the test
one-tenth
of
to test pressure
of the vessel.
up to one-half
Leakage
is not allowed
at the
visual inspection
(
6). Pro Gauge
range
A)
UCS-66:
MDMT - Thickness
combination
curve.
B)
Materials
Materials
2.
Hydrostatic
3.
Design
test performed
temp
as required
= -20 F to 650
OF
C)
of 10 OF (17C)
exemption
in impact
testing
requirement,
reduction
to minimum
-~~--------------------~-
6\, Reinforcement
of Nozzles:
2. Notations:
= Area removed = d x tr = Ar
t, tr
tn, tm
=
=
a, b
3. Limits of reinforcement:
a)
= 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
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
~(
-{
-..>
~
~
~
~
, Nozzle construction shall be conforming to one of the code accepted t}lpe (UW _ 16)
NOTATiONS:
Radius
((
or y.; in.
53
(!)f
COURSE
f\JOTES .
VOLUME - I I
STUDY OF
API 510R
, INSPECTION CODE
/
I
'I
program
IS
to provide a system of
Vessels.
procedure
promoting self-regulatiofJ.and
Each edition,
beginning
revision,
reVISion, or addenda
with the date of issuance shown on the cover page for that edition,
or addenda.
becomes
effective
Each edition,
is
inspected,
time
or
j)
'.
.CHAPTER
..
Pressure Vessel Inspection Code
Maintenance
1.
Scope
1.
This
inspection
alteration,
code covers
the maintenance
inspection,
repair,
2.
and
recognized
other
Vessels
for Petroleum
Code,
and other
vessels
constructed
non-code
or approved
as jurisdictional
special.
3.
This inspection
code
IS
placed in service.
4.
Hie
following
requirements
of this
inspection code
a.
Pressure
vessels
jurisdictional
on movable
structures
covered
by otrler
regulations
')
{"
.,
1.
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
RP 574
,RP 576
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
_\
"CHAP'fER 3
Definitions
Alteration
A physical
be considered
any reinforced
ASME Code
: Abbreviation
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:
a ..
b.
The inspeclion
organization
of an insurance
company
thai is licensed
or
c.
d.
by the jurisdiction
user's
inspection'
program
shall
provide
ddor otherwise
vessel is used.
the controls
not
The
that
are
Construction
Code
Inspection
code
Jurisdiction
Maximum
allowable
working
pressure
at the top of a pressure vessel in its operating position for a designated temperature.
This pressure
thickness
is based on calculations
exclusive
of thickness
pitted)
designated
for
Minimum
allowable
a vessel.
shell thickness
that
On-stream
pressure
vessel
procedures
may
flCl(
inspection
for continued
operation
Non destructive
the suitauility
examination
of a
(NDE)
are used to establish the suitability of the vessel, and the vessel mayor
IS
being camed
OIJt
Because a vess<c:!
m;~y t.'::;
!:1
inspection
means essentially that the vessel is not entered for internal in:>pection.
,
Pressure
vessel
THis dpressure
Pressure
vessel
acceptable
to the owner-user
engineering
disciplines
characteristics
engineer
associated
with
evaluating
and experienced
mechanical
and
in the
material
pressure
vessel
engineer,
regarded
as a composite
by consulting
with appmpriate
The
specialists, should
be
requirements.
Quality
assurance
determine
if materials,
so
Repair
operation
pressure,
the requirements
addition
or replacement
for re-rating
shall be satisfied.
Repair organization
a.
: Anyone
of the following
0n ovmer
WI
2cco;dance
'-j
c.
code ..
d.
Re-rating
Examiner
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
of the
4.3
RESPONS~81L1T1ES
documenting,
and inspection procedures that will meet the requirements of this inspection
code.
These
systems
and procedures
will
be contained
In a quality
a.
Organization
b.
Documentation
procedures.
(
c.
Documentation
d.
c.
Intemal audits for compliance with the quality assurance inspection manual.
--~-~-"-----_
_-------
..
~
~
-"--'---'-"'-'--'-'
_A,
.._._
... _
._
. _
... _
f.
for
and ratings.
g.
Assurance
repairs, alterations,
requirements
met.
~
~
h.
;
I.
Training
requirements
techniques,
for inspection
personnel
regarding
inspection
tools,
base.
,
,
J.
Controls
necessary
welders
and procedures
are used
k.
Controls
personnel
I.
Controls
necessary
nondestructive
examination
(NOE)
necessary
conforming
to the applicable
section of the ASME Code are utilized for repairs and alternations.
m.
{
I..
n.
Controls
necessary
organizations
and calibrated.
so that
the work
of contract
requirements
inspection
or
repair
organization.
o.
Internal
auditing
relieving
devices.
requirements
control
system
,or pressure
.~.4
API AUHOr-<:~SED
PRESSU~E VESSEL INSPECTOR DUTY
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
'.
**********
l'
-'.
i
CHAPTEFI 5
INSPECTION PRACTICES
'5.1
Preparatory
work
( 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 drained, purged, cleaned and ventilated and gas tested before it is
entered.
Where
required,
protective
equipment
should
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
corrosion.
particularly
and failure
Stress
reversals
in parts of equipment
stress.
Of stresses
are common,
are high and
in pressure
pressure
chang~s.
of expansions
------.---
-----~
vessels
Fatigue
ana
to thermal fatigue.
,
Oeterior~tion
above
for 'which
those
temperatures,
and
permanently
Since
chemical
metals
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,
handled in pressure
(
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
[ Temper
embrittlement
however,
to
is a loss
of ductility
attack
below
20 percent
fractures,
the transition
embrittiement,
most brittle
the potential
to temperatures
greater
of a particular
conditions
exposed
and to pressures
graphitization,
and erosion,
:'12)'
and
notch
service (above
cracking,
hydrogen
special circumstances.
5.3
CORROSION-RATE
DETERMINA TfON
conditions
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.
.(
If data on vessels providing the same or similar service are not available,
corrosion
or user's experience
on-stream
hours of service
nondestructive
Subsequent
determinations
thickness
determinations
corrosion
measurements
monitoring
of
or
service.
by using suitable
the
devices
vessel
or
1000
or actual
system.
If it is determined
that an inaccurate
corrosion
the
rate to be used for the next period shall be increased or may be decreased
to
5.4
.<.
;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~'
maximum allowable
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.
("
a.
items necessary
vessel or ve'ssels
Examine the surfaces of shells and heads carefully for possible cracks,
blisters, -bulges, and other
signs of deterioration.
Pay particular
it may be necessary to
Examine
welded
joints
heat-affected
zones
for
If rivet-
at
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,
, c
.\ J
/'
~vid8Iil.:e
(Ii
API
Recommended
Practice
1 ('
tU
572 can
provide
more
'(
CHAPTER 7
Repairs, Alterations, and Re-rating of Pressure Vessels
7.1
GENERAL
in this section.
performed,
the applicable
vessels by welding.
requirements
of the ASME
have to be
to
shall be followed.
7.1.1
Authorization
vessel
organization.
inspector
Authorization
by the authorized
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
about the
Approval
The authorized
shall approve
all specified
pressure
. 1'1u/
I.l
, '
/'
7.1.3
Defect Repairs
by
Corroded
deposit.
examination
and inspection
being performed
appropriate
shall be specified
in the
repair procedure.
7.2
WELDING
7.2.1
Procedures
and Qualifications
requirements
of
7.2.2
Qualification
Records
shall be available
code
qualifications.
These records
repair organization's
performance
qualifications
The
and welding
7.2,3
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
The use of
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
heat
shall normally
heat
if alternations
or
7.2.4
and constructed
Code, a temper
bead welding
may be used
of 350F ( 175C)
interpass temperature
of
is to be
must be met.
in lieu
a,
technique
during welding,
,
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
diameter
electrodes
in
a manner
to
ensure
temper
bead
reinforcement
layer
shall
be
The
removed
c.
d.
e.
The repair
welding
shall be witnessed
by the authorized
f.
The maximum
g.
exemption
criteria
fOUGd in UCS-56
1, of the ASME Code.
(f)
(1)
If the
('"
/
j.J
"
~
':
~)
be
postweld
heat treated
requirements
In
accordance
with
the
applicable
banding
following precautions
a.
The application
pressure
b.
engineers
that the
are met
vessel
engineering
provided
for 360
experienced
is developed
in the
by
appropriate
specialities.
In evaluating
and
developing
procedures,
the
overall
locat, postweld
and local
heat
treatment
resulting
from
the
shell/
shall be considered.
c.
d.
shall be
e.
-r.ts
by the pressure
vessel
, engineer and authorized by the inspector.
Consideration
by
temper
pressurization
embrittfement
of
chromium-molybdenum
alloys
),
minImum
hydrogen
migration
considered by the pressure vessel engineer for factors affecting the following
a.
Outgassing metal.
b.
c.
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
5, paragraph
T-543.
in
This
'() ,)
:
-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
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.
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.
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
/
vessel
code.
examination
7.2.10
Testing
After repairs are completed, a pressure test shall be applied if the authorized
pressure vessel
A pressure test is
'.
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
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
In addition,
the
a.
The repair thickness shall not be more than 50 percent of the required base
b.
specified
tensile strength of the base metal and minimum specified tensile ,of the
c.
The increased thickness of the repair shall have rounded corners and shall be
d.
7.3
RERATING
a.
Calculations
engineer
experienced
or inspection
shall
justify rerating
b.
A rerating
constructio:i
--,,#
of the
--.:....-.---
-"'
--_.-
-.-.-- ..
.:...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
~:
, .. 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
e.
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
,.
'..
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
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:
Construction
Standards
Maintenance
inspection
Cause of Deterioration
Methods of repair
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
Saddfe
cegacds
materials of constrUctions.
--
ends
'1
---.. --------
--~",":'r~,,
__ ----"'-------
__
-~--i
~T'~
~'-T"~
:'!. Co.lsrruction
",' T'~
,,,
r~
~, I"~
f'r~
I :>
C:.]
t'.
construction
5. Reason
5.1
(
"
5.3
to the requirements
it should be maintained
according
to the requirements
for inspection
the
or unsafe operation
Continuity:
Periodic inspection
maintenance
program
t: I .;l
5.4
c]~
e. I ~
( I~
Reliability:
External inspections
operation
may reveal
to be opened.
Defects
improper installation
(.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
~,l.~
el::>
is possible
The
Deterioration
may
be
mechanical,
or
chemical,
in nature.
.~
~ ..
~> .~
5.2
Corloslon
Corrosion
internal
ccrrodents
in refineries
.~
C;. " .~
COrll[)n'.lficJS.
:, .-.
I'''~
;)
..I
I'\.~
,~
'.J
in a pressure
vessel
~~
'-.
authority.
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.
'", 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
of solid particles
6.4
Metallurgical
and Physical
Changes:
or metallurgical
to service
conditions
Examples
of these
changes
6.5
are graphitization,
intergranular
Mechanical
Forces:
temperature
changes, Vibration,
high-temperature
hydrogen
corrosion.
pressure
Thermal
shock,
Cyclic
loads
Faulty Material: PVs may fail due to faulty material usea (Material mix-up) during
fabrication
stage.
Laminations
conditions.
has occurred
during
service
leading to rapid
failure or leaks.
6.7
Faulty Fabrication:
The
use
of
penetration,
welding
techniques
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
..
..
Poor
fabrication
permitted
Imp,oper
:"lj
111
can cause
period.
and cracks .
tolerances
outside
of the range
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
7. Frequency
7.1
Governing
Factors
The frequency
Frequency
of inspection
factors.
factors
corrosion
allowance.
API 510 gives rules for the frequency and extent of inspection
Additional
inspection
of tl18
jurisdiction.
7.2
Opportunities
Inspections
for Inspection
When vessels,
process
are possible:
towers, exchangers
to clean
b.
External
time.
inspections
or an exchanger
is in
service.
These inspections
ladders,
etc.
platforms,
The existence
internally
7.3
Inspection
Scheduling
,'~
..
4
:?
"j
of abnormally
or hot spots
on
Schedule
of sllutciowns
th2 collaboration
jurisdiction
and location
insulated
paint,
for maintenance
of process,
maintenance,
or inspections
is usually arranged
through
by a
8.0 METHODS
Safety precautions
The vessel should be isolated from all sources of liquids, gases, or vapors,
using
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
As a precaution
8.2 Preparatory
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,
,.;-
corrosion
due
to water
accumulation
and Supports
Foundations
Foundations
Platforms
or walkways connected
Depressions
Excessive
Stairways,
The external
platforms,
for
Any necessary
should be corrected
of concrete.
However, if it is excessive
or uneven,
Records
Anchor
Bolts
DistO:ll011 of anchor
bolts
may indicate
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,
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
fireproofing
to bulge.
the
8.4 Nozzles
If any setting of the vessel has occurred, nozzles and adjacent shell area should b~
inspected
cracking
and
The grooves of ring joint flanges should be checked for cracks due to excessive
bolt
distol1ion
tigtltening.
8.5 Grounding
Grounding
IS
Connections
maintained.
These
connections
electncity
Resistance
should
f=(eco[llrl1'2nded resistance
~.
~.:)
J ~
..
;?
~
'...
.J
of lightning or static
not
exceed
the
accepted
values
in
the
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
by measuring
the changes
in
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.
of the
Small distortions
measurements
grinding,
the condition
Metal Surfaces
circumferences
Vessel
determine
The extent
Surface
to beller
measured
may be removed
8.7 External
Buckles
and erosion
8.9 Detailed
Inspection
A del2ilec! !C]spectic:l shoukJ start at end of the vessel and war'" tc'.vard the other end .
.4. systematic
Items
procedure
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.
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.
'J, olded
','.?t
seams in ""el
is amin,
seN,,,
,oat
01 l1igl1-
Welds
should
welded
service
to the
technique
should be considered
examined
Nozzles
connected
measurements
or with
scissor-type.
calipers.
is
inspection
supports
internal
of internal equipment
equipment
screens, grids.
piping, intemal
stiffeners,
(he original
thickness.
thickness
instruments
ultrasonic
The general
sUliaces
and other
condition
of the support
Transfer
If there
"
appears
or direct-reading
calipers,
micrometers,
or
in contact with tray packing should be examined for possible loss of metal by
corrosion.
The condition
the vessel
Inspection
be obtained
appreciable
vessel
The performance
or
In
inside diameter
In most instances,
The
instruments.
direct-reading,
disconnected,
flange.
of operation.
of
instruments.
then efficiency
Therefore,
is
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
is encountered
in determining
Because
piping
connections.
determine
thinness
should
be" thoroughly
inspected
the underside
the location
visually,
its condition.
The sound,
especially
will indicate
any
the remaining
wall
may be measured.
an illustration
although
measurements
(although
some scraping,
and corrosion
Inspection
of this equipment
Figure 31 is
may be mostly
may be necessary.
may be required
Thickness
in some
areas,"
Erosion
Figure
from corrosion.
Erosion is characterized
by a smooth,
appearance;
to a clearly
marked
smooth
detailed
information
for erosion.
exchanger
corroded
bright
usually confined
areas
on corrosion
and
on erosion.
Turbu!ence
plates should be
velocity
ErOSion or corrosion
regularly
at threaded
'The internals
around
of
thickness
checked
the
of their design, ballast and valve-type trays cannot be checked for leakage.
All internal
visual,
of the
leaks,
to the height
beam is directed
tillS
type of erosion.
10
of
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
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:' ~
'=-
t.: ~
p. .
'- :>
~.,
'-
~.
".:>
'-.
....,
~.
f4..
',.
,..-.
fo- ...
~~
i
I
detected visually from the outside of the vessel, unless it is externally insulated. Out-
vessel at the cross section of r.laximum deformation and comparing ii with the inside
::J
.l
~.~
Excllanger s!lells Sllould be checked closely for any defomlation, particulariy after
~.')
..
.. "....
"'~
....
eo,
t
~~.
.~
('"
.. c~.'-".~ ...
..
"
_:~
~,::.,~
b-,~
tuIJ0 ~~i'l,--:!esextremely difficult, and extractions after dif!lc~i: iljsldllations can b~ neariy
h,~
impossible.
~":Y-,~
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
,:;)
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,
~"I .~
~~ II '"".
.
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(1\
'-
u-",
,-""1.
"'\
r"'.
i- ..
'-
f'
-
i
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~
~
-:.,
.I
Wet fluorescent
magnetic-partide
cracks
detecting
surface
inspection
on boilers
should
deaerator
cracking.
recommended
and
and
is
the
fluorescent
magnetic-particle
recommended
information.
zones
Deaerators
checked
testing
of
is
for possible
the
primary
inspection method.
Supports
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
closely
magnifying
for cracks.
glass. a scraper,
have an appearance
cracks
Usually,
visual
inspection
Laminations
in vessel
plates
similar to cracks, but they run at a slant to the plate surface, while
inserted,
channels
If open sufficiently
If a lamination
is suspected
approximately
lamination
heating
to
flaw detector
may be used to
refer to figure
8.10
Limits
of Thickness
must be known,
variables.
COITosion or erosion
comparing
cOllsecutive
inSpeCllJ:1 records
'J
.j
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.
(
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
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1"--.. 0.,_
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.:>
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STUDY OF
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API - RP 576
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1. Scope
...-. ....
~.~
C.~
,""
relieving devices
COmmonly
This publication
control valves.
in tanks, fusible
plugs, and
~-~
~: ...~
~.-
e..
.-;>
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 ~.;)
e' ,~
~"; ,;)
To determine
e ;)
:>
-~
~l
device.
freq~ency.
3. Type of pressure-relieving
e- ~
C:-
To e'.'aluate inspection
('. ::>
t :>
(.
excess
devices
(
fuJ[ety Valve
(i
(4
t'
t,
t:>
e
t,"
C.:
e~.
eo'
t,
~
~
.:>
::>
'.~
-~
.~
':>
~
!i,
"-
'J
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
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.
1,,-*;jjft;~'liII.lloilIi!I_IlII1!!,
__ ""'.
....
~ __
._.
__
,... -r ------------~
~
"-~
\
.~'-,~
~'~~
~->:"'I
'",
~ ~~~
.~
~~,~
a~ Corrosion
~'~-.,~
~~~"-..~
'~-,
'c ,~
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~
c ~~
""
~~~
r~
e. f ~
~-
4.3
c.. r~
e- r ;,)
,
e :~
e I;)
4,5
c... ~
e ;~
~
:>
:>
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L;)
:>
~:, !
\...
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~:
r ~
t'
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;>
t~ l:J
~: ~
':)
-J
_ I:J
:
!
,~
_dl
.J,
of the spring,
which
causes
5. Frequency
5.1
Frequency
products
can
(
Inspection
should be
e [,:>
.~
breakage)
In petrochemical
service, process solids such as c9ke or solidified
sometimes plug various parts of the valve and connected piping.
;)
e
e
e
e
(complete
,"-,;:>
e., ~-_~
e[~
e- i~
,a
Failed spring:
r~
C;~
e .;>
,:)
ltlZl "...
Depending
another
on operating
experiences,
to
r~
"
.)~
~r'~
\l, '. r~
. ,~
~ r~
After a pressure re:ief valve is removed from service, it is usually taken to the shop for
inspection and repair.
~ i~
~ I';'
,."
c ,:)
C
C
I~
C[" ~
Most test blocks are designed to test pressure relief valves with air because it is a safe
and readily available medium.
e ;)
cl
e!~
The air test is generally used to test safety, relief, and safety
pressure and valve tightness.
relief valves
for set
!.~
fC'
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.
""'f;J
valves.
e I'~
e (.:>
[~
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.
I,:)
(:
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The water-system test block includes a positive displacement
other instrumentation.
C',J
and,
t:1~
6. Inspection,
el~
t.'
I ~
t'
I~
t~ I~
~l
I~
tI.~
e"
3.
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.
:;
I;
e.' .:)
..
~ ...
".';)
:)
")
~,
-.,
~'
C:-"J
?
,411i.,
..':"'"
..)
~:----_ ..A~"".~
__ ,,,,,,,
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).
j ;
~.I .;)
it is transported
~: I ::J
& Setting
tl. I ~
~'
Testing
,~._,__
""'-
'-~
~"
"
~~
~'\)
~~."
"
~,~
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.
c~
c~
--
for
~.:)
--
~,.:)
~._;,
~-.;)
n
,-, ,:)
~.:,..~
;.n.
'---.;)
e",;}
e~,\~
~ instructions.
The valve shall be then reassembled according to manufacturer's
c::;.;)
C::.J
e:::;j
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.
e:T.J
e';~
e;~
e~
If a new
pee"u'e I, eequleed, the manufaclueer,
must
not 'el
be exceeded.
of Ihe 'pring
t.. r;)
,
C' ..,;:)
After
the valve
has been adjusted, it should be Popped at least once to prove
the accuracy
of setting
the setting.
t:' ~
~
The....devlallon
of Ihe
for
set pro
== 70pop
psi. pce"u,e
2 P"
~L::>
Fo, p,e"uee
max
set pr '= 'ellef
10% valve,
of WP. that Complywith Sec!;on VIII,Divi,'on 1, of Ihe ASME code,
~
~ ... ~
setting
When Ihe pee"u'e
l
,;)
" te'ted
~'''~
e ~
e- ,~
e :)
e "':J
The discharge should be observed for evidence of leakage, or the test gauge should
Attalnmc:nl
water
from
.... --.
'--
'",,--j
t..:)
t'
~
.-'"
~
..
I'''';
," I ::;
IiriP_IlllIIilIlil~ll/j__
,,'~
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.
VOLUME
-II
STUDY OF
ASME Sec.- IX
r---<-::
.. t"-~ \
'~~~.
~-,;.~
I
r~
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I
~-1-~
CHAPTER - 1
~-J-~
~'i ~
ESTABLISHING WPS.
~i~
~"r-~'
c'l'~
.~. l"~
ASME Section
brazing operators and the procedures that they employ in welding and brazing .
c ..~
e J .:)
I
c.- r~
It is divided into parts, part OW gives requirements for welding and part OS contains
requirements
e'-l-~
~T~
e_.~
e.r-:j
for brazing. For the purpose of this course we shall deal only with part
OW.
e I.,.~
el:)
The purpose
I
el~
e.:)
el:}
el:)
el::>
e I_~
("I",
(:.1..,",
el:)
t.\.
WPS
is intended
essential
to provide direction
qualification
establishes
operator .performing
Art'cle II
Article III
ej:)I"'"
-'"'<.
("nlcle IV
I;
I .:,
.~
,-, I ;
.~j
..,
::i
_~
~
\~,
~
_lIib.
procedure
procedure
qualification
sound metal or the welding operator is able to operate welding equipment properly.
e L ""
~l
the welding
test
Article I
e~j
both
t,\.1 ':>
C':
is capable
and non essential and the acceptable ranges of these variables when using
It is presumed
el~
t.'
qualification
the WPS.
I H."
:-
brazers and
.__
"~~-,,,,-~-..._
.__
~.
,.__
~ __
..
""'~
'"'<~
,",- -'""
,",~.,~
~"r"
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,
rIr" 't~
~.:',:)
and circumferential
In a way it is combination
of 1G,
3G & 4G.
Position
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
the thickness
procedure
qualification
of groove
and
(Refer
of the test
fig.
463.1)
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
similar except
section)
that instead
so
required
qualification
a,d ( it is
of 2 sections
of %
table (fig) gives the diameter limits. It is wortn noting that one, two
dlffen~nt processes
(Refer
welds
fig
qualification
for performance
qualification
limits
of fillet
!:' ~
~n~
~n,~
~.~
WeldinQ Vdriables :
!~
'tr ..
;"')~
Article
~, r~
various
..
welding
processes
"~
variables
....,:,
variables
for performance
C. ~
C,.
T~
Essential
variables
C..
!~
the mechanical
T"~
t..
I~
"-
~.
showing
in P-number,
variables
for procedure
properties
properties
of weldment
e,
supplementary
qualification:
essential
and
essential
of the weldment
(ex. Change
procedure
I:>
;:>
en ::>
e. ::>
for procedures
Supplementary
t.
t.
variables,
Cl~
~ I~
I
t. r~
essential
qualification.
(,_
i ~
essential
variables
for procedure
are those
whose change
welding
variables
for
or
PWHT)
Non essential
variables
for performance
of weldment
variables
(ex. Joint
design,
method
of back
i~
e. :>
e. [~
Essential
variables
for perfor'mance
variables
ability of welder to deposit sound weld (e.g, position, deletion of backing F-number
etc.
c. I ~
e. l~
Change
~l:>
e !~
e .~
e' ~
e- ~
e, ~
e ~
All those
materials
composition
are divided
into various
Pial"
divided
carbon
Lmder
and
t:
steels
st:lHlless
Vi-mOUS
CSi,
Cr-Mn
steel as P8 matenal
depending
on their nominal
;\'l1umbers
arp' groupeo
Ferrous weldirlg
;lild
vje/dlllg
.~
"
as P-1
consumable
.)
performance,
& C-Mn-Si
~:'
('~
P-numbers
2S
/ min. specified
3c stel11tlc
t'
as well
and further
e ~
(~
materials
are classified
composition
1'1
and
dlffererlt
(table 442)
F-Ilumber
depending
composition
(table 432)
IlL;):
and chemical
Refer
ASME Section
1.
2.
3.
4.
5.
(a, b, c, d & e)
6.
IX.
7.
8.
9.
10.
Qualification)
Procedure Qualification
Thickness
Limits and
Test Specimens.
Performance Qualification
and Test
Specimens.
Performance Qualification
diameter limits.
Acceptance
Criteria
QW
4
5.
Procedure
1.
IX
Qualification
Procedure Specimens
Performance
QW 191 Radiographic
Examin2tion
Specimens
Position and
r':'
11"-
~,-~
~'r~
~""' ,,;)
~"'" .;;J
CHAPTER - 2
~~
I .;"
~"'r"~
r .~
,-i"- ""y
:.,:,
..
C. ~
C ~
c~
and
"~
{;.:
:::;
t.'
methods
joint
t;.'; :J
mechanical
e....:..~
(,
t:.~:]:.~
t:.L.:)
~,I.':)
e.\! ~
e:
e']
~"J
~"J
weld
specification
Preparation
specimens
production
>"
."
assemblies
results
will
~.] j
I"s
I 4--'
"~
~~,I l-j
t I ~~
c~,I -~
~~
to be welded
in
for testing.
by the particular
.l~
I "-'
I
joint
preparation
L~
have a representative
procedure
6.QJ)J.Qv91
usually
The matenals
welding
"".'"'
and
e>. I ~
e, ..
\.
application
Testing of representative
and thickness
.{~
e:-. I
~,
the
-. I
e' I
~'4L
meet
produce
Test
~.
e..'L
that
will in fact
e. I ~
e1 ~
..
properties
procedure specification
materials
I ..~
e' I
in a
the
e;_I_~
prescribed
that
requirements.
--'r
:2
analyzed
by the responsible
made available
;or review
parties to determine
whether
These
the test
fU'"
quallf'Cilil""
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
(.
~h~
~rh~
~,-~
.
~,
.;)
Qualifica,!or.
is accomplished
approval
has been
!;;...~
available
.;-....;)
witness
the welding
~....~
factual
knowledge
c: ,:)
production
c ~
At
~r
obtained.
However.
tests have
authentic
been completed
documentary
and
evidEnce must be
,.. .
'h
any
details that
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
.~
C .~
t..' ~
t: ~
Code Qualification
Requirements
AWS
Welding
Structural
Code, in paragraph
qualifying
those welding
t:~.~
:;~
paragraph
51 of that code,
e::>
contract
~'.
e: ....~
t~' .~
e.- ~
requirements.
qualify
a welding
procedures
such
as
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
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
~
~
is authoritative
document.
of the ASME
with
Code
e .~
'-'"
in paragraph
5.12.
qualified
for
of
the requirements
status
ASME
Section
forth
the prequalified
e~' ~
e" : ~
Boiler
sets
or which
procedure
5.5
in accordance
NB-
with NB-
and
and IX
paragra;)ll
In accordarlce
"'/llI,
'~N 28,
requires
tile
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
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-
NC-4321
and so forth-entitled
manufacturer
organization
III, such
Manufacturer
on
ASME
Each
"Eacll
procedure
NB-4381.2
procedure
The
Seclion
Paragraph
qualified
in ASME
and/or
"Procedure
Installer
Specifications
is responsible
NB-4321.
and Qualifications,"
and conduct
done
by his
Chanqes
in a Qualified Procedure
If a fabricator
make
a change
qualifying
listed
For
in that procedure,
tests. Re-qualification
in the governing
example,.
treatment
addition
a welding procedure
may
at some
be necessary
later
to conduct
date to ,
additional
of the essential
variables
has a profound
essential
it
desires
that follows
Its omission
welding.
Heat
of the procedure.
!'-Jote
The
most
Important
re-qualiflcation
weidel
and
conSlcJered
pages
is necessary,
Much
welding operator
classed
the same
qualifications.
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
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
classification
consumables
are
Specifications.
into
and properties
number
of
of consumables
for
sub-sections,
in
other
grouped
words,
together
for carbon
("l&
~~"---
'-.~~
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
and rules
for
and certification
e'~
e"~
Some
E'~"~
C ~
t.
<3
Common
conDlete
Specifications
the list is not exhaustive.
For
l
~
t:.' ,~
C .
~
i
t:Li~
t-' '~
tiLL ~
t ,::>
~~l.
~:' ~
~,
.~
t, ~
,II.,
~~
electrodes
and chromiulll
\'.'21011I9
(GTAW / GMAW
..,.....-~.))
~)J
SFi:, 5.21) Low alloy steel filier meldls for ga~; shif:,ded arc welding (GTAW I GMAW)
~~
~ ~
...
~'~
...
AWS Classification
~-~
American
,-))
~
in an alfa-numeric
of Consumables
~.~~
C~.~
C-~
1. Classification
e~
(Shielded
~<)
AWS - E - XX - YY - G
~~,:)
~--~
e__
:
a
E ..
Coated electrode
XX
'-:..~:)
YY
e..,~
e ~
t'" .;)
2. Classification
e,~
AWS - ER - XX -S - yy
e_;~
:j
i
ER ..
C ;)
"-r
S ..
,,,_I.,
!~
e;~
t
yy
Solid
.~
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
~" '.=>
t.
J _:~
..,
e ~
VMe
r"~
'3.
~;
YYY
~~.
(:.--~(
Ciassificatior. of
(:.--~
~--~I
I--:'-~i
h~
~._~\
;:-,
~\
Flux
1st X
2nd X
Condition of Heattreatment ..
C:.: _~(
as welded
C ;).
Post heat
C,;".~
3rd X
lmpact strength
~-~
Electrode wire
C~_ .::) ,
t.:'__~ i
Composite electrode
yyy
ZM
t._~,
e..'.:.:'~
t.
0
.. ~
"
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 '~
e~
'~
e '~
II
C"
e.: '.~
II;
e- .. ~
e-. I
f\> I .~
__
i~
__
I .~
10
.-::~I .AI
'. i .-
'~
as
Essential Variables are given in comprehensive details in the chapter called "Welding
~~:.; .
~J r ...
fi'.
'...1
,,-",I ....
~~~'~i~~~-.'l]jli!l
_'JlL~!IIIIIIlIUjjH"_JdV-l
r:5
~
~
~""
;:,..~
vi. Post Weld Heat Treatment and finally, the supplementary essential requirement of,
t:,~
~"~
G'l,J
~.:.....,
characteristics, such as chemical composition, mechaniCal properties and weldability.
~3
~.
""'
(Refer Q\I\I-442)
..
,~
,
,,'
...
'~"-3
,r
Assignment of F Numbers
~'"
~
~
..
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"'-
"',. r~
I
t:. ;~
f,autiQI"@!YNote
e:.',
These
t:L~
qualification
e:~[,
CJ.,
t:
i.,
r
assignments
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
t.' ~
t, ~
~.
~.~
~ ...
~'
~
~ ...
~
~
~.
e<. ~
~
1"\, ..
..,
:,::" I ...,
.\,! ~
11
"-"\I~
1J_!l.I~-.-.''!t~.;~iI'IIt:~'llj,Jl:?t:"'''~~~~~~d_~_~;_"ItiaJilMf.~,~~_
~.-."'~~
CHAPTER 4
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
C':~
~:3
~\::~3 .
e::3
e::.~
~'~~
t.':~
t:'
1)
I.,--r~
C":~
.,Rev
and
POR no.
C:::-,l~
~.J.",,\
I,..~.... ~
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.':!~
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)
5)
~::~,.~
t!~
~:.l
ow
o
.
~
~>"'~
~..
j '~
~.L ~
eLL ~
e- I '~
:..' I _~
.
,
I ,:)
f-.>.I
'
12
9)
Additionally OW
1j()1
11)
12)
This is reminder for reviewer for bend and tension test as per QW 451.1
13)
14)
15)
16)
1 :5