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Case ____
Section VIII, Division 1
Weld Repair Without Subsequent PWHT Using the Gas Tungsten Arc Welding
Process

Inquiry: In addition to the Shielded Metal Arc Welding Process, may the Gas
Tungsten Arc Welding Process be used to deposit weld metal for weld repairs to
P-No. 1 Group Nos. 1, 2, and 3 materials and to the weld metals used to join
these materials after the final PWHT but prior to the final hydrostatic test, without
additional PWHT?

Reply: It is the opinion of the Committee that in addition to the Shielded Metal
Arc Welding Process, the Gas Tungsten Arc Welding Process may be used to
deposit weld metal for weld repairs to P-No. 1 Group Nos. 1, 2, and 3 materials
and to the weld metals used to join these materials after the final PWHT but prior
to the final hydrostatic test, without additional PWHT, provided all other
requirements of UCS-56(f) are met.
This Case number shall be shown on the Manufacturer’s Data Report.
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2011a SECTION VIII — DIVISION 1

UCS-12 BARS AND SHAPES (b) Shells of pressure vessels may be made from electric
resistance welded pipe or tubing listed in Table 1A of
(a) Approved specifications for bar and shape materials
Section II, Part D in nominal diameters up to 30 in. (750
of carbon steel are given in Table UCS-23. A tabulation
mm) provided the material is manufactured by the open-
of allowable stress values at different temperatures are
hearth, basic oxygen, or electric-furnace process [see
given in Table 1A of Section II, Part D.
UG-16(d)].
(b) Bolt materials as described in UCS-10 may be used
as bar materials.
(c) Parts made from bars, on which welding is done, UCS-28 THICKNESS OF SHELLS UNDER
shall be of material for which a P-Number for procedure EXTERNAL PRESSURE
qualification is given in Section IX, QW-422 (see UW-5).
(a) Cylindrical and spherical shells under external pres-
sure shall be designed by the rules in UG-28, using the
applicable figures in Subpart 3 of Section II, Part D and
DESIGN the temperature limits of UG-20(c).
UCS-16 GENERAL (b) Examples illustrating the use of the charts in the
figures for the design of vessels under external pressure
The rules in the following paragraphs apply specifically are given in Appendix L.
to the design of pressure vessels and vessel parts that are (c) Corrugated shells subject to external pressure may
constructed of carbon and low alloy steel and shall be used be used in pressure vessels in accordance with PFT-19 of
in conjunction with the general requirements for Design Section I.
in Subsection A and with the specific requirements for
Design in Subsection B that pertain to the method of fabri-
cation used. UCS-29 STIFFENING RINGS FOR SHELLS
UNDER EXTERNAL PRESSURE
UCS-19 WELDED JOINTS Rules covering the design of stiffening rings are given
in UG-29. An example illustrating the use of these rules
When radiographic examination is required for butt is given in Appendix L.
welded joints by UCS-57, joints of Categories A and B
(see UW-3) shall be of Type No. (1) or No. (2) of Table
UW-12. UCS-30 ATTACHMENT OF STIFFENING
RINGS TO SHELL
UCS-23 MAXIMUM ALLOWABLE STRESS Rules covering the attachment of stiffening rings are
VALUES given in UG-30.
Tables 3 (for bolting) and 1A (other materials) in Section
II, Part D give the maximum allowable stress values at UCS-33 FORMED HEADS, PRESSURE ON
the temperature indicated for materials conforming to the CONVEX SIDE
specifications listed therein.2 Values may be interpolated
for intermediate temperatures. (See UG-23.) For vessels Ellipsoidal, torispherical, hemispherical, and conical
designed to operate at a temperature below −20°F (−29°C), heads having pressure on the convex side (minus heads)
the allowable stress values to be used in design shall not shall be designed by the rules of UG-33, using Fig. CS-1
exceed those given in Table 3 or 1A in Section II, Part D or Fig. CS-2 of Subpart 3 of Section II, Part D. Examples
for 100°F (40°C). illustrating the application of this paragraph are given in
Appendix L.
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UCS-27 SHELLS MADE FROM PIPE

UCS-56 REQUIREMENTS FOR POSTWELD (10)
(a) Shells of pressure vessels may be made from seam- HEAT TREATMENT
less pipe or tubing listed in Table 1A of Section II, Part
D provided the material of the pipe is manufactured by (a) Before applying the detailed requirements and
the open-hearth, basic oxygen, or electric-furnace process. exemptions in these paragraphs, satisfactory weld proce-
dure qualifications of the procedures to be used shall be
2
See Appendix 1 of Section II, Part D for the basis on which the performed in accordance with all the essential variables of
allowable stress values have been established. Section IX including conditions of postweld heat treatment

168
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2011a SECTION VIII — DIVISION 1

or lack of postweld heat treatment and including other but in no case more than 400°F /hr (222°C/h). During the
restrictions listed below. heating period there shall not be a greater variation in
Except as otherwise specifically provided in the notes temperature throughout the portion of the vessel being
to Table UCS-56 and Table UCS-56.1, all welds in pressure heated than 250°F (140°C) within any 15 ft (4.6 m) interval
vessels or pressure vessel parts shall be given a postweld of length.
heat treatment at a temperature not less than specified in (3) The vessel or vessel part shall be held at or above
those Tables when the nominal thickness, as defined in the temperature specified in Table UCS-56 or Table UCS-
UW-40(f), including corrosion allowance, exceeds the lim- 56.1 for the period of time specified in the Tables. During
its in those Tables. The exemptions provided in Table the holding period, there shall not be a greater difference
UCS-56 or Table UCS-56.1 are not permitted when post- than 150°F (83°C) between the highest and lowest tempera-
weld heat treatment is a service requirement as set forth ture throughout the portion of the vessel being heated,
in UCS-68, when welding ferritic materials greater than 1⁄8 except where the range is further limited in Table UCS-56.
in. (3 mm) thick with the electron beam welding process, (4) During the heating and holding periods, the fur-
or when welding P-No. 3, P-No. 4, P-Nos. 5A, 5B, and nace atmosphere shall be so controlled as to avoid exces-
5C, P-No. 10, and P-No. 15E materials of any thickness sive oxidation of the surface of the vessel. The furnace
using the inertia and continuous drive friction welding shall be of such design as to prevent direct impingement
processes. Electroslag welds in ferritic materials over 11⁄2
of the flame on the vessel.
in. (38 mm) thickness at the joint shall be given a grain
(5) Above 800°F (425°C), cooling shall be done in
refining (austenitizing) heat treatment. Electrogas welds in
a closed furnace or cooling chamber at a rate3 not greater
ferritic materials with any single pass greater than 11⁄2 in.
than 500°F /hr (280°C /h) divided by the maximum metal
(38 mm) shall be given a grain refining (austenitizing) heat
treatment. For P-No. 1 materials only, the heating and thickness of the shell or head plate in inches, but in no
cooling rate restrictions of (d)(2) and (d)(5) below do not case more than 500°F /hr (280°C /h). From 800°F (425°C)
apply when the heat treatment following welding is in the the vessel may be cooled in still air.
austenitizing range. (e) Except as permitted in (f) below, vessels or parts of
The materials in Table UCS-56 are listed in accordance vessels that have been postweld heat treated in accordance
with Section IX P-Number material groupings of QW-422 with the requirements of this paragraph shall again be
and also listed in Table UCS-23. postweld heat treated after welded repairs have been made.
(b) Except where prohibited in Table UCS-56, holding (f) Weld repairs to P-No. 1 Group Nos. 1, 2, and 3
temperatures and /or holding times in excess of the mini- materials and to P-No. 3 Group Nos. 1, 2, and 3 materials
mum values given in Table UCS-56 may be used. Interme- and to the weld metals used to join these materials may
diate postweld heat treatments need not conform to the be made after the final PWHT but prior to the final hydro-
requirements of Table UCS-56. The holding time at tem- static test, without additional PWHT, provided that PWHT
perature as specified in Table UCS-56 need not be continu- is not required as a service requirement in accordance with
ous. It may be an accumulation of time of multiple postweld UW-2(a), except for the exemptions in Table UCS-56, or
heat treatment cycles. as a service requirement in accordance with UCS-68. The
(c) When pressure parts of two different P-Number welded repairs shall meet the requirements of (1) through
groups are joined by welding, the postweld heat treatment (6) below. These requirements do not apply when the
shall be that specified in either of Tables UCS-56 or welded repairs are minor restorations of the material sur-
UHA-32, with applicable notes, for the material requiring face, such as those required after removal of construction
the higher postweld temperature. When nonpressure parts fixtures, and provided that the surface is not exposed to
are welded to pressure parts, the postweld heat treatment the vessel contents.
temperature of the pressure part shall control. (1) The Manufacturer shall give prior notification of
(d) The operation of postweld heat treatment shall be
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the repair to the user or to his designated agent and shall

carried out by one of the procedures given in UW-40 in
not proceed until acceptance has been obtained. Such
accordance with the following requirements:
repairs shall be recorded on the Data Report.
(1) The temperature of the furnace shall not exceed
800°F (425°C) at the time the vessel or part is placed in it. (2) The total repair depth shall not exceed 11⁄2 in.
(2) Above 800°F (425°C), the rate3 of heating shall (38 mm) for P-No. 1 Group Nos. 1, 2, and 3 materials and
5
be not more than 400°F /hr (222°C / h) divided by the maxi- ⁄8 in. (16 mm) for P-No. 3 Group Nos. 1, 2, and 3 materials.
mum metal thickness of the shell or head plate in inches, The total depth of a weld repair shall be taken as the sum
of the depths for repairs made from both sides of a weld
3
The rates of heating and cooling need not be less than 100°F /hr at a given location.
(56°C/h). However, in all cases consideration of closed chambers and
complex structures may indicate reduced rates of heating and cooling to (3) After removal of the defect, the groove shall be
avoid structural damage due to excessive thermal gradients. examined, using either the magnetic particle or the liquid
NOTE: Section VIII Division 1 pages 170 to 177 consist of Table UCS-56
and have not been included here as part of this item. The remainder of 169
paragraph UCS-56(f)(3) is continued on page 178, which is the next
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2011a SECTION VIII — DIVISION 1

TABLE UCS-56.1 TABLE UCS-57

ALTERNATIVE POSTWELD HEAT TREATMENT THICKNESS ABOVE WHICH FULL RADIOGRAPHIC
REQUIREMENTS FOR CARBON EXAMINATION OF BUTT WELDED JOINTS IS
AND LOW ALLOY STEELS MANDATORY
Applicable Only When Permitted in Table UCS-56
P-No. & Group No. Nominal Thickness Above Which
Decrease in Classification of Butt Welded Joints Shall Be
Temperature Material Fully Radiographed, in. (mm)
Below Minimum Minimum Holding
Specified Time [Note (1)] 1 Gr. 1, 2, 3 11⁄4 (32)
3
Temperature, °F at Decreased 3 Gr. 1, 2, 3 ⁄4 (19)
5
(°C) Temperature, hr Notes 4 Gr. 1, 2 ⁄8 (16)
5A Gr. 1, 2 0 (0)
50 (28) 2 ... 5B Gr. 1 0 (0)
100 (56) 4 ... 5C Gr. 1 0 (0)
150 (83) 10 (2) 15E, Gr. 1 0 (0)
200 (111) 20 (2) 5
9A Gr. 1 ⁄8 (16)
5
9B Gr. 1 ⁄8 (16)
NOTES: 3
10A Gr. 1 ⁄4 (19)
(1) Minimum holding time for 1 in. (25 mm) thickness or less. Add 5
10B Gr. 1 ⁄8 (16)
15 minutes per inch (25 mm) of thickness for thicknesses greater 5
10C Gr. 1 ⁄8 (16)
than 1 in. (25 mm). 3
10F Gr. 1 ⁄4 (19)
(2) These lower postweld heat treatment temperatures permitted only
for P-No. 1 Gr. Nos. 1 and 2 materials. Alternatively, for P-No. 1 Group Nos. 1, 2, and 3
materials, the gas tungsten arc welding process
may be used with the addition of filler metal.
penetrant examination methods, in accordance with Appen-
dix 6 for MT and Appendix 8 for PT.
all welding, the repair area shall be maintained at a tempera-
(4) In addition to the requirements of Section IX for
ture of 400°F–500°F (205°C–260°C) for a minimum period
qualification of Welding Procedure Specifications for
of 4 hr. The final temper bead reinforcement layer shall
groove welds, the following requirements shall apply:
be removed substantially flush with the surface of the base
(a) The weld metal shall be deposited by the man-
material.
ual shielded metal arc process using low hydrogen elec-
12 trodes. The electrodes shall be properly conditioned in (5) After the finished repair weld has reached ambient
accordance with Section II, Part C, SFA-5.5, Appendix temperature, it shall be inspected using the same nonde-
A6.11. The maximum bead width shall be four times the structive examination that was used in (f)(3) above, except
electrode core diameter. that for P-No. 3, Group No. 3 materials, the examination
(b) For P-No. 1 Group Nos. 1, 2, and 3 materials, shall be made after the material has been at ambient temper-
the repair area shall be preheated and maintained at a ature for a minimum period of 48 hr to determine the
minimum temperature of 200°F (95°C) during welding. presence of possible delayed cracking of the weld. If the
(c) For P-No. 3 Group Nos. 1, 2, and 3 materials, examination is by the magnetic particle method, only the
the repair weld method shall be limited to the half bead alternating current yoke type is acceptable. In addition,
weld repair and weld temper bead reinforcement technique. welded repairs greater than 3⁄8 in. (10 mm) deep in materials
The repair area shall be preheated and maintained at a and in welds that are required to be radiographed by the
minimum temperature of 350°F (175°C) during welding. rules of this Division, shall be radiographically examined
The maximum interpass temperature shall be 450°F to the requirements of UW-51.
(230°C). The initial layer of weld metal shall be deposited (6) The vessel shall be hydrostatically tested after
over the entire area using 1⁄8 in. (3 mm) maximum diameter making the welded repair.
electrodes. Approximately one-half the thickness of this
layer shall be removed by grinding before depositing subse-
quent layers. The subsequent weld layers shall be deposited
using 5⁄32 in. (4 mm) maximum diameter electrodes in such UCS-57 RADIOGRAPHIC EXAMINATION
a manner as to assure tempering of the prior weld beads
and their heat affected zones. A final temper bead weld In addition to the requirements of UW-11, complete
shall be applied to a level above the surface being repaired radiographic examination is required for each butt welded
without contacting the base material but close enough to joint at which the thinner of the plate or vessel wall thick-
the edge of the underlying weld bead to assure tempering nesses at the welded joint exceeds the thickness limit above
of the base material heat affected zone. After completing which full radiography is required in Table UCS-57.

178
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ASME 2011a SECTION VIII, DIVISION 2

(2) The circumferential soak band width may be varied away from the nozzle or attachment weld requiring PWHT,
provided the required soak band around the nozzle or attachment weld is heated to the required temperature and held
for the required time. As an alternative to varying the soak band width, the temperature within the circumferential band
away from the nozzle or attachment may be varied and need not reach the required temperature, provided the required
soak band around the nozzle or attachment weld is heated to the required temperature, held for the required time, and
the temperature gradient is not harmful throughout the heating and cooling cycle. The portion of the vessel outside of the
circumferential soak band shall be protected so that the temperature gradient is not harmful.
(b) The procedure in paragraph (a) may also be used to postweld heat treat portions of vessels after repairs.
6.4.3.7 Local Area Heating of Double Curvature Heads or Shells. Postweld heat treatment is performed by heating a
local area around nozzles or welded attachments in the larger radius sections of a double curvature head or a spherical
shell or head in such a manner that the area is brought up uniformly to the required temperature and held for the
specified time. The soak band shall include the nozzle or welded attachment. The minimum soak band size shall be a circle
whose radius is the widest width of the weld attaching the nozzle, reinforcing plate, or structural attachment to the shell,
plus the nominal thickness as defined in paragraph 6.4.2.7, or 50 mm (2 in.), whichever is less. The portion of the vessel
outside of the soak band shall be protected so that the temperature gradient is not harmful.
6.4.3.8 Heating of Other Configurations. Postweld heat treatment performed by local area heating of other
configurations such as “spot” or bulls eye” local heating not addressed in paragraphs 6.4.3.2 through 6.4.3.7 is permitted
provided that other measures (based upon sufficiently similar documented experience or evaluation) are taken that
consider the effect of thermal gradients, all significant structural discontinuities (such as nozzles, attachments, head-
to-shell junctions), and any mechanical loads which may be present during PWHT. The portion of the vessel outside of the
soak band shall be protected so that the temperature gradient is not harmful. The soak band shall include a circle that
extends beyond the edges of the attachment weld in all directions by a minimum of the nominal thickness defined in
paragraph 6.4.2.7 or 50 mm (2 in.), whichever is less.

ðaÞ 6.4.4 OPERATION OF POSTWELD HEAT TREATMENT

The operation of postweld heat treatment shall be carried out by one of the procedures given in paragraph 6.4.3 in
accordance with the following requirements.
(a) When post weld heat treatment is performed in a furnace (see paragraph 6.4.3.2), the temperature of the furnace
shall not exceed 430°C (800°F) at the time the vessel or part is placed in it.
(b) Above 430°C (800°F), the rate of heating shall be not more than 220°C/hr (400°F/hr) divided by the maximum
metal thickness of the shell or head plate in inches, but in no case more than 220°C/hr (400°F/hr) and in no case need it
be less than 55°C/hr (100°F/hr). During the heating period there shall not be a greater variation in temperature
throughout the portion of the vessel being heated than 140°C (250°F) within any 4.6 m (15 ft) interval of length.
(c) The vessel or vessel part shall be held at or above the temperature specified in paragraph 6.4.2 for the period of time
specified in this paragraph. During the holding period, there shall not be a difference greater than 85°C (150°F) between
the highest and lowest temperatures throughout the portion of the vessel being heated, except where the range is further
limited in paragraph 6.4.2.
(d) When post weld heat treatment is performed in a furnace (see paragraph 6.4.3.2), during the heating and holding
periods, the furnace atmosphere shall be so controlled as to avoid excessive oxidation of the surface of the vessel. The
furnace shall be of such design as to prevent direct impingement of the flame on the vessel.
(e) Above 430°C (800°F), cooling shall be done at a rate not greater than 280°C/hr (500°F/hr) divided by the maximum
metal thickness of the shell or head plate in inches, but in no case need it be less than 55°C/hr (100°F/hr). From 430°C
(800°F), the vessel may be cooled in still air.

6.4.5 POSTWELD HEAT TREATMENT AFTER REPAIRS

6.4.5.1 Except as permitted in paragraph 6.4.5.2 below, vessels or parts of vessels that have been postweld heat
treated in accordance with the requirements of paragraph 6.4 shall again be postweld heat treated after welded repairs
have been made.
6.4.5.2 Weld Repairs Made after Postweld Heat Treatment . Weld repairs to P-No.1 Gr. Nos. 1-3 materials and to
P-No. 3 Gr. Nos. 1-3 materials, and to the weld metals used to join these materials, may be made after the final PWHT but
prior to the final hydrostatic test without additional PWHT provided that all the requirements below are satisfied. The
welded repairs shall meet the requirements shown below. These requirements do not apply when the welded repairs are
minor restorations of the material surface such as those required after the removal of construction fixtures and provided
that the surface is not exposed to the vessel contents.
(a) PWHT is not a service requirement defined by the user.
(b) The material is not required to be impact tested to quality toughness properties in accordance with paragraph 3.11.

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ASME 2011a SECTION VIII, DIVISION 2

(c) The Manufacturer shall give prior notification of the repair to the user or to his designated agent and shall not
proceed until acceptance has been obtained. Such repairs shall be recorded on the Data Report.
(d) The total repair depth shall not exceed 38 mm (1-1/2 in.) for P-No. 1 Gr. Nos. 1-3 materials and 16 mm (5/8 in.) for
P-No. 3 Gr. Nos. 1-3 materials. The total depth of a weld repair shall be taken as the sum of the depths for repairs made
from both sides of a weld at a given location.
(e) After removal of the defect, the groove shall be examined, using either the magnetic particle or liquid penetrant
examination methods in accordance with Part 7.
(f) In addition to the requirements of Section IX for qualification of Welding Procedure Specifications for groove welds,
the following requirements shall apply.
(1) The weld shall be deposited by the manual shielded metal arc process using low hydrogen electrodes. The
electrodes shall be properly conditioned in accordance with Section II, Part C, SFA-5.5. The maximum bead width shall be
four times the electrode core diameter.
(2) For P-No. 1 Gr. Nos. 1-3 materials, the repair area shall be preheated and maintained at a minimum temperature
of 95°C (200°F) during welding.
(3) For P-No. 3 Gr. Nos. 1-3 materials, the repair weld method shall be limited to the SMAW half bead weld repair and
weld temper bead reinforcement technique. The repair area shall be preheated and maintained at a minimum
temperature of 175°C (350°F) during welding. The maximum interpass temperature shall be 230°C (450°F). The initial
layer of weld metal shall be deposited over the entire area using 3 mm (1/8 in.) maximum diameter electrodes.
Approximately one-half the thickness of this layer shall be removed by grinding before depositing subsequent layers. The
subsequent weld layers shall be deposited using 4 mm (5/32 in.) maximum diameter electrodes in such a manner as to
ensure tempering of the prior weld beads and their heat affected zones. A final temper bead weld shall be applied to a
level above the surface being repaired without contacting the base material but close enough to the edge of the underlying
weld bead to ensure tempering of the base material heat affected zone. After completing all welding, the repair area shall
be maintained at a temperature of 205°C (400°F) to 260°C (500°F) for a minimum of 4 hr. The final temper bead
reinforcement layer shall be removed substantially flush with the surface of the base material.
(g) After the finished repair weld has reached ambient temperature, it shall be examined using the magnetic particle or
liquid penetrant examination methods in accordance with Part 7. If the examination is by magnetic particle method, only
the alternating current yoke type is acceptable. For P-No. 3 Gr. No.3 materials, the examination shall be made after the
material has been at ambient temperature for a minimum period of 48 hr to determine the presence of possible delayed
cracking of the weld. In addition, welded repairs greater than 10 mm (3/8 in.) deep in materials, and in welds that are
required to be examined using the radiographic method in accordance with Part 7, shall be examined using the
radiographic method in accordance with Part 7.
(h) The vessel shall be hydrostatically tested after making the welded repair. Alternatively, for P-No. 1
Group Nos. 1-3 materials,
6.4.6 POSTWELD HEAT TREATMENT OF NONFERROUS MATERIALS
the gas tungsten arc
6.4.6.1 Postweld heat treatment of nonferrous materials is normally not necessary nor iswelding it desirable. Except as
process may be
required in paragraphs 6.4.6.2, 6.4.6.3, and 6.4.6.4, postweld heat treatment shall not be performed except by agreement
used with the
between the purchaser and the Manufacturer. The temperature, time and method of heat treatment shall be covered by addition of
agreement. filler metal.
6.4.6.2 If welded, castings of SB-148, Alloy CDA 954 shall be heat treated after all welding at 620°C - 640°C (1150°F
- 1200°F) for 1.5 hr for the 25 mm (1 in.) of cross section thickness plus 0.5 hr for each additional 25 mm (1 in.) of section
thickness. The material shall then be air cooled.
6.4.6.3 Within 14 days after welding, all products of zirconium Grade R60705 shall be heat treated at 500°C - 610°C
(1000°F - 1100°F) for a minimum of 1 hr for thicknesses up to 25 mm (1 in.) plus 0.5 hr for each additional 25 mm (1 in.)
of thickness. Above 430°C (800°F) cooling shall be done at a rate not greater than 280°C/hr (500°F/hr) divided by the
maximum metal thickness of the shell or head plate in inches but in no case more than 280°C/hr (500°F /hr). From 430°C
(800°F), the vessel may be cooled in still air.
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6.4.6.4 Postweld Heat Treatment of UNS Numbers N08800, N08810 and N08811 Alloys.
(a) Pressure boundary welds and welds to pressure boundaries in vessels with design temperatures above 540°C
(1000°F) fabricated from UNS No. N08800 (Alloy 800), UNS No. N08810 (Alloy 800H), or UNS No. N08811 (Alloy 800HT)
shall be postweld heat treated. The postweld heat treatment shall consist of heating to a minimum temperature of 885°C
(1625°F) for 1.5 hr for thicknesses up to 25 mm (1 in.), and for 1.5 hr plus 0.04 hr/mm (1 hr/in.) of thickness for
thicknesses in excess of 25 mm (1 in.). Cooling and heating rates shall be by agreement between the purchaser and
Manufacturer. As an alternative, solution annealing in accordance with the material specification is acceptable. Postweld
heat treatment of tube-to-tubesheet and expansion bellows attachment welds is neither required nor prohibited.

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