API – 510 CERTIFICATION COURSE NOTES

PART - 1

SECTION 2

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 STUDY OF ASME Sec. VIII Div. 1

1. ASME BOILER & PRESSURE VESSEL CODES

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

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

Section I ..Power Boilers.

Section II Material specifications.

Part A Ferrous materials,
Part B Non Ferrous Materials
Part C Welding rods, electrodes, filler metals.
Part D Material properties.

Section III Nuclear Power Plant Components.

Section IV Heating Boilers.

Section V Non destructive Examinations.

Section VI Care and operation of Heating Boilers.

Section VII Rules for care of Power Boilers.

Section VIII Division 1 - Pressure Vessels

Division 2 Alternative Rules ( Pr. Vessel)

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 Division 3 Rules for constructive of High
Pressure Vessels.

Section IX Welding and Brazing Qualifications.

Section X Fiber glass reinforced Plastic Pressure

Vessels.

Section XI Rules for in service inspection of Nuclear

Power Plant Components.

3) ISSUE FREQUENCY : ASME Issues completely new edition of all sections after
three years on 1st of July of the year of issue. Latest edition
issued on : 1st July 1998. Addenda to the latest edition are
issued on 1st July every year.

1998 Edition with 1998 Add. - 1st July 98.

1999 Addenda - 1st July 99

2000 Addenda 1st July 2000.

A fully revised edition incorporating all above addenda would be

issued on 1st July 2000. Prior to July 1998, all addenda were
being issued on 31st December of every year.

4) APPLICABILITY : The editions and addenda become applicable after six months
from date of issue. Thus, 1 st Jan. 2000, the construction of
Pressure Vessels shall be as per 1998 edition and 1999
addenda. However, for old contracts spilling over beyond 1 st
Jan 2000, the old applicable edition and addenda are valid.

5) CODE INTERPRETATION : ASME issue written replies know as "Interpretations"

to the inquiries concerning technical aspects of the code These
are issued twice in a year (July and December) and are sent to
"Edition - subscribers" as up-date service.

6) CODE CASES : Boiler and Pressure Vessels committee meets regularly to

consider proposed additions and revisions to the code. At the
same time it may formulate code cases to clarify ' Intent' of
existing requirements. These are published as code-Case

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 books. It is published along with new editions and supplements
are automatically sent to subscribers of code case book till new
edition is published.

7) CODE STAMP : Certificate of authorization to use stamps is granted by ASME.

These stamps represent the code symbol. Typical code symbols are U, U2, S, etc.,
Manufacturer's facilities and organization are subjected to joint review by
representative of inspection agency and ASME Designee before granting
authorization.

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 the interest of safety.
All the boilers and pressure vessels made to ASME Code Section I (power boilers),
Section VIII Div. 1 & 2 (unfired pressure vessels ) and Section III (nuclear vessels).,
need to be fabricated by approved Works who hold code stamps in recognition of their
operating quality system. These equipments are inspected and certified by qualified
ASME Authorized Inspectors.

SALIENT FEATURES OF ASME CODES

Every ASME Code starts with specifying the scope of the code in terms of capacity,
size and pressure and other limitations if any. It also 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 identify and categorize
various methods of construction / fabrication.

The codes specify the required N.D.T. and other inspections. They also specify the
accept / reject criteria.

What is most important about the ASME Code is that is covers a vast field of
manufacturing activity without sermonizing. They are user friendly, and keep pace with
changing technologies. No wonder - the Users and the Manufactures world over have
adopted the ASME codes whole heatedly. There are more boiler and pressure vessels
built under ASME codes than those under all other codes taken together.

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The participants are advised to refer the actual code clauses and extract information
from the latest codes applicable. ASME code is even evolving document and one has
to refer to the latest applicable edition and addenda. These notes will help in
understanding the code, and should not be referred to as the "Code " it self.

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2. INTRODUCTION TO ASME SECTION VIII DIV. 1

Scope of the Code : ASME Section VII Div. 1 : 1998:

Definition of a pressure vessel as per Code:

Containers for containment of pressure (external or internal), obtained from an
external source, or by application of heat (through direct or indirect source), or
by combination thereof. ASME Sec. VIII Div 1 covers mandatory requirements
specific prohibitions, and non - mandatory guidance for pressure vessel
materials, design, fabrication, examination, inspection, testing and certification.

Scope : Exclusions

Following pressure vessels are not included in the purview of ASME Sec.VIII
Div.1

i. those covered by other sections.

ii. Pressure containers which are integral parts (or components) of rotating
machinery.
iii. Piping System beyond battery limits
iv. Pipe fittings, valves, pipe components and other accessories, beyond
battery limits.
v. Vessels with incident loading of external or internal operating pressure not
exceeding 15 psi (No limitations on size).
vi. Vessels having inside diameter or width/height/cross section diagonal not
exceeding 6" (No limitations on length or pressure)
vii. Vessels for pressures exceeding 3000 psi.
viii. Vessels for Human occupancy

Inclusions :

Following are included in the scope of this Code :

Unfired Steam Boilers (with pressure relief devices as per ASME Sec. I)
Evaporators & Heat Exchangers.
Process heat generated steam boilers.
Directly fired steam boilers - which are NOT COVERED by Section I, III & IV
Gas fired jacketed steam kettles with jacket pressures 50 psi and below

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 Battery Limits
(a) For external connections
i. Welding ends, for welded external connection
ii. Threaded joints for screwed connections
iii. First Flange face for bolted connections
iv. Sealing surface for proprietary connections
(b) Weldment of pressure part to non-pressure part.
(c) Manhole and handhole covers - for vessel openings.
(d) Sealing surfaces for instruments, gauges, etc.

Responsibilities :

i. Manufacturer's :
(a) Compliance of all requirements of Code by himself, and by all others
(i.e. Vendors)
(b) Providing proper certification of materials and construction.
(c) Providing applicable design calculations.
(d) Establishing a mandatory Quality System.

ii. Inspector's:
(a) Monitoring quality control.
(b) Verification of design calculations.
(c) Conducting specified inspections.
(d) Code stamping.
(e) Certification.

Code Composition :

The code content is organised in 3 sub-sections and two Appendices as follows:-

i) Sub-section A - General Requirements
ii) Sub-section B - Requirements pertaining to methods of fabrication
iii) Sub-section C - Requirements pertaining to classes of materials
iv) Mandatory Appendices
v) Non-Mandatory Appendices

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General Requirements:

Design:
The User shall assure himself that the design, material and construction of the
vessel, will be suitable for intended service, with respect to safety, intended
performance, retention of satisfactory mechanical properties, and protected from
deterioration during the vessel's intended service life. A relatively high "factor of
safety" (previously 4, presently 3.5) is adopted to take care of the incidental
material abuse during construction and service.

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

Methods of fabrication: requirements are detailed in subsection B :

UW - for welded vessels
UF - for forged vessels
UB - for brazed vessels
ULW - for layered construction
[Alternative Rules]

Requirements based on materials :

Requirements based on materials adopted and other specifications are referred

to in the following clauses of subsection C of the ASME Code Section VIII
Divn.1. The stress values have been tabulated in the Part `D' of Section II.

UCS - for Carbon and low alloy steels

UHA - for high alloy (stainless) steels
UNF - for non-ferrous materials
UCL - for clad materials
UHT - for high tensile, heat treated Ferritic Steels (such as Q & T)
UCI & UCD - for Cast Iron & Cast Ductile Iron Steels.
ULT - for low temperature application using materials of higher
permissible stress values

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 3. MATERIAL REQUIREMENTS

Prior to describing the material requirements of ASME Sec. I, a brief review of

elementary Metallurgy will be useful.

1) TYPES OF CARBON STEELS

Low Carbon Steels
Steels with less than 0.15 percent Carbon, are known as low carbon steels and are
easily joined by welding, brazing or soldering. These steels have very low hardenability,
though are capable of being hardened to 30 to 40 HRC, when quenched or rapidly
cooled. Condenser tubes with 0.06 to 0.18 % C (ASTM A179) is a common example of
low Carbon steel.

Mild Steel
Carbon steels containing % C of 0.15 to 0.30 are commonly called mild steels. These
are the most commonly used steels in pressure vessels and steel structures, owing to
their good strength, weldability and ability to sustain abuse during fabrication and
handling. Such steels with 0.20 % C and 1.0% Mn, can be welded without preheat, post
heat or other special precautions when the joint thickness is less than 1".

Medium Carbon Steel

Carbon steels containing 0.30 to 0.50 % C.
Medium Carbon steels containing 0.30 to 0.35 % C with moderate manganese content
have a fair weldability. But Carbon content of the steel increases, it becomes difficult to
weld, with HAZ tending to be quite hard and low in toughness with susceptibility
towards cold cracking. Preheating and post heating becomes necessary.

High Carbon Steel

Carbon steels with % C content of 0.50 upto 1.0 % fall in this category. These are
difficult to weld to being unweldable. These high Carbon steels are commonly used in
applications requiring high hardness or abrasion resistance. Dies, punches, shears, etc.
are made from high Carbon tool steels that also contain moderate amounts of other

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alloys like Cobalt and Vanadium. These steels have outstanding hardness at room
temperature and some of them have high hot hardness.

Weldability
Weldability of carbon steel generally decreases with increasing Carbon content. Effects
of Carbon and other elements on the weldability of Carbon steels can be estimated by
equating them to a percentage Carbon equivalent defined as follows : -

% Mn % Cr + % Mo + % V
% Carbon Equivalent (CE) = % C + ---- + ------------------------
6 5

% Ni + % Cu
+ --------------
15

2) LOW ALLOY STEELS : UPTO 5% ALLOYING ELEMENTS

Additions of elements such as Nickel, chromium, molybdenum, manganese, Silicon,
together with appropriate heat treatment, can markedly improve the properties of steels,
such as mechanical strength, toughness, corrosion resistance, etc., although often at
the expense of reduced weldability.

Total alloy additions, in low alloy steels, are usually less than 5%,and are normally
made in combinations. The majority of these low-alloy steels fall into the following
types:

(i) high strength low-alloy structural steels,

(ii) automotive and machinery steels,
(iii) steels for low temperature service, and
(iv) steels for elevated temperature service.

Modern structural design is using low alloy steels that have higher mechanical
properties than the plain Carbon and structural steels. A yield strength of 50,000 psi
and tensile strength of 70,000 psi are achieved in the as-rolled condition by adding two
or more alloying elements, and adequate weldability is maintained by restricting the
Carbon content to 0.20 % maximum.

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Some of the low alloy steels are heat treated to achieve upto 100,000 psi yield strength
and they have better notch toughness than the ordinary Carbon steel grades. Proper
choice of filler metal and welding procedures will develop comparable properties in the
welded joints of these steels.
A wide variety of low alloy steels has been developed for use in machinery parts. These
steels, many of which are commonly weldable have been classified according to
chemical composition by the AISI/UNS Numbering System.
In order to meet the needs of cryogenic service (less than -80 deg C ), low alloy steels
with adequate notch toughness at sub-zero temperatures have been developed. Fine
grained aluminium treated killed steels with 2.5%, 3.5% and 9% Nickel additions are
frequently used for cryogenic services.

Low alloy steels have also been developed for high temperature service in welded
structures such as steam boilers, oil refining towers and chemical processing retorts.
Additions of chromium and molybdenum give these steels resistance to oxidation,
higher creep and higher stress rupture values at elevated temperatures of upto 1100 F
(593 deg. C)

3) HIGH ALLOY STEELS

This group consists of high quality, expensive stainless steels of outstanding
mechanical strength & ductility, corrosion resistance, and oxidation resistance at
elevated temperatures.

Stainless steels resist attack by corrosive media at atmospheric or elevated

temperatures. They contain atleast 12 percent chromium. There are ferritic, martensitic
and austenitic, and duplex grades of stainless steels. Austenitic grades have
substantial amounts of Nickel. Other alloying elements such as Molybdenum and
Titanium are added as stabilizers to avoid Chromium depletion during welding. Duplex
Stainless Steels have a balanced matrix of ferrite and austenitic microstructure which
provides higher resistance to corrosion (such as by salt laden media.)

4) CAST IRON

Cast irons are most nearly like pig iron and they are produced in foundries by further
refining of pig iron in a cupola. Even after refining, Cast irons contain large amounts of
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Carbon and significant amounts of other impurities. In comparison with steel, grey and
white cast irons are very brittle.

White Cast Iron : Very hard and brittle. Used principally for abrasion resistant castings.
Malleable Iron : Relatively ductile form of cast iron resulting from heat treatment of
special white cast irons.

Grey Cast Iron : Comparatively soft and machinable but also brittle. Carbon is present
as large flakes of graphite in a pure iron or steel matrix.

Nodular or Ductile Iron : Chemically similar to grey cast iron, but because of special
treatment while molten, the graphite Carbon is present as spheres or nodules rather
than flakes. This greatly improves ductility.

Weldability : Most cast irons require special welding techniques; they are difficult to
weld because of their high Carbon & impurity content and brittleness.

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 COMMON ASTM SPECS. FOR C.S. PLATES

Sr Plate Composition % Engg. properties

No Spec.
C P S Si Mn T.S. Y.S. Elog
(max) (max) (max) (x1000 (x1000 %
psi) psi)

1. A36 0.26 0.04 0.05 -- -- 58 - 80 36 20

2. A283Grc 0.24 0.04 0.05 -- -- 55 - 65 30 25

3. A285Grc 0.28 0.035 0.045 -- 0.90* 55 - 75 30 28

(max)

4. A515Gr60 0.24 0.035 0.04 0.15 - 0.90* 60 - 80 32 25

0.30 (max)
Gr70 0.31 0.035 0.04 0.15 - 0.90* 70 - 90 38 21
0.30 (max)

5. A516Gr60 0.21 0.035 0.04 0.15 - 0.8 - 60 - 80 32 25

0.30 1.25
Gr70 0.27 0.035 0.04 0.15 - 0.8 - 70 - 90 38 21
0.30 1.25

Remarks : -

1. Structural Quality Plates & Shapes.

2. Structural Steel for Bending / Forming (Low & Med. T. S. )

3. Plates may be ordered as rolled or norm. (P. V. plates, Low & Med. T. S.)

4. Plates >= 2" thk. Must be normalized for < 2" purchaser's option
(P. V. plates, High & Med. Temp. service)

4. Plates >= 1.5" thk. Must be normalized for < 1.5" purchaser's option
(P. V. plates, Moderate & Low Temp. service)

* Optional. If present, not to exceed specified maximum.

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 CARBON & ALLOY STEELS

(selection of steels based on temperature)

STEEL TYPE TYPE TYPICAL TEMP.

LIMIT (DEG. F)
MODERATE TEMP.
1. C - Steels SA 285 grC (3/4 in. thk max) 600 (max)
SA 515 All Grades
775 (max)
SA 516 All Grades

ELEVATED TEMP
2. C - 1/2 Mo SA 204 gr B, C 875 (max)

3. C - 5/4 Mn - 1/2 Mo SA 302 gr B 875 (max)

4. 1/2 Cr - 1/2 Mo SA 387 gr 2 1000 (max)

5. 1Cr - 1/2 Mo SA 387 gr 12 1100 (max)

6. 5/4 Cr - 1/2 Mo - Si SA 387 gr 11 1150 (max)

7. 9/4 Cr - 1 Mo SA 387 gr 22 1200 (max)

LOW TEMP
8. C - Steel (F. G.) SA 516 All Grades ( -50 )
(Impact tested)

9. 5/4 Ni Steels SA 203 gr A or B ( -90 )

10. 7/2 Ni Steels SA 203 gr C or D ( -150 )

CRYOGENIC TEMP
11. 9 Ni Steel SA 353 ( -320 )

12. Austenitic S.S. SA 240 Type 304, 3041, 347 ( -425 )

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5) MATERIAL OVERVIEW (ASME CODES SECT. VIII Div 1)

Material subject to stress due to pressure (i.e. pressure parts) shall conform to one of
the specifications given in ASME Code Section II, and shall be limited to those that are
permitted in the applicable Part (such as UCS,UNF,UHT etc.) of the subsection C.

Permitted Specifications for Plates, Forgings, Castings, Pipes & Tubes, Fasteners,
Rods and Bars are covered in the ASME Code Section II Part A (for ferrous materials)
& Part B (for non- ferrous materials). These are designated by a suffix SA for ferrous
materials, and SB for nonferrous materials respectively. Materials are to be identified
with Certified Mill Test Certificates issued by Steel / Raw Material / Product
Manufacturer, and verified whether all requirements of the Specification and grade are
complied with, before correlating with identification markings as required by the relevant
material specification.

"Partially" identified materials, where identification markings can be ascertained as

being authentic, but material certificate is not available, or is certified to a Specification
not permitted or not recognized by ASME Sect. VIII Div I, may be accepted provided
check analyses / tests are carried out on representative sample/s and satisfy Code
approved specifications. In such cases Vessel or part manufacturer needs to re-certify
the material to the Specification and grade, based on the findings.

The maximum allowable stress values for different service temperatures for these
material specifications and grades are stipulated in ASME Code Section II Part D -
Properties of Materials.

Permitted Specifications for Welding Consumables are covered by ASME Code

Section II Part C. These specifications are given a designation number with a suffix
SFA or SFB for suitable classification and grading.

Prefomed or Prefabricated Pressure Parts when made by other than the pressure
vessel manufacturer, shall conform with all the applicable requirements of the Code,
including service restrictions, shop inspection, and furnishing of partial data reports in
Form U2. with For welding consumables, the marking or tagging of the materials,

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containers or packages, if done as per the applicable Consumable Specification, may
be accepted in lieu of Certified Test report.

6. MATERIAL REQUIREMENTS ( SECTION VIII STIPULATIONS)

General Requirements are discussed here for understanding purpose only. For specific
query one should refer to applicable code book and addenda.

General Requirements

Material types

a) Steel & Low Alloy Steels with max. 0.35% Carbon

b) High alloy steels ( stainless steels and alloys )
c) Non ferrous (Al, Cu, Ni, Cu Ni, Ni Cu etc.)
d) Compatible welding Consumables ( ASME Section II Part C )

Product Forms and Typical Specifications

a) Plates (SA 515/516/240/285)

b) Castings (SA 216/351/217/352)
c) Forgings (SA 181/105/182 etc.)
d) Pipes & Tubes (SA 106/312) (SA 179/213)
e) Fasteners (SA 193/194/307)
f) Bars & Shapes (Sections) SA 36/283/479

Max. Allowable Stress Values (MASVs):

MASVs at various service temperatures for each acceptable material
specification are given in ASME Section II- Part D. For vessels designed to
operate at low temperature, generally the MASV at 100 Deg.F. is used.

Corrosion Allowance :
This is provided over and above the thicknesses calculated for pressure vessels,
based on service experience. All design calculations are required to be made
with vessel dimensions in corroded condition.

PWHT Requirements :
Detailed in
UCS-56 & Table UCS-57 for CS & low alloy steels
UHA-32 & Table UHA-32 for high alloy steels ( SS )
UNF-56 for non-ferrous materials

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Use of Structural Steels for pressure parts
( SA 36/ SA 283 )

a) Limitations :
i) not permitted for lethal service
ii) should not be used for unfired steam boilers
iii) Design temperature only (-) 20 Deg.F. to (+) 650 Deg.F.
iv) for thicknesses below 5/8" (16mm) only

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

Check Tests for materials used for pressure parts

a) Check test allowed only in the case of partial identification :
b) Check test requirements :-
Each piece is tested for chemical composition & mechanical
properties. Acceptance criteria as per permitted specification for
which the material is being qualified.

Cast, forged, rolled and die-formed pressure parts :

These shall be made from materials of permitted specifications; and should

meet/or be suitable for design conditions of completed vessel. NDT [RT/PT/MT]
and Heat treatment (Norm/SR) as applicable must be conducted prior to its
release for attachment to the pressure vessel. Partial data report (form U2)
needs to be issued for such components , in evidence of code compliance.

Mill under tolerance

a) Plates with 0.01 inch or 6% under tolerance (whichever is smaller) may be
used for full design pressure, instead of at the given design thickness
specified.
However if material specification allows greater under tolerance (e.g.
0.3mm for a 10mm thick plate), then ordered thickness for the material
should be sufficiently greater.
b) For pipe or tube - ordered by its nominal wall thickness, the manufacturing

17
 under tolerance shall be taken into account. For S.S & M.S. pipes, the
manufacturing under tolerance is -12.5%. For M.S. tubes, it is zero
(tolerance +20/-0). For S.S. tubes. The tolerance limits are given in a
separate chart.

ANSI Standards for flanges, threads, pipe schedules, pipe fittings, etc. adopted
by ASME Code, with acceptable edition (year of publication) are given in Table
U-3 of the ASME-VIII-1 Code.
Standard tables for dimensions and tolerances of pipes, tubes, fittings and
flanges, as per ANSI B16.9, B16.11, B36.10, B36.19, & B 16.5 should be
referred to.
7. MATERIALS FOR LOW TEMPERATURE SERVICES :
a) Carbon and low alloy steels : Impact test requirements with respect to
minimum design metal temperature in service are explained in UCS-66
of ASME VIII-1 See Fig. UCS-66 and UCS-66.1 for Carbon Steel and low
alloy steel materials and weldments of comparable chemistry.
b) UNF 65 : Non ferrous materials have marked resistance to lowering in
impact values at subzero temperatures. As such no impact tests required
upto :
i) Wrought aluminium alloys : -425 Deg.F. (-254 Deg. C)
ii) Copper and copper alloys } : -325 Deg.F. (-198 Deg. C)
Nickel & Ni alloys }

iii) Titanium and zirconium : - 75 Deg.F. (-60 Deg. C)

c) UHA 51 : Austenitic Stainless Steels too exhibit notch toughness at

cryogenic temperatures.

i) For Types 304,304L,316,316L & 347, upto -425 Deg.F.(-254 Deg.

C) – impact tests are waived.

- For Ferritic Stainless/High Alloy Steels like Types 409, 410, 430, etc.,
impact tests are required at any service temperature below -20
Deg.F. (-29 deg. C)

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 4. GENERAL DESIGN PRINCIPLES

A. BASIC REQUIREMENTS :

1) Minimum thicknesses of shell and heads:-

i) After rolling and forming – in general 1.6mm (1/16") + corrosion
allowance
(a) above not applicable to UHT materials & PHE Plates
(b) for unfired steam boilers : 6.4mm (1/4") + corr. allow.
(c) for compressed air service: 2.4mm(3/32") + corr. allow.
ii) Mill under tolerance
a) Plates with 0.01 inch or 6% under tolerance (whichever is smaller)
may be used for full design pressure, instead of at the given design
thickness ordered.
However if material specification allows greater under tolerance
(e.g. 0.3mm for a 10mm thick plate), then ordered thickness for
the material should be sufficiently greater.
b) For pipe or tube - ordered by its nominal wall thickness, the
manufacturing under tolerance shall be taken into account. For S.S
& M.S. pipes, the manufacturing under tolerance is -12.5%. For
M.S. tubes, it is zero (tolerance +20/-0). For S.S. tubes it is given in
separate charts.
2) Quality factor for Castings
A quality factor of 80% is multipled to allowable stress values for castings when
computing design thicknesses.
3) Shapes covered by the Code :
For Vessels of cylindrical and spherical shapes, ASME Code Section VIII Div.1
provides design rules in the general sub-section [Part UG]. For vessel ends,
hemispherical, ellipsoidal, and torispherical shapes are preferred over flat ends.
For transitions, toriconical or conical shapes are preferred (in that order.)
Other shapes are considered unconventional and conditions for design,
construction and safe operation are set forth in Clause U-2 (g)

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4) Corrosion Allowance :
The user shall specify corrosion allowance for vessels subject to thinning by
corrosion, erosion or mechanical abrasion - to be provided for the desired life of
the vessel, by a suitable increase in the thickness of the material over that
determined by the design formulae.
5) Tell Tale Holes :
Tell Tale holes are used to provide some positive indication when the thickness
has been reduced to a dangerous degree. Tell Tale holes of 1/16" to 3/16"
diameter and to a depth of not less than 80% of the thickness of the seamless
shell, are provided on the opposite surface to that where deterioration is
expected.

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,
have internal threads for fitting nipples for air tests, and also act as Vent holes.
6) Openings for Drain :
Vessels subject to corrosion shall be provided with a suitable drain opening at
the lowest point practicable in the vessel; or a pipe may be used extending
inward from any other location to within 1/4" of the lowest point.
7) Linings :
Corrosion resistant or abrasion resistant linings, whether or not attached to the
wall of the vessel shall not be considered as contributing to the strength of the
vessel wall.
Exception : Vessels designed to Part UCL of the Code.
8) Design Temperature of Vessels :
i) Maximum Temperature is the mean metal temperature-through thickness-
expected under operating conditions.
ii) Minimum Design Temperature is the lowest temperature expected in
service.

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9) Design Loadings :
i) Internal or External Design Pressure.
ii) Dead Weight of the Vessel : Weight of the vessel and normal contents of
the vessel under operating or test conditions [including additional
pressure due to additional weight due to static head of liquids].
iii) Super imposed static reactions - from weight of attached equipment [such
as motors, machinery, other vessels, piping, linings, insulation].
iv) Loading due to attachment of internals, vessel supports, lugs, rings, skirts,
saddles and legs.
iii) Loadings due to cyclic and dynamic reactions owing to pressure
variations or
iv) temperature variations, or from equipment mounted on the vessel and
mechanical loadings.
v) Wind,snow,and seismic reactions,where applicable.
vi) Impact loadings due to fluid shock.
viii) Loadings due to temperature gradients and differential thermal expansion.

10) Maximum Allowable Stress Values :

These are the maximum unit stress permitted in a given material used in the
construction of the vessel as per the Code.
In ASME Code Section VIII Div.1, the maximum allowable stress values for
temperatures of minus 20 Deg.F.to 650 Deg.F., [and in particular for 100
Deg.F. ] are generally equivalent to Ultimate Tensile Strength divided by a factor
of safety of 3.5 (approx). or two-third of yield strength whichever is lower, refer
ASME Section II-D
a) Maximum Allowable Stress Values In Tension
For various design temperatures, the maximum allowable stress values in
tension, for following types of materials are charted out in ASME Section
II Part D, and referred to in following sub-sections of ASME Code Section
VIII Division 1. Section II Part D also provides MASVs for other sections of
the ASME code.
- carbon steels ...................... UCS-23
- non-ferrous metals ...................... UNF-23
- high alloy steels ...................... UHA-23
- cast iron ...................... UCI-23
- cast ductile iron ...................... UCD-23
- ferritic steels with enhanced properties.. UHT-23
- special steels and aluminium alloys ...... ULT-23
operating at cryogenic temperatures

21
 b) Maximum Allowable Stress Values Under External Pressure
[Longitudinal compressive strength for cyl. shells and tubes].
This shall be smaller of (a) above, i.e. maximum allowable tensile stress
value, OR, (b) the value of factor B, as determined from the applicable
material chart in mandatory Appendix-5 of ASME Section VIII Division 1.

11) Thickness of shells under internal pressure :

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

seams, and a longitudinal stress along its circumferential seams. The incidental
circumferential stresses are almost twice as much as the longitudinal stresses in
any given vessel. Therefore we need to calculate only the thickness required to
sustain the circumferential stress, along the longitudinal seams, for the given
design conditions [design pressure and design temperature]. The formula is valid
when P does not exceed 1/25SE and thickness does not exceed one-half of the
inside radius.
a) For cylindrical shells : (Using inside dimensions)
t, inches = P x Ri / (SE - 0.6P) or P = SEt / (Rit + 0.6t)
where - `t' is the corroded min. thickness of shell, inches
`Ri' is the inside radius of the shell,inches (corroded)
`Ro' is the outside radius of shell, inches (corroded)
`P' is the design pressure in psig
`S' is the maximum allowable stress value in tension, psi
`E' is the Joint Efficiency [Refer to Table UW-12 ]
Di is Inside diameter of shell (corroded)
Do is Outside diameter of shell

b) Alternate Formula for cylindrical shells : (Using outside dimensions)

t, = P x Ro / (SE + 0.4P) or P = 2SEt / (Ro - 0.4t)

c) For spherical shells : (Inside dimensions)

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

[ Limitations : thickness shall not exceed 0.356R

P shall not exceed 0.665 SE ]
22
 d) Alternate formula for spherical shells : (Outside dimensions)
t, inches = P x Ro / (2SE + 0.8P) or P = 2SEt / (Ro - 0.8t)
Spherical shell formulas are valid when thickness does not exceed
0.356R, or P does not exceed 0.665 SE.

12) Thickness of shells and tubes under external pressure :

Cylindrical shells, tubes and spherical shells under external pressure are subject
to buckling loads, either owing to internal vacuum and external atmospheric
pressure, or owing to a differential pressure acting externally.

Such vessels need stiffening supports, and the unsupported span between the
stiffeners (L), decides the vessel thickness. The Appendix-5 of the Code
provides various charts giving values of Do / t, plotted against L / Do, where `Do'
is the outer diameter of the vessel.[Refer UG-28 of ASME Section VIII Div.1]

13) Thickness of FORMED HEADS with Pressure on Concave Side

The required thickness at the thinnest point after forming of ellipsoidal,
torispherical & hemispherical heads under pressure on the concave side shall be
computed by under noted formulae :
a) For Ellipsoidal Heads : ( 2 : 1 type)
t, = P x Di / (2SE - 0.2P) or P = 2SEt / (Do + 0.2t)
- Alternately,
- t = PDo / (2SE + 1.8P) or P = 2SEt / (D - 1.8t)
- A good approximation of 2 : 1 Ellipsoidal head is one with knuckle radius of
0.17Di and spherical radius of 0.90Di.

b) For Torispherical Heads : (when r = 0.06 x L)

t, = 0.885 x P x L / (SE - 0.1P) or P = SEt / (0.885L + 0.1t)
- Alternate Formula for Torispherical Dished Ends (when r > 0.006L)
t, = P x L x M / (2SE - 0.2P) or P = SEt / (LM + 0.2t)
where L = inside spherical crown radius
M = 1/4 x [ 3 + ( L / r ) 1/2 ]
r = is the inside knuckle radius in inches.
Limitations : Knuckle radius shall not be less than 6% of inside crown radius [ Ri ],
nor less than three times knuckle thickness. Ri shall be less than Do.

23
 c) For Hemispherical Heads : The formula Hemispherical shell can be adopted

14) Joint Efficiencies

Joint Efficiency `E' referred to above are charted out in Table UW-12 as
applicable to weld joints completed by an arc or gas welding process. Joint
Efficiency depends on the type of joint and on the degree of radiography
examination of the joint. Table UW-12 of ASME Code Sec. VIII Div. 1 details
joint description, limitations, joint categories and degree of radiography
examination for each type number [Type 1 to Type 6 ] of the weld seam. Fig.
UW-3 shows weld joint locations of Categories A, B, C & D.

15) Formed Heads, Pressure on Convex Side

The required thickness at the thinnest point after forming of ellipsoidal,
torispherical or hermispherical heads shall be greater of the following
thicknesses
a) The thickness as computed for heads with pressure on the concave side
as given in (13) above, and,
b) Thickness as computed by the procedure given in UG-28 and Mandatory
Appendix-5 for Heads.

16) Minimum Thickness of Unstayed Flat Heads and Covers :

t, = D x [ CP / SE ] 1/2

where C = a factor depending upon the method of attachment of the flat head
D = Inside diameter of shell inches.
The above formula is applicable to both welded and bolted methods of
attachments. Extra moments applied to the cover by bolting, are to be
incorporated.
17) Openings in Pressure Vessels :
a) Shape of the openings : Openings in cylindrical and conical portions of
vessels, or in formed heads, shall preferably be circular, elliptical or
obround. Openings of other shapes shall be provided with a suitable
radius at all corners.

24
 b) Size of the openings : Properly reinforced openings, in cylindrical shells of
diameter of upto 60 inches, shall not exceed half the vessel diameter, and
in any case not over 20 inches. For vessel diameter of over 60 inches, the
openings shall not exceed 1/3rd the vessel diameter and in no case
exceed 40 inches. For larger openings, supplemental rules apply.

18) Reinforcement of Openings :

a) Reinforcement required for openings in shells & heads
The principle is that material removed shall be equal to material added.
This is achieved by providing doubling plate either outside or inside the
shell or head.

The limitations are, on the outer diameter of the doubling plate, which
shall not be greater than twice the size of the finished opening, and its
thickness shall not be greater than the provided thickness of the
shell/head.

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
and/or inside the shell.
b) Reinforcement waived for single openings, in the case of,
- finished opening size 3 1/2" diameter in shell or head of thickness
3/8" or less;
- finished opening size 2 3/8" diameter in shell or head of thickness
over 3/8";
- Threaded studded or expanded connections where hole cut in the
shell or head is not more than 2 3/8" diameter.
c) Opening may be located through a welded circumferential seam joints,
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 ] in a shell plate, shall not
be placed near the edge of the weld in the main joint, closer than
1/2 inch, for plates 1 1/2 inch thick or less.

25
 d) Reinforcement of Multiple Openings :
Combined reinforcement can be provided for multiple openings, provided
the minimum distance between centers of any of these two openings is
1 1/3rd times their average diameter and the area of reinforcement
between any two openings is atleast equal to 50% of the total required for
the two openings.

When the distance between the centers of any two openings is less than
1 1/3rd times their average diameter, then no credit for reinforcement is
allowed for materials between these openings, and supplemental rules
need to be applied.
e) Reinforcement for Openings in Flat Heads :
i) So far as the opening in a flat head does not exceed one half of the
flat head diameter (or the shortest span),it shall have a total cross
sectional area of reinforcement not less than that given by `A',
where, A = 0.5 x d x t;
d = finished diameter of the circular opening
& t = nominal thickness of the vessel wall
In other words, the flat head may be required to be thicker by the amount
of reinforcement required.

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

thickness of flat heads shall be provided.

19) Nozzle Neck Thickness :

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

a) thickness computed for applicable design conditions as per the

formulae, plus corrosion allowance,
t = PRi / SE - 0.6P, OR t = PRo / SE + 0.4P

b) the smallest of the following :

(i) calculated thickness (plus corrosion allowance) of the vessel or
head on which nozzle is located with E = 1.0.

26
 (ii) the minimum thickness of the standard wall pipe (Schedule 40 of
ANSI B 36.10) plus corrosion allowance.
20) Inspection Openings :
All pressure vessels for use with compressed air, and those subject to internal
corrosion, erosion or mechanical abrasion are required to be provided with
suitable manhole, handhole, or other inspection openings for examination and
cleaning.
Inspection openings are waived :
a) for vessels upto 36" ID, if tell-tale holes are provided at a spacing of one
hole per ten square feet or a fraction thereof of internal vessel surface
area, with a minimum of four uniformly spaced holes. This exception is not
for compressed air vessels.
b) for shell side of fixed tube heat exchangers;
c) other exceptions are detailed in UG-46 C, D & E.
d) for sizes of mandatory inspection openings: see UG-46F.

21) Permissible Out-Of Roundness for Shells and Formed Heads :

a) For internal pressure,
(Di Max - Di Min) divided by Di Nom = 1% Max.
b) For external pressure, Refer Fig.UG-80.1 : Max. plus/minus deviation `e',
from true circular form, shall be between 0.020 t to 1.0 t, as plotted on the
curves with Do / t on Y axis and L/ Do on X axis, where L = design length.

c) Heads: out of profile + 1 1/4 D / - 5/8 D

for Hemispherical Head, use L=0.5D in the ratio L/Do.

****

27
 Welded Joint Values (UW - 12)

____________________________________________________________

Efficiency allowed
Type of joint and radiography percent
____________________________________________________________

1) Double-welded butt joints (Type 1)

Fully radiographed 100

Spot-radiographed 85
No radiograph 70

2) Single-welded butt joints

(backing strip left in place) (Type 2)

Fully radiographed 90
Spot-radiographed 80
No radiograph 65

3) Single-welded butt joints (Type 3) 60

____________________________________________________________

28
 5. FABRICATION REQUIREMENTS

1. GENERAL (UW - 26)

(a) The rules in the following paragraphs apply specifically to the fabrication of
pressure vessels and vessel parts that are fabricated by welding. These shall
be used in conjunction with the general requirements for Fabrication in
Subsection A, and with the specific requirements for Fabrication in
Subsection C that pertain to the class of material used.
(b) Each Manufacturer or parts Manufacturer shall be responsible for the quality
of the welding done by his organization. He shall conduct tests not only of
the welding procedure to determine its suitability to ensure welds which will
meet the required tests, but also of the welders and welding operators to
determine their ability to apply the procedure properly.
(c) No production welding shall be undertaken until after the welding procedures
which are to be used have been qualified. Only welders and welding
operators who are qualified in accordance with Section IX shall be used in
production.
(d) Welders not in the employ of the Manufacturer (Certificate of Authorization
Holders) may be used to fabricate pressure vessels constructed in
accordance with this Division, provided all the following conditions are met.

(1) All Code construction shall be the responsibility of the Manufacturer.

(2) All welding shall be performed in accordance with the Manufacturer's
welding procedure specifications which have been qualified by the
Manufacturer in accordance with the requirements of Section IX.
(3) All welders shall be qualified by the Manufacturer in accordance with the
requirements of Section IX.
(4) The Manufacturer's Quality Control System shall include as a minimum :
(a) a requirement for complete and exclusive administrative and technical
supervision of all welders by the Manufacturer;
(b) evidence of the Manufacturer's authority to assign and remove welders
at his discretion without involvement of any other ortanization;

29
 (c) a requirement for Assignment of Welder Identification symbols;
(d) evidence that this program has been accepted by the Manufacturer's
Authorized Inspection Agency which provides the inspection service.
(5) The Manufacturer shall be responsible for Code compliance of the vessel
or part, including Code Symbol stamping and providing Data Report
Forms properly executed and countersigned by the Inspector.

2. QUALIFICATION OF WELDING PROCEDURE (UW-28)

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

recorded in detail by the manufacturer.
(b) The procedure used in welding pressure parts and in joining load-carrying
nonpressure parts, such as all permanent or temporary clips and lugs, to
pressure parts shall be qualified in accordance with Section IX.
(c) The procedure used in welding non pressure-bearing attachments which
have essentially no load-carrying function (such as extended heat transfer
surfaces, insulation support pins, etc.), to pressure parts shall meet the
following requirements.
(1) When the welding process is manual, machine, or semiautomatic, procedure
qualification is required in accordance with Section IX.
(2) When the welding is any automatic welding process performed in
accordance with a Welding Procedure Specification (in compliance with
Section IX as far as applicable), procedure qualification testing is not
required.
(d) Welding of all test coupons shall be conducted by the Manufacturer.
Testing of all test coupons shall be the responsibility of the Manufacturer.
Qualification of a welding procedure by one Manufacturer shall not qualify
that procedure by one Manufacturer except as provided in QW - 201 of
Section IX.

30
3. FORMING SHELL SECTIONS AND HEADS :
The following provisions shall apply in addition to the general rules for forming given in
UG-79,

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

 Vessel shell sections, heads, and other pressure boundary parts of carbon and low
alloy steel plates fabricated by cold forming shall be heat treated subsquently when
the resulting extreme fiber elongation is more than 5% form the as-rolled condition
and any of the following conditions exist.

(1) The vessel will contain lethal substances either liquid or gaseous (see UW-2).
(2) The material requires impact testing.
(3) The thickness of the part before cold forming exceeds 5/8 in. (16 mm).
(4) The reduction by cold forming from the as-rolled thickness is more than 10%.
(5) The temperature of the material during forming is in the range of 250 0F to 9000F
( 1210C to 4820C).

The extreme fiber elongation shall be determined by the following formulas :

For double curvature (for example, heads),

% extreme fiber elongation = (75t/R) (1 - R/r)

for single curvature (for example, cylinders),

% extreme fiber elongation = 50 t/R) ( 1 - R/r)
Where,
T = plate thickness, in.
Rf = final center line radius in.
R = original center line radius (equals infinity for flat plate), in.
When vessel shell sections, heads, or other pressure boundary parts of carbon or low
alloy steel plate are cold formed by other than the Manufacturer of the vessel, the
required certification for the part shall indicate whether or not the part has been heat
treated.

31
4. GENERAL PRECAUTIONS IN FABRICATION

i. Structural discontinuities should be avoided. Square corners of pads

should be rounded off before fitment and welding . Unwelded faces of
flame cut edges should be ground smooth and sharp edges ground
round.
ii. Welding of minor items direct to structural and pressure parts should be
avoided. Use of intermediate / doubling pad is preferred.
iii. Toes and brackets and ends of stiffeners should land on stiffened plating
iv. 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, skip welding, low heat input, minimum weld deposits
will prevent deformation and local bulking.
vii. Shrinkage allowance for main seam should be provided for at the fitup
stage, in order to obtain final dimensions within tolerance limits.
viii. Avoid all kinds of metallurgical and mechanical notches.

Tests

Structures are subjected to direct or compressive proof load to check their

buckling strength. Pressure vessels are subjected to tensile loading by means of
a test pressure. Ability to withstand such loading is the proof of their integrity.
Equipments under test should be adequately supported. Pressure gauges
should be calibrated and verified for accuracy, with a “master” traceable to
national standards.

5. CRITICAL AREAS IN WELDING FABRICATION

1. Climatic Conditions for Welding

32
 No welding of any kind shall be done below base metal temperature of 0 deg F.
Between 0 deg F and 32 deg F, preheating to 60 deg F - i.e. warm to hand, is
recommended prior to welding.

Further, when surfaces 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 be
done unless welders and the work are properly protected and covered.

2. Cutting, Fitting and Alignment

Gas cut edges for welding should be smooth, uniform, free of loose scale, slag,
oil, paint, etc. prior to welding. Preferably they should be ground down to bright
metal and slightly preheated.

Welding edges of plates should be aligned and retained stress-free in position

during welding operation, by using tack welds, clamps, etc. Tack welds should
be examined visually for defects, which if found should be removed.
_______________________________________________________________
ALIGNMENT TOLERANCES : Joint categories Refer Table UW-33
Section Thickness, in. A B, C & D

Upto 1/2, incl. 1/4 t 1/4 t

Over 1/2 to 3/4 incl. 1/8 in. 1/4 t
Over 3/4 to 1 1/2 incl. 1/8 in. 3/16 in
Over 1 1/2 to 2, incl. 1/8 in. 1/8 t
Over 2 Lesser of Lesser of
1/16t or 3/8" 1/8t or 3/4"

NOTE : Offsets within allowable tolerance shall be given a minimum of 1:3 taper
transition, if necessary, by adding additional weld metal.

3. Finish of the Longitudinal and Circumferential Seams :

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

33
 Maximum Reinforcement, in.
______________________________________
Mat'l Nom.Thk,in C.Seam in pipe & tubing Other Welds

Less than 3/32 3/32 1/32

3/32 to 3/16, incl. 1/8 1/16
Over 3/16 to 1/2,incl 5/32 3/32
Over 1/2 to 1, incl. 3/16 3/32
Over 1 to 2, incl. 1/4 1/8
Over 2 to 3, incl. 1/4 5/32
Over 3 to 4, incl. 1/4 7/32
Over 4 to 5, incl. 1/4 1/4
Over 5 5/16 5/16

4. Fillet Welds :
Fillet welds shall have adequate penetration into the base metal at the root and
side wall 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 NDT cleared in first go leaves the product rejected
from distortion point of view.
6. Control of welding – a Special Process
In short, there is a vast difference in Quality Control of Welding fabrication
inspection and other inspection activities. In welding fabrication, systematic
monitoring of activities from material procurement to packing and delivery stage
has to be ensured by Q. C. personnel to achieve the results.

6. WELD REPAIRS
Vessel or parts of vessel which are to be weld repaired may need to be postweld heat
treated after the repairs have been made, if it is the design or service requirement. A
formal Repair Procedure needs to be written down, with step by step instructions and
precautions, including non destructive examination, as applicable, clearly delineated.
This Weld Repair Procedure should be approved by the Customer / User and the

34
Authorized Inspector (AI), and recorded on Data Report. For Carbon Steels, "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 permitted provided relevant WPS /
PQR / WPQR are established, and subject to obtaining permission of ultimate User and
AI.

A Typical Repair procedure for CS and LAS :

1. Remove defect completely by trepanning (boat shaped groove)
2. Magnetic Particle Inspection (MT) of the area, to ensure that defect is completely
removed.
3. Preheat the area to 150 Deg C, and maintain the temperature during weld repair.
4. Build up the area employing appropriate WPS and Welder, and using large
(5mm dia) low hydrogen type electrodes with routine precautions such as
interpass cleaning.
5. Upon filling up the groove fully, weld over one more run, known as temper bead,
to grain refine the underlying 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. Apply NDT (RT or UT as required by Design, Service or Repair Procedure).
9. Post Weld Heat-treat as per requirement.

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

applicable Material Specifications and Parts UCI & UF, of the Code's subsection
B. Repairs to stainless steel will involve trepanning, dye check, low heat input in
welding, complete filling up with compatible electrodes/ filler wires, using
optimally low currents. Final NDT would be PT (dye check) and RT where
applicable. PWHT - if at all, only solution annealing, with Client's concurrence.

35
Surface Weld Metal Build Up
Deposits of weld metal are applied to the surface of base metal for the purpose :
a. Restoration of base metal thickness for strength consideration ; or
b. modifying the configuration of weld joints in order to provide tapered transitions
as follows :
i. Butt weld procedure qualification is required as per ASME Section IX for
the thickness of weld deposited.
ii. 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.

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. POSTWELD HEAT TREATMENT

All welds in the Pressure Vessels or Pressure Vessel parts require to be given a
Postweld Heat Treatment at a soaking temperature not less than that specified in under
noted Tables, when the nominal thickness [as defined below] of the weldment,
including corrosion allowance, exceeds the limits given in these Tables.

Table UCS-56 for carbon and low alloy steels

UHA-32 for high alloy steels
UHT-56 for ferritic steels with enhanced tensile properties
and UNF-56 for specific non-ferrous materials

The above Tables specify the minimum nominal thicknesses above which the postweld
heat treatment is mandatory. These Tables also specify holding (soaking) temperatures
and holding times for different thicknesses and different types of materials classified
into P Numbers & Group Nos by the Code.

For commonly used materials given below, PWHT becomes mandatory above nominal
thicknesses mentioned below :

36
- For carbon steels, nominal thickness above 31.75mm

- For low alloy steels of grades 1 Cr 1/2 Mo, 2 1/2 Cr.-1 Mo etc., at nominal
thickness above 16mm, and for grades such as 5 Cr. 1/2 Mo and 9 Cr. 1 Mo.
PWHT is required for all thicknesses.

- For austenitic stainless steels [Type 304, 316, etc.] PWHT is neither required
nor prohibited.

- For non-ferrous materials, PWHT is normally not necessary nor desirable,

except for alloys like CDA-954, Zirconium grade R60705 alloy NO8800, etc.

- For UHT materials [ferritic steels with enhanced tensile properties], PWHT is
required for all thicknesses.

TABLE UCS - 56

POSTWELD HEAT TREATMENT REQUIREMENTS FOR CARBON AND

LOW ALLOY STEERLS

Normal Minimum Holding Time at Normal Temperature

Holding For Nominal Thickness [See UW - 40(f)]
Temperature,
0
Material F, Minimum Up to 2 in Over 2 in to 5 in Over 5 in
P - No. 1 1100 1 hr/in., 15 2 hr plus 15 2 hr plus 15
Gr. Nos. 1, 2, min minimum min for each min for each
3 additional inch additional inch
over 2 in over 2 in
Gr. No. 4 NA None None None

NOTES :

(1) When it is impractical to postweld heat treat at the temperature specified in this
Table, it is permissible to carry out the postweld heat treatment at lower
temperature for longer periods of time in accordance with Table UCS - 56.1.

(2) Postweld heat treatment is mandatory under the following conditions :

(a) for welded joints over 1 1/2 in nominal thickness

37
 (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 200 0 F during
welding.

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

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

Nominal thickness is defined in clause No. UW-40(f) of ASME Code Section VIII
Div.1. For pressure vessels or parts thereof, it is the greatest weld thickness of the
equipment or part of the equipment which has not been previously post weld heat
treated.

Thus, the nominal thicknesses in the following cases are:

1. In a full penetration weld joining materials of same thickness, it is a total depth of
the weld, exclusive of any permitted weld reinforcement.
2. In groove welds, nominal thickness is the depth of the groove
3. In a groove and fillet type of weldment, nominal thickness is the depth of the
groove, or the throat thickness of the fillet, whichever is greater.
4. In a fillet weld, nominal thickness is its throat dimension.
5 In stud welds, nom. thickness is the diameter of the stud.
6. When parts of unequal thicknesses are joined together, then the nominal
thickness is,
- thinner of the adjacent parts butt welded.
- the thickness of the shell in a corner joint
- the depth of actual weldment across the nozzle neck, including through the
reinforcement pad.
- the thickness of the nozzle neck, butt welded to a Weld Neck Flange
- the thickness of the weld in tube to tube connection
- the depth of the repair weld, in a repair joint.

38
Operation Of PWHT
The PWHT can be represented as a time and temperature cycle, recorded on a chart.
The heating and cooling rates as well as the soaking temperature and its holding time
are important, and are specified in the Tables above.

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

enclosed furnace. The equipment may be heated in more than one heat in a furnace,
with an overlap of atlas 5 feet of the heated sections of the vessel shall be provided. At
the same time, the portion outside the furnace shall be shielded in such a manner that
temperature gradients are not harmful.
Local postweld heat treatment , for example, of a heavy section, or a circumferential
seam individually, may also be done in more than two or three heats, provided the
heating is done uniformly and the portion outside the heated band is suitably protected
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.

For carbon and low alloy steels, the maximum heating rate is specified as 200
Deg.C.per hour per inch thickness, while the maximum cooling rate allowed, after the
soaking period, is 278 Deg.C per hour per inch thickness.

The maximum loading and unloading temperatures should preferably be 300 Deg.C., to
avoid thermal shock, though a temperature upto 400 Deg.C. is allowed by the Code.

The minimum holding temperature, or what is known as the soaking temperature,

varies for different types of materials, designated by P Numbers in ASME Code. For
carbon steels the minimum soaking temperature is 593 Deg C. For low alloy steels the
soaking temperatures ranges from 630 to 720 Deg C, depending upon the content of Cr
& Mo.

The spatial variation in holding temperature during soaking period in a furnace or

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

During the heating and holding periods the furnace atmosphere should be so
controlled, as to avoid excessive oxidation of the vessel skin surface. Neutral or

39
reducing atmospheres are recommended. Burner locations should be designed to
prevent direct flame impingement on vessel surface.

Benefits of PWHT
1. Stress Relief : Relieving of locked up stresses in weldments, dispersal of peaks &
valleys of stress levels homogeneously in a welded structure, and affording it a
dimensional stability.
2. Tempering: Softening hard zones, such as at HAZ and in cold formed components
3. Providing escape route to nascent Hydrogen entrapped in welds, thus precluding
possibility of underbead cracking. All of the above assure a safe and reliable welded
equipment.

Summary of Postweld Heat Treatment Requirement

All carbon-and low-alloy steel seams must be postweld heat-treated if nominal
thickness exceeds 1 1/4 in or 1 1/2 in if preheated to 200 0 F before welding.
Some materials must be postweld heat-treated at lower thickness.
Vessels containing lethal substances must be postweld heat-treated.
Unfired steam boilers (DP more than 50 psig)
Carbon-steel vessels for service at lowered temperature must be postweld heat-
treated unless exempted from impact test.
For welder vessels the details of PWHT temperature and holding time are
describe in following table of the code.
Carbon- and low-alloy steel vessels UCS-56, UCS-66, UCS-67, UCS-79,
UCS-85
High-alloy steel vessels UHA-32

40
8. PRESSURE TESTING OF VESSELS :

A) Hydrostatic Test
Test must be at least 1 1/2 times the maximum Allowable working pressure
multiplied by the lowest ratio of the stress value for the test temperature to that
for the design temperature

If the allowable stress at design temperature is less than the allowable stress at
test temperature the hydrostatic test pressure must be increased proportionally.
Thus
allowable stress at test temperature x MAWP
Test pr. = 1.3 x
allowable stress at design temperature

Inspection must be made at a pressure not less than 2/3 of test pressure.
Corrosion allowance may be in calculating test pressure. The maximum
allowable working pressure may be assumed to be the same as the design
pressure when calculations are not made to determine the maximum allowable
working pressure.

B) Pneumatic Tests
Pneumatic test may be used instead of hydrostatic test when :
1. Vessels are so designed and supported that they cannot safely by
filled with water.
2. Vessels for service in which traces of testing liquid cannot be tolerated
are not easily dried.
Test pressure must not be less than 1.1 times maximum allowable working
pressure multiple by the ratio of stress value S for test temperature of vessel to
the stress value S for design temperature.

The pressure in the vessel shall be gradually increased to not more than one-
half 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 pressure shall be reduced to a value equal to9/10 of

41
 the test pressure and held for a sufficient time to permit inspection of the vessel.
Leakage is not allowed at the time of the required visual inspection.

6. INSPECTION & TESTING

1. MANUFACTURER'S RESPONSIBILITY

The Manufacturer has the responsibility of assuring that the quality control, the detailed
examinations, and the tests required by this Division are performed, The Manufacturer
shall perform his specified duties.

(1) the Certificate of Authorization from the ASME Boiler and Pressure Vessel
Committee authorizing the Manufacturer to fabricate the class of vessel being
constructed [ UG - 117 (a)];
(2) the drawings and design calculations for the vessel or part [ 10-5 and 10-15 (d)];
(3) identification for all material used in the fabrication of the vessel or part ( UG - 93);
(4) securing Partial Data Reports [UG - 120©];
(5) access for the Inspector : The Manufacturer of the vessel shall arrange for the
Inspector to have free access to such parts of all plants as are concerned with the
supply or manufacture of materials for the vessels, when so requested. The
Inspector shall be permitted free access, at all times while work on the vessel is
being performed, to all parts of the Manufacturer's shop that concern the
construction of the vessel and to the site of field erected vessels during the period
of assembly and testing of the vessel. The Manufacturer shall keep the Inspector
informed of the progress of the work and shall notify him reasonably in advance
when vessels will be ready for any required tests or inspections.
(6) Examination of all materials before fabrication to make certain they have the
required thickness, to detect defects [UG-93 (d)], to make certain the materials are
permitted by this Division (UG-4), and that traceability (UG-77) to the material
identification (UG-93) has been maintained.
(7) Documentation of impact tests when such tests are required (UF-5, UCS-66, UHA-
51, UHT-6, and ULT-5);
(8) Concurrence of the Inspector prior to any repairs (UG-78, UW-38, UF-37, and UF-
38);

42
(9) Examination of the shell and head sections to confirm they have been properly
formed to the specified shapes within the permissible tolerances (UG-79, UG-80,
UG-81, UF-27, and UF-29);
(10) Qualification of the welding and/.or brazing procedures before they are used in
fabrication [UG-84 (h), UW-28(b),and UB - 31];
(11) Qualification of welders and welding operators and brazers before using the
welders or brazers in producti9nn work (UW-29, UW-48,UB-32, and UB-43);
(12) Examination of all parts prior to joining to make certain they have been properly
fitted for welding or brazing and that the surfaces to the joined have been cleaned
and the alignment tolerances are maintained (UW-31, UW-32, UW-33, and UB -
17);
(13) Examination of parts as fabrication progresses, for material marking (UG-94),
that defects are not evident (UG-95), and that dimensional geometries are
maintained (UG-96 and UF-30);
(14) Provision of controls to assure that all required heat treatments are performed
(UW-2, UW-10, UG-85, UF-31, and 10-11);
(15) Provision of records of mondestructive testing examinations performed on the
vessel or vessel parts. This shall include retaining the radiographic film if
radiographic examinations are performed (UW-51, UW-52, and 10-10);
(16) Making the required hydrostatic or pneumatic test and having the required
inspection performed during such test (UG-99, UG-100, and UW-50);
(17) Applying the required stamping and/or nameplate to the vessel and making
certain it is applied to proper vessel (UG-116, UG-118, and UG-119);
(18) Preparing required Manufacturer's Data Report and having it certified by the
Inspector (UG-120);
(19) Providing for retention of radiographs (UW-51), ultrasonic test reports (12-4), and
Manufacturer's Data Reports (UG-120) for a period as specified.

2. INSPECTOR'S RESPONSIBILITY :
The Inspector shall make all inspections specifically required of him plus such other
inspections as he believes are necessary to enable him to certify that all vessels which
he authorizes to be stamped with the Code Symbol have been designed and
constructed in accordance with the requirements of this Division. Some, but not all, of

43
the required inspections and verifications, which are defined in the applicable rules, are
summarized as follows :
(a) verifying that the Manufacturer has a valid Certificate of Authorization [ UG-117 (a)]
and is working to a Quality Control System [UG-117(e)];
(b) verifying that the applicable design calculations are availabel [U-2(b), U-2(c), 10-5,
and 10-15 (d)];
(c) verifying that materials used in the construction of the vessel comply with the
requirements of UG-4 through UG-14 (UG-93);
(d) verifying that all welding and brazing procedures have been qualified (UW-28, UW-
47, and UB-42);
(e) verifying that all welders, welding operators, brazers, and brazing operators have
been qualified (UW-29, UW-48, and UB-43);
(f) verifying that the heat treatments, including PWHT, have been performed (UG-85,
UW-10, UW-40, UW-49, and UF-52);
(g) verifying that material imperfections repaired by welding were acceptably repaired
[UG-78, UW-52(d)(2)©, UF-37, and UF-47©];
(h) verifying that weld defects were acceptably repaired [UW-51© and UW-52©];
(i) verifying that required nondestructive examinations, impact tests, and other tests
have been performed and that the results are acceptable (UG-84, UG-93, UW-50,
UW-51, UW-52, and UB-44);
(j) making a visual inspection of vessel to confirm that the material identification
numbers have been properly transferred (UG-77, and UG-94);
(k) making a visual inspection of the vessel to confirm that there are no mateial or
dimensional defects (UG-95, UG-96, and UG-97);
(l) performing internal and external inspections and witnessing theh hydrostatic or
pneumatic tests (UG-96, UG-97, UG-99, UG-100, and UG-101);
(m) verifying that the required marking is provided (UG-115) and that any nameplate
has been attached to the proper vessel;
(n) signing the Certificate of Inspection on the Manufacturer's Data Report when the
vessel, to the best of his knowledge and belief, is in compliance with all the
provisions of the Division.

3. MATERIAL TEST CERTIFICATES

44
Materials for Pressure Equipment
As per the ASME codes Section VIII Divisions 1 & 2 and Sec.1 all the materials used
for pressure equipment should be from one of the approved specifications covered by
ASME Section II Parts A & B.
Raw Materials and Components
Materials should be purchased from reputed Steel makers, forge shops and foundries,
with covering certificates meeting all the relevant requirements of the Material
Specifications and grades. Component manufacturers like dished end makers, pipe
fitting manufacturers should comply with Partial Data Report (Form U-2) along with their
own manufacturing certificates.

Material Identification
Identification markings on the materials are required to be co-related with the
Certificates for authentication of the genuineness of the material. And prior to further
processing, the material markings need to be transferred suitably for retaining
traceability throughout.

Scrutiny of Test Certificates

This is the pre-eminent requirement in the material identification exercise, and is
sometimes overlooked. The undernoted checklist may be found useful in this important
activity.

1. Reputed Manufacturer : Raw Material : Plates Forge Shop, Foundry etc.

2. Certificate Format : Is it as per relevant ASME Section - II requirement.

3. Third Party Certificate : Is it by a reputed Inspection Agency like Lloyd's, BV,

DNV, Arab Inspection Co., covering inspection and certification at the steel mill ?
and what is the scope ?

4. Steel Mill certificate : Does it address the material in hand ?

Is corelatable with identification markings found on material ?
Are the markings fully in compliance with the relevant Specification, grade and
applicable general requirements ?

45
 Do the markings appear to be authentic ?
Finally, verify whether the certificate is authentic and "original ",a photo- copy will
not do.
5. Details to be verified in the Material Test Certificate
* Melting Method / Melting Practice
* Deoxidation Practice
* Vacuum Degassification
* Heat Treatment Condition
* Product Form : Plates, Forgings, Castings, Pipe Fittings, Fasteners,
Tabulars--and method of manufacturing
* Amount of work done from ingot stage to final product, in case of plates
and forgings
* Quality Control Requirements of the relevant specification
-Test Frequency/Test Lots
-Chemical Composition of the particular cast or heat .
Carbon Steel:% C,Si,Mn,S,P & Trace Elements Ni, Cr, Mo, V, Cu & N
.Stainless Steels:% C,Cr,Ni,Mo, Si,Mn,S,P,Ti & Nb .
Non-Ferrous Matls:% Cu,Ni,Zn, Sn,Pb,& traces of S,P&Fe

-Physical Properties :
Physical Properties of the representative test and heat treatment lot:
Tensile, ductility (bend test ,% elongation, Yield Point, Notch toughness
(Impact), Hardness and Microstructure.

-Non-Destructive Examination :
Internal flaw check by UT:- SA 435 for plates check for extent/grid of
scanning; SA 578 Class 1 for Forgings SA 609 for Castings; check
whether required by order, complied with and duly certified and stamped
accordingly.

4. INSPECTION ACTIVITIES DURING FABRICATION

a. Prefabrication Inspection
 Scrutiny of welding procedure specifications and qualification records
 Study of fabrication and testing plans

46
  Verification of base metal specification and quality with material
received.
 Examination of welding machines and consumables
 Checking joint designs and preparations

b. Inprocess Inspection
 Verity compliance of welding procedures and fabrication plans.
 Measuring and controlling preheat and interpass temperatures.
 Controlling deployment of qualified welders and operators for specific
operations.
 Control of welding consumables, interpass cleaning and final welding
finish.
 Inprocess visual and non-destructive examination
 Control of repair activities.

c. Final Inspection
 Inspection of final cleaning, surface dress up and marking for
identification.
 Non-destructive testing
 Dimensional check
 Visual inspection and verification with customer specifications
 Post weld heat treatment control
 Documentation.

5. TESTS FOR LOW TEMPERATURE OPERATION

Preamble
Carbon steels and low alloy steels undergo a drastic change in their room temperature
ductility,at sub-zero service temperatures. Different types of materials exhibit different
types of transition behaviour. It is observed that there is a sudden, phenomenal drop in
their notch-toughness properties below the "transition" range of temperature, which is a
matter of concern.

Metallurgical Explanation

47
Body centered cubic or Ferritic alloys exhibit a significant transition in behavior when
impact tested over a range of temperatures. Above transition temperature range,
impact specimens fracture in a "ductile" manner, absorbing relatively large amounts of
energy. At lower temperatures, i.e. below the transition temperature range, the impact
test specimens are found to fracture in a brittle (cleavage) manner, absorbing less
energy. And within the transition temperature range, the fracture is a mixture of ductile
and brittle nature.

Significance of Impact Tests in Materials and Weldments

That a material is not vulnerable to a sudden drop in notch-toughness at the lowest
specified service (or design) temperature, can only be proved by conducting Charpy V-
notch Impact tests on representative test samples, at reference (the lowest service)
temperature. Grain refined carbon steel forgings and wrought materials ( thoroughly
worked and normalized ) generally exhibit good notch toughness. Use of special carbon
steel electrodes developed for good impact properties, along with stringer bead welding
techniques to ensure low heat input (1.2 to 1.8 kJ/mm) go a long way in overcoming the
brittle behavior of carbon steel materials and weldments at sub-zero service
temperatures.

Test Method
The test method is described in ASME SA-370 specification, and ASME Code Sec.VIII
Div.1 requirements are stipulated in clause UG-84 of the Code.

Test Specimens : For above 11mm and upto 38mm thickness plate or a material
section, each impact test comprises of a set of three test specimens of a standard size
of 10 x 10 mm square and 55mm long, having a 2mm deep vee notch, with a smooth
curve at the bottom of the central veenotch. For thinner sections and plates, subsize
specimens are acceptable, but at a lower test temperature, as stipulated in UG-84.
For materials below 2.5mm thickness, such as in the case of heat exchanger tubes,
impact tests are waived. For plates thicker than 38mm, three sets of impact test
specimens are required to be tested, drawn from various cross sections of the plate and
the weldment. In the case of weldments three additional test pieces are drawn from HAZ.
Orientation of the notch is generally perpendicular to the surface of the plate; for other
product forms it is specified in relevant material specification. And in the case of

48
weldments, orientation of notch in weld zone (WZ) and heat affected zone (HAZ) is
stipulated in applicable subsection of the Code.
The Impact test results are measured in terms of energy absorbed by the notched
specimen (in ftlbs or kgm or joules). The notched test specimen, cooled down to the
reference temperature separately, is placed astride two supports of an anvil with its
notch centralized. The test specimen, upon being subjected to an impact by the striking
edge of a freely swinging heavy pendulum, is broken under a momentum of about 120
ftlb. The energy absorbed by the test piece is measured on a calibrated scale, in units
of kgm or joules or ftlbs as the case may be.
Acceptance Criteria is : the average of three test results being a minimum of 15 ftlbs
(2.1 kgm) average, and at the same time, the lowest of the three values being not less
than 12 ftlbs (1.7 kgm).

Notch Tough Ferritic Steels

Grain refined & austenitised, in other words normalized, carbon steels with compatible
electrodes such as AWS designated E-7018-1 display excellent notch toughness
properties upto -46 Deg C. Some carbon steels, such as ASME SA 537 Class 1 are
guaranteed for low temperature operations upto -60 Deg C.ASME Code Section VIII
Div 1 has evolved what are known as "Impact Test Exemption Curves" (see Fig UCS-
66), which assigns minimum Design Metal temperatures for various nominal
thicknesses of various grades of materials. Curves A,B,C and D classify in ascending
order the notch toughness properties of the materials.

A careful study of the Fig UCS-66 would indicate that fine grained and heat treated
materials fall below curve D, and have better impact properties, as compared to those
under C, B and A curves. For bolting materials (fasteners), test exemptions are
given separately.

Impact Test Exemptions for Stainless Steels and Non Ferrous Materials
Austenitic stainless steels and non-ferrous materials like Aluminum, Copper and Nickel
materials show excellent to good notch toughness properties at even cryogenic
temperatures. Welding procedures for these materials need to be necessarily
established to prove that impact properties of Weld zones and Heat affected zones
meet service requirements.

49
Stainless Steel materials and weldments Ref: UHA 51
For Types 304, 304L, 316, 316L & 347 impact tests waived upto -425 Deg.F.
For other types of austenitic steels (Types 309,310, 310S - in annealed condition)
- impact tests waived upto -325 Deg.F. Exceptions given in UHA 51(b) & (c),
are explained below:
- If types 309, 310, 310S, etc. as post weld heat treated upto 1650 Deg.F., then
impact tests are required at any service temperature below -20 Deg.F.
- For Ferritic Stainless/High Alloy Steels like Types 409, 410, 430, etc., impact
tests are required at any service temperature below -20 Deg.F.
- For weldments of types 304, 316, 347, only weld procedures with selected
consumables need to be qualified, and weld metal analyses need to be carried
out, for service temperatures below -20 Deg.F. HAZ impact tests are in any case
required for both procedure and production test plates for service temperature
below -20 Deg.F.

Non Ferrous Materials : Ref. UNF 65 :

Marked resistance to lowering in impact values at subzero temperatures.No impact
tests are required for undernoted materials, upto the temperatures mentioned :
i) Wrought aluminum alloys : -425 Deg.F.
ii) Copper and copper alloys } : -325 Deg.F.
Nickel & Ni alloys }

********

50
 7. NDE OF PRESSURE VESSELS

Selection of a particular NDT technique :

Following tables give selection of NDT technique selection w.r.t. welding discontinuity
and also the generally applicable NDT w.r.t weld joint types.

Applicable NDT methods / Welding Discontinuities

Applicable NDT Methods

Discontinuities
RT UT PT MT VT ET
Porosity  * a *b a *
Slag Inclusion   NA *b NA *
Incomplete fusion *  NA * b
NA *
Incomplete Penetration   NA * NA *
Undercut  * * *  *
Overlap NA *   * *
Cracks *   a
 b
a 
Laminations NA  a,c b,c a,c NA
Note 1 :
a. Surface
b. Surface and slightly subsurface
c. Weld preparation or edge of base metal
 Applicable method
* Marginal applicability depending on other factors such as material thickness,
Discontinuity size, orientation and location
Note 2 :
Leak testing can reveal only through and through leaks.

Applicable NDT methods for Weld joint types

Joints NDT Methods

RT UT PT MT VT ET
Butt      
Corner *     *
T *     *
Lap * *    *

Note 1 :
 Applicable method
* Marginal applicability depending on other factors such as material thickness,
Discontinuity size, orientation and location

51
Note 2 :
Leak testing can reveal only through and through leaks.

2. CODE REQUIREMENTS OF NDE (ASME Sec. VIII Div.1)

2.1 RADIOGRAPHY REQUIREMENT :

a) Full Radiography
Conditions for which full radiography is specified are the following :

1) All but welds in the shell and heads of vessels used to contain lethal
substances must be fully radiographed.
2) If the plate or vessel wall thickness at the weld joint exceeds the thickness
given in table UCS-57, UNF - 57, and UHA - 33, then full radiography is
required. (e.g. P. No. 1, gr 1,2, 3 require full radiography - UCS 57)
3) Butt welds unfired steam boilers with a design pressure exceeding 50 psi.
4) All butt welds in nozzles for vessels 1) & 3) above. In others, category B and
C welds upto NPS 10 and upto 1 1/8 in. thk. do not required radiography.
5) All category A and B welds shall be Type no.(1) or Type no.(2) and shall be
radiographed accordingly.(UW - 12)
6) Category B and C welds (excluding those in nozzles in 4 above) which
intersect the Category A welds shall be at least spot radiographed.
7) Weld metal build up ( 1 : 3 taper) to be radiographed same as joint itself.

b) Spot Radiography
1) Butt welded joints Type (1) or (2) of Table UW - 12 if design efficiency is
selected for spot radiography.
2) If spot radiography is specified for entire vessel then radiographic
examination is not required of category B and C butt welds in nozzles less
than NPS 10 or 1 1/8 in. thick.

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

52
 2.2 ULTRASONIC EXAMINATION :
Ultrasonic examination may be substituted for radiography for the final
closure seam of a pressure vessel.

2.3 MAGNETIC PARTICLE EXAMINATIONS :

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

2.4 LIQUID PENETRANT EXAMINATIONS :

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

3. NDT ACCEPTANCE STANDARDS :

1. Magnetic Particle Examination [ MT ] - Mandatory Appendix 6

Magnetic Particle Examination shall be performed in accordance with the written
procedure certified by the Manufacturer to be in accordance with the
requirements of T-150 of ASME Section-V.
1.1 NDE Personnel :
a. Shall have a vision, with correction if necessary, to enable reading a
Jaeger Type No.2 Standard Chart at a distance of not less than 12
inches; and shall be capable of distinguishing and differentiating contrast
between colours used. This requirement shall be checked annually.
b. Shall be competent and duly certified in MT techniques.
1.2 Evaluation of Indications :
Indications will be revealed by retention of magnetic particles in the orientation of
the possible defects. All such indications are not necessarily imperfections,
however, since excessive surface roughness, magnetic permeability variations
[such as at the edge of heat affect zones], etc., may also produce similar
indications.

53
 An indication is the evidence of a mechanical imperfection. Indications which
have dimensions greater than 1/16th of an inch are considered "relevant".
a) A linear indication is one having a length greater than three times the
width.
b) A rounded indication is one of circular or elliptical shape with a length
equal to, or less than three times its width.
c) Any questionable or doubtful indications shall be re-examined to
determine whether or not they are relevant.
1.3 Acceptance Standards
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) relevant linear indications;
b) relevant rounded indications greater than 3/16 inch;
c) four or more relevant rounded indications in a line separated by
1/16 inch or less, edge to edge.
d) An indication of an imperfection may be larger than the
imperfection that causes it; however, the size of the indication is
the basis for acceptance evaluation.
2. Liquid Penetrant Examination [ PT ] - Mandatory Appendix 8
Liquid Penetrant Examination shall be performed in accordance with the written
procedure certified by the Manufacturer to be in accordance with the
requirements of T-150 of ASME Section-V.
2.1 NDE Personnel :
a. Shall have a vision, with correction if necessary, to enable reading a
Jaeger Type No.2 Standard Chart at a distance of not less than 12
inches; and shall be capable of distinguishing and differentiating contrast
between colours used. This requirement shall be checked annually.
b. Shall be competent and duly certified in PT techniques.
2.2 Evaluation of Indications :
An indication is the evidence of a mechanical imperfection. Only indication which
have dimensions greater than 1/16th of an inch shall be considered "relevant".
a) A linear indication is one having a length greater than three times the
width.

54
 b) A rounded indication is one of circular or elliptical shape with a length
equal to, or less than three times its width.
c) Any questionable or doubtful indications shall be re-examined to
determine whether or not they are relevant.
2.3 Acceptance Standards
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) relevant linear indications;
b) relevant rounded indications greater than 3/16 inch;
c) four or more relevant rounded indications in a line separated by 1/16 inch
or less, edge to edge.
d) An indication of an imperfection may be larger than the imperfection that
causes it; however, the size of the indication is the basis for acceptance
evaluation.
3. Ultrasonic Examination of Welds [ UT ] - Mandatory Appendix 12
Ultrasonic Examination shall be performed in accordance with the written
procedure certified by the Manufacturer to be in accordance with the
requirements of T-150 of ASME Section-V.
3.1 Competence of NDE Personnel
UT Examination Personnel shall be qualified and certified in accordance with
Employer's written practice, as per SNT-TC-1A.
3.2 Acceptance - Rejection Standards
These Standards shall apply unless other standards are specified for specific
applications within this Division.
Imperfections which produce a response greater than 20% of the reference level
shall be investigated to the extent that the operator can determine the shape,
identity ,and location of all such imperfections, and evaluate them in terms of the
acceptance standards given in (a) and (b) below:-
(a) Indications characterized as cracks, lack of fusion or incomplete penetration are
unacceptable regardless of length.
(b) Other imperfections are unacceptable if the indications exceed the
reference level amplitude and have lengths which exceed :
... 1/4 inch for t upto 3/4 inch;

55
 ... 1/3 t for t from 3/4 in. to 2 1/4 in;
... 3/4 in. for t over 2 1/4 in;
where t is the thickness of the weld excluding any allowable
reinforcement. For a butt weld joining two members having different
thicknesses at the weld, t is the thinner of these two thicknesses. if a full
penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in t.
3.3 Report of ultrasonic examination, including Record of repaired areas and results
of re-examination, duly verified by the Inspector, shall be retained by the
Manufacturer and incorporated in the Manufacturer's Data Report [ MDR ].
4. Radiographic Examination of Welds [ RT ] - Clauses UW-51 & UW-52
All welded joints subject to radiography shall be examined in accordance with
Article 2 of ASME Section V.
4.1 NDE Personnel :
RT Examination Personnel shall be qualified and certified in accordance with
Employer's written practice, as per SNT-TC-1A.
4.2 Evaluation of Radiographs : 100% Radiography :
The requirements of ASME Section V Article 2 Clause T-280 are used as a
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 on the radiographs of welds and characterized as
imperfections are unacceptable under the following conditions or acceptance
criteria, and the repairs are re-radiographed and evaluated to the same
acceptance criteria.

Acceptance Criteria : The following imperfections are unacceptable.

Any indication characterized as a crack or zone of incomplete fusion or
penetration; Any other elongated indication on the radiograph which has length
greater than : ... 1/4 inch for t upto 3/4 inch;
... 1/3 t for t from 3/4 in. to 2 1/4 in;
... 3/4 in. for t over 2 1/4 in;
where t = the thickness of the weld excluding any allowable reinforcement. For
a butt weld joining two members having different thicknesses at the weld, `t' is

56
 the thinner of these two thicknesses. If a full penetration weld includes a fillet
weld, the thickness of the throat of the fillet shall be included in t.

Any group of aligned indications that have an aggregate length greater than `t'
in a length of 12t, except when the distance between the successive
imperfections exceeds 6L, where L is the length of the longest imperfection in
the group;
Rounded indications in excess of that specified by the acceptance standards
given in Appendix 4 of ASME Code Sec.VIII Div 1.
4.3 Evaluation of Spot Radiography : UW-52 of ASME VIII - 1.
Spot Examination of welds by radiography shall be made in accordance with
Article 2 of ASME Section V. Minimum length of spot radiograph shall be 6
inches [150mm].

Acceptance Criteria : For Spot Radiography

i. Welds in which indications are characterized as cracks or zones of
incomplete fusion or penetration shall be unacceptable.
ii. Welds in which indications are characterized as slag inclusions or cavities
shall be unacceptable if the length of any such indication is greater than
2/3t where `t' is the thickness of the weld excluding any allowable
reinforcement.
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 a fillet weld, the thickness of the throat of the fillet shall be
included in `t'.
iii. If several indications within the above limitations exist in line, the welds
shall be judged acceptable if the sum of the longest dimensions of all
such indications is not more than `t' in a length of `6t' [or proportionately
for radiographs shorter than `6t'], and if the longest indications considered
are separated by atleast 3L, of acceptable weld metal where L is the
length of the longest indication.
The maximum length of acceptable indications shall be 3/4 in. Any
indication shorter than 1/4 in. shall be acceptable for any plate thickness.
iv. Rounded indications are not a factor in the acceptability of welds not
required to be fully radiographed.

57
 Evaluation and Retests in the case of Spot Radiography:
When a spot radiograph is acceptable in accordance with the above criteria,
the entire weld line represented by this spot radiograph is acceptable.

When a spot radiograph discloses an indication unacceptable to above criteria,

then two additional spots shall be marked by the Inspector, in the weld line
represented by the original spot 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.

4. ADVANTAGES / LIMITATIONS OF THE NDT METHOD :

The advantages and limitations of the NDT method can be used to determine
which method will provide the best results for a particular test. For example
radiography can detect cracks whose major planes are aligned parallel with the
radiation beam; such cracks are usually normal to the plate surfaces.
Radiography, however, usually cannot detect laminations in plate or cracks
oriented parallel to the plate surface. On the other hand, Ultrasonic can more
readily detect cracks oriented in either direction provided the proper scanning
technique is used.
Acceptance standards :
The statement “the weld shall be of radiographic quality” has no meaning unless
acceptance standards are stated. Acceptance standards define different types of
characteristics of discontinuities and whether particular types of discontinuities
are permissible. If a particular type of discontinuity is permissible, then the
acceptance standards must specify the maximum size at which that discontinuity
is acceptable. Acceptance standards are an integral part of most codes and
specifications and are commonly used as reference in purchase specifications.

58
 8. QUALITY CONTROL PROGRAMME

Note : Candidates are advised to go through the latest edition of Appendix 10 of

ASME Section VIII Div. 1, Quality Control System before going through this
chapter.

1.0 Examination : ASME Code VIII-1 requires that an independent quality system is
established in-house by each manufacturer to ensure that the design, materials
and workmanship as specified are checked at each stage of manufacture for
compliance with requirements. The in-house quality control exercise is called
”Examination”.
1.1 Inspection : Third party inspector is known as “Authorized Inspector [ AI ]”, who
is suitably qualified and recognized as per ASME Section VIII Div.1 Clause UG-
91. He is further required to carry out `INSPECTION' at stipulated stages.
1.2 Mandatory Appendix 10 describes in brief the quality system required, and
highlights essential features.
1.3 The Quality System : It should suit individual Company's existing culture. A
written description of the system in the form of a Quality Manual, and should
depict the process employed to manufacture a Code item.
1.3.1 Authority and Responsibility : Top Management should clearly define authority
and responsibility of persons performing quality related functions, and vest in
them the requisite organizational freedom, authority and independence to
monitor and verify the functioning of the system, to identify quality related
problems and to initiate, recommend and provide solutions.
1.3.2 Organogram : This describes the inter-relations between Top Management and
the departments, and the responsibility matrix within the organization.
Drawing Design Calculations and Specification control.
1.3.3 Document Control : Current revisions of Drawings, Design Calculations and
specifications only should be used. Changes and revisions should be duly
authorized and diligently conveyed through appropriate channels.
1.3.4 Material Control : Appropriate, Code approved material only should be used in
construction. Materials should be identifiable and corelatable with material TCs,
which should be verified to comply with Code requirements. Handling and
storage should ensure traceability of material.

59
1.3.5 Examination and Inspection Programme
a) Manufacturer's Responsibility
i) Obtaining Certificate of authorization from ASME BPV Committee to
fabricate the class of vessel being constructed.
ii) Preparation of fabrication drawings and design calculations for the vessel
iii) Identification and traceability of materials used in construction / fabrication
of vessel.
iv) Partial Data Reports ( Form U2): Data Reports for parts for pressure
vessel parts, which are supplied by a sub-vendor, and which are required
to be examined and inspected, shall be obtained [in duplicate] from the
sub-vendor.
v) The Authorized Inspector [ AI ] shall be given free access to all areas of
the works where relevant manufacturing work is being performed. He
shall be given access to the relevant documents.
vi) All materials shall be examined prior to fabrication to make certain that -
- they have the required minimum thickness / scantlings
- the defects and imperfections, if any, are detectable/detected and
eliminated in the interest of the safety of the vessel.
- only Code permitted/approved materials are used.
- the material identification and traceability are maintained.
- impact test properties, if required, are verified and recorded.
vii) Concurrence of Authorized Inspector prior to Repairs shall be obtained.
Defective material that cannot be satisfactorily repaired shall be rejected.
Acceptance of repairs and repaired items shall be obtained from
INSPECTOR.
viii) Formed shells and heads shall be examined to specified shapes,
permissible tolerances, using templates, gauges and instruments.
ix) Welding procedures and performances shall be qualified prior to being
employed in construction.
x) All parts shall be examined prior to and at fitup stage, to ensure that the
surfaces at the joints are cleaned thoroughly, and aligned within tolerance
limits.

xi) Examination ( in-process ) to ensure that:-

60
 - traceability of material identification,
- evidence of defects cropping up, and
- dimensional geometries are taken care of.
xii) Ensuring that Inspector has accepted the results of non-destructive
testing, and that all the NDT is satisfactorily performed, recorded, and
documents maintained and retained for prescribed period of time.
xiii) Performing prescribed pressure tests on the completed pressure vessel -
hydrostatic or pneumatic, under the witnessal of the AI and Client's
representative if required.
xiv) Applying stamping/code stamp/nameplate on the vessel tested to
satisfaction of the Inspector.
xv) Preparation of Manufacturer's Data Report [MDR] (Format U-1) and
obtaining certification/endorsement thereof from the Authorized Inspector.
MDRs shall be retained for prescribed period of time.

b) INSPECTOR'S Responsibility :
i) Verification that manufacturer has fulfilled his responsibilities as described
above.
ii) Performing internal and external examination of the vessel.
iii) Visual inspection of the vessel to ensure that there are no material or
dimensional defects.
iv) Witnessing hydrostatic or pneumatic tests on the Vessel.
v) Verification that results of all the tests performed are acceptable.
vi) Verifying that required marking for identification is provided, and name
plate attached.
vii) Signing Certificate of Inspection and MDR (Format U-1), when the vessel
is completed as per the Code.

c) Quality Plan :

At the outset, a quality plan shall be prepared by Manufacturer indicating

fabrication stages of operations where specific examinations and inspections are
to be performed. Hold points for inspection shall be marked by the Authorised
Inspector.

61
 1.3.6 Disposal of Non Conformity : A system for recording and correcting/eliminating
non-conformities shall be prepared, and after approval by the Authorized
Inspector, documented and implemented. Completed component and equipment
shall fully comply with Code requirements.
1.3.7 Welding shall comply with requirements of ASME Section IX, and the application
Code. The responsibilities and interfaces shall be clearly defined here.
1.3.8 Non-Destructive Examination : Procedures for identifying appropriate NDT
Techniques, in compliance with Code requirements shall be established. Written
practices for conducting ND examinations shall have AI's approval and shall be
implemented as prescribed.
1.3.9 Heat Treatment Control : Quality System shall identify heat treatments
applicable for materials, vessel components and completed vessel. Review of
heat treatment methods, arrangements and furnace time temperature records,
by AI shall be provided.
1.3.10 Calibration : Measuring Instruments and Test equipments shall be identified,
listed, required accuracies established, and calibrated at predetermined intervals
with Masters whose accuracy is in turn calibrated/traceable to National
Standards. Records of calibration and validity shall be displayed and be made
available for scrutiny.
1.3.11 Quality Records : Typical Formats of Inspection Reports, Registers, Records
related to Quality measurements and observations, identification labels, tags and
stickers, should be CONTROLLED (i.e. format as prescribed, approved,
available for review and referred to in the manual).
1.3.12 Relief Valves : Only approved type of Relief Valves, duly inspected and
accepted by ASME designated representative shall be used.
1.3.13 Authorized Inspector : Reference shall be made to Authorized Inspector as
defined in UG-91. Controlled Copy of Manual shall be made available to him.
He shall have access to all drawings, calculations, specifications, procedures,
process sheets, repair procedures, records, test results and any other
documents pertaining to inspection of the pressure vessel/s under his purview.
Note : The above discussion will help a Quality Control Manager to develop his own
Quality System in line with Appendix 10 of ASME Section VIII Div. 1 which is a
mandatory requirement before applying for ASME certificate.

62
 9. CODE STAMPING OF PRESSURE VESSELS

1.0 PROCEDURE FOR OBTAINING THE CODE SYMBOL AND

CERTIFICATE OF AUTHORISATION :

Users of pressure vessels prefer to order ASME Code vessels because they
know that such vessels will be designed, fabricated, and inspected to an
approved quality control system in compliance with a safe standard.

Pressure vessel manufacturers want the Code Symbol and Certificate of

Authorization so that they will be able to bid for code work, thereby broadening
their business opportunities. They also believe that authorization to build code
vessels will enhance the reputation of their shop.

If a company is interested in building Code vessels according to the ASME

Section VIII, Div. 1, “Pressure Vessels” Code, they should acquaint themselves
with Code Par, U-2, which requires the manufacturer to have a contract or
agreement with a qualified inspection agency employing authorized inspectors.
This third party in the manufacturer’s plant, by virtue of being authorized by the
state to do Code Inspection, is the legal representation which permits the
manufacturer to fabricate under state laws (the ASME Code).

Note : Application to Nation Boiler Board may be made to following address :

The National Board of Boiler and Pressure Vessel Inspectors
1055, Crupper Avenue,
Columbus, Ohio – 43229, USA

Manufacturers who want to construct Code vessels covered by section VIII,

division 1, obligate themselves with respect to quality and documentation. (see
code appendix X, “Quality Control Systems”) A survey will be required for the
initial issuance of an ASME Certificate of Authorization and for each renewal.
The evaluation is performed jointly by the authorized inspection agency and the
jurisdictional authority concerned which has adopted, and also administers, the
applicable boiler and pressure vessel legislation. Where the jurisdictional
authority does not make the survey, or the jurisdiction is the inspection agency,

63
the National Board of Boiler and Pressure Vessel Inspectors will be asked to
participate in the survey.
After the survey has been jointly made to establish that a quality control system
is actually in practice, the National Board representative, if involved, and the
jurisdiction authority will discuss their findings with the manufacturer. If the
manufacturer’s system does not meet code requirements, the company will be
asked to make the necessary corrections. The survey team will then forward
their report to the ASME with the recommendation that the manufacturer receive
the certificate of Authorization or, if failure to meet standards exists, that it not be
issued.

All code shops must follow the above procedures in order to obtain the Code
Symbol. If the shop wants the Code Certificate of Authorization, they should
write to the Secretary of the Boiler and Pressure Vessel Code Committee,
stating their desire to build such vessels. To help the secretary and the sub
committee on code symbol stamps evaluate the shop, the application must
describe the type and size of vessel the shop is capable of building and the type
and size of their equipment, especially fabricating equipment. If possible, they
should arrange with some authorized inspection agency, such as that of their
state, city, or insurance company, to undertake the inspection service after their
shop has received ASME certification. They can then inform the ASME that
specific inspection arrangements have already been made.

The secretary will send a statement of your request to the Subcommittee on

Code Symbol Stamps. A request will also be made to the chief inspector of the
particular state, city, or other inspection agency governing your company and/or
the National Board of Boiler and Pressure Vessel Inspectors, to make a survey
that will determine whether or not the company has a quality control system that
is capable of designing and fabricating pressure vessels by ASME Code rules.

The secretary receives a report of this survey and will then forward the report to
the subcommittee on code symbol stamps. Should they judge favorably, the
company will be issued a Code Symbol and Certificate of Authorization. A
manufacturer with the ability, integrity, and quality control system to design and

64
 fabricate good pressure vessels will have no difficulty in obtaining code
authorization.

2.0 THE IMPORTANT AREAS FOR PREPARING FOR THE “U’ STAMP
CERTIFICATION

2.1 Engineering Department.

- (Design Engineer shall be thorough in ASME Design.)

- Computer programs if used shall have validation.
- Purchase order requirements (POS) shall be clearly mentioned .
Ensures codes availability (ASME Section VIII Division 1, Section II
A,B,C,D, Section IX, Section V, SNT-TC-1A 92 and 96)

2.2 Material Control

- System for procuring right material
- System for receiving inspection
- System for storage and issue of Material. (electrode storage and issue –
critical area)

2.3 Fabrication & Welding Control

- Good shop practices
- WPS-PQR-WPQ & its application (ASME Section IX)
- Welder’s and welding supervisor’s training
- PWHT Control
- Calibration Control

2.4 Inspection & Testing

- Quality Plan
- Inspection & Test plan
- Inspection Procedures
- Control of non-conformance
- Reports

2.5 NDT
- Level III appointment and Written Practice
- Development at NDT and supporting procedures
- Demonstration of NDT Procedures
- Qualification & Certification of NDT personnel
- Calibration of NDT equipment.

2.6 Drafting Quality manual (Refer Appendix. 10 Section VIII Div. 1)

2.7 Liasoning with Authorized Inspector.

65
 The above areas are some at the critical areas wherein one has to start work
immediately while preparing for ASME Certification.

3.0 GENERAL CHECKLIST FOR PREPARATION FOR ASME

CERTIFICATION BY AN EMPLOYER

3.1 Formation of steering committee to guide the project.

Generally Quality Assurance Manager as a team leader and Design Manager,
Purchase Manager, Welding Manager, QC Manager, NDT Level III & Production
& Stores Manager as members.

3.2 Formation of working groups I

In each of the above areas like Design & Drawing, Purchase, Materials, Quality
Control, Welding , NDT, Stores and Production working groups (2 to 3 key
persons) shall be formed..

3.3 Identifying the areas of operation in 3.2 and ensure that

a. All the code requirements are identified correctly.
b. All the code requirements are understood by the personnel concerned.
(Here, ASME awareness Training and areawise training shall start)
Group reading and discussing code clauses will help.
c. Different procedures are to be identified and drafted including Written
Practice for NDT. If level III person is not available such person shall be
appointed.
d. Draft Quality Control Manual is made.
e. Identify Demonstration vessel and start working on it.
f. NDT personnel Training and Certification by Level III to be started.
g. Calibration of equipments

3.4 Interface of different procedure and finalization of Quality Control Manual.

3.5 NDT personnel qualification and completing procedures .

66
3.6 Implementation of Procedures & Internal Audits.

3.7 Contract with Authorized Inspector Agency

3.8 Authorized Inspector’s Audit / corrections.

3.9 Demonstration of NDT procedures to Authorized Inspector.

3.10 Consolidating W.P.S. / P.Q.R. Authorized Inspector’s satisfaction.

When Authorized Inspector gets convinced that the company is ready for
certification, apply to ASME with proper fees.

 Demo Vessel execution – drawings, materials, procedures etc.

 Authorized Inspector’s Audit / Correction
 ASME Certification Audit
 It gets certified maintaining and updating Quality System as per code
Revisions.
 Periodical Surveillance Audits and renewal after 3 years.

4. MARKING AND REPORTS :

GENERAL : The marking and certification of all pressure vessels built under this
Division shall comply with the requirements of the following paragraphs,

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

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

67
Required Marking :

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

(1) (a) the official Code U Symbol shown in Fig. UG-116 sketch (a) on vessels
inspected in accordance with the requirements in UG-90 through UG-97 (when
inspected by a user's Inspector as provided in UG-91, the word USER shall be
marked above the Code Symbol); or
(b) the official UM Symbol shown in Fig. UG-116 sketch (b) on vessels constructed in
accordance with the provision in U-1 (j).
(2) name of the Manufacturer of the pressure vessel preceded by the words "certified
by";
(3) maximum allowable working pressure -------- psi at ------------- 0F.
(4) minimum design metal temperature -------------- 0F ------------psi37
(5) Manufacturer's serial number;
(6) Year built.
(b) (1) The type of construction used for the vessel shall be indicated directly under the
Code Symbol by applying the appropriate letter(s) as follows : vessesls having
Category A, B, or C joints (except nozzles or for example, Arc welded ----- W.
(c) When a vessel is intended for special service and the special requirements have
been complied with [see UG-120 (d)], the appropriate lettering shall be applied as
listed below :

Lethal Service L
Unfired Steam Boiler UB
Direct Firing DF.

This lettering shall be separated by a hyphen and applied after the lettering of (b)
above.
(d) When a vessel has been radiographed in accordance with UW-11, marking shall be
applied under the Code Symbol as follows :
(1) "RT 1"- Vessel fully radiographed
(2) "RT 2" when the complete vessel satisfies the requirements of UW-11(a)(5) and
when the spot radiography requirements of UW-11(a)(5)(b) have been applied; or

68
(3) "RT 3" when the complete vessel satisfies the spot radiography requirements of
UW-11(b); or
(4) "RT 4" when only part of the complete vessel has satisfied thehradiographic
requirements of UW-11(a) or where none of the markings "RT 1", "RT 2", or "RT 3"
are applicable.
(e) (1)The letters HT shall be applied under the Code Symbol when the complete
vessel has been postweld heat treated as provided in UW-10.
(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-10.
(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 be
marked by the parts Manufacturer with the following :
(1) the official Code Symbol shown in Fig. UG-116 sketch (a), above the word "PART";
(2) name of the Manufacturer of the part of the pressure vessel preceded by the words
"certified by";
(3) the Manufacturer's serial number.

This requirement does not apply to such items as handhole covers, mandhole covers
and their accessories.
(g) Removable pressure parts shall be permanently marked in a manner to identify
them with the vessel or chamber of which they form a part. This does not apply to
manhole covers, handhole covers, and their accessory parts.

********

69
 CHAPTER 10

TOPICS FROM ASME SEC. VIII DIV. 1 FOR NUMERICAL

QUESTIONS IN API-510 CERTIFICATION EXAM.

1 ) Joint Efficiencies calculations :

(A) Weld categories (UW-3): A, B, C, D

(B) Type of Radiographs

RT – 1: Full length, full radiography of all but welds

(except NPS 10 or t n > 1¼”)

RT – 2: Cat – A: Full length

Cat – B: T – joints UW – 11 (a) 5 (b)

RT – 3: Spot radiography (UW – 52)

RT – 4: Partial / No radiography

(C) Joint Efficiencies (Table UW-12) – Values of E

(D) For seamless Heads & Vessels sections E = 1.0

(E) For piping E = 1.0 (seameless)

E = 0.85 (ERW)

2 ) static head Calculations :

1) Static Head conversion:

1 ft = 0.433 psi

70
 1 mtr = 0.1 bar

2) Vessel MAWP: MAWP on the basis of following:

a) Vessel is one indivisible unit

b) MAWP at top most point of vessel
c) Highest Pr and weakest part

3) Part MAWP: MAWP on basis of:

a) Conditions at each course is difference

b) MAWP would be different based on differing static head
c) Nozzles at different elevations will have different “part
MAWPs”

Vessel MAWP (psig) = Part MAWP – 0.433 (static head)

(approx formula)

4) Depth dished heads:

Hemisp = D/2 + skirt length (if any)

2:1 Ellip = D/4 + skirt length.

D = I.D. of Head

3 ) Internal Pressure calculations :

Thickness of shells under internal pressure :

.
a) For cylindrical shells : (Using inside dimensions)

t, inches = P x Ri / (SE - 0.6P) or P = SEt / (Rit + 0.6t)

where - `t' is the corroded min. thickness of shell, inches

`Ri' is the inside radius of the shell,inches (corroded)
`Ro' is the outside radius of shell, inches (corroded)
`P' is the design pressure in psig
`S' is the maximum allowable stress value in tension, psi
`E' is the Joint Efficiency [Refer to Table UW-12 ]

71
 Di is Inside diameter of shell (corroded)
Do is Outside diameter of shell

The formula is valid when P does not exceed 1/25SE and thickness does not exceed
one-half of the inside radius
b) Alternate Formula for cylindrical shells : (Using outside dimensions)

t, = P x Ro / (SE + 0.4P) or P = 2SEt / (Ro - 0.4t)

c) For spherical shells : (Inside dimensions)

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

[ Limitations : thickness shall not exceed 0.356R

P shall not exceed 0.665 SE ]
d) Alternate formula for spherical shells : (Outside dimensions)
t, inches = P x Ro / (2SE + 0.8P) or P = 2SEt / (Ro - 0.8t)

Spherical shell formulas are valid when thickness does not exceed
0.356R, or P does not exceed 0.665 SE.

Thickness of FORMED HEADS with Pressure on Concave Side :

a) For Ellipsoidal Heads : ( 2 : 1 type)

t, = P x Di / (2SE - 0.2P) or P = 2SEt / (Do + 0.2t)
- Alternately,
- t = PDo / (2SE + 1.8P) or P = 2SEt / (D - 1.8t)

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

0.17Di and spherical radius of 0.90Di.

b) For Torispherical Heads : (when r = 0.06 x L)

t, = 0.885 x P x L / (SE - 0.1P) or P = SEt / (0.885L + 0.1t)
- Alternate Formula for Torispherical Dished Ends (when r > 0.006L)
t, = P x L x M / (2SE - 0.2P) or P = SEt / (LM + 0.2t)
where L = inside spherical crown radius

72
 M = 1/4 x [ 3 + ( L / r ) 1/2 ]
r = is the inside knuckle radius in inches.

Limitations : Knuckle radius shall not be less than 6% of inside crown radius [ Ri ],
nor less than three times knuckle thickness. Ri shall be less than Do.

c) For Hemispherical Heads : The formula Hemispherical shell can be adopted

Minimum Thickness of Unstayed Flat Heads and Covers :

t, = D x [ CP / SE ] 1/2

where C = a factor depending upon the method of attachment of the flat head
D = Inside diameter of shell inches.
The above formula is applicable to both welded and bolted methods of
attachments. Extra moments applied to the cover by bolting, are to be
incorporated.

4) Pressure testing calculations:

HYDROSTATIC TEST

Test shall be conducted at test pressure given by:

Test Pr. = 1.3 MAWP x Stress at test temp.

Stress at design temperature

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

 Inspection must be made at a pressure not less than test pressure / 1.3

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

73
  The maximum allowable working pressure may be assumed to be the same as
the design pressure when calculations are not made to determine the maximum
the maximum allowable working pressure

 Any non-hazardous liquid may be used with/without corrosion inhibitor

0 0
 Test temp shall exceed MDMT by 30 F (17 C) when low temp operation is
specified

 Test gauge range = 1.5 to 4 times test pressure

PNEUMATIC TESTS

Pneumatic test is used instead of hydro test when:

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

2. Vessels for service in which traces of testing liquid cannot be tolerated are
not easily dried

Test pressure must not be less than 1.1 times maximum allowable working pressure
multiple by the ratio of stress value S for the test temperature of vessel to the stress
value S for design temperature

1) The pressure in the vessel shall be gradually increased up to one-half of the

test pressure

2) Thereafter, the test pressure shall be increased in steps of approx. one-tenth of

the test pressure until the required test pressure has been reached

3) Then the pressure shall be reduced to test pressure /1.1 , and held for a
sufficient time to permit inspection of the vessel. Leakage is not allowed at the
time of the required visual inspection

4) Test temp shall exceed MDMT by 30 0 F (17 0C)

5) Pr. Gauge range = 1.5 to 4 times test pressure

5) Impact testing :

Determine MDMT:

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

74
 1. P No 1, gr. No. 1 and 2
a. Materials A thickness < 0.5 inch
b. Materials B, C, D thickness < 1.0 inch

2. Hydrostatic test performed as required

3. Design temp = -20 0 F to 650 0F

4. No cyclic or thermal shock loading

B) UCS-66 : MDMT - Thickness combination falls on or above the relevant curve.

Impact test is not required (Exact values in Table 66)

C) UCS-68 (c) : If PWHT is performed when it is not design requirement, reduction

of 30 0F (17 0C) in impact testing exemption temp may be given to minimum
permissible temp from Fig UCS-66 for P No 1 materials

6) Reinforcement of Nozzles :

1. Principle of Reinforcement

Additional area required = Area removed = d x tr = Ar

2. Notations: (All refer to corroded conditions)

t, tr = Shell thickness provided, required respectively

tn, trn = Nozzle thickness provided, required respectively
a, b = Fillet weld sizes: nozzle to pad, pad to shell respectively

3. Limits of reinforcement:

a) Parallel to vessel wall on either side of opening axis

= dia (d) opening in corroded condition or

= d/2 + t + tn …………Use larger value

b) Normal to vessel wall

= 2 1/2 t or
= 2 1/2 tn + te ………..use smaller value

( te = Thickness of reinforcement element)

4. Areas available

A1) In shell = d (t - tr)

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

75
 A2) In Nozzle = 2.5 t (tn-trn)
= 2.5 tn (tn-trn) ……..Use smaller value

A3) Weld Joints = a2 + b2

5. Pad area required

Ap = Ar - [ A1 + A2 + A3]

7) Attachment welds for nozzles :

NOZZLES (UW – 16)

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Radius = 1/8 in. (3.2 mm) minimum blend radius

r1 = minimum inside corner radius, the lesser of

¼t or ¾ in.

t = nominal thickness of vessel shell or head, in.

tn = nominal thickness of nozzle wall, in.

tw = dimensional of attachment welds (fillet,

single-bevel, or single-J), measured as
shown in Fig. UW-16.1, in.

te = thickness of reinforcing plate

tmin = the smaller of ¾ in. or the thickness of the

thinner of the parts joined by a fillet, single-
bevel, or single-J weld, in.

t
tc = not less that the smaller of ¼ in. or 0.7 min

t
t1 or t2 = not less than the smaller of ¼ in. or 0.7 min

*******
Chapter 11

ASME SEC. VIII DIV.1 ADDENDA – 1999 HIGHLIGHTS

• FIG. UW-1 6.1, NOTES REORGANIZED

• UW-35, HEADING ON CENTRE COLUMN OF TABLE REVISED TO SHOW THAT

THIS WELD REINFORCEMENT MEASUREMENT APPLIES TO ALL
CIRCUMFERENTIAL BUTT WELDS, NOT JUST IN PIPES AND TUBES

77
• UW-40(F)(5), THICKNESS TO BE USED IN ESTABLISHING PWHT
REQUIREMENTS FOR JOINTS BETWEEN PARTS OF UNEQUAL THICKNESS
MAY BE TAKEN AS THE PREFORMING THICKNESS SHOWN ON THE MTR IN
LIEU OF MEASUREMENT

• PART UF, SOME MATERIALS OF CONSTRUCTION WERE ADDED

• TABLE UCS-56 FOR P-NO. 1 MATERIALS, RELIEF FROM MANDATORY PWHT

FOR TUBE-TO-TUBESHEET WELDS FOR TUBES NOT GREATER THAN 2”
DIAMETER. PREHEAT PREDICATED ON CARBON CONTENT OF TUBESHEET
MATERIAL

• UCS-66(B), NEW RULES FOR FLANGE AND FLAT HEAD MDMT

DETERMINATION DOWN TO
-550F. NEW TERM MAP (MAXIMUM ALLOWABLE PRESSURE) HAS BEEN
INTRODUCED. CAN REDUCE FLANGE MDMT BY SAME AMOUNT AS NOZZLE
NECK OR SHELL IS REDUCED

• UCS-66(G) HAS A REQUIREMENT TIGHTER THAN THAT PERMITTED BY UG-

84(B)(2) AND TABLE UG-84.4 FOR MATERIALS WITH AN MSYS _ 40 KSI BUT
PERHAPS LESS RESTRICTIVE THAT PERMITTED BY UG-84(B)(2) AND TABLE
UG-84.4 FOR MATERIALS WITH AN MSYS > 55 KSI

• FIG. UCS-66.2, GENERAL NOTES REARRANGED AND NEW GN (8) ADDED

• UCS-1 60, NEW PARAGRAPH RE OPERATION AT TEMPERATURE LOWER

THAN MDMT @ MAWP. APPLICABLE TO VESSELS OR VESSEL PARTS WITH
ADDITIONAL THICKNESS BEYOND THAT REQUIRED JUST FOR PRESSURE

• UNF-57 & -58, CAUTIONS ADDED WITH REGARD TO GRINDING OUT OF

DEFECTS IN WELDS WHEN NO REPAIR WELDING IS DONE. APPLIES TO
SPECIFIC ALLOYS

78
• UHA-42, CERTAIN WELD METALS WITH COLUMBIUM CONTENT EXCEEDING
1.00% ARE PERMITTED FOR WELDING SPECIFIC MATERIALS UNDER
LIMITED DESIGN CONDITIONS

• UHA-51 (e), TITLE CHANGED TO CLARIFY THAT THIS SUBPARAGRAPH

APPLIES TO WELDING PROCEDURE QUALIFICATION ASME SECTION VIII
DIVISION 1.

*********

79