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API 510
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Table of Contents
API CODES
API 510 Corrosion Rates and Inspection Intervals
Scope
Inspection Interval
10
11
15
Corrosion rates
15
16
16
API 576 Pressure Relieving Devices
Scope
19
19
22
23
23
26
27
Causes of Deterioration
28
Methods of Inspection
29
36
IRE Chapter 11
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43
48
58
59
61
69
93
94
96
107
113
120
Pressure Testing
UG-20 Design Temperature
127
UG-22 Loadings
129
UG-25 Corrosion
130
131
132
135
138
API 510
140
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146
147
147
147
148
161
UCS-66 Materials
164
164
UCS-68 Design
164
Practical Knowledge
170
171
172
174
175
Section IX
176
177
179
181
Welding Documentation Review
182
186
189
API 510
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195
Article 5 Ultrasonics
198
199
201
202
204
Corrosion
217
220
222
226
228
229
230
Appendix
Helpful information for the API Exam
Listing of where to find answers to API questions in Section VIII ASME
236
237
240
248
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Section 3
Inspection Practices
Preparatory Work:
Often questions are asked about what must be done before entry into a vessel. draining,
cleaning, purging and gas testing also the warning of personnel in the area, both inside and
outside the vessel, etc.. Checking of safety equipment is necessary as well as inspection
tools.
Modes of Deterioration and Failure:
Some of the listed modes of deterioration are fatigue, creep, brittle fracture, general corrosion
stress corrosion cracking, hydrogen attack, carburization, graphitization, and erosion. A
general question may be asked such as; list six modes of deterioration or a more specific
question such as; what is creep dependent upon.
Corrosion-Rate Determination:
One important aspect of vessel maintenance and operation is the determination of how
frequently a vessel needs to be inspected. This can be largely driven, by the rate at which a
vessel is corroding. There are three methods recognized by API 510 for this determination.
a. A corrosion rate may be calculated from data collected by the owner or user on vessel
providing the same or similar service.
b. Corrosion rate may be estimated from published data or from the owner user's experience.
c. After 1,000 hours of service using corrosion tabs or on-stream NDE measurements.
If the estimated rates are in error they must be adjusted to determine the next inspection date.
Maximum Allowable Working Pressure Determination:
The continued use of a pressure vessel must be based on calculations using the current
edition of the ASME Code or the edition the vessel was constructed to. A vessels MAWP
may not be raised unless a full rerating has been performed in accordance with section 5.3.
In corrosive service the wall thickness used in the calculations must be the actual thickness as
determined by the inspection. but must not be thicker than original thickness on the vessel's
original material test report or Manufacturer's Data Report minus twice the estimated
corrosion loss before the next inspection.
Defect Inspection:
Careful visual examination is the most important and most universally accepted method of
inspection. Other methods that may be used to supplement visual inspection are magnetic
particle, ultrasonics, eddy current, radiographic, penetrant and hammer testing ( when the
vessel is not under pressure). Vessels shall be checked visually for distortion. Internal
surfaces should be prepared by an acceptable method of cleaning, there is no hard and fast
rule for cleaning. External surfaces may require the removal of parts of the insulation in an
area of suspected problems or to check the effectiveness of the insulating system. Sometimes
deposits inside a vessel act to protect its metal from attack. It can be necessary to clean
selected areas down to bare metal to inspect those areas if problems are suspected from past
experience or if some indication of a problem is present.
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Inspection of Parts:
a. The surfaces of shells and heads should be checked for cracks, blistering, bulges, or other
signs of deterioration. With particular attention paid to knuckle regions of heads and support
attachments.
b. Inspect welded joints and their heat affected zones for cracks or other defects. Rivets in
vessels shall be inspected for general corrosion, shank corrosion. If shank corrosion is
suspected hammer testing or angle radiography can be used.
c. Examine sealing surfaces of manways, nozzles and other openings for distortion, cracks
and other defects. Pay close attention to the welding used to make these attachments.
Corrosion and Minimum Thickness Evaluation:
Corrosion occurs in two ways, general (a fairly uniform wasting away of a surface area) or
pitting(the surface may have isolated or numerous pits, or may have a washboard like
appearance in severe cases). Uniform wasting may be difficult to detect visually and
ultrasonic thickness measurements are normally done for that reason. A pit may be deeper
than it appears and should be investigated thoroughly to determine its depth. The minimum
actual thickness and maximum corrosion rate may be adjusted at any inspection for any part
of a vessel. When there is a doubt about the extent of corrosion the following should be
considered for adjusting the corrosion rates.
a.
For an area of considerable size where circumferential stress governs the least
thickness may along the most critical element of the area may be averaged over a
length not exceeding the following:
1. For vessels with an inside diameter of 60 inches or less one half the vessel
diameter or 20 inches whichever is less.
2. For vessels with an inside diameter greater than 60 inches one third the vessel
diameter or 40 inches whichever is less.
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f. As an alternative to the above the thinning components may be evaluated using the
rules of Section VIII Division 2 Appendix 4 of the ASME Code. If this approach is
used consulting with an engineer experienced in pressure vessel design is required.
g. When corrosion is located at a weld with a joint efficiency less than 1.0 and also in the
area adjacent to the weld special consideration must be given to the calculations for
minimum thickness. Two sets of calculations must be performed to determine the
maximum allowable working pressure; one for the weld using its joint efficiency and
one for the remote area using E equals 1.0. For purposes of these calculations the
surface at the weld includes one (1) inch on either side of the weld or twice the
minimum thickness whichever is greater.
h. When measuring a ellipsoidal or torispherical head the governing thickness may be as
follows:
1. The thickness of the knuckle region with the head rating calculated using the
appropriate head formula.
2. The thickness of the central portion of the dished region, in which case the dished
region may be considered a spherical segment whose allowable pressure is
calculated using the Code formula for spherical shells.
The spherical segment of both ellipsoidal and torispherical heads shall be considered to
be in an area located entirely in with a circle whose center coincides with the center of
the head and whose diameter is equal to 80 percent of the shell diameter. The radius of
the dish of torispherical heads is to be used as the radius of the spherical segment. The
radius of the spherical segment of ellipsoidal heads shall be considered to be the
equivalent spherical radius K1D, where D is the shell diameter (equal to the major axis)
and KI is as given in Table 1.
Section 4
Inspection and Testing or Pressure Vessels
and Pressure-Relieving Devices
General:
Section 4 requires that pressure vessels be inspected at the time of installation unless a
Manufacturer's Data Report is available. Further all pressure vessels must be inspected at
frequencies provided in Section 4. These inspections way be internal or external and may
require any number of nondestructive techniques.
The inspection may be made while the vessel is in operation as long as all the necessary
information can be provided using that method.
External Inspection:
The frequency for the external inspection of above the ground vessels shall be every 5 years
or at the quarter corrosion rate life whichever is less. This inspection should be performed
when the vessel is in service if possible.
Things to be checked shall include the following:
a. Exterior insulation
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b.
c.
d.
e.
Supports
Allowance for expansion
General alignment
Signs of leakage
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Pressure-Relieving Devices:
One of the major concerns for pressure relief devices is their repair. Pressure relief devices
must be repaired by qualified organizations having a fully documented written quality control
system and repair training program for repair personnel. No hard and fast rule is given for
the testing of relief devices the interval between tests is dependent on the service conditions
of the device. There are minimum of 15 items that should be addressed in the written quality
control documentation. Such as a Title page, Revision log, Contents Page, Statement of
Authority, Organizational Chart, etc. . Previous Exams have required naming 6 of these 1 5
items.
Records:
Pressure vessel owners and users must maintain permanent and progressive records on their
pressure vessels. Items that should be included are Manufacturer's Data Reports, vessel
identification numbers, RV information, results of inspection and any repairs or alterations
performed.
Section 5
Repairs, Alterations and Rerating of Pressure Vessels
General:
Section 5 covers repairs and alterations to pressure vessels by welding and the requirements
that must be met when performing such work. These repairs and alterations must be
performed to the edition of the ASME Code that the vessel was built to.
Authorization:
Prior to starting any repairs or alterations the approval of the API 510 Inspector and in some
cases an engineer experienced in pressure vessels must be obtained. The API 510 Inspector
may give approval to any routine repairs if the Inspector has satisfied himself that the repairs
will not require pressure tests.
Approval:
The API Inspector must approve all repairs after inspection and after witnessing any required
pressure tests.
Defect Repairs:
No crack may be repaired without prior approval of the API Inspector. If such repairs are
required in a weld or plate they may be performed using a U- or V-shaped grove to the full
depth and length of the crack. The U or V is then filled with weld metal. If the repair will be
to an area that is subject to serious stress concentrations an engineer experienced in pressure
vessels must be consulted. Corroded areas may be built up after proper removal of surface
irregularities. All welding for repairs must comply with Section 5.2 of this Code. The
amount of NDE and inspection shall be included in the repair procedure.
Welding:
All repair and alteration welding must be in accordance with the applicable requirements of
the ASME Code.
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Problem #4
Calculate the remaining service life of the tower of problem #1.
.070" corrosion allowance from Problem #3
.0075" corrosion rate from Problem #2
.070 " = 9.33 Yrs.
.0075
Internal inspection equals half of the remaining service life, but not greater than ten (10)
years.
9.33 Yrs. =
2
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4.6 Yrs.
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A vessel was last inspected internally in July of 1983. During that inspection it was
determined to have a remaining life of 16 years. What is the latest date of the next
internal inspection? (4.3) [1997 6.3]
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ANSWERS TO QUIZ #1
1.
answer: API-510
2.
answer: is the maximum gauge pressure permitted at the top of a pressure vessel in
its operating position for a designated temperature.
3.
4.
5.
answer: Inspector who has not been actively engaged in an API inspection within the
previous 3 years. Re-certify by written examination.
6.
7.
8.
9.
answer: At ambient temperature, carbon, low alloy, and other Ferritic Steels.
10.
11.
12.
answer: 1991
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A pilot operated safety valve has been installed in heavy crude service. Is this
okay? (2.2.1.5.3)
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Answers Quiz#3
1. Check pop pressures, extend check for external conditions, and conform to specifications.
2. Corrosion, damage seat surfaces, and improper length of piping? (4.2)
3. Surface corrosion, stress corrosion.
4. No.
5. Performance of the devices in the particular service.
6. Precautions should be taken to prevent the release of hydrocarbons, hydrogen sulfide 7.
(H2S), or other hazardous materials in the systems and to prevent the ignition of iron
sulfides in the piping.
8. Average operation conditions, the number and severity of upsets and their effect on the
valve, the extent of any leakage while in service and other evidence of malfunctioning.
9. To hole the deposits of corrosion the corrosion products and its importance because they
may be loose and drop out during transportation & shop fabrication.
10. To vent air and vapor in tanks when filling and to admit air when air drawn down.
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Section 3
Construction Standards
The first unfired pressure vessels were constructed to the design of the user or manufacturer.
This was true until about 1930 after that time the API/ASME Code or the American Society
of Mechanical Engineers Code (ASME) was used. In 1956 the API/ASME Code was
discontinued and the ASME Code was adopted as the standard for the construction pressure
vessels within its scope. Section VII Divisions 1 and 2 of the ASME Code are the unfired
pressure vessel Codes. Section VII Division 1 is the Code the vast majority of vessels are
built to; Section VII Division 2 used for vessels in high pressure service or where lower
factors of safety are desired. Division 2 has more restrictions on construction, materials,
inspection and nondestructive examination than Division 1. These restrictions usually result
in a vessel that would be thinner than that required by Division 1 and the resulting cost
savings could be significant is some instances.
Heat exchangers are built using both the ASME Code and the Standards of Tubular
Exchanger Manufacturers Association (TEMA).
Section 4
Maintenance Inspection
The basic rule for the maintenance of a vessel in service is to maintain it to the original
design and the edition of the Code it was constructed under. If the vessel is re-rated this is
may done using the original or latest edition of the Code. This implies that persons
responsible should be familiar with the original construction edition of the Code and the
latest edition of the Code if a vessel has been re-rated. In addition personnel responsible for
these vessels must be familiar with any nations state, county or city regulations. The ASME
has minimum requirements for construction, inspection and testing of pressure vessels that
will be stamped with the Code Symbol however jurisdictions may have more restrictive
requirements. Compliance with ASME Code may not be enough to satisfy a jurisdiction's
requirement.
Section 5
Reasons for Inspection
The main reason for inspection is to determine the physical condition of a vessel. With this
information the causes and rate of deterioration can be established and safe operations
between shutdowns can be determined. Correcting conditions causing deterioration and
planning for repairs and replacement of equipment can also be done using the inspection
information. Scheduled shutdowns and internal inspections can prevent emergency
shutdowns and vessel failures. Periodic inspection allows the for the forming of a well
planned maintenance program by using data such as corrosion rates to determine replacement
and repair needs. External visual inspections along with the thorough use of various
nondestructive examination techniques can reveal leaks, cracks, local thinning and unusual
conditions.
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Section 6
Causes of Deterioration
The causes of deterioration are many but fall into several general categories as follows:
inorganic and organic compounds. steam or contaminated water, atmospheric corrosion.
These types of corrosive agents fall into the class of chemical and electrochemical attack.
Attack is also possible from erosion and, or impingement. The attack could come from any
combination of the above examples.
Corrosion is the prime cause of wear in pressure vessels. The most common internal
corrodents are sulfur and chloride compounds. Caustic, inorganic acids, organic acids and
low pH water can also cause corrosive attack in vessels.
Erosion is the wearing away of a surface that is being hit by solid particles or drops of liquid.
It is similar to sandblasting and is usually found where changes in direction or high-speed
flow is present. It occurs in such places as inlet nozzles and the vessel wall opposite the
nozzle. Outlet nozzles are likely spots when fast flowing products are in use. In some
instances corrosion and erosion are found together.
Metallurgical and physical changes can occur when a vessel material is exposed to fluids the
vessel contains. Elevated operating temperatures also contribute to these problems. The
changes that take place may be severe enough to result in cracking, graphitization, hydrogen
attack, carbide precipitation, intergrannular corrosion, embrittlement and other changes.
Mechanical forces such as thermal shock, cyclic temperature changes (high to low temps on
a frequent basis), vibrations, pressure surges, and external loads can cause sudden failures.
Cracks, bulges and torn internal components are often a result of mechanical forces.
Faulty materials can build in failure into a pressure vessel or one of its components. Bad
materials can result in leakage, blockage, cracks and even speed up corrosion in some. The
selection of an improper material for new construction of or for a repair to a vessel will often
result in the same type of failures as will proper materials that have manufacturing or
fabrication defects.
Faulty fabrication includes poor welding, improper or lack of heat treatment, tolerances
outside those permitted by Codes and improper installation of internal equipment such as
trays and the like. Any of these types of faulty fabrications may result in failures due to
cracks or high stress concentrations, etc., in vessels.
Section 7
Frequency and Time of Inspection
Many things determine the frequency of inspection for pressure vessels. Chief among the
reasons is corrosion rates that are determined by the service environment. Unless there are
insurance or legal reasons, the Frequency of inspection should be based n information from
the first inspection performed, using either on stream or internal methods.
Normally inspection planning will allow for the next inspection to occur when at least half
the original corrosion allowance remains. Other factors such as a need for frequent cleaning
may provide an opportunity to shorten the inspection frequency. If the process fluids or
operating conditions change, shorter inspection frequencies may be needed to determine what
effects the new conditions may have had.
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Opportunities for inspections will require the input of all groups involved; process,
mechanical and inspection personnel. The opportunity may have to be made if any laws
require a frequency or the insurance company has a requirement for it in the policy written on
the equipment. A convenient time for inspections, of course, is any time equipment is
removed from service for cleaning. Also if a vessel or exchanger was removed for
operational reasons, an inspection might then become needed to insure the integrity of the
equipment before returning it to service.
Another consideration for the inspection of vessels is the review of the in service operational
records to look for pressure drops and out of the ordinary conditions that might indicate a
problem.
Section 8
Methods of Inspection and Limits
To perform a proper inspection it is important to know the history of the vessels to be
inspected. Knowing what repairs have been required in the past and inspecting the repair
after it has been in service may help to develop better repair methods. It may also help to
locate similar problems. In every case, careful visual inspection is a requirement. Knowing
the service conditions of a vessel allows the concentration of efforts in areas known to have
problems in a particular service.
Safety precautions before entering a vessel are of the utmost importance. Vessels have small
openings and often many internal obstructions that make getting out of one quickly nearly
impossible. The bottom line is: make sure it is safe to enter a vessel. Such things as isolation
of lines by blinding, purging and cleaning along with gas testing prior to entry cannot be
overlooked. In some cases protective clothing and air supply systems are called for if entry
is desired before cleaning to look at the vessel's existing conditions for indications of
problems. Always inform personnel inside and outside a vessel that inspection personnel are
entering the vessel. Loud noises made by inspection or maintenance might scare others,
causing injury.
Preparatory work needed for vessel inspection should include checking in advance to make
sure all equipment is present and is in usable condition.
External inspections should start with ladders, stairways, platforms and walkways connected
to the vessel. Loose nuts, broken parts and corroded materials must be searched for by visual
inspection and hammer testing for tightness. Since corrosion is most likely to occur where
water can collect, these areas should be inspected carefully, using a pick or similar object.
Slipping hazards such as slick treads should be looked for and noted on the inspection report.
Foundations and supports must be inspected for the condition of the fireproofing. The
settling of foundations, spalling (flaking) and cracking of the fireproofing are always a
concern.
In cases where equipment is supported by cradles, moisture between the cradle support and
the vessel may cause corrosion. If the area where a vessel and a cradle join has been scaled
with a mastic compound, the mastic seal should be checked gently with a pick to check its
water tightness. Some settling of any foundation is to be expected. However, if the settling
is noticeable, the extent must be determined for future reference.
Anchor bolts can be examined by scraping away and looking for corrosion. The soundness
can be determined with blow of a hammer to the side of the bolt or its nut. Checking the nuts
for tightness and the bolts with ultrasonics for breaks is sometimes appropriate. Any
distortion of the bolts may indicate serious foundation settlement.
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Concrete supports are inspected with same concerns as concrete foundations. Close attention
to any seals and the possibility of trapping moisture because of faulty seals should be
investigated.
Steel supports should be examined for corrosion, distortior4 and cracking. If corrosion is
severe, actual measurements of the remaining thickness should be performed and a corrosion
rate established just as in a vessel. Wire brushing, picking and tapping with a hammer is
frequently used inspection techniques. Most of the time corrosion can be slowed or
prevented by proper. painting alone. Sometimes protective barriers such as galvanizing are
required. As part of steel support inspection, vessel lugs should be examined using the same
methods of wire brushing, etc., described above. Welds used to attach lugs can develop
cracks and some cracks can then run into the vessel's walls. If a vessel's steel supports are
'insulated and an indication of leakage is present, the insulation must be removed to
determine if corrosion under insulation has occurred.
Guy wires are cables that stretch from different points of a vessel to the ground where they
are anchored to underground concrete piers (deadmen). Inspection of these guy wires must
include checking the connections for tightness and the cables for the correct tensions. The
connections consist of turnbuckles used for tightening and U bolt clips for securing. An
connectors must be checked for proper installation and the presence of corrosion- The cable
must be checked for corrosion and for broken strands.
Nozzles and adjacent areas are subject to distortion if the vessel foundation has moved due to
settling. Excessive thermal expansion, internal explosions, earthquakes, and fires can cause
damage to piping connections. Flange faces should be checked for squareness to reveal any
distortion, If evidence of distortion is found cracks should be inspected for, using nondestructive examination. All inspections should be external and internal whenever possible.
Visible gasket seating surfaces must be inspected for distortion and cuts in the metal seating
surfaces. Wall thickness readings must also be taken on nozzles and internal or external
corrosion monitored.
Grounding connections must be inspected for proper electrical contact. The cable
connections should be tight and properly connected to the equipment and the grounding
system. All grounding systems should be checked for continuity (no breaks) and resistance
to electrical flow, Continuity checks are usually made using electrical test
equipment such as an Ohm meter. lie resistance readings are recommended to be between 5
and 25 Ohms.
Auxiliary equipment such as gauge corrections, sight glasses, and safety valves may be
visually inspected while the vessel is still in service. Inspection while a vessel is 'm service
allows the presence of excessive vibrations to be detected and noted. If excessive vibrations
exist, engineering (;an determine if any additional measures are required to prevent fatigue
failures.
Protective coatings and insulation should be inspected for their condition- Rust spots or
blistering are common problems associated with paint and are easily found by visual
inspection. Scraping away a loose coating film will often reveal corrosion pits. These pits
should be measured for depth and appropriate action taken. Insulation can usually be
effectively visually inspected. If an area of insulation is suspected, samples may be cut out
and examined for its condition. Insulation supporting clips, angles, bands, and wires should
be examined.
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External surface corrosion appears in forms other than rust. Caustic embrittlement, hydrogen
blistering and soil corrosion are also found on the external surfaces of equipment. Area of a
vessel that need special attention often depends on its contents. When caustic is stored or
used in a vessel, the areas around connections for internal heaters should be checked for
caustic embrittlement. In caustic service, deposits of white salts often are indications of leaks
though cracks. Hydrogen blistering is normally found on the inside of vessels, but can
appear on the outside if a void in the vessels material is close to the outer surface. Unless
readily visible, leaks in a vessel are best detected by pressure testing. Cracks in vessels are
normally associated with welding and can he found using close visual inspection. In some
services nondestructive tests to check for cracks is justified and should be performed. Other
concerns when performing external inspection are bulges, gouges, and blistering. Hot spots
when found in service should be monitored and thoroughly evaluated by an engineer
experienced in pressure vessels.
Internal inspections should be prepared for by assembling all necessary inspection equipment
such as tools, ladders, and lights.
Surface preparation will depend on the type of problems that a vessel may have in a
given service. Ordinarily the cleanliness required by operations is all that is needed for many
inspections. If better cleaning is required, the inspector can scrape or wire brush a small
area. If serious conditions are suspected, water washing and solvent cleaning may not be
enough to reveal problems. In these instances, power wire brushing, abrasive grit blasting,
etc., may be required.
Preliminary visual inspection should be preceded by a review of reports of previous
inspections. Preliminary inspection usually involves seeking out known problem areas based
on inspection experience and service. Many vessels are subject to a specific type of attack
such as cracking in areas such as upper shell and heads. Preliminary inspection may reveal a
need for additional cleaning for a proper detailed inspection.
Detailed internal inspections should start at one end of a vessel and progress to the other end.
A systematic approach such as an item check list will help to prevent overlooking hidden but
important areas. All parts of vessel should be inspected for corrosion. hydrogen blistering,
deformation, and cracking. In areas where metal loss is serious, detailed thickness readings
should be taken and recorded. If only general metal loss is present, one thickness reading on
each head and shell may be enough. Larger vessels require more measurements.
Pitting corrosion will require local examination by first scraping the surface and then and
measuring the pit depth. Pit gauges allow for measuring pit depth if an uncorroded area
adjacent to the pit is available to gauge from In the case of large pits or grooves, a straight
edge and steel rule often will allow measurement by spanning the large area and lowering the
steel rule into the pit and measuring the depth.
Hammer testing is often a good method of finding thin areas. Experience is needed to
interpret the sounds made by hammering. Usually a dull thud will indicate a loss of metal or
thick deposits. Hammer testing must never be used for inspecting vessels or components
under pressure. If cracks are suspected or found their extent may be determined by cleaning
and nondestructive testing.
Welded seams deserve close attention when in services where amine, wet hydrogen sulfide,
caustic, ammonia, cyclic, high temperature and other services. Welds in high strength steel
(above 70,000 psi tensile) and coarse grain steels, and low chrome alloys should always be
checked carefully for cracking. All of the above conditions promote cracking in welds and
adjacent base metals.
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Nozzles should be checked for corrosion and their welds for cracking at the time of the
vessels internal inspection. Normally ultrasonic thickness readings will reveal any loss of
metal in nozzles and other openings in a vessel. Internal equipment such as trays and their
supports are visually inspected accompanied by light tapping with a hammer to expose thin
areas or loose attachments. Conditions of trays must be determined to check for excessive
leakage caused by poor gasket surfaces or holes from corrosion. Excessive leakage can
cause operational problems and may lead to poor performance of a vessel or unscheduled
shut downs.
Inspection of metallic linings must determine if the lining has been subjected to service
corrosive attack, that linings are properly installed, and that no cracks or holes are present in
the lining. Most problems with linings are found by careful visual inspections. Tapping the
lining lightly with a hammer can reveal loose lining or corrosion. Welds around nozzles
deserve special attention due to cracks or holes that are often found in these areas. If the
surfaces of the lining are smooth, thickness measurements using ultrasonic techniques may
be performed. If required, small sections of lining can be cut out and measured for thickness.
A very useful method of tracking the corrosion rate of linings, is by the welding of small tabs
at right angles to the lining when the lining is first installed. These tabs are made of the same
material and thickness as the lining and can be easily measured at the time of installation and
at the next inspection to determine the rate of corrosion taking place in the vessel.
Remember that both sides of the tab are exposed to the corrosion and the lining's loss must be
determined by dividing the tab's loss by two. A bulge in a liner can be caused by a leak in the
liner permitting a pressure or a product build tip between the liner and the protected base
metal.
Nonmetallic liners are made of many different materials such as glass, plastic, rubber.
ceramic, concrete, refractory, and carbon block or brick liners. The primary purpose when
inspecting these types of linings is to insure that no breaks in the lining are present. These
breaks are referred to as holidays. Bulging, breaking, and chipping are all signs that a break
is present in the lining. The spark tester method if very effective in finding breaks in such
nonmetallic linings as plastic, rubber, glass, and paint. The device uses a high voltage with a
low current to find openings in linings. The electrical circuit is grounded to the shell and the
positive lead is attached to a brush. As the brush is swept over the lining, if a break is
present, electricity is conducted and an alarm is sounded. A little warning: this is obviously
not a device to be used in a flammable or explosive atmosphere nor should the device have
such a high voltage value that it can penetrate through a sound lining. The spark tester is not
useful for brick concrete, tile, or refractory linings. Remember linings can be damaged
during a careless inspection; often just by dropping a tool.
Concrete and refractory linings often spall (flake away) or crack. This damage is readily
detected during a visual inspection. Minor cracks may take some gentle scraping to find. If
bulging is obvious cracks may also be present. If any break is present, fluid has probably
leaked in between the lining and the outer shell and may have caused corrosion. Light
tapping with a hammer can reveal looseness that is normally associated with leakage of
linings.
Thickness measuring techniques such as ultrasonics, limited radiographic techniques.
corrosion buttons. and the drilling of test holes; are used to determine if any wall loss has
occurred. The most common technique is ultrasonics. Ultrasonics can detect flaws and
determine thicknesses also. Its principle of operation involves the sending of sound waves
into the material and measuring the time it takes the sound to return to the sending unit.
referred to as a transducer. Sound travels through a given material at a known speed, and
when properly calibrated, the UT equipment uses the known speed and time of travel to
determine the thickness in the area being tested,
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In thickness measurements using radiographs, the placement of a device such as step gage (a
device of a known material and thickness) in the radiographic image is compared to the
image of the piping or vessel wall and the thickness determined by measurement.
Corrosion buttons are made of a material that are not expected to corrode in a given service
and then installed in pairs at specific locations in the vessel. Measurements are taken by
placing a straight edge across the two buttons and then gauging the depth with a steel rule or
some other measuring device. When corroded surfaces are very rough, test holes through the
vessel may be used to measure the wall thickness. A variation on test holes is depth drilling.
In this technique, small holes are drilled to a known depth (not all the way through) in the
new vessel wall, then plugged with corrosion resistant plugs to protect the bottom of the hole
from corrosion. During internal inspections the plugs are removed and depth readings are
taken. Any wall loss that has occurred is detected by the hole depth becoming more shallow
than the original reading.
Special methods of detecting mechanical changes include nondestructive techniques, acid
etching small areas to find cracks, and sample removal. Acid etching requires abrasive
cleaning and the application of an appropriate (for the metal) chemical usually acid. The
etching approach allows fine cracks to stand out in contrast to the base metal. Sample
involves the removal by mechanical cutting out a small portion of the area of interest and
then analyzing it under a microscope. Often the filings created during the removal can be
cleaned and then subjected to a chemical analysis. A weld repair to the site of sample
removal will be required and should be made as carefully as any welded repair.
Metallurgical change tests can be made using many of the same techniques described in
mechanical changes. Additional tests include hardness chemical spot, and magnetic tests.
Portable harness testers such as the Brinell will detect poor heat treatment, carburization and
other problems that involve a change in hardness. Chemical tests to a small portion of a
metal will reveal the type of metal to determine if the wrong metal has been installed
possibly during a pervious repair. Magnetic tests are used to determine if a material such as
austenetic stainless steel; normally not magnetic, have become carburized, which will allow
the austenetic stainless to become attracted to a magnet.
Testing
Hammer testing used during visual inspection will reveal conditions such as; thin sections.
tightness of bolts and rivets, cracks in linings, lack of bond in refractory and concrete linings.
The hammer is also used to remove scale for spot inspection. Hammer testing is an art
learned from experience and caution is warranted whenever using this method. It is not
smart to hammer on anything under pressure and hammering on some piping systems can
dislodge scale or debris and plug up a portion of the system such as a catalyst bed.
Pressure and/or vacuum tests are per-formed when a vessel is first built and then applied after
entering service if any serious problem has been disclosed, which brings into question the
integrity of the vessel. After major repair work, a pressure test is normally required. Some
jurisdictions and company's policies require tests on a time basis even if no repair work has
been done. These types of tests often involve raising the internal pressure above normal
operating pressure and the possibility of damage to the vessel from the test exists. Pressure
tests should applied carefully by qualified personnel using calibrated gages with positive
control of the test equipment. The object is to reveal any problems, not to create one. Most
of the time these tests use water or some other fluid (hydrostatic) permitted by the Codes.
During hydrostatic testing of a vessel pressure drop, leaks and deformation (bulging) in the
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vessel may be revealed. If the vessel's supports can not hold the weight of the fluid or the
vessel cannot tolerate contamination by the testing fluid, a gas test (pneumatic) may be used.
Pneumatic testing, by its nature, can be more dangerous than hydrostatic testing. Caution is
always advisable during a pneumatic test, and it is normally the last choice of types. The
reason for this is that gas that has been compressed has a great deal of stored energy, and if
failure occurs, it will likely be explosive. Have you ever blown out a car tire? During a
pneumatic test, a soap solution is often applied to weld seams and fittings and then, looking
for bubbles, leaks can be revealed. Another method, sound detection, uses special listening
devices to bear and locate the leaks. Another sound based device is Acoustic Emissions. As
a vessel is pressurized, it emits sounds from any flaws present in the metal. By using several
listening devices attached to different parts of the vessel, the location of a serious flaw is
found by using triangulation. Some vacuum vessels can be tested with internal pressure
rather than a vacuum. If a vacuum vessel can be pressure tested, it is the preferred method
because it is easier to detect leaks with internal pressure.
Vacuum tests are conducted by creating a vacuum inside the vessel and observing the
vacuum gage for any loss of vacuum that might occur. If the vacuum remains unchanged the
assumption is made that no leak exists.
Testing temperature can be very important with some pressure vessel materials due to the
brittle characteristics of these metals at low temperatures. The ASME recommends that the
test temperature be at least 30F above the minimum design metal temperature to prevent the
risk of brittle fracture. A brittle fracture can be compared to glass breaking and shattering.
For that reason every effort must be made to prevent it. In combination with a pneumatic test
and its stored energy; a brittle failure would be a devastating bomb. For all materials the
general recommendation for test temperature is 70F minimum and 120F maximum for
safety when conducting a pressure test, no unnecessary personnel should be allowed in the
area until the test is complete. Pneumatic tests must follow a procedure described in the
ASME Code that raises the pressure in small steps with short stops at each step.
Pressure testing of exchanges can be performed when they are first shut down and before
bundle removal in order detect any leaks that might have been present during recent service.
If leaks are detected during the initial test, partial disassembly can be performed and the test
pressure reapplied to locate the source of the leaks. Heat exchangers may also be
disassembled and cleaned, inspected, repaired if needed, then reassembled and tested. If a
leak is detected in the exchanger after re-assembly, disassembly will again be required to
repair the leak. The method of testing an exchanger will depend on its design. Some can be
tested with their channel covers removed if of the fixed tube sheet design with the pressure
applied to the shell side. If a tube in the bundle is discovered to be leaking at other than the
tube sheet roll, it may be plugged with a tapered plug which effectively removes that tube
from service. If the leak is located where the tube is rolled (expanded) into the tube sheet, an
attempt to re-roll the tube is usually made and the test pressure reapplied. Often tube bundles
are tested out of their shells if of the floating head design. Leaks are easily detected, but this
approach requires a separate shed test. During pressure tests leaks in shells, tubes, gasketed
areas, and distortion are looked for in the exchanger parts.
Limits of thickness must be determined prior to inspection and must be known in order to
perform an effective inspection. The retiring thickness and the rate of deterioration are
needed to determine the appropriate action should a problem be uncovered during an
inspection. The importance of inspection records becomes obvious when it is required to
make a decision whether to repair, replace, or just to continue the operation of a vessel. If the
retiring thickness is known prior to the inspection, a plan of action in the event of excessive
wall loss can be prearranged. Almost all vessels, when new, will contain excess thicknesses
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above what are required by the Codes they were built to. Extra thickness can be required by
the design as sacrificial metal (corrosion allowance) in the vessel parts.
Extra thickness can be due to the nominal plate thickness as opposed to the actual thickness
required by calculation, i.e., the shell has a required thickness of .435 " and .500 plate is
used because .435" is not manufactured. Owners, Users or Codes may require that the metal
cannot be less than a certain thickness in a particular service. Sometimes a reduction in
pressure or temperature for a vessel will allow its continued service with thinner metal.
Methods of repair to vessels should be reviewed to insure that they comply with any Codes
or standards that may apply. Several jurisdictions recognize the minimum repair techniques
of the API. Other jurisdictions require that the repairs be made to the National Board of
Boiler and Pressure Vessel Inspectors (NBBPVI), National Board Inspection Code-23
(NBIC) and that the repair concern holds a valid R (Repair) Stamp from the NBBPVI. In
addition to using a concern holding the R Stamp an NBBPVI Repair form R1 may also be
required. In some instances, Insurance Carriers will require that the NBIC be followed and
that an NBIC Authorized Inspector in their employ approves the repair. Repairs made to
vessels by welding will require visual inspection as a minimum and may also involve various
nondestructive examinations (NDE) methods based on the severity of the repair and the
original NDE used in the construction Code. Unless the Inspector can accept a sound
technical argument against requiring a pressure test after a major repair, one should be
applied. If the repair to a vessel involves cracks special preparation of repair area is required.
The major concern in crack repairs is the complete removal of the crack. Cracks may be
removed by chipping, flame, arc, or mechanical gouging. Any crack removal technique that
uses high heat input to the affected area can cause the crack to grow, so caution must be used
with those techniques. In cases where many cracks are present it is normally better to replace
the entire section of the material. Shallow cracks may be removed by grinding using a
blending method if the final thickness does not fall below the minimum required.
Inspection records and reports are important and are required by most Codes and
jurisdictions such as the State, API, and the NBBPVI NB-23. These reports are of three
types: Basic Data, Field Notes, and Continuous File. The basic data includes original
manufacturer's drawings and data reports as well as design information. Field notes are notes
about and measurements of the equipment and may be written or entered into a computer
data base. Usually field notes are in the form of rough records inspections and repairs
required. Continuous files include all information about a vessel's operating history, previous
inspection reports, corrosion rate tables (if any) and records of repairs and replacements.
Copies of reports containing the location, extent, and reasons for any repairs should be sent
to all management groups such as Engineering, Operations, and Maintenance departments.
Heat Exchangers are used to transfer heat from one gas or liquid to another gas or liquid
without the two fluids mixing. Heat exchangers fall into classes: condensers and coolers. A
condenser has the effect of changing a gas fluid to a liquid or partial liquid fluid and
ordinarily use water as the coolant. Coolers lower the temperature of a fluid and may use
water or another process fluid of a lower temperature as the coolant. Sometimes air is used
to lower the temperature of a fluid. The equipment is then referred to as an air cooler.
Into a tube sheet by rolling (expanding) them into the tube sheet holes. In heat exchangers,
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after rolling tubes, the ends are sometimes welded to the tube sheet for sealing purposes. In
some cases the tubes are inserted into the tube sheet and packing rings are installed to seal
the area around the tube ends. The method of construction used is dependent on the service
intended for the exchanger. There are four basic design types of shell and tube heat
exchangers. They are: One Fixed Tube Sheet with a Floating Head (the most common), Two
Fixed Tube Sheets, One Fixed Tube Sheet with U-Tubes, and Double Tube Sheet (used when
even the slightest leak cannot be allowed).
Reboilers and Evaporators perform the opposite function of the condenser or cooler. They do
what their names imply: boil and evaporate. In general they use steam or a hotter fluid from
a process to boil or evaporate another fluid. The Reboiler is normally used to boost heat back
up to a desired level at some intermediate step of a process stream.
Some Other types of heat exchangers include: Exposed Bundle, Storage Tank Heaters, Pipe
Coils (either single or double pipe), Box-Type Heater Coils, and Plate-Type.
Inspection of Exchanger Bundles should start with the establishment of any general corrosion
patterns. Inspecting an exchanger bundle when it is first removed can reveal the type(s) and
locations of corrosion and deposits. Visual inspection techniques include light scraping and
hammering testing with a very light ball peen hammer (4 to 8 oz) to locate corrosion and
thinning. The inside of the tubes may be partially inspected using borescopes, fiber optics,
and specialized probes. Since only the outside of tubes in the outer portion of a bundle can
be seen, inner tubes must be inspected using NDE techniques such as Eddy Current or
Ultrasonics. In some instances a tube may selected for removal and splitting for inspection.
The results of this destructive examination can then be used to determine the probable
general condition of the remaining tubes. Other portions of the exchanger such as the tube
sheets, baffles, impingement plates, floating head, and channel covers will require visual
inspection and may require measuring to determine their conditions.
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2.
3.
When carbon steel will not resist corrosive fluids, what method of construction is
normally used for such a vessel? (2.3)
4.
5.
Prior to 1930, what specifications were unfired pressure vessels built to in refineries?
(3.0)
6.
Why is it important to have access to previous editions of the ASME Codes? (4.0)
7.
Name three types of information gained from the inspection of a pressure vessel.(5. 1)
8.
List the basic forms of deterioration. Name the effects these basic forms have. (6.1,
6.2, 6.3, 6.4, 6.5, 6.6 and 6.7)
9.
What is the most important factor in determining the inspection frequency of a pressure
vessel? (7. 1)
10.
Answers to Quiz #4
1.
Cylindrical, Spherical & Spheroidal
2.
The cylindrical sector section is made up of a number of thin concentric cylinders
fabricated together one over the other until the obtained
3.
It may be lined with other metals or non-metals
4.
Demisiter pads, traps, baffles, spray nozzles
5.
User or manufacturer
6.
A pressure vessel has to be mentioned under the ASME code it was built to & codes are
revised constantly
7.
Physical conditions, type, rate and causes of deterioration
8.
Electrochemical, chemical, mechanical or combination of all three. Corrosion, erosion,
metallurgical, physical change, mechanical forces
9.
Rate or corrosion remaining corrosion allowance
10. To detect defects and to measure wall thickness
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2.
3.
Before an inspection starts in a vessel, who else besides the safety man should be
informed? (8.2.1)
4.
5.
List at least six items that should be inspected on the external of a pressure vessel.
(8.3.2,.3,.4,.5,.6,.7,.8,.9,.10,.11,.12,.13)
6.
Abrasive grit blasting, power wire brushing etc., are usually required under what
conditions? (8.4.2)
7.
If a vessel has had previous internal inspections, what should be done prior to your
inspection? (8.4.3)
8.
9.
10. Under what operating conditions should weld seams in a pressure vessel be given special
attention? (8.4.4)
Answers to Quiz #5
1. Pressure & temperature conditions under which the vessel has been operational since last
inspection contents & function of vessel serves in the process.
2. Magnetic particle-wet or dry, dye penetrant, ultrasonic shear wave
3. All persons working around the outside. The vessel that people will be working inside
the vessel.
4. Flashlight, scraper, plastic bags, & hammer
5. Ladders, walkways, platforms, external scratches, stairways(connected to vessel),
tightness of bolts, floor plates, nozzles & guy wires.
6. Type & location of deterioration
7. Review the previous records
8. Welded seams and adjacent areas, sharp change in shape, nozzles, & baffles.
9. To avoid overlooking but obscure important items
10. When the service of vessel is Amine, Wet Hydrogen Sulfide, Caustic Ammonia, Cyclic,
High Temperature or other services that may promote cracks.
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When examining linings, name the three most important conditions to check. (8.4.5)
2.
3.
4.
Where a corroded surface is very rough, what may be done to measure thickness?
(8.4.7)
5. How may cracks be made to stand out from the surrounding areas being inspected?
(8.4.8)
6.
Who should make the decision to trepan metal from a vessel for metallurgical
evaluation? (8.4.8)
7.
8.
9.
When testing a vessel pneumatically what should be on hand to aid in the visual
examination? (8.5.2)
10.
If it is possible to use internal pressure to test a vacuum vessel, what advantage does
that method offer? (8.5.2)
Answers to Quiz #5
1.
No corrosion, lining properly installed, no holes or cracks exist.
2.
A high voltage low current electrode(brush type) is passed over the lining, the other
end is attached to the end of the vessel. Electric arc will pass between electrode and
the hole in the lining
3.
A light tapping on lining will make lessor evident with sound & feel.
4.
Drill test hole to determine thickness.
5.
Etching method (acid)
6.
By someone who knows how to analyze the problems related to the repair of sample
house.
7.
Magnetic Test
8.
Supplement visual inspection e.g. thin walls in vessel, loose bolts & nuts, rivets,
cracks in metallic linings, lack of bond in concrete to remove scale.
9.
Soap solution, ultrasonic sound tester or both.
10.
Leaks from an internal pressure are more easily located.
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If a given exchanger begins leaking for the first time in its service life, what should be
done? (8.5.3)
3.
4. Before taking credit for excess thickness found in a vessel when doing calculations for
retirement or rerating, what must also be considered? (8.6)
5.
6.
7.
Why should care be taken when arc gouging a crack before a welded repair? (9)
8.
What must an inspector consider when recommending the filling of pits with an
epoxy? (9)
9.
10.
ANSWERS TO QUIZ #7
1.
A leak may be detected by observing & point such as a disconnected nozzle or an open
bleeder.
2.
Inspection should be performed to determine the nature of deterioration
3.
The code edition of that code it is rated under and whether any regularities of and
allowable repairs must be determined.
4.
Safety, Temperature & Pressure
5.
Applicable code & standards under which it is to be rated should be studied to assure
methods of repair will not violate appropriate requirements
6.
For al major repairs
7.
Because the heat will cause cracks to lengthen or
8.
That the pits are not large enough or close enough together to represent a general
thinning of the component.
9.
All information on the vessel operating history description and measurement from
previous inspections, corrosion rate tables(if any) and records of repair & replacement.
11.
Operations, Maintenance & Engineering
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Explain the difference between condensers, coolers and air coolers. (A. 1)
Show by sketch what is meant by One Fixed Tube Sheet with Floating Head, Two
Fixed Tube Sheets, One Fixed Tube Sheet with U Tubes. (A.2.2, 2.3, 2.4)
3.
4.
5.
What principle of cooling is used with exposed tube bundles? (A.3.2, 3.3)
8.
9.
Why is it important to inspect exchanger bundles when they are first pulled from a
shell? (A.9. 1)
10.
ANSWERS TO QUIZ#8
1.
Condensers transfer heat by vapors to another fluid
Coolers cools hot by a lower temperature
Air-coolers air is used to reduce temperature of fluid by air.
2.
3.
Where minute leaks from one fluid to another cannot be tolerated
4.
a.) fixed tube sheet type b.) u-tube type
5.
Water flows or sprayed on bundles
6.
Draft coolers-on top or below tube bank, forced draft coolers-below tube bank
7.
They are in shape and of small diameter with minimum wall thickness
8.
Bottom of storage tank
9.
Because the color type location of scales and a. help to pinpoint corrosion problems
10. The outside surface of tubes opposite shell inlet nozzles, adjacent to the baffles are tube
sheets
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API CHAPTER II
CONDITIONS CAUSING DETERIOTATION OR FAILURES
Introduction
Chapter II is under revision at this time, it is to be replaced with API RP 571, Recognition of
Conditions Causing Deterioration or Failure at some future date. Accordingly our coverage
of the subject will be based on the present API 510 Authorized Pressure Vessel Inspector
Body of Knowledge dated August 1994. Of the information contained in Chapter II, only
knowledge that pertains to pressure vessels may be included in the examination questions.
This is per the published Body of Knowledge. The coverage of Chapter II will be limited to
the required information on the test.
Corrosion is a major source of expense in refinery and chemical plants. Many times a piece
of equipment will corrode its way into retirement as opposed to simply wearing out. The
three major groups of corrosion are corrosive products in crude oils, corrosion from
chemicals used or processed, and environmental corrosion.
Corrosive components found in crude oil that cause the most metal loss in pressure vessels
are thought to be one or more of the following: Hydrogen chlorides and inorganic and
organic chlorides, Hydrogen sulfide, mercaptans, and organic sulfur compounds, Carbon
Dioxide, Organic acids, and Nitrogen compounds. Most of the above mentioned components
attack the front end of a process system.
Crude oils contain salt, which can never be totally removed. The salt will generate various
chemical compounds when broken down in a processing system. Some of the compounds
are: Hydrogen chloride and Organic and Inorganic chlorides. Such things as Magnesium and
Calcium chloride, when dissolved in water and heated, attack the metal in the form of
Hydrochloric acid, which is very corrosive. This process is called hydrolysis.
Hydrogen sulfide is believed to be the most active of the sulfur compounds in causing
corrosion. Some hydrogen sulfide is present in the crude oil, and more may be generated
during the refining process. Outside of corrosion, the most serious problems caused by
Hydrogen Sulfide are blistering and embrittlement.
Carbon Dioxide, when combined with water, is corrosive. The water and carbon dioxide
combine to form carbonic acid. The water will usually be introduced from two sources: the
decomposition of bicarbonates in or added to crude oil or from steam used to aid in
distillation of crude oil.
Organic Acids, while not very corrosive at low temperatures, can be very corrosive at their
boiling temperatures. When organic acids have corroded carbon steel, a very smooth surface
is left and metal loss is not readily apparent during visual inspection.
And Cyanide. These two chemicals, while not causing corrosion directly, contribute to it by
breaking down a protective layer of scale which has formed on the metal leaving the metal
subject to Hydrogen Blistering and other problems discussed in the above paragraphs. The
Ammonia and Cyanide will directly cause pitting and worm-holing type attack in copper and
brasses.
Corrosive Materials added to the process add significantly to metal loss caused by corrodents
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already present in the crude oil that is being refined. Chemicals commonly added in refining
processes are Sulfuric Acid and Hydrogen Fluoride, Phenol Phosphoric Acid, Caustic
(sodium hydroxide), Mercury, Ammonia, Chlorine, and Aluminum.
Alkylation Units utilize either Sulfuric Acid or Hydrofluoric Acid as a catalyst. Sulfuric Acid
is the least corrosive of the two chemicals and corrosion occurring in equipment using
Sulfuric Acid may be very erratic attacking particular points in the process stream Sulfuric
acid is generally less corrosive at high concentrations of 85% or more. Hydrofluoric Acid is
very corrosive to steel unless it is kept at concentrations above 65% Hydrogen Fluoride.
Phenol (carbolic acid) is used in the manufacture of lubricating oils and aromatic
hydrocarbons. At temperatures below 400F and without water present, carbon steel is
usually not severely corroded by Phenol. Above 400F, carbon steel may corrode rapidly m
Phenol service.
Phosphoric Acid is used as a catalyst in polymerization units either in liquid or deposited as
pentoxide on clay pellets. Unless water concentrations are above a certain level, corrosion is
rare from Phosphoric Acid. When water is present in the required concentrations, Phosphoric
Acid will attack carbon steel very aggressively. Penetration of carbon steel in 8 hours can
occur.
Caustic is used primarily for neutralization of acids and grease manufacture. Caustic can be
used and stored in carbon steel vessels and is generally not corrosive as long as the vessel has
been stress relieved and temperatures are kept at a safe level. At temperatures above 200F,
it will cause general corrosion in carbon steel.
Mercury is found in instrumentation and can enter vessel by mishap. If the mercury enters it
will cause stress corrosion attack in copper and monel.
Ammonia is used for refrigeration and neutralizing acids in plants. If Ammonia is allowed to
contact copper-based alloys in pH ranges of 8.0 and above, severe corrosion as general metal
loss occurs, and stress corrosion cracking then occurs. Blue salt deposits on equipment are a
clear indication of general corrosion by Ammonia.
Chlorine is used to treat water for cooling towers and to manufacture Sodium Hypochlorite
for treating oils. If water is not present, Chlorine corrosion of carbon steel is minor.
Present. It will hydrolyze in water and form hydrochloric acid and cause severe pitting
corrosion in carbon steel. Austenitic stainless steel under the above conditions will be
subject to inter-granular corrosion and stress corrosion cracking.
Environmental Corrosion in refineries most commonly affects carbon steel. The water and
oxygen present in the atmosphere will cause severe corrosion on unprotected carbon steel.
This type of corrosion is usually galvanic and can be severe if water is allowed to penetrate
insulation.
Important Corrosion types include Intergranular, Graphitic corrosion of cast iron, Stress
Corrosion Cracking, Polythionic Acid, Dezincification, Galvanic, Contact Corrosion and
Biological Corrosion. The following paragraphs give a general definition to the various
types of corrosion.
Intergranular Corrosion can occur in austenetic stainless steels when they are heated up to a
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range from 750F to 1650F and cooled down. In the temperature range mentioned above,
complex carbides are formed of chrome and other elements which then migrate to grain
boundaries leaving those areas lacking the chrome which is intended to help resist. This loss
of chrome is followed by corrosive attack around grain boundaries and Intergranular
Corrosion occurs.
Graphitic Corrosion is the low-temperature corrosion of gray cast iron in which metallic iron
is converted into corrosion products, leaving the graphite intact.
Stress Corrosion Cracking is the spontaneous cracking of metals under the combined action
of stress and corrosion.
Polythionic Corrosion is a result of iron sulfide scale reacting with oxygen and water. This
normally occurs at the time of shutdowns of vessels.
Dezincification is a corrosion that occurs when copper-zinc alloys containing less than 85%
copper are used in water service. It occurs in three forms: plug, layer, and intercrystalline.
Galvanic Corrosion occurs between metals in contact with each other having different
electrical potentials. It is the same type chemical exchange found in a common wet or dry
cell battery. An electrolyte must be present for this type of corrosion to occur, and normally
the electrolyte is water or acids.
Contact Corrosion (crevice corrosion) happens at the contact surfaces between a piece of
metal and another piece of metal or a piece of metal and a nonmetal. A corrodent such as
water must present.
Biological Corrosion is related to the presence of organisms (bugs) in a contact with a metal.
They can be fairly large (macro) or very small (micro) organisms. An example of a macroorganism is a barnacle. Examples of microorganisms are bacteria, slime, and fungi. One of
the primary places that microorganism biological corrosion is found is on
electrolyte solution which speeds up contact or crevice corrosion.
Erosion of metals is found frequently in vessels and piping of refineries and chemical plants.
It amounts to a wearing away by the abrasive action of a moving stream of a liquid or gas. If
solids are contained in the gas or liquid, the erosion will be accelerated and could be
compared to blasting with a water and sand mixture.
The Effects of High Temperature on Strength of a metal can result in the failure of the metal
suddenly (stress rupture) or slowly (creep).
Creep happens to metal held at high temperatures for long periods of time and is defined as
the flow or plastic deformation at stresses that would not cause metal flow at a lower
temperature. It is based on time at an elevated temperature and stress level.
Stress Rupture is a brittle failure that gives very little warning, with little if any deformation,
and is related to stress at high temperature. It can be considered the end result of creep in
some metals.
Page 42 of 310
API CHAPTER II
Find the answers to these questions by using the stated Chapter II paragraph at the end of the
question.
Quiz #9
1.
2.
3.
4.
5.
6. May Hydrogen Sulfide cause corrosion even at low temperature? If so, where can it be
found? (202.023)
7.
8.
9.
10.
ANSWERS TO QUIZ #9
1.
Corrosion from components in crude oil, chemicals used in refinery processes,
environmental corrosion.
2.
Hydrogen chloride, hydrogen sulfide, carbon dioxide, ---- oxygen and water, organic
acids, nitrogen ---3.
Salt
4.
Hydrochloric acid
5.
Dfl
6.
Yes storage tanks
7.
Crude oil-decomposition of bicarbonates, steam distillation
8.
Sulfuric acid, hydrogen fluoride, phenol, caustic, phorous acid, mercury ammonia,
chlorine, al
9.
85% or more.
10.
Page 43 of 310
PART UW - WELDING
Objectives
Student should understand and be capable of applying the following concepts:
A.
B.
Joint Categories.
C.
Joint Types.
D.
E.
F.
G.
Page 44 of 310
PART UW - WELDING
Introduction
Section VIII Division 1 has a system of identification for welds in vessels and vessel parts.
This system assigns types to welds; the form of weld (double welded, etc.) determine its
type. The locations of welds in a vessel or vessel part determine their category. In some
instances the type will be mandatory based on Category and Service. In other cases it will be
optional; the designer makes a choice from the acceptable Types. Radiography requirements
also depend on Type, Service and Category.
The Code also assigns a way of measuring the quality of a butt joint which is based on the
Type and extent of radiography used.
Page 45 of 310
PART UW - WELDING
Definitions
The following are definitions for use in Part UW. Doing calculations on shells, heads,
nozzles and the like will depend on knowing these definitions.
Welded Joints
1.
Weld Types
3.
Type is the description of a welded joint. For example, a single-welded butt joint with
backing that remains in place.
Weld Categories
4.
Determination of Category for a joint depends on the location of the joint in a vessel or
vessel part. As an example the circumferential seam joining two shell courses is a
Category of weld.
Shell Course
Shell Course
Category
Page 46 of 310
PART UW - WELDING
UW-2 Service Restrictions
Service restrictions apply to four classes of vessels.
*
Lethal Service
For determination of a Butt joint's service restrictions by Types (how made) and Categories
(locations) permitted in a vessel read UW-2.
Vessels used to contain lethal substances require that all major butt welded Joints be fully
radiographed (with some exceptions for heat exchangers).
If they are Category A joints they must be of type No. (l) of Table UW-12. If they are
Category B joints they must be of either Type No. (1) or Type No. (2). Similar restrictions
apply to the other classes listed above.
Page 47 of 310
PART UW - WELDING
UW-3 Welded Joint Category
A quick reference system for specifying joint requirements is the assigning of
categories by location, to welds in a vessel. For instance for a vessel in lethal
service the Code requires that butt joints be of a specific type based on their
physical location in the vessel and that the butt welds be fully radiographed.
A statement like "All category A joints shall be Type No. (1)." is a short hand
way of saying the following:
"All longitudinal welds within main shells, communicating chambers,
transitions in diameter, or nozzles; any welded joint within a sphere, within a
formed head, or within the side plates of a flat sided vessel, circumferential
welded joints connecting hemispherical heads to main shells, to transitions in
diameter, to nozzles, or to communicating chambers shall be Type No. (1).
As you read through the Code paragraphs think of how difficult it would be to
restate a complete description every time you find a specified requirement
based on Joint Category.
The best way to understand and thereby learn joint category is by the use of
graphics. Fig. UW-3 of Paragraph UW-3 provides a brief graphical
representation. An expanded use of graphics for each Category follows.
Page 48 of 310
PART UW - WELDING
UW -3 Welded Joint Category
Case Study 1
The term "Category" as used here in defines the location of a joint in a vessel,
but not the type of joint.
UW-3(a)(1) Category A. Longitudinal welded joints within the main shell,
Communicating chambers, transitions in diameter, or nozzles; any welded
joint within a sphere, within a formed or flat head, or within the side plates of
a flat-sided vessel; circumferential welded joints connecting hemispherical
heads to main shells, to transitions in diameter, to nozzles, or to
communicating chambers.
CATEGORY A JOINTS
HEMI
HEAD
COMMUNICATIONS
CHAMBER
MAIN SHELL LONGITUDINAL SEAM
SEAMS IN A
SPHERE
HEMI HEAD TO
TRANSISTION
NOZZLE
LONGITUDINAL
SEAM
TRANSISTIONS
HEMI HEAD TO
NOZZLE
Page 49 of 310
PART UW - WELDING
UW -3 Welded Joint Category
Case Study 2
The term "Category" as used here in defines the location of a joint in a vessel, but not the
type of joint.
UW-3(a)(2) Category B. Circumferential welded joints within the main shell, communicating
chambers, nozzles, or transitions in diameter including joints between the transition and a
cylinder at either the large or small end; circumferential welded joints connecting formed
heads other than hemispherical to main shell, to transitions in diameter, to nozzles or to
communicating chambers.
NOZZLE
MAIN SHELL
Page 50 of 310
PART UW - WELDING
UW -3 Welded Joint Category
Case Study 3
The term "Category" as used here in defines the location of a joint in a vessel, but not the
type of joint.
UW-3 (a)(3) Category C. Welded joints connecting flanges. Van Stone laps, tubesheets, or
flat heads to main shell, to formed heads, to transitions in diameter, to nozzles, or
communicating chambers; any welded joint connecting one side plate to another side plate of
a flat sided vessel.
NOZZLE
NOZZLE
CAT. C
FILLET WELD
CAT. C BUTT
WELD
CAT. C BUTT
WELD
CATEGORY C
CATEGORY C
SIDE PLATES
C
C
CATEGORY
C
C
Page 51 of 310
PART UW - WELDING
UW -3 Welded Joint Category Case Study 4
The term "Category" as used here in defines the location of a joint in a vessel but not the type
of joint.
UW-3 (a)(3)Category D. Welded joints connecting communicating chambers or nozzles, to
main shell, to spheres, to transitions in diameter, to heads, or to flat sided vessels, and those
joints connecting nozzles to communicating chambers (for nozzles at the small end of a
transition in diameter, see Category B).
COMMUNICATING CHAMBER
CAT. D
FILLET
COMMUNICATING CHAMBER
CAT. D
BUTT WELD
MAIN SHELL
MAIN SHELL
CAT. D
FILLET NOZZLE
CAT. D
BUTT WELD NOZZLE
TRANSISTION
CATEGORY D
Page 52 of 310
HEAD CATEGORY D
2.
3.
D
C
E
A
D
B
A
A
B
B
A
A
A
Page 53 of 310
A complete set of radiographs shall be kept on file until the final acceptance of the
inspector.
2.
3.
That paragraph T-285 of Article 2 is a guide only and that final acceptance of
radiographs is based on the ability to see the correct penetrameters image and the
specified hole or wire size as applies.
4.
How repairs of defects shall be made in accordance with UW-35 and the techniques for
re-inspecting the weld after repair. The repair need not be radiographed if prior to the
repair it has been demonstrated to the inspector's satisfaction that Ultrasonic Testing
can disclose the defect. In which case ultrasonics can be used to examine the repair for
acceptance.
5.
6.
That the limits of elongated indications are based on the materials thickness.
7.
That unacceptable aligned indications are based on total length of a group and the
material's thickness.
UW-51 contains the unacceptable indications for Full Radiography. Also definitions of
nominal thicknesses for welded joints and weld repairs. Details of Spot Radiography are
covered in UW-52.
Page 54 of 310
One spot radiograph for every 50 ft of weld or fraction thereof for a joint efficiency
from column b of Table UW- 12.
2.
3.
The inspector chooses the location of the spot radiography. If the inspector approves
and cannot be present the fabricator can then choose the location of the spot
radiography. Notice that there is no specific location; the welders should never be able
to predict the inspector's choice of location.
4.
The spot radiography used to pick a joint efficiency from column b of TableUW-12 will
not satisfy the requirements of other paragraphs such as UW-11 (a)(5)(b); a spot
radiograph required for the choosing of a joint efficiency from column A of Table 12.
5.
Spot radiographs must follow the same rules as full radiographs for techniques. The
minimum length of the spot examined must be 6 inches.
6.
7.
Slag inclusion or cavity evaluation is based on the thickness of the weld excluding any
weld reinforcement (cap). The thickness is based on thinner member if two different
thickness that have been joined by a butt weld. If a fillet is welded over a full
penetration weld its throat must be included in the thickness (t). Indications in a line
are described with acceptance standards.
8.
Rounded indications are not a factor in the acceptability of welds not required to be
fully radiographed.
Page 55 of 310
When a spot radiograph is acceptable the entire weld increment represented is accepted.
For example if a longitudinal weld has 65 feet of weld metal only the first 50 feet could
be accepted by a single 6 inch spot radiograph. The remaining 15 feet is represented in
the next declared 50 feet increment.
10.
If the first spot radiograph reveals welding that does not comply then two additional
spots in the same weld increment away from the first spot shall be radiographed
(tracers). The choosing of the two spots follow the same rule as the first spot
radiograph.
11.
If the tracers pass then repair and radiography is allowed for the area that was rejected
in the first spot radiograph.
12.
If either of the tracers fail there are two options. Cut out the entire increment, re-weld
then applies spot radiography again or apply full radiography and repair all defects
found.
The spot radiography described above is not applied to any specific Category of weld. In a
given 50 feet of weld increment there may be Category A, B, C, and D butt welds. The
inspector will choose the exact location of the spot radiograph. In cases where spot
radiography is a specific requirement of another paragraph of the Code the location for the
spot radiograph is stated within that paragraph. The spot radiography of UW-52 cannot serve
double duty; it will not satisfy the spot radiography requirements of any other paragraph. It
allows the use of a joint efficiency from column B of Table UW-12 for all categories of butt
joints in that 50 feet increment. If the 50 feet increment were to stop in the middle of a joint
the efficiency of that joint could not come from column B until the next 50 feet increment
was spot radiographed.
Page 56 of 310
Butt welds in the shell and heads of vessels used to contain a lethal substance.
2.
When the least nominal thickness at a butt weld exceeds a limiting thickness, which is
based on the type of material used in the vessels welded construction.
3.
Butt welds in the shells and heads of unfired steam boilers having an operating pressure
greater than 50 psi.
4.
Butt welds in nozzles, communicating chambers, etc. in (1) or (3) above attached to
vessels sections or heads that exceed certain limits on thickness or diameter.
5.
Categories A & D butt joints. Where full radiography is not mandatory; but desired to
obtain a joint efficiency from column A of Table UW- 12. Spot radiography must also
be applied to Category B and C butt joints.
Page 57 of 310
Page 58 of 310
UW-11
(a) Full Radiography. The following welded joints shall be examined for their full length
in a manner prescribed in UW- 51:
UW-11 (a)(1) All butt welds in the shells and heads of vessels used to contain lethal
substances [see UW-2(a)];
[UW-2(a) limits Category A butt welds to Type 1 and Category B to Type 1 or 2 of Table
UW- 12].
HEMI HEAD
ELLIPTICAL
LETHAL SERVICE
MUST HAVE FULL RT
CATEGORY A
TYPE 1 ONLY
CATEGORY B
TYPE 1 OR 2
Page 59 of 310
Full Radiography. The following welded joints shall be examined for their full length in
a manner prescribed in UW-51:
UW - 11 (a)(2) All butt welds in which the least nominal thickness at the welded joint
exceeds 1 1/2 in. or exceeds the lesser thickness prescribed in UCS-57. Category B and C
butt welds in nozzles and communicating chambers that neither exceed NPS 10 nor 1 1/8 in.
wall thickness do not require any radiographic examination;
P-1 Material Per UCS-57 >1-1/4" Full RT
[Least
1 NO RT required
1-1/2" thick full RT
required
24
Category A
and C butt
weld Full
RT
NPS 20 Category
1-1/2" thick
Full RT
2 thick Full RT
Nominal
Page 60 of 310
Full Radiography. The following welded joints shall be examined for their full length in
a manner prescribed in UW-51:
UW- 11 (a)(3) All butt welds in the shells and heads of unfired steam boilers having a design
pressure exceeding 50 psi, [see UW-2(c)];
[UW-2(c) limits Category A butt welds to Type 1 and Category B to Type 1 or 2 of Table
UW- 12 ].
UNFIRED STEAM BOILER PRESSURE EXCEEDS 50 PSI
MUST HAVE FULL RT
HEMI HEAD
ELLIPTICAL HEAD
Category A
Type 1 Only
Category B
Type 1 or 2
Page 61 of 310
ELLIPTICAL HEAD
MUST HAVE FULL RT
Category A
Type 1 Only
Category B
Type l or 2
Page 62 of 310
Full Radiography. The following welded joints shall be examined for their full length
in a manner prescribed in UW-51:
UW- 11 (a)(5) All Category A and D butt welds in vessel sections and heads where the design
of the joint or part is based on joint efficiency by UW- 12 (a), in which case:
(a)
Category A and B butt welds connecting the vessel sections or heads shall be of Type
No. 1 or Type No. 2 of Table UW- 12;
(b)
Type 1 E = 1.0
Type 2 E - .90
For hemi head and shell
calculations only
Seamless Elliptical
head see UW-12 (d)
Spot RT
Type 1 or 2 per UW-11 (a) (5) (b)
Page 63 of 310
Exercises
1.
For a vessel in lethal service what butt joints must be radiographed in addition to all
butt joints in the shell and heads? (\f by
2.
A joint efficiency from Column A of Table UW-12 is desired for a Category A butt joint
in a shell, what extent of radiography must be applied to this Category A butt joint?
What additional requirement must be met?
3.
If the least nominal thickness of a butt joint in a vessel exceeds a certain thickness
based on the material used in its construction what amount of radiography must be
applied?
4.
Full radiography is required by UW-11 (a)(2) may it be assumed that all butt joints have
been fully radiographed? Why or why not?
5.
A vessel shell contains a Category A butt welded longitudinal joint and a Category D
butt welded joint. Must both of these be fully radiographed to use a joint efficiency
from Column A of Table UW-12?
Category A, B & C that exceed diameter 10 NPS or 1-1/8 thickness in nozzles and
chamber
2.
3.
Full RT for all Butt joints that exceed the specified thickness except B category joints
that do not exceed 10" NPS or 1-1/8 thickness.
4.
No-Some thickness requirements may exceed the limit for the material used. Its the
thickness of the welded joint that determines the RT requirement.
5.
Yes by the requirement that both A & D butt welds shall be shot.
Page 64 of 310
15,000 LBS
STRESS EQUALS 15,000 POUNDS PER SQUARE INCH
Ultimate Stress is the stress value at which a material breaks (fails)
ULTIMATE STRESS
ONE SQUARE INCH
OF MATERIAL
60,000 LBS
Page 65 of 310
OF MATERIAL
28,000 LBS.
FAILURE STRESS DUE TO FLAW 28,000 POUNDS PER SQUARE INCH
In the Code formulas the Stress Allowed must be multiplied by the joint efficiency 'E'. So SE
always appear in the formulas. The reason for using E is to make an adjustment for how
certain it is that the welded joint is equal to a seamless piece of material. In the case of full
radiography the conclusion that the material is as strong as seamless is made and an
Efficiency for a Type No. 1 joint can be 1.0. For a Type No. 2 .90 can be used. Spot
Radiography allows lower joint efficiencies and No Radiography still lower.
Page 66 of 310
Page 67 of 310
Page 68 of 310
WELDED
RIVETED
In the case of a riveted shell a true circle could never be accomplished due to the natural
offset in alignment. Still the term joint efficiency has hung on. Riveted construction was
eliminated from the Code after 1971. As before we will utilize graphics to help in
understanding joint efficiencies. Modified Table UW- 12 which follows with its graphics
will explain joint types and the limits of radiography.
Type 1-Category
A, B, C & D
API 510
Column B
Column C
Type 2-Category
A, B, C & D
Type 3-Category
A, B & C
Type 4-Category A
Full RT
Spot RT
No RT
E = 1.0
E = .85
E = .70
E = .90
E = .80
E = .65
RT Not
Applicabl
e
RT Not
Applicabl
e
E = .60
RT Not
Applicabl
e
RT Not
Applicabl
e
E = .55
RT Not
Applicabl
e
RT Not
Applicabl
e
E = .50
RT Not
Applicabl
e
RT Not
Applicabl
e
E = .45
Page 70 of 310
ELLIPTICAL HEAD
SPOT RT
TYPE 1 - CATEGORY A
SPOT RT
TYPE 1 - CATEGORY B
The above example has 100 feet of weld total. All the welders are in the radiographs.
Everybody got their picture taken. This vessel would be marked RT 3. Individual joints can
be chosen for Spot RT and a joint efficiency from column b used for that component or joint.
If that is done the marking becomes RT 4. All of this assumes Full RT is not mandatory.
Page 71 of 310
ELLIPTICAL HEAD
TYPE 1-CATEGORY A
TYPE 1-CATEGORY B
The seamless elliptical head calculations in the above example would require an E of .85.
This is per UW-12 (d). As you will see in UW-12 (d) seamless components are special cases.
UW-12 (d): Seamless vessel sections and heads shall be considered equivalent to welded
parts of the same geometry in which all Category A welds are Type No. 1. For calculations
involving circumferential stress in seamless vessel sections or for thickness of seamless
heads E = 1.0 when the spot radiography requirements of UW-11 (a)(5)(b) are met. E = .85
when the spot radiography requirements are not met, or when the Category A or B welds
connecting seamless vessel sections or heads are Type No. 3, 4, 5, or 6 of Table UW-12.
Type No. 3, 4, 5 and 6 joints will not produce interpretable radiographs per the ASME Code.
Therefore the E used to calculate a seamless component using one of these Types must be
taken as .85 by default.
API 510
Page 72 of 310
Seamless Elliptical Hd
=
Seamless Shell
=
When any of the above examples is joined to another component by a Type 1 or 2 joint then
the Spot RT of UW-11 (a)(5)(b) must be performed to allow an E of 1.0 in their calculations.
Examples: Categories, A (Hemi head) or B (head with skirt) or when any of the above
examples is joined to another component by a type C (weld neck).
Category A Full RT
Type 1 E = 1.0
Type 2 E = .90
For Shell Calculations
E = 1.0
For Head
Category A Full RT
Type 1 or 2
E = 1.0 or .90
For Shell Calculations
Spot RT
Type 1 or 2
Spot RT
Type 1 or 2
E = 1.0
For Elliptical Head
E = 1.0
For Shell
E = 1.0
For Shell Calculations
Spot RT
Type 1 or 2
Spot RT
Type 1 or 2
API 510 Module
PART UW - WELDING
API 510
Page 73 of 310
2.
3.
Stress In heads.
Circumferential stress applies stress in a shell along its length. This stress acts to split a shell
along its length and is often referred to as Hoop Stress. The shell may be seamless or may
contain longitudinal seams. In either case failure in the circumference will usually occur
similar to that shown in the drawing above. A Code calculation is required to determine the
thickness required or pressure allowed on the shell for circumferential stress.
There are two possible cases for a vessel's circumferential stress calculation with a single
shell course. The shell is seamless or it has a longitudinal seam. The UG-27 circumferential
formulas are used for calculation of thickness required or pressure allowed in both cases.
The difference between the two conditions is in how the E is picked for use in the
calculation. We will examine the two separately.
Page 74 of 310
TYPE No. 1 OR 2
CATEGORY 9 NO SPOT RT
ELLIPTICAL HEAD
SEAMLESS SHELL E = .85
Page 75 of 310
What type of butt joint has been used to make the long joint? (Per Table UW-12
limitations only two are allowed)
a.
Type No. 1
or
b.
Type No. 2
2.
3.
Has the spot radiography of UW-11 (a)(5)(b) been applied to any intersecting Category
A, B or C welds?
There are many combinations which can be made from the factors above, all resulting in
different joint efficiencies. Examples of a few problems should help in the understanding of
the other situations. In the following examples all vessels have less than 50 linear feet of
welds total and were made by the same welder.
Page 76 of 310
Shells
Example A: Shell course with a Type No. 1 longitudinal seam that has been fully
radiographed. The vessel has ellipsoidal heads on both ends and the Spot RT of UW-11 (a)
(5)(b) has been applied.
ELLIPTICAL HEAD
Fully radiographing the Type No. 1 Category A longitudinal seam and performing the Spot
RT of UW-11 (a)(5)(b) allows the use of an E from column A of Table UW-12. The E from
Column A, for a Type No. 1 is 1.0. This is in agreement with Paragraph UW-12 (a).
Example B: Shell course with a Type No. 2 longitudinal seam that has been fully
radiographed. The vessel has ellipsoidal heads on both ends and the Spot RT of UW-11 (a)
(5)(b) has been applied.
Fully radiographing the Type No. 2 Category A longitudinal seam and performing the Spot
RT of UW-11 (a)(5)(b) allows the rise of an E from column A of Table UW-12. The E from
Column A , for a Type No. 2 is .90. This is also in agreement with Paragraph UW- 12(a).
Page 77 of 310
Shells
Example C: Shell course with a Type No, 1 longitudinal seam that has been fully
radiographed. The vessel has ellipsoidal heads on both ends and the Spot RT of UW-11 (a)
(5)(b) has not been applied.
CATEGORY B
NO SPOT RT
E = .85
TYPE NO. 1 - CATEGORY A
FULL RT
Fully radiographing the Type No. 1 Category A longitudinal seam but not performing the
Spot RT of UW-11 (a)(5)(b) requires the use of an E from column B of Table UW-12. The E
from Column B, for a Type No. 1 is .85. This is in agreement with Paragraph UW-12 (a).
Example D: Shell course with a Type No. 2 longitudinal seam that has been fully
radiographed. The vessel has ellipsoidal heads on both ends and the Spot RT of UW-11 (a)
(5)(b) has not been applied
CATEGORY B
NO SPOT RT
E = .80
TYPE NO.2 - CATEGORY A
FULL RT
Fully radiographing the Type No. 2 Category A longitudinal seam but not performing the
Spot RT of UW-11 (a)(5)(b) requires the use of an E from column B of Table UW-12. The E
from Column B , for a Type No. 2 is .80. This is also in agreement with Paragraph UW- 12
(a).
Page 78 of 310
Shells
The conclusion drawn from examples C and D above is that applying full radiography to the
longitudinal joint offers no benefit unless accompanied by the Spot RT of UW-11 (a)(5)(b).
The Type No. 1 joint E of example C is the same as if it was only Spot Radiographed since
it's E must come from Column B of Table UW-12. This is also the case for the Type No. 2 of
example D. These joints would have the same joint E if they had been spot radiographed.
Full Radiography was a waste. The Code does this to discourage more than one level of
radiography between butt welded joints. It is unlikely you will ever see actual cases like
examples C and D.
LONGITUDINAL STRESS / CIRCUMFERENTIAL JOINTS
At this point we will begin discussing the Longitudinal Stress that causes stress around vessel
walls and in Circumferential Joints. Commonly referred to as the girth.
Longitudinal stresses tend to tear the vessel into two pieces, separate shell courses or pop off
the head. This is the second calculation required for a shell.
For our examples we will use a vessel with two shell courses and ellipsoidal heads on both
ends. Keep in mind that we are calculating the stresses on Circumferential Joints (Girth
Joints); those which are affected by longitudinal stress. Longitudinal stress rarely determines
the required thickness or allowed pressure on a shell. The reason is; the stress created by
internal pressure in the longitudinal direction is only half that of in the circumferential
direction. Normally circumferential stress governs and determines the required thickness or
pressure allowed for a shell. The Joint Efficiency for these Categories of butt welds may be
taken directly from Table UW-12 based on their Type. Radiography applies when they are of
Type No. 1 or Type No. 2. RT does not apply to Types 3, 4, 5 and 6.
Page 79 of 310
Shells
Example A. Two seamless shell courses closed with ellipsoidal heads without radiography
applied to circumferential Type No. 1 butt joints. The E used for longitudinal stress
calculations of both shell courses is .70.
E = .70
E = .70
ALL JOINTS
CATEGORY B
NO RT
TYPE No- 1
E = .70
Example B: Two seamless shell courses closed with ellipsoidal heads with spot radiography
applied to circumferential Type No. 1 butt joints. The E used for the calculations of both the
shell courses is .85.
ALL JOINTS
CATEGORY B
E =. 85
E =. 85
SPOT RT
TYPE No. 1
E = .85
49 FEET OF WELD TOTAL
Example C: Two seamless shell courses closed with ellipsoidal heads with full radiography
applied to circumferential Type No. 1 butt joints. The E used for the calculations of both the
shell courses is 1.0.
E = 1.0
E= 1.0
ALL JOINTS
CATEGORY B
RT
TYPE No. 1
E= 1.0
If the above vessels had been made using Type No. 2 joints the joint efficiencies would be .
65, .80 and .90 respectively based on the same radiography,
Page 80 of 310
Stress In Heads
The last E to consider is the one used to calculate thickness required or pressure allowed
for formed and forged heads. Internal pressure creates stress that acts to rupture the walls of
heads.
Each kind of head has a Code formula for its calculations. Two classes of heads are joined to
vessels by circumferential joints. One class is joined to the shell with a Category B or C
circumferential butt joint; these are heads that have a flange. Some examples are
Torispherical, Ellipsoidal and forged Flat heads. Forged Flat heads are joined by Category C
circumferential joints and are treated the same for determining their E as the other two. The
other class is joined to the shell with a Category A butt joint; it is a Hemispherical head with
out a flange.
The first examples have ellipsoidal heads that may be joined to the shell using a Type No. 1
or Type No. 2 joint. It is also representative of a torispherical head since both have a flange
(skirt). The ellipsoidal head forms a Category B joint with the shell and is seamless.
The second examples have formed hemispherical heads without a flange. The joint formed
by the attachment of the hemispherical head to the shell is a circumferential Category A.
Hemispherical heads may be joined using either a Type No. 1 or a Type No. 2 joint provided
no service restriction from UW-2 applies. If a service restriction applies the Category A butt
joint must be of Type No. 1. The shell used in all examples is over 24 inches in O.D. and
over 5/8 inch thick. Per Table UW-12 only Type No. 1 or Type No. 2 joints are allowed for
these conditions.
When seamless heads, that have a flange (skirt), are attached to shells a Category B joint is
created. This Category B joint will have a joint efficiency based on its Type and the amount
of radiography that was applied.
Page 81 of 310
Stress In Heads
This joint efficiency will not be used in the calculation of the head's required thickness or its
pressure allowed. This E is used in the longitudinal stress calculations for the shell. The
Category B joint may be thought of as belonging to the shell. For a seamless head which is
joined by a Category B butt joint there are only two possibilities for the E used in the head
calculations. The E used will either be 1.0 or .85. The E is determined based on the
requirements of UW-12 (d). The question then becomes has Spot RT been applied to the
Category B butt joint. If it has the E is 1.0. If it has it not the E is .85.
Example A: Category B butt joint of Type No. 1 or Type No. 2 has not received Spot RT. E =
.85 for the head's thickness or pressure calculation. The shell's longitudinal stress calculation
E will be .70 or .65 depending on which Type of joint was used.
Shell E = .70 or .85
Category B
No RT
HEAD E = .85
Example B: Category B butt joint of Type No. 1 or Type No. 2 has received Spot RT. E = 1.0
for the head's thickness or pressure calculation. The shell's longitudinal stress calculation E
will be .85 or. 80 depending on which Type of joint was used.
Page 82 of 310
Heads
The last case to consider for seamless heads that form a Category B or C joint with a shell is
when the joint is of Type No. 3, 4, 5 or 6 of Table UW-12. Since these types are not
considered radiographicable by the Code the Spot RT cannot be applied. UW-12 (d) states
that the head under this condition shall always be calculated using E = .85. The shell's
longitudinal calculations would use an E based on the Type No. of the joint and this E would
then come directly from Table UW-12.
The most common mistake in the calculation of seamless heads attached by Category B
joints is the use of the E found in table UW-12 based on the type of joint.
That E belongs in Longitudinal shell calculations. The E used for the seamless head is based
only on the application of Spot RT. If Spot RT has not or cannot be performed (as is the case
for Types 3, 4, 5, or 6) an E of .85 shall be used. If it can and has E = 1.0. END OF STORY.
Until they change the Code again!
The last formed head of concern is the Hemispherical. A hemispherical head formed from a
solid piece of plate without a flange is only seamless as long as it is lying on the shop floor;
when welded to another component such as a shell it now has a Category A joint. Read UW3 (a)(1) again to confirm this statement. The Category A joint formed after welding to a shell
belongs to the hemispherical head. The rules regarding seamless shells and heads in UW- 12
(d) specify that the spot radiography of UW-11 (a)(5)(b) must be applied to use an E of 1.0
for a seamless head's thickness or a shell's circumferential stress calculation. Since our
hemispherical head will always have a Category A joint (seam) the conditions of UW-12 (d)
do not apply. The bottom line is that a formed hemispherical head without a flange can never
be seamless. Spot radiography on the Category A joint does have a use if the hemispherical
head is welded to a seamless shell or to a shell in which all Category A & D butt joints have
been fully radiographed. The shell's circumferential stress could then be calculated using an
E of 1.0.
ATTENTION - ATTENTION
HEMISPHERICAL HEADS ONLY CONTAIN CATEGORY A JOINTS.
Page 83 of 310
Heads
The following examples will use a formed hemispherical head and a seamless shell.
Example A: Seamless shell course with a hemispherical head. Spot RT has not been
applied. The Category A joint may be a Type No. 1 or a Type No. 2 of Table UW-12.
E =.65 or .70.
HEMI
E =.70
Or
E =.65
SEAMLESS SHELL
E = .85
CATEGORY A
NO RT
Example B: Seamless shell course with a hemispherical head. Spot RT has been applied.
The Category A joint may be a Type No. 1 or a Type No. 2 of Table UW-12.
E = .80 or .85.
HEMI
E =.85
OR
E =.80
SEAMLESS SHELL
E =1.0
CATEGORY A
TYPE No. 1 OR 2
SPOT RT
Example C: Seamless shell course with a hemispherical head. Full RT has been applied.
The Category A joint may be a Type No. 1 or a Type No. 2 of Table UW-12.
E =.90 or 1.0.
HEMI
E = 1.0
OR
E =.90
SEAMLESS SHELL
E = 1.0
CATEGORY A
TYPE 1 OR 2
FULL RT
Page 84 of 310
Summary Of Part UW
The main points of Part UW for the API Exam are the following:
1.
2.
3.
4.
The Spot RT described in UW-11 (a)(5)(b) is used for Seamless or equivalent components.
This spot radiography is different than applying spot radiography to the entire vessel.
Typically Exam problems will be stated in this manner 'A seamless torispherical head is
being replaced due to corrosion. The head has an O.D. of 60 inches and is joined by a Type
No. 1 joint . UW-11 (a)(5)(b) has been applied'. The statement that UW-11 (a)(5)(b) has been
applied will be the only thing you need to determine the E to use in the head's calculation.
This can also be stated as the vessel's Data plate is stamped RT 2. RT markings and their
meanings will be explained in the coverage of Paragraph UG-116 REQUIRED MARKING.
This will also serve as a review of paragraphs UW-11 and UW-12.
Page 85 of 310
Exercises UW-12
Determine the efficiencies for calculation of the following vessel parts.
SEAMLESS SHELL
HEMI
ELLIPTICAL
CATEGORY D FILLET
SEAMLESS
SPOT RT
NO RT
TYPE 2 - CATEGORY B
TYPE 1 CATEGORY A
SPOT RT
Torispherical
1.
2.
3.
4.
5.
6.
7.
Page 86 of 310
Exercises UW-12
HEMI
ELLIPTICAL
CATEGORY D
BUTT WELD
FULL RT
SPOT RT
TYPE 2-CATEGORY B
SPOT RT
TYPE 1-CATEGORY A
FULL RT
Torispherical
1.
2.
3.
4.
5.
6.
7.
Page 87 of 310
Page 88 of 310
PART UG
GENERAL REQUIREMENTS
API 510
Page 89 of 310
B.
C.
Calculate the thickness required for Circular Unstayed Flat heads (Part MAWP).
D.
E.
F.
Calculate Hydrostatic and Pneumatic Test pressures. Describe Procedures for Tests.
G.
H.
1.
J.
K.
Page 90 of 310
?
0.500"
15,000 psi
1.0
18.0"
18.5"
SEt
UG-27(c)(1) P=
7500
= 409. 8
psi
R + 0.6t
SEt
App 1 (1 - 1) P=
18.3
7500
=
409.8
psi
R. - 0.4t
18.3
If calculations for a thickness required are being made the same approach may be taken. The
next step in this instruction will be to apply cases where this is an appropriate option. Our
next example will deal with corrosion.
Example 2. A cylindrical vessel shell has been found to have a minimum thickness of .353".
Its original thickness was .375". May this vessel remain in service given the following
variables?
P=
T=
S=
E=
R=
300 psi
0.353"
13,800 psi
.85
12.0 +(.375-.353) = 12.022 This adjusts is for the corroded inside
R=
12.0 +0.375 (orig. t)=12.375" This finds the original outside radius
radius
Page 91 of 310
R+0.6t
4140.69
=
338.46
338.46
12.2338
R0 - 0.4t
4140.69
=
12.2338
ANSWER: YES
338.46 psi > 300 psi
Important adjustments must be made for both approaches. The case of inside radius requires
an increase of the inside radius due to corrosion. If the outside radius is not given, the
original thickness must be added to the original inside radius to determine the outside radius;
but the thickness used in the pressure allowed calculation of App: 1 (1 - 1) must be the
existing thickness given in the stated problem. As can be seen from the above examples
either method yields the same results as long as the rules are followed properly. The method
you use is a matter of personal preference. These adjustments, along with others such as
static head, add to the difficulty of otherwise simple arithmetic. In every case, careful work
is a requirement for successful calculations.
As a check on the calculations for pressure allowed, calculations for thickness required can
be performed. Our next examples are used to determine if the vessel may operate at the 300
psi desired and be in compliance with the Code.
Page 92 of 310
t =
300 x 12.022
=
SE - 0.6P
3606.6
=
= .3122"
11550
t =
300 x 12.375
=
SE+ 0.4P
3712.5
=
= .3132
11,850
ANSWER:
.3122" <.353"
or
.3132" <.353"
The slight difference in the thicknesses required has to do with the inside radius increasing to
12.022 inches from the original 12.0 inches due to corrosion. Both of the above answers are
correct using 300 psi. By increasing the pressure used in the thickness calculations to
338.46, the thicknesses required are identical for both formulas.
For the next part of our instruction we will begin doing some simple shell calculations using
UG-27 Thickness of Shells under Internal Pressure.
In this paragraph, formulas are given for the calculation of minimum thickness and
maximum pressure for cylindrical and spherical shells. Special attention must be paid to
circumferential stress within the cylindrical shell. This stress category normally will
determine the minimum thickness or maximum working pressure of the vessel.
Let's do a simple shell calculation now. We will use a shell which is seamless. You may find
the following approach helpful in keeping track of the data. As the problems become more
difficult, it becomes harder to track the variables if you are not organized.
API 510
Page 93 of 310
1.
Make a simple drawing of the vessel or head you are calculating values for. This
helps identify the variables the next step.
2.
List what is required to know. We will call these givens. These will come from the
stated problem.
3.
State all the code paragraphs that apply, i.e., UG-27, UG-22, etc,
Drawing:
Givens:
t=
P=
R=
S=
E=
etc.
Code Paragraph UG-27 (c) (1)
SEt
P =
Etc.
R + 0.6 t
Page 94 of 310
Givens:
P=
?
t=
.406*
R=
6.0 Remember this formula uses Radius not Diameter.
S=
16,600 psi
E=
1.0
From UG-27 (c) (1) Circumferential Stress
SEt
P=
R + 0.6 t
16,600 x 1.0 x.406
P=
6739.6
=
= 1079.44 psi
6.2436
*Mill Under tolerance must be considered when designing a vessel shell using pipe. For
most pipe, it is 12.5 % of the nominal thickness. This will usually require ordering the next
schedule up to meet a required thickness. The example above could arrive with a thickness
of as little as .355
Page 95 of 310
Givens:
t=
P=
R=
S=
E=
Cat. A Type 1
?
100 psi
24"
15000
.70 (Table UW-12)
Circumferential Stress
PR
t=
SE - 0.6 P
100 x 24
2400
t=
=
(15,000 x .70)-(0.6 x 100)
= .2298
10440
Page 96 of 310
Page 97 of 310
Cat. B Type 1
Spot RT
Givens:
t=
?
P=
50 psi
D=
10'-0"
R=
5'-0" = 60
S=
17500
E=
.85 from table UW-12
UG-27(C)(2)
PR
t =
2 SE + 0.4 P
50 x 60
3000
t =
=
(2 x 17,500 x .85) + (0.4 x 50)
Page 98 of 310
= .1007
29770
t=?
10 0 I.D.
Givens:
t=
?
P=
50
R=
60"
S=
17500
E=
1.0 (UW-12(a) and UW-11(a)(5))
Cat. A Type 1
Full R.T.
3000
t=
=
(17,500 x 1.0) - (0.6 x 50)
Q.
= .1717
17470
The thickness required above is not double the thickness required for the
Circumferential joint. Why?
Page 99 of 310
Drawing:
2.
What is the maximum allowed working pressure on a shell made of SA-515 gr. 60?
The shells inside radius is 52 inches, and the shell's thickness is .850 inches. The allowable
stress for the shells material is 15,000 psi at 500 F. The joint efficiency of the shells
Category A joints is 1.0 .
Givens:
t=
P=
S=
E=
R or R0=
Drawing:
I.D. of Skirt
TORISPHERICAL
0.885PL
t=
SE - 0.1P
Knuckle Radius
Outside Radius
L
Inside Crown Radius
HEMISPHERICAL
L
PL
Sperical Radius
t=
Inside Diameter
2SE - 0. 2P
The same pressure and stress values will be used for all heads.
100 psi
17500 SA-515 Gr70 plate 650 degrees F.
.85 for spot RT of Hemispherical head joint to shell
1.0 for seamless heads ( Ellipsoidal and Torispherical)
48" for the inside spherical radius for the hemispherical head
96" for the inside crown radius of the torispherical head
96" for the torispherical head
96" inside diameter of the ellipsoidal and hemispherical heads
Required wall thickness, inches
Problem # 1
Given the above data find the required thickness of a seamless ellipsoidal head.
Drawing:
ELLIPTICAL
96.0
t=
2SE - 0.2 P
100 x 96
9600
t=
=
(2 x 17,500 x 1.0) - (0.2 x 100)
= .2744
34980
From UG-32(f)
PL
t=
2SE - 0.2P
Solving for t:
100 x 48
4800
t=
=
(2 x 17,500 x 0.85) - (0.2 x 100)
= 0.1614
29730
L=96.0
t=?
O.D. 96.0
0.885PL
t=
SE - 0.1P
Solving for t:
0.885 x 100 x 96
8496
t=
=
(17,500 x 1.0) - (0.1 x 100)
= .4857
17490
UG-32
Exercises
Use the overview portions of UG-32 to determine the formulas and use Part UW to determine
the joint efficiencies.
1.
Calculate the required thickness of a 2 to 1 Ellipsoidal head with an inside, diameter
of 48 inches. The vessels will have a MAWP of 350 psi and will be in lethal service. The
joint used to join the head to shell will be a Type No. 2 from Table UW-12. The stress
allowed on the head's material will be 15,000 psi.
Givens:
t=
?
P=
S=
E=
D=
Drawing:
2. A Torispherical head has corroded to a thickness of'.353; its inside crown radius is 56
inches. The head's material has a stress allowable of 13,800 psi at 500F. The shell is
seamless and the spot radiography of UW-11 (a)(5)(b) has been applied to the vessel. Can
this head remain in service at 100 psi per Code?
Givens:
t=
?
P=
S=
E=
L=
Drawing:
Drawing:
4.
What would the required thickness for an Ellipsoidal head he given the same variables
as used in Problem # 3 above? The Category B weld that will attach this head would not
have UW-11 (a)(5)(b) applied.
Givens:
t=
P=
S=
E=
D=
Drawing:
Those attached by Fillet welds and those attached by other than Types Nos. 1 or 2 are not
radiographical by the Code rules. Seamless circular flat heads which are butt welded must
follow the rules for circumferential butt welds contained in UW-11 and UW-12(d) when
choosing the Efficiency for their thickness calculations. These heads are treated in the same
way as formed heads for their E used in calculations. If a flat head is attached using fillet
welds. it cannot be radiographed, and if the flat head is seamless the E used to calculate its
thickness will always be 1.0 .
If the Circular Unstayed Flat Head were constructed of two half moon pieces using a butt
weld, the head would then contain a Category A joint per UW-3. The Type of butt weld and
the amount of radiography would determine the E; the resulting E would be the joint
API 510
Category A
Butt Weld
The only formula that will be used for the calculations on the test is the one of UG-34(c)(2)
#1. Thickness required will be the only type of problem asked according to the API 510
Body of Knowledge.
t=d
CP/SE
The definitions of the variables in the formula are shown in the figures of Figure UG-34.
UG-34. The d is the inside diameter of a head or shell as given in each figure; the C is a
factor that depends on the method of attachment, shell dimensions and other factors listed in
UG-34 (d). The E was discussed above; t and P are thickness and pressure. The C can get a
little tricky in figures (e), (f), (g) and (b-2) of Fig. UG-34. In these four figures there is a
note that states: C = 0.33 x m; where in the other figures it is stated that C will equal a
specific value, 0.17 etc. also all figures list a minimum C value. Figures (e), (f), (g) and (b-2)
require an extra calculation to determine the C before the head's thickness can be calculated
using the formula above. Again that calculation is C = 0.33 x m.
The term m is defined in the nomenclature of UG-34 as being the thickness required of the
shell divided by the actual thickness of the shell.
tr
m=
ts
IF this type of problem is given, stating only the actual thickness of the shell, a thickness
required calculation using the formula of UG-27 (c)(1) must be performed. The E used will
be 1.0 for the shells required thickness calculation. The inside diameter of the shell will be
equal to the d of the flat head, and the shell's material allowable stress must be given. The
pressure will be the same as required for the flat head. The following examples will
demonstrate the operations required.
.375
?
100 psi
10.0 in
17500 @ 450F
1.0 For any seamless head attached by fillet welding.
0.33 x m
From: UG-34(c)(2)
t=d
CP/SE
Step 1. Calculate the thickness required of the shell using the UG-27(c)(1) circumferential
stress formula.
PR
t=
SE - 0.6 P
100 X 5
t =
500
=
= .02866
17,440
ts
.375
t = 10
20 / 17500
t = 10 .0011428
t = 10 x .0338053 = .3380"
ANSWER: t = .338" minimum
Wasn't that fun
Problem # 2
A Forged Flat Circular Unstayed Head has been attached to a shell similar to fig. (b- 1) of
Fig.UG-34. The circumferential weld attaching the head to the shell is a single welded butt
joint with a backing strip which remains in place, The Data Report for the vessel indicates
that no radiography has been performed. The heads inside diameter is 26 inches. The
vessel's name plate indicates a MAWP of 150 psi. The allowable stress of the forged heads
material is 15,000 psi per the Data Report. Uniform corrosion has occurred to this head
leaving the flat part with a minimum thickness of 1.252". Can this vessel remain in service
without repair or replacement of the heads?
Drawing:
Givens:
t=
?
P=
150 psi
d=
26 "
S=
15,000 psi
E=
.85 per UW-12(d).
C=
0.17 per fig. (b-1)
From UG-34(c)(2):
t = d CP/SE
t = 26 0.17 x l50 / 15,000 x .85
t = 26
25.5 / 12,750
t = 26 .002
t = 26 x .0447213 = 1.16275
1.252 > 1.16275" ANSWER: YES
API 510
Drawing:
ts=
t=
P=
Ss=
Sh =
Es =
Eh =
D=
State Code Paragraph(s) and Formula(s):
2. The unit engineer has questioned the wisdom of repairing the head in Problem # 1 and
thinks that a flat head attached similar to UG-34 (f) would offer some advantages for the
future plans in the unit. His calculations specify that the new flat head would require a
thickness of 1.375. Do you agree?
API 510
Givens.
Drawing:
ts=
t=
P=
Ss=
Sh=
Es=
Eh =
d=
State Code Paragraph(s) and Formula(s):
API 510
t = 1.25
40 Do
API 510
70
LENGTH
From UG-28 (c) Cylindrical Shells and Tubes. The required minimum thickness of a shell or
a tube under external pressure, either seamless or with longitudinal butt joints, shall be
determined by the following procedure.
(1) Cylinders aving
Do values > 10
t
Testing to see if this paragraph applies:
Do = 40
t = 1.25
Do
40
=
= 32
1.25
Step 1. Our value of Do is 40 inches and L is 70 inches. We will use these to determine the
ratio of:
L
70
=
Do
= 1. 75
40
Step 2. Enter the Factor A chart at the value of 1.75 determined above.
Step 3. Then move across horizontally to the curve D o / t = 32. Then down from this point to
find the value of Factor A which is .0045.
Step 4. Using our value of Factor A calculated in Step 3, enter the Factor B (CS-2) chart on
the bottom. Then vertically to the material temperature line given in the stated problem (in
our case 500F).
Step 5. Then across to find the value of Factor B. We find that Factor B is approximately
13000.
Step 6. Using this value of Factor B, calculate the value of the maximum allowable external
pressure Pa using the following formula:
4B
Pa =
3(Dot)
4x13,000
Pa =
52,000
=
3(32)
= 541.66 psi
96
L =78
Do = 4.5"
t = .531
Check ratio of Do / t = 4.5 / 0.531 = 8.47
8.47<10
Do / t < 10
Therefore, use UG-28(c)(2)
Step 1. Using the same procedure as given in UG-28(c)(1) obtain the value of B.
Determine the ratio for and L / Do and Do / t
L / Do = 78/ 4.5 = 17.33
[From UG-28(c)(2)]
API 510
Step 2. Using the value of B obtained above calculate the value Pa1 using the following
formula:
Pa1 =
[[ / D t] 0.0833] B
Pa1 =
2.167
2.167
8.47
Step 3. Calculate the value of Pa2 where S is the lesser of 2 times the maximum allowable
stress in tension at the design metal temperature from the stress tables or 0.9 times the yield
strength of the material at design temperature. Values of the yield strength are obtained from
the applicable material chart as follows:
(a). For a given temperature curve determine the B value that corresponds to the right hand
side termination point of the curve.
(b). The yield strength is twice the B value obtained in (a) above.
Use the Lesser of:
2 times the maximum stress allowed in tension
or
0.9 times yield strength at temperature.
(Case 1.): 2 x 14,400 psi = 28,800 psi
or
(Case 2.): 2 x 13,900 psi = 27,800 psi x 0.9 = 25,020 psi
So use 25,020 psi in the calculation of Pa2
Pa 2 =
2S
Dot 1 1 / Dot
] [1 [1 / 8.47]]
Pa 2 = [2 x 25,020] / 8.47
Drawing:
P=
Temp. =
t=
L=
Do=
2.
A high pressure heat exchanger has experienced corrosion on the external surfaces of
its tubes. A tube thickness was found to be .730" thick. This tube has a corroded minimum
outside diameter of 5.98". The total external pressure is 900 psi at 800F. The tubes are
made of a material with a minimum yield of 38,000 psi, a maximum allowable stress at
design temperature of 10,200 psi, and are 105 inches long. Will this tube's thickness allow
continued operation at the present temperature and external pressure? Show all work and
quote code paragraphs used,
Givens:
Drawing:
P=
Temp.=
t=
L=
Do=
The material shall be limited to P-No. 1, Gr. No. 1 or 2 and nominal thickness
(a)
(b)
(2)
The completed vessel shall be hydrostatically tested per UG-99(b), (c), or (k).
(3)
Design temperature is no warmer than 650 degrees F and no colder than -20
degrees F' Occasional operating temperatures colder than -20 degrees F are
acceptable when due to lower seasonal. atmospheric temperature.
(4)
(5)
UG- 22 Loadings
The loadings to be considered in designing a vessel shall include those from:
(a)
(b)
weight of the vessel and normal contents under operating or test conditions
(this includes additional pressure due to static head of liquids);
(c)
(d)
API 510
(e)
(f)
(g)
(h)
API 510
API 510
6.
1.
2.
3.
4.
5.
6.
7.
Hydrostatic
If the test is required it shall be conducted after welded repairs.
The test pressure must at least be 1 1/2 times the MAWP
The test pressure shall be adjusted for lowest ratio of stresses.
Any non-hazardous fluid may be used if below its boiling point.
It is recommended that the metal temperature during hydro test be maintained at
least 30F above MDMT to minimize the risk of brittle fracture. Testing fluid
must not exceed 120F
Following the application of hydro pressure a visual inspection shall be
performed at 2/3 of the test pressure.
Pneumatic
If the test is required it shall be conducted after welded repairs.
The welded repairs shall be subjected to the tests required by UW-50.
The test pressure must at least be 1. 25 times the MAWP
The test pressure shall be adjusted for lowest ratio of stresses.
The metal must be maintained at least 30F above MDMT to minimize the
risk of brittle fracture.
The test pressure shall be raised at a gradual rate to not more than 1/2 the test
pressure and then raised by 1/10th of the test pressure until the test pressure is
reached.
A visual inspection must be made at 4/5ths the test pressure. The visual may
be waived if the requirements listed in UG-100 are met.
The following written procedures will help to clarify the process. The ratio of stresses
adjusts for the different strengths of materials at different temperatures. This will be
explained during classroom instruction.
API 510
API 510
1.
Calculate the test pressure using the rules of UG-98 and UG-99.
2.
Any fluid in compliance with UG-99 may be used. The temperature of the
testing fluid and the vessel shell shall be as described in UG-99 and API 510.
3.
4.
5.
If the test pressure will exceed the setting of lowest relief device, relief devices
shall be removed , blinded or have test clamps installed.
6.
Vents shall be provided at all high points to purge air while the vessel is being
filled.
7.
Before applying pressure, inspect all test equipment to insure it is tight and
that low pressure filling fines and other appurtenances that should not be
subjected to the test pressure have been disconnected.
8.
9.
Slowly raise the vessel to the test pressure. Hold for an appropriate time based
on vessel size.
10.
Lower the vessel to 2/3 the test pressure and make a visual inspection of all
joints and connections.
Calculate the required hydro test pressure for a vessel using the
following conditions.
Material
Design Temp.
Test Temp.
MAWP
SA-516 Gr. 65
700F
85F
350 psi
Step 1: Determine the ratio of stresses for SA-516 gr. 65 for the test and design temperatures.
(a).
(b)
API 510
API 510
1.
Prior to administering a pneumatic test, insure that the NDE of UW-50 for
welded repairs has been applied.
2.
Calculate the test pressure using the rules of UG-98 and UG-100.
3.
The metal temperature during pneumatic test shall be maintained at least 30F
above the minimum design metal temperature to minimize the risk of brittle
fracture.
4.
5.
6.
If the test pressure will exceed the setting of lowest relief device, relief devices
shall be removed, blinded or have test clamps installed.
7.
Before applying pressure inspect all test equipment to insure it is tight and that
low pressure filling lines and other appurtenances that should not be subjected
to the test pressure have been disconnected.
8.
9.
The pressure in the vessel shall be gradually raised to not more than one-half
the test pressure. Thereafter, the test pressure shall be increased in steps of
approximately one-tenth of the test pressure until the test pressure has been
reached.
10.
Lower the vessel to four-fifths the test pressure and hold for a sufficient time
to make a visual inspection of all joints and connections.
SA-516 Gr. 65
700F
350 psi
Step 1: Determine the ratio of stresses for SA-516 gr. 65 for the test and design
temperatures.
(a). From Table 1A Section II Part D.
Stress allowed at 700F = 15,500 psi Stress allowed at 85F = 16,300 psi
(b)
1.25 x MAWP x
API 510
Slowly raise the pressure to approximately one-half 459.375 psi which equals
229.6 psi.
b.
2.
3.
4.
5.
API 510
An indicating gage shall be connected directly to the vessel. If it is not readily visible
to the operator of the test equipment an additional gage shall be used which is visible
to operator for the duration of the test.
2.
When doing large vessel pressure tests it is recommended to have a recording gage in
addition to the indicating gage.
3.
Dial type indicating gages shall have a range of about double the maximum test
pressure, but in no case shall the range of the gage be less than 1 1/2 times nor more
than 4 times the maximum test pressure.
4.
Digital gages having a wider range may be used as long as they provide the same or
greater accuracy of the dial type.
5.
All gages shall be calibrated against a standard dead-weight tester or a calibrated
master gage.
6.
API 510
2.
API 510
A pneumatic test of a vessel will be conducted to a pressure of 310 psi. Describe the
steps for raising the vessel to the test pressure. At what pressure shall the visual
examination take place?
A nozzle is being attached to a shell as shown in Fig. UW-16.1 (i) using two
equal size fillet welds. The shell's thickness is 7/8 in. and the nozzle's
thickness is 1/2 inch. The fillet welds are 3/8 inch in leg size. Does this meet
Code?
t1
7/8
t2
API 510
t1
7/8
t2
Step 1: Determine the throat size of a 3/8 in. leg size fillet weld.
Leg Size 3/8 or .375
Throat
Size
Throat size equals .707 times leg size.
0.707 x 0.375 = .265 = t1 or t2
API 510
We could stop here and answer the question with a No! But let's finish up with the second
test of size required for an illustration of the technique required.
Step 4: Test to see if:
t1 or t2 not less than
the smaller of or .707 tmin
Not less than the smaller of .250 or .707 x
.707 x .500" = .3535"
So not less than .250". Both t1 and t2 are .265".
.265 > .250 Fillet welds are adequate in the second test. However a fillet weld size must
pass both tests!
API 510
Case 2.: Based on material thicknesses determine the minimum leg size of equal sized fillet
welds to the next 1/16th inch. In our problem thicknesses are 7/8 inch (shell) and
1/2 inch (nozzle) . We have already determined that 3/8 inch leg fillet welds are too
small. So let's determine what size of equal leg fillet welds are required rounded up
to the next 1/16th inch.
This is a case where you are really coming in through the back door; that is to say, you are
not checking to see if an existing or proposed Fillet weld leg size is large enough. You are
in fact. determining the minimum size for a thickness combination. The approach is to set
up the formulas given in Fig. UW-16.1 (i) and determine the minimum values so as to
make the shoe fit.
Step 1: Determine tmin.
tmin. = the smaller of or
So tmin =
Step 2.: Determine .707 tmin
.707 x .500" = .353"
Step 3.: Determine 1 1/4 tmin.
1.25 x .500" = .625"
From Fig. UW- 16.1 (i) we are given that:
t1 + t2 1 1/4 tmin
And
t1 + t2 not less than
the smaller of
or .707 tmin
Let's stop and examine the formulas given above to make sure we understand what is being
said. First, this business of throat 1 plus throat 2 being greater than or at least equal to 1.25
times tmin. .If that's the case, then to figure out the minimum throat size of one equal sized
fillet weld, we need only calculate 1.25 x t min and divide it by two. Next, what is really is
being said in " t1 or t2 not less than the smaller of or. 707 tmin." is that the Code does not
allow a fillet welds with a throat smaller than 1/4". This is to prevent a very large fillet
weld on one side and what amounts to a small seal weld on the other side. This keeps the
heat input balanced across the parts joined. A 1/4" throat requires a leg size of .353" about
3/8.
A:
B:
C:
API 510
A fillet weld has a leg size of 1 1/8". What is its throat size?
2. A fillet weld has a throat size of .600". What is its leg size rounded up to the next
fractional 1/16"?
API 510
4
3/8
API 510
1 = 5
5/8
2
1 =4
Example:
After the above calculation, the stress reduction factor is multiplied times the actual area of
the repad, and the lesser area that is determined must be used in the calculations for
reinforcement.
Example:
Given: Repad cross-sectional area equals 2 square inches and the stress
reduction factor equals .857. Find the area that may be used in
reinforcement calculations.
.857 x 2 = 1.714 square inches
However, if the material used is stronger than the material being reinforced, no credit may be
taken for the higher strength material used as reinforcement. For the calculations you must
use the strength of reinforcement as being the same as the vessel or head being reinforced.
API 510
2
3
The extra wall thickness in the shaded area in the drawing above cannot be counted as
helping reinforce both the openings. It can be counted for one or the other but not both. The
minimum spacing for the openings above to avoid this situation is 4. It must be divided
between the two in proportion to the ratio of the two opening's diameters. In this case, 50/50.
If the openings where different diameters the ratio of their openings would he calculated and
the shade area split up accordingly.
The next situation involves more than two openings spaced closely together. In that
configuration, the minimum distance between any two of these openings shall be 1 1/3 times
their average diameters and the area of reinforcement between any two openings must he at
least equal to 50% of the total area required for the two openings. This means you are not
allowed to set the openings too closely to each other and take any credit for the shaded areas.
3.333
5.999
3
2
6
5.333
API 510
If the openings are closer together than permitted by UG-42(b), no credit is allowed for any
of the metal between the openings, and the reinforcement calculations must be performed as
given in UG-42 (c) as shown below. The nozzle wall thicknesses of the individual openings
cannot be figured in as available reinforcement. The calculation becomes one for a single
larger hole. Again no credit is allowed for metal between the individual openings or any of
the nozzle thicknesses. Its just one big hole containing all the other openings and its
reinforcement will be the one calculated.
2.5
5
3
2
6
4.75
D
I
A
M
E
T
E
R
API 510
A vessel opening is being reinforced with a pad. The pad has an allowable stress of
15,000 psi. The vessel's wall has an allowable stress of 14,800 psi. What is the
resulting ratio of stress to be used in the pads area calculation?
2.
A 6 in. nozzle is being added in a vessel wall next to an existing 4 in. nozzle. What is
the closest they may be placed together with out overlapping their areas of
reinforcement?
3.
Three nozzles are to be installed such that they clustered so closely together that they
are less than 1 1/3 their average diameters apart. How will the area of reinforcement
be calculated?
API 510
API 510
B.
The vessel and the nozzle walls usually have excess thickness above that required to
resist pressure. This excess thickness is counted toward reinforcement. Corrosion allowance
cannot be included in areas A1 or A2 below.
GIVEN AS A1 and A2. The shaded areas are the extra metal.
A1
A2
T required
C.
If the nozzle extends inside the shell, within certain limits this nozzle metal can be
counted, less any corrosion allowance.
GIVEN AS A3
A3
D. The welds used to attach the nozzle to the shell count as area available for reinforcement.
Interior weld area would be less corrosion allowance.
GIVEN AS A4
A4
API 510
E. All of this reinforcement must fall within certain limits. The extra metal in the shell and
nozzle cannot be counted outside the calculated limits.
X
F. If any of the above mentioned reinforcement has a lower stress value than the vessel's wall
its area counted toward reinforcement must be decreased proportionally.
Example:
Nozzle
Vessel
15,000
---------- = .857 Stress Reduction Factor
17,500
If we had, for instance, 2.5 sq. in. of excess wall in the nozzle, we would multiply it by the
stress reduction factor to find the area allowed to be used in the calculations .857 x 2.5 = 2.14
sq. in..
2.14 sq. in. would be all that could be considered as counting, toward reinforcement.
However, the reverse is not true if the nozzle has a greater stress value than the shell; no
credit may be taken for it. All stress values would then he the same as the shell's.
API 510
Corrosion Allowance
H.
The area of reinforcement must be satisfied for all planes through the center of the
opening and normal to the vessel wall.
NORMAL
ALL PLANES
I. The required cross-sectional area shall be the area of the shell or head required to resist
pressure which is given as A. If the sum of A1+A2+A3+A4 is equal to or greater than A
the opening, is adequately reinforced. If not, more reinforcement must be added. Usually
this be in the form of a reinforcement pad. Its area is found as follows.
A - (A1+ A2+ A3 + A4)= Area required for the repad.
REPAD
A5
This type of problem can get complicated very quickly, mostly by the number of steps
involved. However, the API 510 Exam Body of Knowledge has simplified the problems.
This was done by limiting this type of problem as follows:
API 510
a.
b.
c.
d.
e.
In the following example, the problem will be worked using those guidelines. Remember,
this type of problem is worth no more than simplest Code calculation possible on the exam.
Plan your study time with this in mind. Since the problem may not even be on the if you
spend all your time studying these and nothing else, the outcome is obvious. Also, unless you
are really comfortable with these problems, it is best to do them last. They eat up a lot of
time and you could find yourself rushing through the remaining problems--not a desirable
situation!
API 510
b.
All fr = 1.0
All F = 1.0
All E = 1.0
All required thicknesses are given
There will be no nozzle projecting inside the shell
The inspector should be able to compensate for corrosion allowance. Weld strength
calculations are excluded.
Although it has not been listed under reinforcement, sizing of the fillet welds will probably be
required since it is elsewhere in the material.
The best approach is to work a problem typical of what can be expected and explain each
aspect above as it is required to solve the problem.
Problem:
A vessel made of SA-515-gr. 70 rolled and welded plate is having a 6 inch
NPS schedule 80 seamless nozzle added similar to Fig. UW-16.1 (a) with a
fillet weld of 1/2" in leg dimension. The shell's actual thickness is 7/8 inch.
The nozzle's actual thickness is 0.432", and it has an O. D. of 6.625". A
corrosion allowance of .125" is required.
API 510
Drawing:
t = .432"
leg =.500"
t=.875"
Step 1. Check the fillet weld throat size. The fillet weld throat in this Figure
of UW-16 is indicated as tc. In the nomenclature of paragraph UW-16, t c is
required to be not less than the smaller of 1/4" or 0.707 t min. Our tmin is the
nozzle which is .432".
.707 x .432" = .305" So tc can be no smaller than 1/4"(.250").
Since the throat size of a fillet weld is determined by multiplying .707 times
the leg size and our leg size is given as . We calculate as follows.
.707 x .500" = .353". This is larger than and the throat of the fillet weld is
adequate.
Step 2. Check to see if a corrosion allowance is specified. If so it must be
deducted from the actual thickness of the shell and nozzle prior to
calculations. Also the I. D. of the nozzle must be increased by two times the
corrosion allowance. In our problem the corrosion allowance is .125".
Shell actual t =.875"
Corrosion .125'
Shell t to be used .750" adjusted for corrosion
API 510
Nozzle actual t
Corrosion
Nozzle t to be used
Nozzle I.D.
Nozzle I.D.
Nozzle I.D.
Nozzle I.D.
.432"
-.125
.307" Adjusted for corrosion
O. D. -2(wall t - c.a.)
6.625-2(.432-.125)
6.625-2(.307)
6.625-.614 = 6.01 " Adjusted for corrosion
OR
OR
A41
2
= Outward nozzle weld = (leg) fr2 Area of outward fillet
API 510
c.a. =.125
t shell = .750
I.D. = 6.01
c.a.
125
All dimensions after corrosion allowance
Step 5. List Givens Adjusted for corrosion:
d=
t=
tr=
tn =
trn=
E=
F=
fr=
Leg size =
1.0
nozzle and shell stress allowables the same
. 500
API 510
API 510
API 510
The impact test specimen test plates must be subjected to same heat treatments
as the vessel. The location for removal of specimens from test plates are
described in UG-84 (g). The thickness of a test plate determines the number
of test specimens required and also the location of their removal from the test
plate.
For test plates 1 1/2 inch or less two sets of three (3) specimens must be taken.
One set from the weld with the notch located in the weld as shown in Fig.
UG-84 and one set from the heat affected zone (HAZ) with the notch located
so that as much HAZ material as is possible is included in the resulting
fracture.
For test plates over 1 1/2 inch three sets of three (3) are required. One set
from the weld metal and one from the HAZ. A third set is required to be taken
from the weld metal as near as is possible to the center of the weld.
The acceptance details for these impact tests is found in UG 84 (c)(5)(c)(6)
and in the notes of Fig. UG-84.1. Figure UG-84.1 is used to determine the
minimum acceptable absorbed energy for a set of test specimens. To use
Figure UG-84.1, the material thickness is found along the bottom of the chart.
From that point, move straight up to the line that represents the minimum yield
of the material wider consideration, then left to the value of absorbed energy
required to pass the test. Notice that this value is called an average.
GENERAL NOTES at the bottom of the chart require that no one specimen
shall have an absorbed energy value less than 2/3 of the average required for
all three.
API 510
2.
3.
4.
5.
How many sets of specimens are required for a weld procedure test
coupon 1 3/4
inches thick?
6.
When welding a procedure test plate for impact testing what must the P
No. and
Group No. be? What type of heat treatment must be applied to the test
plate?
7.
Name the two types of test specimens required for all welding
procedures. Hint,.
Where do they come from?
API 510
API 510
2.
3.
4.
5.
API 510
UCS-66 Materials
Step 2. UCS-66 (a)
Turn your attention to Figure UCS-66 impact Test Exemption Curves and
Table UCS-66. The Graph and Table are used to determine the minimum
temperature a material thickness can be operated at without mandatory impact
testing. The graph has four curves: A, B, C and D. In Figure UCS-66 along
with the graph is a listing of carbon and low alloy steels. This listing of
materials is used to determine the curve on the Graph or in the Table for a
given material. After finding the curve for the material, there are two choices.
Use the graph of Figure UCS 66 or the Table UCS 66 to determine the
minimum temperature for a given thickness. It is recommended to use the
Table. The Table and the Graph are the same. The Table is a lot easier to use
with accuracy. USE THE TABLE. If the material thickness is operated at or
above the temperature listed in Table UCS-66, impact tests are not required. If
the material thickness is to operate below the given minimum temperature,
impact testing is required. The temperature found in the table is the MDMT of
that material thickness without Impact Testing being required.
Step 3. UCS-66(b)
When a material in tension is being used at some stress value below its
allowable design stress at the MDMT, a reduction in temperature is permitted
This reduction is subtracted from the given temperature for the material in
Table UCS 66. If after taking the reduction. the resulting temperature is colder
than the minimum design metal temperature desired for the vessel, impact
testing is not required. This is called the coincident Ratio. When a material is
operating at a relatively high temperature it has lower stress allowed than at
room temperature. Many vessels operate alternating between elevated and
low temperatures. The lower stress allowed at the elevated temperature will
require thicker material than needed at the lowest temperature.
The thicknesses required for the two temperatures can be different, and
normally the thickness required for the vessel is determined using the higher
temperature stress allowed. So if at the lower temperature and often lower
pressure we have extra wall thickness we can take credit for. How much is
determined by calculating the coincident Ratio, then entering Figure UCS-66.1
at the calculated Ratio? Normally on the API 510 Exam, the Ratio is stated,
and then all that is required is to apply the graph of Figure UCS-66.1.
If the vessel is in a fixed stationary position and its coincident Ratio is below
1.0, the reduction allowed by UCS-66(b) and Figure UCS-66.1 may be taken
only when the following is true.
(b)(1): The MDMT is - 50F or warmer.
If the MDMT is colder than - 50F.
(b)(2): Impact testing is required of all materials unless (b)(3) applies.
If the MDMT is colder than - 50F but no colder than -150F and the
coincident Ratio of stress is equal to or less than 0.4.
(b)(3): Impact testing is not required.
API 510
UCS-68 Design
Step 4.
UCS-69(a) Design rules for carbon and low alloy steels stipulate requirements
about construction of the vessel or part. The main points are: mandatory joint
types, required post weld heat treatments below -50F unless the vessel is
installed in a fixed (stationary) location, and the coincident Ratio of stress is
less than 0.4.
UCS-68(b) Welded Joints must be postweld heat treated when required by
other rules of this Division or when the MDMT is colder than - 50F and for
vessel installed in a fixed (stationary) location the coincident Ratio is 0.4 or
greater.
UCS-68(c) Notice a reduction of 30F below that of Figure UCS-66 for P-1
materials if post welded heat treatment is performed when it is not otherwise
required in the Code. This means that 30F can be subtracted from the
temperature found in Table UCS-66. If the adjusted temperature is below that
desire, Impact Tests are not required. It is exempt. If a statement about heat
treatment is made in a particular problem the task becomes finding out if heat
treatment was required or not. If it is not mentioned, it must be concluded that
it was not performed and therefore the exemption cannot be taken.
Givens:
Material =
Thickness =
Min. Yield =
MDMT=
Coincident Ratio =
API 510
API 510
Impact tests are required for the values of the MDMT of - 25F.
2.
3.
4.
What is the minimum design temperature allowed for a 1 thick plate of SA-515
Gr. 70"
5.
If the coincident Ratio is 0.6 for the plate of question number 4 what is its new
minimum temperature with out impact tests?
API 510
API 510
Plate is the only pressure vessel material that must always have a Mill Test Report
(MTR)or Certificate of Compliance (C of C) provided. The inspector shall examine
these documents for compliance to the material specification.
2.
All other product forms must be marked in accordance with their material
specification. For examp1e, pipe marked SA- 106 gr. B.
3.
All materials to be used in a vessel must be inspected before fabrication to find as best
as is possible defects which would affect the safety of the vessel. The following
describes the inspections required.
API 510
a.
Cut edges of and parts made from rolled plate for serious laminations,
shearing cracks, etc.
b.
Materials which will be impact tested must be examined for surface cracks.
c.
When forming a Category C corner joint as shown in figure UW-13.2 with flat
plate thicker than , the flat plate must be examined before welding by
magnetic particle or dye penetrant nondestructive examination. Exceptions
from this NDE are given for certain joints of figure UW-13.2 .
d.
The inspector must assure himself that thickness and other dimensions of the
material comply with the requirements of this Division.
e.
f.
The inspector must verify that all required tests have been performed and are
acceptable (Impact tests, NDE, etc.).
g.
The inspector must confirm material I.D.'s have been properly transferred.
h.
The inspector must confirm that there are no dimensional or material defects,
perform internal and external inspections and witness pressure tests.
The official Code U or UM symbol. If Inspected by the Owner/User of the vessel the
word USER shall be marked on the vessel.
2.
3.
4.
5.
6.
Year built.
7.
The type of construction used for the vessel must be marked directly under the Code
symbol by the use of the appropriate letter as listed in the Code.
Type of Construction
Letter(s)
W
P
B
RES
8.
If a vessel is built using more than one type of construction all shall be indicated.
9.
API 510
10.
The MAWP must be based on the most restrictive part of the vessel.
11.
RT 1 When all pressure retaining butt welds, other than B and C associated with nozzles
and communicating chambers that neither exceed NPS 10 nor 1 1/8 thickness have been
radiographically examined for their full length in a manner prescribed in UW-51, full
radiography of the above exempted Category B and C butt welds if performed, may be
recorded on the Manufacturer' Data Report.
RT 2" Complete vessel satisfies UW-11 (a)(5) and UW-11 (a)(5)(b) applied.
RT 3 Complete vessel satisfies spot radiography of UW-11 (b).
RT 4 When only part of the vessel satisfies any of the above.
*A separate section follows which is devoted to the meanings of RT markings:
12. The letters HT must be used when the entire vessel has been postweld heat treated.
13.
The letter PHT when only part of the vessel has been postweld heat treated.
14.
15.
Parts of vessels for which Partial Data Report are required shall be marked by the
parts manufacturer with the following:
"PART"
Name of the Manufacturer
The manufacturer's serial number.
These requirements do not apply to items like manhole covers, etc.
16.
API 510
Certified by
Johns Trailer and Vessel Welding
350 psi at 300F
W
RT 1
HT
L
MAWP
-20F at 200 psi
MDMT
0000001
S/N
1994
Year
API 510
API 510
SECTION IX PART QW
Article I Welding General Requirements
Overview
Since this article covers the requirements in general terms it is often given just cursory
attention or skipped altogether. This is a mistake for anyone wishing to be competent in
applying this section of the ASME Code.
It is mandatory to read every article of Section IX in order to apply the code rules and since
many questions on an exam could come from this article alone, it should not be overlooked.
As an example, the purpose of a welding procedure is given in paragraph QW-100.1. In the
very given next paragraph, welders' performance qualification tests are addressed. In QW100.3 it is stated that a Welding Procedure Specification written and qualified in accordance
with the rules of Section IX may be used in any construction built to the requirements of the
ASME Boiler and Pressure Vessel Code or the ASME B-31 Code for Pressure Piping. In the
next paragraph you are cautioned that other Sections of the Code state the conditions under
which Section IX requirements are mandatory, in whole or in part.
Also in QW-120, QW-130 and QW-132 of this article, test positions are listed with written
definitions and references to Article IV where illustrations of these positions are to be found.
Types and purposes of tests are addressed in the paragraphs of QW-141.1 through QW-141.5,
and all the subsequent paragraphs contain explanations of the tests and examinations
required. Acceptance criteria is listed for each type of test described.
Beginning with QW-190, other types of tests and examinations are listed, most notable being
radiographic and liquid penetrant examinations. Here you are referred to Section V, and then
told the acceptance standards of QW-191.2 and QW-195.2 respectively shall be met.
API 510
Please notice the definitions of essential and nonessential variables given in QW-251.2 and
QW-251.3 Welding Variables Procedure Specifications (WPS) start at QW-252 and end at
QW-265. These paragraphs are in tabular form and cover some fourteen (14) different
welding processes. Within these tables for each process are lists of variables, and whether or
not they are essential, nonessential or supplementary essential. These paragraphs in tabular
form also reference where in the other code paragraphs specific requirements and definitions
can be found.
API 510
In QW-320 retests and renewal of qualifications are divided into two categories. Immediate
retest by mechanical or radiography means, and retest after further practice.
QW-321.1 outlines the mechanical tests and basically says the welder will make two
consecutive test coupons for every position he failed, all of which must pass the test
requirements. Retest by radiography is laid out in QW-321.2. How to handle situations
dealing with further training is found in QW-321.3.
Renewal of a welder's qualification for a process is mandatory when he has not used the
process for the time limits as given in QW-322.1 (a) and (b).
The QW-350 paragraphs have all of the variables for welders and here you will find what
changes to his essential variables will require a welder to requalify.
QW-352 to QW-357 are in tabular form in order to easily determine the essential welders
variables for each process.
QW-360 to QW-364 have the essential variables for welding operators.
API 510
API 510
API 510
Groove Design
Looking in the box labeled joints, we see that information on grooves may be found in
paragraph QW-402.1. A change in groove from double vee to single vee can be made with
only a revision in the WPS.
Here, why not enter All Joints in the WPS? Then you can legally use any you need now or
later. If you specify "U" groove on the WPS, you must use only U grooves in production or
revise the WPS to reflect the new groove. Also, you must use a U groove when performing
the PQR. Although the PQR need not list any of the nonessential variables, the signature of
the manufacturer's representative is testament to using one of the grooves listed on the WPS.
Backing:
The deletion of backing is a nonessential variable specified in QW-402.4. If
we do not want to place unnecessary restrictions on ourselves we can state this variable as
being "With Or Without Backing"; or simply place X's in both blocks..
Root Spacing:
Here again this is a nonessential variable.
possible. Do not leave this blank e.g. 1/32nd to 1/16th inches.
Retainers:
"With or Without" is appropriate. Don't leave it blank. If you are not going to
use retainers you should so indicate. "No retainers used".
Base Metals
In this category there are no nonessential variables. There are only essential and
supplementary essential variables. Supplementary essential variables apply only when
impact properties are required. They put restrictions on the base metal material that can be
qualified with any one PQR. It also puts restrictions on the base metal thickness range that
can be qualified when running a PQR.
Group Number: A change in a group number becomes an essential variable when impact
properties are required of the base material.
T Limits Impact: In QW-403.6 the minimum thickness ranges qualified by impact testing is
called out.
T/t Limits > 8 in.: This is the first essential variable in the base metal category. It becomes
effective when trying to qualify welds greater than 8 inches in thickness.
Change in T Qualified: Essentially it stipulates that the welding procedure depending on the
thickness of the coupon used in the PQR is qualified for a range of base metal thickness. If
base metal thickness goes beyond that qualified, a new PQR will be required.
t Pass > 1/2 in.: This variable speaks to weld passes that deposit a weld metal layer greater
than 1/2 inch in thickness. When weld metal is deposited in a thickness greater than 1/2 in., it
has a different range than lesser thicknesses. A t pass greater than 1/2" limits the base metal
qualified to 1.1 x T, where T is the thickness of the PQR test coupon.
Change in P-No.: Any change in P-Numbers requires requalification of the procedure.
Change in P-No 9 / 10: Here we find changing from P-No. 9A to P-No. 9B is considered a
change but not the reverse.
API 510
Filler Metals
In the filler metal category, all three types of variables apply. The first two have to do with
chemistry and the types of electrodes used in the welding process. The F number is a
grouping of electrodes that have similar characteristics in the way that they produce
mechanical properties. Deposition is also similar among F Numbers. A-Numbers are
chemical limitations and all electrodes that fall under the same A-Number have similar
chemical properties. A-Numbers apply only to ferrous materials.
Change in F-number: Requires requalification of the procedure.
Change in A-Number: Requires requalification of the procedure, except as given in QW404.5, which says that A-No. 1 and A-No. 2 can be exchanged.
Change in Diameter: Since this is a nonessential variable changing it does not demand
requalification of the procedure. However, you should revise the WPS to reflect the change.
Change in Diameter > 1/4 in.: This is used as a supplementary essential variable. It says
that if impact properties are necessary and an electrode of greater than 1/4 inch is used, that
size electrode must be qualified for impact properties in the weld.
Change in AWS Class: Requires requalification as a supplementary variable if impact
properties are required. This is an SFA number given in Section II of the ASME Code.
Change in t: A change in the thickness of deposited weld metal beyond the range qualified.
Change in AWS Class: This is a nonessential variable where impact properties are not
required. It must be addressed on the WPS however.
Position
There are three (3) variables listed for position. Notice that unless impact properties are
required position is a nonessential variable. Again when specifying position as a nonessential
variable, don't box yourself in, Just say "all".
Addition of a Position: Nonessential but the WPS must be revised if one position is given
then another is used in production.
Change in Position: A supplementary essential variable, which becomes essential when
impact properties are required. Specifically when you change from any position to vertical
uphill progression. Also if changing from a stringer bead in the vertical uphill to a weave
bead. Either will require requalification of the procedure.
Preheat
There is one essential variable, one supplementary essential, and one nonessential variable
listed in this category.
Decrease > 100 degrees: If a procedure is qualified at a given preheat, a reduction of that
preheat by greater than 100 degrees in production requires requalification of the WPS.
API 510
Preheat Maintenance: This is the continuance of preheat temperature after the completion
of welding. Will preheat be maintained for a given time or will the weld be allowed to cool
in air and not monitored?
Increase > 100 degrees:(interpass temp.): If the weld requires impact values using the
Shielded Metal Arc process, the interpass temperature must be maintained below some
maximum temperature. If the interpass temperature is increased by more than 100 degrees
over what was qualified, the procedure must be requalified.
Post Weld Heat Treatment
The first variable given is a change in postweld heat treatment. This is an essential variable.
While it is not always necessary to postweld heat treat a material, a change in postweld heat
treatment or the lack of is an essential variable and must be reflected on the WPS and the
PQR.
Change in PWHT: If PWHT will not be performed, this should be indicated on the WPS by
entering the words: No Postweld Heat Treatment" or simply None". If PWHT is required
and then changed from that specified on the WPS, the WPS must be requalified since it is an
essential variable.
PWHT (Time and Temperature Range): Again when impact properties are required of a
weldment, a change in the time span of PWHT or the temperature range will require
requalification of the procedure.
Thickness Limits: As indicated, this is an essential variable. It deals with exceeding the
upper transformation temperature of alloys. It says that if the test coupon being heat treated
exceeds the upper transformation temperature of the alloy the maximum thickness qualified is
1.1 times the thickness of the test coupon as opposed to two times the coupon thickness
allowed if the upper transformation has not been exceeded. See QW-451 for T limits.
Electrical Characteristics
Change in Current or > Heat input: This is a supplementary essential variable that deals with
impact properties. Here if the heat input due to welding is changed or the type of current is
changed resulting in an increased deposition of weld metal the procedure must be requalified
for impact values.
Change in the Type of Current or a Change in the Current or Voltage Range: These are
both nonessential, but if changed in the Shielded Metal Arc Process, the WPS must be revised
to reflect the change.
Technique
Change in String or Weave Bead: Nonessential, but if other than that qualified on the WPS,
the WPS must be revised to reflect the change for production.
Change in Method of Cleaning: Same as above.
Change in Method of Back Gouge: Same as above.
API 510
Backing is often over looked. Since the addition or deletion of backing is a nonessential
variable the best course would be to state with or without in the WPS. Retainers and Root
Gap must also be listed on the WPS. These should not be left blank.
Sizes of electrodes are again nonessential and listing all sizes that are manufactured of a
certain classification that will be used for production is wise. If a 1/32nd rod is given for
WPS and 1/8th is used for production the WPS will need to be revised.
Finally, check each category of variable required on the SMAW table QW-253 to see if it has
been addressed on the WPS. If it is given as not applicable, make sure that it is a true
statement. If it is left blank, by very definition, that is an error. Also, check the specifications
to see that they are given correctly and match on the WPS and PQR.
If we are given a E-7018 filler metal and it is listed as having a F-number of 3, is that correct?
It is given in table QW-432 as having a F-No. of 4. To recap, if a variable; essential,
nonessential and if needed supplementary essential variable is listed in the paragraph for a
process, it must be addressed on the WPS.
API 510 Body of Knowledge has a step by step procedure for the review or WPS's and
PQR'S. The approach starts with the review of last page of the PQR. The following is a
reproduction of that fist with added comments to help with clarification
a. It must be determined if impact tests are present. The reason of course is because if
impact tests are present, supplements essential variables do apply to the review. If
they are present, it then becomes a bit more difficult to review the documents.
b. At the bottom of the PQR is a signature line for the manufacturer. This line must
contain a signature, not a typed name.
c. Turn to the front of the WPS and verify that the WPS references the PQRs number.
The reverse is not true the PQR may or may not reference the WPS. A WPS can be
written from a very old PQR and often is.
d. Place the WPS and PQR side by side and verify that:
1. All essential (and supplementary essentials if present) variables are present have
been addressed on the WPS and PQR. By using the paragraph in Section IX
Article II, that applies to the process used, check each box in the WPS and PQR
against the Code paragraph line by line.
2. The essential variables on the WPS must be supported by the PQR. Is the post
weld heat treatment required on the WPS and is it present on the PQR, etc.?
e. Review the WPS for the presence of all nonessential variables that are required of the
welding process used. If peening is present in the Code paragraph that applies to the
process, it should be mentioned directly in the WPS 'No Peening' for example. That
line should not be blank or contain N/A . Peening is applicable or it would not be
present in the Code paragraph.
f. Look at the PQR. Are all the mechanical tests present? Are they of the correct types
and of the correct number.
g. Check for mistakes such as the wrong P number for a material, Wrong F number for a
welding rod, etc.
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Joints (QW-402)
1. Joint (groove) design is addressed, i.e. not blank. No mistake here.
2. Backing is addressed. The two x's are to indicate with or without backing.
3. Backing addressed as metal in the box below, however retainers are not addressed.
This is the first mistake - RETAINERS NOT ADDRESSED
4. Root spacing has been addressed by the sketch.
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4. A-No. addressed as #1. This is correct for mild carbon steel electrodes, the A-No.
will not change until an alpha numeric is added to the end of an electrode designation.
For example if the electrode listed been listed as E-7018 B2, this would indicate that
the deposited weld metal had a different chemistry and that its A-No. would be other
than #1. There is no way to determine directly the A-No for these modified electrodes
in Section IX. If the chemistry of such an electrode's deposited weld metal is known it
may be compared that given for the various A-Nos. and identified in that way. The
only thing known for sure is that it cannot be an A-No. 1 when it contains something
like Al or C2 behind the AWS numbers.
Weld Metal (QW-404)
1. Thickness Range - Since we are using only one electrode for production the weld
metal thickness range will be same as the base metal thickness range. This means this
could be left blank and would be answered by default. To better understand this, look
at the WPS, notice we have spaces to list up to three electrodes. For example, say we
used E-6010 and E-7018, then each would require a weld metal thickness range.
2. The remaining spaces are for information only and can be left blank if so desired in
the case of the SMAW process. This would not be true if another process were used
which required this information.
Reminder-All variables that apply to a given welding process must be addressed on the
WPS (notice this is not true of the PQR). This includes Essential, Supplementary Essential
(only when notch toughness applies), and Non-essential.
Back of the WPS
Positions (QW-405)
1. Positions are instructions to the user, that is what positions are permitted in the
production of a weld using this WPS. It is a nonessential variable as listed in QW253. It has been addressed and therefore no mistake exists. Think about, it would
rather be difficult to use a WPS that only allowed the 6G position. In most cases such
a WPS would be revised or re-written to include more than a single position. This is
not however a mistake, since the non-essential variable has been addressed.
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Preheat (QW-406)
1. The minimum preheat has been given as 60F. Preheat becomes essential when
welding is performed with a preheat greater than 100F less than that stated on the
WPS. In this WPS it would require that welding preheat be lowered to -39F. Preheat
must be stated on the WPS, it is needed to confirm that the PQR was not performed
with a preheat more than 100F below that stated for production welds on the WPS.
There is not a mistake unless preheat is riot given. Some WPS's simply state Warm
to the touch.
2. The interpass temp is listed, and thats fine however it is not required on this WPS
because there are no toughness test results present on the PQR.
3. Preheat maintenance is not addressed, this is an error by omission. All essential and
nonessential variables listed for a given process must be listed. The important thing
to remember is that preheat maintenance is listed in QW-253 for the SMAW process,
and it must be addressed. The statement None would have been good enough.
Gas (QW-408)
1. Shielding gas is not used with this process-ignore this block for SMAW
Technique (QW-410)
1.
2.
3.
4.
5.
6.
7.
8.
1.
This form listing details of different process passes and filler metals. With only
one filler metal and process such as we have in this WPS/PQR it is normally left blank. If
it is not and any differences are found with it and the body of the WPS they are
API 510
meaningless and should be ignored. DO NOT list any of these as mistakes on the answer
sheet.
Recap of mistakes found on the WPS
1.
2.
3.
4.
The first statement to be made about review of a PQR is that PQRs do not require nonessential variables be listed on them. Confirmation of this statement is found in paragraph
QW-200.2. Since non-essential variables need not be recorded on the PQR they can be and
should be totally ignored during the PQR review. There cannot be a mistake on a nonessential variable listed on a PQR. It is not required to be there and if it is, it cannot be
wrong. WPSs can be written from PQRs that are very old, the interest in the PQR is in the
essential variables that it supports. These include the P No., F No., base metal thickness,
postweld heat treatment, and the rest of the essential variables for a given process.
Front of the POR
Joints (QW-402)
1.
Blank not a mistake, doesn't need to be addressed (non-essential)
1.
2.
3.
4.
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Toughness tests have not been performed, fillet weld tests don't apply to groove weld
procedures, and we have already checked for a signature.
Second WPS/PQR review
Remove Wee Welders WPS and PQR from the appendix and review those for mistakes
just as was done with Confusion Weldings WPS and PQR.
The mistakes are as follows see if YOU agree.
API 510
Back of PQR
Toughness test results are not present so Supplementary Essential Variables do not
apply during the review.
The PQR has a typed name and not a signature. This is a mistake!
WPS
API 510
API 510
T-273 says that direction of the central beam should be centered on the area of interest. T-274
lists a formula for the determination of Geometric Unsharpness; each variable in the formula
is explained. T-275 requires the use of location markers and that they be placed on the part
and not the exposure holder/cassette. The graphics in Figure T-275 detail the different
locations of the markers.
T-275.1 Single Wall Viewing contains information on placement of location markers. There
are three situations: Source Side markers, Film Side Markers and either Side Markers in this
sub paragraph.
Image Quality indicators are to be selected in accordance with T-276. You are referred to
Table T-276 for both penetrameters hole type designation the essential hole and the wire size
of Wire type indicators are listed. Table B-220 of Article 2, Non-mandatory Appendix B may
be used to determine approximate equivalence between hole penetrameters and wire
penetrameters.
T-276.2 (a) Welds with Reinforcements states that the thickness of the penetrameters is based
on the nominal single wall thickness plus the estimated weld reinforcement not to exceed the
maximum allowed in the referencing Code Section. Backing rings or strips are not
considered during penetrameter selection.
T-277 begins the particulars of use for penetrameters. T-277.1 states where they are located.
T-277.2 deals with how many penetrameters are required.
T-277.3 limits shims placed between the hole type penetrameters and the part to a material
radiographically similar to the weld metal, Shims shall exceed the penetrameter dimensions
such that the outline of at least three sides of the penetrameters image shall be visible in the
radiograph.
T-280 Evaluations starts with T-281 Quality of radiographs. Contained in T-281 are such
things as the condition of the radiograph. The film shall be free of mechanical, chemical or
other blemishes so as not to mask or confuse the image in the area of interest. T-282.1 renders
density limitations with the actual values listed.
T-282.2 allows for variation of density through the area of interest. It is limited to minus
15% to plus 30% from the body of the hole penetrameter or adjacent to the designated wire of
a wire type penetrameter. Also the exceptions for shim use are detailed.
IQI Sensitivity requirements of T-283 are stated as being sufficient to display the hole
penetrameter and its designated hole. Wire types shall display the designate wire size.
Restrictions are in this sub-paragraph.
T-284 Excessive Backscatter says that the letter "B" should not appear as described in T-223.
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T-285 Geometric Unsharpness Limitations as calculated using the formula of T-274 shall
conform and not exceed those listed in this subparagraph based on material thickness. T-291
deals with documentation minimum requirements. T-292 states that the manufacturer shall
examine and interpret the radiograph prior to submittal to the inspector.
Nonmandatory Appendix A of Article 2 contains technique sketches for pipe or tube welds.
Other techniques may be used. Appendix B compares hole wire sizes. Appendix C gives
sketches for hole types penetrameter placement, again nonmandatory.
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Penetrant can be applied by any suitable means, such as dipping, brushing or spraying other
techniques of application are also contained here in subparagraph T-642.
T-643 specifies Penetration Time (dwell) as critical and references the SE Standards given in
T-610.
T-644 Excess penetrant removal is required by this paragraph only after the specified
penetration time. Methods of penetrant removal begins in T-644.1 with water washable.
T-644.2 talks to Post Emulsifying and T-644.3 addressees Solvent Removable penetrant.
Development of the penetrant shall be applied as soon as possible after penetrant removal
according to T-646. The thickness of coating must be controlled so as to draw out any
indications or conversely mask an indication.
Information on the application of Dry and Wet Developers is contained in T-646.1 and T646.2 respectively.
Interpretation of penetrant test directions begin in T-647.1. Final interpretation shall be made
within seven (7) to thirty (30) minutes. The developing time is specified in T-646.3.
Paragraphs T-647.2, T-647.3 and T-647.4 pertain to the particulars of interpretation.
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API 510
ADVANCED MATERIAL
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Case 1. To determine static head based on an elevation from a stated problem it must be
understood that elevations are normally taken from the ground level for an existing
vessel including any base the vessel is on. You must subtract the GIVEN elevation
form the TOTAL elevation to determine vertical feet of static head above the given
elevation.
Example: A vessel has an elevation of 18 feet and is mounted on a 3 foot base. What is
the static head pressure of water at the 11 foot elevation which is located at the
bottom of the top shell course?
7
11
18
You must realize it is the number of vertical feet above the GIVEN elevation in question
which causes the static head at that point. To find the static head you must subtract the
elevation of the GIVEN point from the TOTAL elevation given for the vessel.
18' feet total
-11' desired point
7' total static head
Static head pressure at 11' elevation is: 7 x 0.433psi = 3.03 psi
API 510
Case 2. Static head at a point in a vessel must be added to the pressure used (normally vessel
MAWP) when calculating the required thickness of the vessel component at that
elevation.
Example: Determine the required thickness of the shell course in Case 1. The vessel's
MAWP (Always measured at the top in the normal operating position) is 100 psi. The
following variables apply:
Givens:
t=?
t=
SE - 0.6P
S=
E=
R=
15,000 psi
1.0
20
Since the bottom of this shell course is at the 11 foot elevation the pressure it will see is 100
psi + the static head.
or
100 + 3.03 = 103.03 psi
103.03x20
20606
t=
=
(15,000 x l.0) - (0.6 x l03.03)
API 510
= .1379"
14938.18
Case 3. You must subtract static head pressure when determining the MAWP of a vessel. If
given a vessel of multiple parts and the MAWP for each of the parts, the MAWP of the entire
vessel is determined by subtracting the static head pressure at the bottom of each part to find
the part which limits the MAWP of the vessel.
Example:
A vessel has an elevation of 40 feet including a 4 foot base. The engineer has
calculated the following part MAWPs to the bottom of each part based on each part's
minimum thickness and corroded diameter. Determine the MAWP of the vessel.
Design pressure at the bottom of:
Top Shell Course 28' Elev. 406.5 psi
Middle Shell Course 16.5' Elev. 410.3 psi
Bottom Shell Course 4' Elev. 422.8 psi
12
406.5 psi
28
40
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406.5 psi
28
23.5
40
410.3 psi
16.5
40.0' elev.
-16.5' elev.
23.5' head
406.5 psi
28
36
410.3 psi
16.5
422.8 psi
4
API 510
The final step in determining the MAWP of the vessel at its top is to subtract the static head
of water from the calculated MAWP'S at each given point. The lowest calculated pressure
will be the maximum gage pressure permitted at the top of the vessel.
Bottom of top shell course 406.5 5.196 = 401.3 psi
Bottom of mid shell course 410.3 - 10.175 = 400.125 psi
Bottom of btm shell course 422.8 - 15.588 = 407.212 psi
Therefore the bottom of the middle shell course MAWP determines the MAWP of the entire
vessel.
400.125 psi
Static Head
10.175 psi
410.3 psi
16.5
40
API 510
Case 4. As part of calculating hydrostatic head on a vessel you will be required to determine
the depth of two types of heads, 2 to 1 ellipsoidal and hemispherical. You will be given only
the diameter of the vessel and using this you must calculate the head's depth which in turn is
used to find the hydrostatic head at the bottom of the head.
Example:
A vessel has an inside diameter of 48 inches. Determine the depth of a
hemispherical and a 2 to 1 ellipsoidal head with a 2 inch straight flange. The approach here is
based on the fact that the heads diameters will match the vessel's diameter and therefore will
be the same. In this case 48 inches.
Hemispherical Head
Our hemispherical head has an inside diameter of 48 inches which means it has a radius of 24
inches. The radius is the depth of the Hemispherical head
Shell I.D. 48
Radius 24"
Depth 24"
API 510
2 to 1 Ellipsoidal Head
An ellipsoidal head's I. D. will be the same as the shells. The inside diameter of an
ellipsoidal head is also its major axis. This fact is the basis of finding the depth of a 2 to 1
ellipsoidal head. Notice that we are strictly talking about 2 to 1 ellipsoidal heads.
The 2 to 1 refers to the ratio of the Major Axis to the Minor Axis of a ellipse which is used to
form the head.
Of course only half of the Minor Axis is used for the head.
2 to 1
Major Axis
48"
1/2 Minor AXIS
12
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14 depth
70
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To find the total hydrostatic head on the hemispherical head at its bottom you must add all of
the head that exists above it including the shell and the ellipsoidal head. We calculate as
follows.
70' total elevation
-8 to the top of hemi head
62' hydrostatic head
+ 2.666 depth of hemi head
64.666 total feet head
64.666' x 0.433psi 28.0 psi to the bottom of the hemi head.
0.6495 psi
70
8
28.0 psi
API 510
A 100 foot tall column is being hydrostatically tested. The vessel's MAWP is 100 PSI
at 750F. The vessel's material has an allowable stress of 13,500 PSI at MAWP, its
material allowable stress at 70F, the test temperature is 15,000 PSI. What is the
required hydrostatic test pressure?
B.
The vessel above is under full hydrostatic test pressure in an operating unit during the
summer. A plant wide evacuation alarm sounds and all test personnel leave. Four
hours later, upon the all clear, the test crew finds that the gauge pressure on vessel has
risen to an unacceptable pressure. How could this have been avoided?
C.
The test gauge for the test above is located at the 30' elevation of the vessel what will
be its gauge pressure during the test and at what pressure shall the visual inspection
take place as read from the gage at the 30' elevation?
API 510
ANS/UG-99
Solution A: Hydrostatic Test Pressure Per UG-99(b)
15,000 PSI
x 1.5 x 100 = 166.66 PSI
13,500 PSI
Solution B:
Per UG-99(h), a relief valve set at 1 1/3 the pressure could have been installed.
Solution C:
2/3 x test pressure plus static head at 30' elevation. Per UG-99(g)
API 510
196.97
.300
.349
60-0
.440
.595
API 510
Solution A:
TOP COURSE.
Metal loss equals the previous thickness minus the present thickness.
Previous .3125"
Present -.3000"
.0125 Metal Loss
SECOND COURSE.
Corrosion rate equals metal loss per given unit of time.
Previous .3750"
Present -.3490"
.0260" Metal Loss
Total loss 0.260"
Corrosion Rate = --------- .006" / Per YR.
Total time 4.5 Years
THIRD COURSE.
Remaining Corrosion Allowance equals the actual thickness minus the required thickness.
Original Thickness
Original Corrosion Allowance
Required Wall Thickness
Actual Wall Thickness
Required Wall
Remaining Corrosion Allowance
API 510
.500"
-.125"
.375"
.440"
-.375"
.065"
BOTTOM COURSE.
Remaining service life equals the remaining corrosion allowance decided by the corrosion
rate.
1.
Required Thickness
Original Thickness
Original Corrosion Allowance
Required Thickness
2.
.625
-.125
.500
3.
.595
-.500
.095
Corrosion Rate
Original Thickness
Present Thickness
Metal Loss
.625
-.595
.030
Metal Loss
.030
Time
=0067 / Year
4.5 Years
Corrosion Rate = .0067 / Year
4.
.095
= 14.2 Years
Corrosion Rate
.0067 / Year
Remaining Service Life = 14.2 Years
API 510
TYPE 1 CAT. A
FULL RT
t=?
60
TYPE 1
SPOT
CAT. B
RT
Givens:
tr = ?
D = 60.0"
R = 30"
P = 350 + 11 psi static head
S = 17,500 from stress table
E = 1.0 per UW-12 (a)
UG-27(c)(1) CIRCUMFERENTIAL STRESS
PR
t=
SE - 0.6 P
361 x 30
t=
= .6266
(17,500 x 1.0) (0.6 x 361)
ANSWER T = .6266
API 510
Cat A Type 1
.500 t
40" O.D.
Givens:
t= .500"
P= ?
S=
13,000 from stress table
E=.85 RT 3 for Type 1
OD = 48.0"
RO = 24.0"
APPENDIX 1
SEt
P=
RO - 0.4t
SOLUTION:
13,000 x .85 x .500
P=
= 232.24 psi
(24.0) - (0.4 x .500)
API 510
t=?
48
Givens:
t = .500"
D = 48.0" L = 24.0"
P = 500 PSI + (0.433 psi x 4') = 1.732 = 501.732
S = 15,000
E = .70
UG-32(f)
PL
t=
2SE - 0.2 P
501.732 x 24.0
tR =
= .5761
(2 x 15,000 x 0.7) - (0.2 x 501.732)
Answer: NO.
API 510
.375
36
Givens.
t = .240"
D = 36.0" + [(.375 -.240) x 2] = 36.0 + .270 + 36.270" adjusted for corrosion!
P = 175 PSI + 5.3 psi static head = 180.3 psi
S = 13,500
E= 1.0 from UW-12(d)
UG-32(d)
PD
t=
2SE - 0.2P
180.3 x 36.270
tR =
= .242
(2 x 13,500 x 1.0) - (0.2 x 180.3)
.240" < .242"
Answer: NO
API 510
Givens:
t = .750
ts = .500
tR = .375
P = 300
S = 15,000
D = 36.0"
E = 1.0 Because the flat head is seamless.
C= .33 x m = 33 x .375 = .33 x .750 = .247
.500
UG-34(c)(2)
t=d
CP/SE
.247 x 300
t = 36.0
15,000 x 1.0
74. 1
t = 36.0 X
= 2.53 inch
15,000
Answer: NO.
API 510
.375
36
Givens:
t = .375 (formed head)
P = 150
S = 15,000
E = 1.0 Seamless. Flat Head
C = 0.25 per UG-32 (o)
d = 6.0
t=d
CP/SE
(0.25)(150)
t = 6.0
=0. 300
(15,000) (1.0)
0.375" > 0.300"
Answer: No repairs are required. The flat spot meets t required for an
equivalent flat head. See UG-32 (o), found near the end of UG-32.
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API 510
Notch
Location
WELD
WELD
WELD
WELD
WELD
WELD
HAZ
HAZ
HAZ
Notch
Type
v
v
v
v
v
v
v
v
v
Test
Temp.
-25F
-25F
-25F
-25F
-25F
-25F
-25F
-25F
-25F
Value
ft/lb's
21
20
15
22
22
14
19
19
20
UG-84 WPS
SOLUTION:
Step (1)
Per UG-84(h)(2)(c) the test specimens must meet or exceed the values for the
thickness of the range qualified in the welding procedure. Per QW-451.1 Section IX. This
procedure will be qualified from 3/16 inch to 8 inches.
Therefore:
Going to Table UG-84.1 and entering on the bottom line at any value greater than 3
inches, then moving up to the 38 KSI curve, then across to the minimum impact values on
the left, we find a minimum impact value of 18 ft./lbs.
Step (2)
(a)
(b)
Calculate averages
W-1 21
W-4 22
W-2 20
W-5 22
W-3 +15
W-6 +14
56 3 = 18.6
58 3= 19.3
H-1 19
H-2 19
H-3 +20
58 3= 19.3
(c)
Note (b) of Figure UG-84.1 states that one specimen shall not be less
than 2/3 the average energy required for three specimens. Only one (1)
specimen is allowed to fall below the min. avg. of three per UG-84(c)(6).
The minimum acceptable value of a single specimen is as follows:
Acceptance values = 2/3 x 18 = 12
Answer: All values meet minimums and the procedure's impact tests pass.
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API 510
SEt
P=
R0 - 0.4t
Givens:
t original = .875 "
t present = .745 "
P=?
S = 15,000 psi
E = 1.0
R0 = 14.87" R0 = 30/2 = 15-(.875-.745) = 15-0.13 = 14.87" this adjusts the o.d. wall loss
P= 15,000 x l.0 x .745 = 766.88 psi
14.87 - (0.4 x .745)
The trick here is knowing to adjust the outside radius for corrosion, remember it will decrease
when there is external corrosion. The opposite is true for internal corrosion.
2.
From: UG-27 (c)(1)
SE - 0.6P
Givens:
t req. = ?
P=
375 psi
S=
17,500 psi
E=
.90
t=
PR
R = 36 / 2 = 18
375 x 18
t=
=.4347"
(17,500 x .90) - (0.6 x 375)
In order to take .90 for the E on the category A joint, it must have full RT and the
circumferential joint must meet the spot RT required by UW-12(a),
API 510
3.
P=
SEt
R + 0.6t
Givens:
t =
.875
P=
?
S=
13,000 psi
E=
.80
R=
60 / 2 = 30
13,000 x .80 x .875
P=
= 298.11psi
30 + (0.6 x .875)
4.
PR
SE - 0.6P
t=?
P = 650 psi
S = 15,000 psi
E = 1.0
R = 50 / 2 = 25
650 x 25
t=
= 1.112
(15,000 x l.0) - (0.6 x 650)
Here you must remember that UW-12(a) will not allow the use of a joint E from
column A unless the requirements of UW-11(a)(5) have been applied. If the spot RT had not
been performed the E would be taken from column B and have a value of .85.
API 510
5.
t=
PR
or P = SEt
SE - 0.6P
R - 0.6t
Givens:
t = 1.28
P = 200 PSI
S = 14,800 psi
E = 1.0
R = 14 / 2 = 7' x 12 = 84" Inside radius corroded = 84 + (1.375 -1.28) = 84.095
t=
200 x 84.095
= 1.145" or P = 14,800 x l.0 x l.28 = 223.23psi
(14,800 x 1.0) - (0.6 x 200)
84.095 + (0.6 x l.28)
The answer to the question is YES it may remain in service. Notice that since both pressure
and thickness are known that either calculation can be made. It does not matter which is
used.
API 510
t=
0.855PL
SE - 0.1P
(Torispherical Formula)
Givens:
t=?
P = 250 psi
S = 14,800 psi
E = 1.0
L= 50" crown radius
0.855 x 250 x 50
t=
= .7487
(14,800 x l.0) - (0.1 x 250)
2.
t=
PD
2SE - 0.2P
Givens:
t=?
P=
250 psi
S=
14,800 psi
E=
.85
D = 50" inside diameter
250 x 50
t=
= .4978
(2 x14,800 x .85) - (0.2 x 250)
3.
t=
PL
2SE - 0.2P
Givens:
t=?
P = 250 psi
S = 14,800 psi
E = .85
L = 36.115" inside spherical radius
250 x 36.115
t=
= .3595
(2 x14,800 x .85) - (0.2 x 250)
ANSWER: NO
API 510
CP
t=d
SE
GIVENS:
t=?
t = .505" actual thickness of the shell
P= 250 psi
S =for head material 15.500 psi
S =for shell material 17,500 psi
d = for head 36"
D = for shell 36" inside
E = 1.0 for a seamless head
C=?
Step 1.
From: UG-27 (c) (1) we use the t = formula to find that the shell's required which is
.259" remember to use the shell's material stress in this calculation.
Step2.
Using the actual thickness of shell and its calculated reg. thickness find "m"
tr
m=
=
ts
Step 3.
.259
= .51
.505
API 510
APPENDIX
API 510
API 510
Use full page dividers as tabs, these allow the turning of a large numbers of pages
without difficulty. The stick on kind will tear out the page holes.
2.
Use the API Body of Knowledge and this text book to tab the important pages of all
of the ASME Code books. Below is a listing of the minimum number of suggested
tabs for each of the ASME Code books. Also write on both sides of the tabs in order
to go back and forth easily.
Section VIII
PV definition U-1
Mill Under Tolerance UG-16
Corrosion UG-25
Thickness of Shells UG-27
Formed Heads UG-32
Opening UG-36
Material UG-77
Markings UG-116
Service Restrictions UW-2
Joint Categories UW-3
Radiographic Exam UW-11
Joint Efficiencies UW-12
Attachment Welds UW-16
Procedures for PWHT UW-40
Heat Treatment Carbon and Low Alloys UCS-56
Impact Tests UCS-66, 67, 68
Appendix 1 (1-1) Formulas for OD calculations on shells
Appendix L Example Calculations
API 510
Section IX
Article I
1.
2.
3.
4.
Article II
5.
6.
7.
Article III
8.
9.
10.
11.
QW-300 General
QW-301 Tests
QW-320 Re-tests and Renewal
QW-350 Welding Variables for Welders
Article IV
12.
Weld data
13.
P-Numbers
14.
Alternate Base Metal
15.
F- Numbers
16.
Definitions
Section V
Article 2 Radiography
1.
2.
3.
4.
5.
6.
Article 5 Ultrasonics
1.
T-522 Written Procedures
2.
T-534 Checking and Calibration
3.
T-542.7 Examination of Welds
4.
T-590 Reports and Records
Article 6 Liquid Penetrant
1.
2.
3.
4.
API 510
T-621 Procedure
T-650 Procedure / Technique
T-670 Examination
T-676 Interpretation
Page 227 of 310
API 510
(WPS)
(See QW-200.1. Section IX. ASME Boiler and Pressure Vessel Code)
See section IX for samples
(WPS)
(See QW-200.1. Section IX. ASME Boiler and Pressure Vessel Code)
API 510
D
B
API 510
UW-11
1. Category A joints in nozzles and communicating chambers and category B joints in
nozzles and chambers which exceed either 10 NPS or 1 - 1/8 wall thickness.
2. The category A joint must be fully radiographed and the spot radiography of UW-11 (a)
(5)(b) must be applied per UW- 12 (a).
3. Full radiography for all butt joints which exceed the specified thickness, excluding the
category Bs that do not exceed the 10" NPS or 1- 1/8 inch thickness.
4. It may not be assumed that all joints have been radiographed. The thickness of some
joints may not exceed the limit for the material used. Remember it is the least nominal
thickness at the welded joint which determines the requirement.
5. Both joints must be radiographed by the requirement that all A and D butt welds shall be
shot.
UW-12 # 1 page 91
1.
2.
3.
4.
5.
6.
7.
E=
E=
E=
E=
E=
E=
E=
UW-12 # 2 page 92
1. E = 1.0 based on full RT of all category A and D joints and the spot RT applied to
the category B joint attaching the Ellipsoidal head (see UW-12 (a)).
2.
E = .80 based on the joint E from column B of the welded joint used for the
Ellipsoidal head
3.
4.
5.
6.
7.
E = .80 based on the joint E from column B of the welded joint used for the head and
spot RT.
API 510
UG 27
1.
t=
PR0
SE + 0.4P
Givens:
t=?
P = 500 psi
S = 15,000 psi
E= 1.0 per UW-12 (d)
R0 = 12.75 / 2 = 6.375
500 x 6.375
t=
= .2097
(15,000 x l.0) - (0.4 x 500)
2.
t=
SEt
R + 0.6t
Givens:
t=
P=
.850
?
S=
E=
R=
15,000 psi
1.0
52
15,000 x 1.0 x .850
P=
= 242.81 psi
52 + (0.6 x .850)
ANSWER:
MAWP is 242.81 psi
API 510
UG 32
1.
t=
PD
2SE - 0.2P
Givens:
t=
?
P=
350 psi
S=
15,000 psi
E=
1.0 full RT per UW-11 (a) (1) in butt joints in shells and heads
D=
48" inside diameter
350 x 48
t=
= .5613
(2 x 15,000 x l.0) - (0.2 x 350)
ANSWER: required t = .5613"
2.
t=
0.885PL
SE - 0.1P
Givens:
t=
.353
P=
100 psi
S=
13,800 psi
E=
1.0
L=
56" crown radius
0.885 x 100 x 56
t=
= .3593
(13,800 x l.0) - (0.1 x 100)
ANSWER:
API 510
UG-32
3.
t=
PL
2SE - 0.2P
Givens:
t=
?
P=
200 psi
S=
17,500 psi
E=
Spot RT. 85
L=
32.0" inside spherical radius (D/2)
200 x 32.0
t=
= .2154
(2 x 17,500 x .85) - (0.2 x 200)
ANSWER: the required thickness =.2154"
4.
t=
PD
2SE - 0.2P
Givens:
t=
?
P=
200 psi
S=
17,500 psi
E=
.85 No spot RT per UW-12(d)
D=
64.0"
200 x 64
t=
= .4308
(2 x 17,500 x .85) - (0.2 x 200)
ANSWER: thickness required =.4308"
API 510
UG-34
CP
1. 4. From: UG-34 (c)(2)
t=d
SE
Givens:
t=?
t = .500" actual thickness of the shell
P = 75 psi
S = for head material 13,800 psi
S = for shell material 15,000 psi
d = for head 42"
D = for shell 42" inside
E = 1.0 for shell calculation (Shell E is always 1.0 for a flat head calculation)
E = 1.0 per UW-12 (d), this is a forged head but is treated like a formed head. Read the
paragraph for the Fig UG-34 (b-2)
C= 0.33 x m = ?
Step 1. Calculate the Shell's required thickness
From: UG-27 (c) (1) we use the t = formula to find that the shell's required which is .
1053" remember to use the shell's material stress in this calculation.
Step 2. Using the actual thickness of shell and its calculated req. thickness find "m"
tr
.1053
=
ts
=.2106
.500
= 1.3846"
API 510
See answer #1. It is the exact same problem. The important aspect of these problems
is how the C is arrived at. If the C is the same the answer will be the same if in fact it
is a replacement head made of the same materials!!!
UG-28
D0
values 10
t
Testing to see if this paragraph applies.
(1)
Cylinders having
D0=54
D0
54
=
= 48.08
t =1.123
1.123
60,000
=
3(48)
= 416.66 psi
144
416.66 psi > 350 psi ANSWER: YES, your answer may be slightly different
+or5% due to the variation in reading the factor A and B charts. This is
acceptable.
API 510
2.
L= 105
P=
900 psi
emp. = 800F
t=
.730
L=
105
D0 = 5.98"
S=
10,200 psi
D0 =
5.98"
t = .730
Check ratio of D0/t
= 5.98/0.730 = 8.19
8.19<10
D0/t<10
Therefore, use UG - 28(c)(2)
Step 1. Using the same procedure as given in UG-28(c)(1) obtain the value of
B.
Determine the ratio for L/D0 and D0/t
L/D0 = 105 / 5.98 = 17.55 D0/t = 598 / 0.730 = 8.19
[From UG-28(c)(1)]
API 510
Step 2. Using the value of B obtained above calculate the value Pal using the following
formula:
2.167
Pa l =
- 0.0833 B
D0/t
2.167
Pal = 8.19 - 0.0833 11,800 = 2139.2 psi
Step 3. Calculate the value of Pa2 where S is the lesser of 2 times the maximum allowable
stress in tension at the design metal temperature from the stress tables or 0.9 times the yield
strength of the material at design temperature. Values of the yield strength are obtained from
the applicable material chart as follows:
(a).
For a given temperature curve determine the B value that corresponds to the
right hand side termination point of the curve.
(b).
Pa2= 2S
D0/t
1- 1
D0/t
Pa2= 2 x 20,400
8.19
1- 1
8.19
API 510
UG-99 / 100
16,700
1. A.
1.5 x 225 x
= 383.41psi
14,700
B.
2 /3 x 383.41 = 255.61psi
C.
Minimum gage range 1-1/2 x 383.41 = 575 psi (use 600 psi)
Maximum gage range 4 x 383.41 = 1533.64 psi (use 1500 psi)
Of course the gage measure would be rounded up or down to closest standard range!
2. A.
B.
API 510
Raise the Pressure to 1/2 the test pressure x 310 psi = 155 psi
Raise the pressure in steps of 1/10 of the ultimate test pressure 310 psi = 31 psi
1.
155+31 = 186 psi
2.
186+31 = 217 psi
3.
217+31 = 248 psi
4.
248+31 = 279 psi
5.
279+31 = 310 psi
6.
2/3 x 310 = 248 psi inspection pressure. Notice that this is the same pressure
as found in step three on the way up to test pressure.
UW-16
Throat = Leg Size x .707
Leg Size = Throat / .707
1.
2.
Leg Size = .600 / .707 = .8486 therefore the next 1/16 would be a 7/8 inch leg.
13 / 16< .8486 < 7/8 (14/16) or .8125<.8486<.875
UG-40 / 41 / 42 / 45
1.
Ratio = 15,000 / 14,800 = 1.0135 therefore use 1.0 credit cannot be taken for the
higher
strength of the pad's material, only the reverse is true, that is you must reduce the area
that the pad provides if it is of a lower strength than the shell.
2.
The centers can be no closer than the sum of their diameters and still be considered
isolated openings, in this case 6 + 4 = 10 inches. The answer is: their centers can be
no closer than 10 inches with out the areas of reinforcement overlapping.
3.
The area of reinforcement must that of a hole which would contain all of the nozzles
with in it. It is treated as if it were on large hole for reinforcement calculation.
UG-37 Reinforcement
1.
2.
3.
API 510
Corrosion allowance must be deducted from all surfaces in contact with the corrosive
substance.
A= d tr F +2tn tr F(1-frl) Area required
Answer: 4 points for the reinforcement and 4 points for the hydrostatic calculations.
Which one takes the most study time? Which one of these are you most likely to do
in actual practice? Which one of these is the most likely to be on the exam?
UG-84
1.
2.
3.
4.
5.
6.
7.
UG-20 / UCS-66 / 68
1.
2.
3.
4.
5.
1.
P = Set / R0 - 0.4t
Givens:
toriginal = .875 "
tpresent = .745
P=
?
S=
15,000 psi
E=
1.0
R0=
14.87 R0= 30 / 2 =15-(.875-.745) = 15-0.13 = 14.87 this adjusts the o.d.
wall loss
15,000 x l.0 x .745
P=
= 766.88 psi
14.87 - (0.4 x .745)
The trick here is knowing to adjust the outside radius for corrosion, remember it will
decrease when there is external corrosion. The opposite is true for internal corrosion.
API 510
2.
= .4347
(17,500 x .90) - (0.6x 375)
In order to take .90 for the E on the category A joint, it must have full RT and the
circumferential joint must meet the spot RT required by UW-12(a).
3.
From: UG-27(c)(1)
P=
SEt
R + 0.6t
Givens:
t=
.875
P=
?
S=
13,000 psi
E=
.80
R=
60 / 2 = 30
13,000 x .80 x .875
P = 30 + (0.6 x .875) = 298.11 psi
4.
From: UG-27(c)(1)
t=
PR
SE - 0.6P
Givens:
t=
?
P=
650 psi
S=
15,000 psi
E=
1.0
R=
50 / 2 = 25
650 x 25
t = (15,000 x l.0) - (0.6 x 650) = 1.112"
Here you must remember that UW-12(a) will not allow the use of a joint E from
column A unless the requirements of UW-11(a)(5) have been applied. If the spot RT had not
been performed the E would be taken from column B and have a value of .85.
API 510
5.
From: UG-27(c)(1)
t=
PR
SE - 0.6p
or P =
SEt
R + 0.6t
Givens:
t=
1.28
P=
200 psi
S=
14,800 psi
E=
1.0
R=
14' / 2 = 7' x 12 = 84" Inside radius corroded = 84+(1.375-1.28)
84.095
200 x 84.095
= 223.23psi
84.095 + (0.6 x l.28)
?
250 psi
14,800 psi
1.0
50" crown radius
0.885 x 250 x 50
t=
= .7487"
(14,800 x l.0) - (0.1 x 250)
2.
From: UG-32(d) t =
PD
2SE - 0.2P
Givens:
t=
?
P=
250 psi
S=
14,800 psi
E=
.85
D = 50" inside diameter
250 x 50
t=
= .4978
(2 x 14,800 x .85) - (0.2 x 250)
API 510
3.
From: UG-32(f)
t=
PL
2SE - 0.2P
Givens:
t=
?
P=
250 psi
S=
14,800 psi
E=
.85
L=
36.115" inside spherical radius
250 x 36.115
t=
= .3595
(2 x 14,800 x .85) - (0.2 x 250)
ANSWER:
4.
From: UG-34(c)(2)
NO
CP
t = d SE
Givens:
t=
?
t=
.505" actual thickness of the shell
P=
250 psi
S=
for head material 15,500 psi
S=
for shell material 17,500 psi
d=
for head 36"
D = for shell 36" inside
E=
1.0 for a seamless head
C=
?
Step 1. Calculate the Shell's required thickness
From:
Step 2. Using the actual thickness of shell and its calculated required thickness find
"m"
From: The definitions of variables in and fig. UG-34(e) m = tr = .259 = .51
ts .505
Step 3. Calculate the value of C
From: Fig. UG-34(e) C = .33 x m = .33 x .51 = .1683
Since the minimum that C is allowed to be in this geometry is .20 use C = .20 to
solve.
Step 4. Calculate the required t of the flat head
t = 36 .20 x 250 = 36 .0032258 = 36 x .0567961 = 2.044
15,500 x l.0
Answer No: 1.984" < 2.044
API 510
API 510
API 510
REVIEW QUESTIONS
Section 1 - General
1.
What does the acronym API stand for? (Cover of API 510)
American Petroleum Institute
2.
What does the acronym ASME stand for? (Forward API 510)
American Society of Mechanical Engineers
3.
The primary code for the inspection of pressure vessels after they enter service is?
(1.1.1)
API 510
4.
What equipment can be inspected by the alternative rules in Section 6 of the API 510
code? (1.1.2.1)
All pressure vessels in NATURAL RESOURCE SERVICE such as drilling, production,
gathering, transportation, lease processing, and treatment of liquid petroleum, natural
gas, and associated salt water (brine).
5.
6.
7.
8.
What type of pressure vessels are exempt from periodic inspection requirements?
(1.1.2.2)
a. Pressure vessels on movable structures covered by other jurisdictional
requirements.
b. All classes listed for exemption from the inspection scope of the ASME Code
Section VIII, Division 1.
c. Pressure vessels that do not exceed specified volumes & pressures.
9.
API 510
10.
11.
ASME Boiler & Pressure Vessel Code is often abbreviated as what? (1.2.2)
ASME Code
12.
In what situation would the term "applicable requirements of ASME Code" be used?
(1.2.2)
When an item is covered by requirements of a new construction code, or if there is a
conflict between the two codes, the requirements of API 510 shall take precedent for
vessels that have been placed in service. EXAMPLE of INTENT -- The phrase
"applicable requirements of the ASME Code" has been used instead of the phrase "in
accordance with the ASME Code.
13.
14.
15.
16.
What does the term "inspection code" refer to in API 510? (1.2.6)
API 510, Pressure Vessel Inspection Code
API 510
18. Define Maximum Allowable Working Pressure (MAWP) as it relates to API 510. (1.2.8)
(Sect VIII UG-98)
The maximum gage pressure permitted at the top of a pressure vessel in its operating
position for a designated temperature that is based on calculations using the minimum
(or average pitted) thickness for all critical vessel elements, not including corrosion
allowance or loading other than pressure.
19.
20.
21.
Because the vessel may be in operation while an on-stream inspection is being carried out,
the vessel is not entered for internal inspection.
22.
24.
25.
26.
API 510
28.
What are the education and experience requirements for becoming an inspector? (2.2)
a.
b.
c.
d.
What documents will be covered in the certification test for inspectors? (Appendix B)
The latest edition of API 510 and the applicable portions of Sections V, VIII, and IX of
the latest edition of the ASME Code
29.
Recertfication by written test will be required for API authorized pressure vessel inspectors
who have not been inspectors within the previous three years.
Section 3 - Inspection Practices
30.
31.
What must an inspector do before entering a vessel that has been in service? (3.1)
a. Obtain an entry PERMIT from operations or safety.
b. Assure that the vessel is properly secured - BLINDED.
c. Assure that someone outside the vessel is designated to assist in the case of
emergency. (STANDBY)
32.
Explain the safety precautions and procedures that should be taken when performing an
internal inspection. (3.1)
a.
b.
c.
d.
e.
f.
g.
API 510
33.
Name several types or causes of Deterioration and Failure in pressure vessels. (3.2)
a.
b.
c.
d.
34.
The actual or estimated levels of what three quantities must be used in any evaluation
of Creep? (3.2)
a. Time
b. Temperature
c. Stress
35.
At ambient temperatures carbon, low alloy and other ferritic steels may be susceptible
to what? (3.2)
Brittle Failure
36.
37.
38.
What three methods may be used to determine the probable rate of corrosion? (3-3)
a.
b.
c.
39.
How (What should you use) should MAWP for the continued use of a pressure vessel
be established? (3.4)
By using the Code to which the vessel was fabricated or by using the appropriate
formulas and requirements of a later edition of the ASME Code to establish the design
temperature and pressure.
40.
What is the most important and the most universally accepted method of inspection?
(3.5)
Careful visual examination
API 510
41.
42.
43.
44.
List other methods that may be used to supplement visual inspection. (3.5)
a. Magnetic-particle examination
b. Fluorescent or dye-penetrant examination
c. Radiographic examination
d. Ultrasonic thickness measurement & flaw detection
e. Eddy current examination
f. Metallographic examination
g. Acoustic emission testing
h. Hammer testing
i. Pressure testing
45.
List the inspections, which include the features that are common to most vessels and
that are most important. (3.6)
a. Examine the surfaces of shells and heads carefully for possible cracks, blisters,
bulges, and other signs of deterioration.
b. Examine welded joints and the adjacent heat-affected zones for service-induced
cracks or other defects.
c. Examine the surfaces of all manways, nozzles, and other openings for distortion,
cracks, and other defects.
46.
Name two reasons why it is necessary for the API 510 inspector to examine flange
faces. (3.6)
a. To look for distortion
b. To determine the condition of gasket-seating surfaces
Corrosion may cause what two forms of loss? (3.7)
47.
a.
b.
48.
Name three ways the minimum thickness of a pressure vessel can be determined. (3.7)
a.
b.
c.
API 510
49.
For a corroded area of considerable size in which the circumferential stresses govern,
the least thickness along the most critical element of the area may be averaged over a
length not exceeding what? (3.7)
a.
b.
For vessels with inside diameters less than or equal to 60 inches (1 50 centimeters),
one half the vessel diameter or 20 inches (50 centimeters), whichever is less.
For vessels with inside diameters greater than 60 inches, one third the vessel
diameter or 40 inches (100 centimeters), whichever is less.
50.
51.
When should the design by analysis methods of Section VIII, Division 2, Appendix 4,
of the ASME Code be used? (3.7.)
a. To determine if components with thinning walls, which are below the minimum
required wall thickness, are adequate for continued service.
b.
To evaluate blend ground areas where defects have been removed.
52.
What do you use to determine if the thickness at the weld or remote from the weld
governs the allowable working pressure when the surface at the weld has a joint factor
other than 1.0? (3.7.g)
For this calculation, the surface at a weld includes 1 (2.5 centimeters) on either side of
the weld, or twice the minimum thickness on either side of the weld, whichever is
greater.
53.
Describe the governing thickness when measuring the corroded thickness of ellipsoidal
and torispherical heads. (3.7.h)
a. The thickness of the knuckle region with the head rating calculated by the
appropriate head formula.
b. The thickness of the central portion of the dished region, in which case the dished
region may be considered a spherical segment whose allowable pressure is
calculated by the code formula for spherical shells.
54.
What is the spherical segment of both ellipsoidal and torispherical heads? (3.7.h)
That area located entirely within a circle whose center coincides with the center of the
head and whose diameter is equal to 80% of the shell diameter.
55.
On torispherical heads, what is used as the radius of the spherical segment? (3.7.h)
Radius of the dish
56.
The radius of the spherical segment of ellipsoidal heads shall be considered to be what?
(3.7.h)
The equivalent spherical radius K1D, where D is the shell diameter (equal to the major
axis) and K1 is given in Table 1.
API 510
58.
Name two factors to be considered when inspection intervals are being determined.
(4.1)
The risk associated with operational shutdown and start-up and the possibility of
increased corrosion due to exposure of vessel surfaces to air and moisture.
59.
How often should each above ground vessel be given a visual external inspection? (4.2)
At least every 5 years or at the quarter corrosion-rate life, whichever is less.
60.
When making an external inspection, what shall the inspection include? (4.2)
a.
b.
c.
d.
61.
62.
What is the minimum interval for checking the insulating system or outer jacketing of
vessels that are known to have a remaining life of over 10 years or that are protected
against external corrosion? (4.2)
5years
63.
64.
If the remaining safe operating life is less than 4 years, what is inspection interval? (43)
Interval may be the full remaining safe operating life up to a maximum of 2 years.
API 510
65.
Under what conditions would a vessel with corrosion rate less than 0.001 inch
(0.025 millimeter) per year be exempt from an internal inspection? (4.3)
a.
b.
c.
d.
e.
66.
Write the corrosion rate formula to be used when determining the safe remaining life of
a vessel. (4.3)
t
actual -tminimum
Remaining Life (years) = -------------------corrosion rate
Where: tactual = the thickness, in inches millimeters), measured at the time of
inspection for the limiting section used to determine the minimum allowable thickness.
t
minimum = the minimum allowable thickness, in inches (millimeters), for the limiting
section or zone.
67.
68.
When conducting a pressure test as part of a periodic inspection, what shall the shell
temperature be during the test? (4,4)
Shell temperature shall not be less then recommended by the applicable section of
ASME Code or 70 degrees F(20 C) and not greater than 120 degrees F (50 C).
69.
When should pneumatic testing be done and what are some of the considerations to be
taken into account? (4.4)
Pneumatic testing may be used when hydrostatic testing is impracticable because of
temperature, foundation or process reasons, however, the potential personnel and
property risks should be considered.
70.
71.
When a pressure relief valve requires repair, who shall make this repair? (4.5)
Testing and repairs shall be made by a repair organization experienced in valve
maintenance. The repair organization shall have a written quality control system with
the minimum requirements as listed in 4.5 of the API 510 code and maintain a training
program to insure the qualifications of the repair personnel.
API 510
72.
73.
Pressure vessel owners and users are required to maintain permanent and progressive
records of their pressure vessels. What things are included in these records? (4.6)
a.
b.
c.
d.
e.
What must be done before any repairs or alterations are performed? (5.1)
All proposed methods of execution, all materials, and all welding procedures that are to
be used must be approved by the API authorized pressure vessel inspector and, if
necessary, by an engineer experienced in pressure vessel design, fabrication, or
inspection.
75.
Can an inspector authorize repairs to ASME Section VIII, Division 2 vessels? (5.1.1)
Yes, under the conditions that repairs are limited or routine repairs and he has assured
himself that a pressure test will not be required. Otherwise, prior consultation with, and
approval by, an engineer experienced in pressure vessel design is required.
76.
Who shall approve all specified repair and alteration work? (5.1.2)
The API authorized pressure vessel inspector, after the work has been proven to be
satisfactory and any required pressure test has been witnessed.
77.
78.
All repair and alteration welding shall be in accordance with what code? (5.2)
ASME Code
79.
API 510
80
When may preheating to not less than 300 degrees F be considered as an alternative to
postweld heat treatment? (5.2.3)
For alterations or repairs of vessels initially postweld heat treated as a code requirement
and constructed of P-1 and P-3 steels listed in the ASME Code.
81.
Preheat - 350 deg. F minimum & maintain during welding. Maximum interpass
temp of 450 deg. F.
Initial layer entire measuring 1/8" electrode. Remove 1/2 layer by grinding.
Subsequent layers with 5/32" electrodes. Final layer removed substantially flush
with surface of base material or previous weld layer.
Heat input - control with specific current & voltage.
After weld repair maintain temp of 500 deg F( 50 deg.) for minimum 2 hours.
Inspector to witness repairs welding.
Weld metal deposited by the manual shielded metal arc process (SMAW)
using low hydrogen electrodes. Maximum bead width 4 times electrode core
diameter.
Maximum depth of repair not greater than max. thickness exempt from PWHT in
accordance with UCS 56, ASME SEC.VIII DIV 1.
82.
Can local postweld heat treatment (PWHT) be substituted for 360-degree banding? On
what materials? (5.2.5)
YES provided the following conditions are met:
a. Application is reviewed and procedure developed by engineer experienced in
pressure vessel design & PWHT requirements.
b. In evaluating the suitability of a procedure, all applicable factors (base metal
thickness, material properties, etc.) are considered.
c. Preheat of 300 degree or higher per WPS is maintained.
d. PWHT temperature is maintained for distance not less than 2 times base metal
thickness measured from weld. Minimum of 2 thermocouples is used.
e. Heat is applied to any nozzle or other attachment in PWHT area.
83.
API 510
84.
85.
When making a repair or alteration, what should the acceptance criteria include? (5.2.8)
NDE techniques that are in accordance with the applicable sections of the ASME Code
or another applicable vessel rating code.
86.
87.
88.
89.
API 510
3.
Safety maintained
Periods of operation without shutdown extended - well planned maintenance
program
Rate of deterioration often reduced
Future repair and replacement requirements estimated
a.
b.
c.
d.
5.
List the 4 general classifications of things that cause deterioration upon coming into
contact with a vessel surface. (6.1)
a. Organic & inorganic compounds
b. Contaminated or freshwater
c. Steam
d. Atmosphere
6.
API 510
7.
8.
9.
Sulfur
Chloride compounds
10.
11.
Micro structural or metallurgical changes which may affect the mechanical properties
resulting in cracking.
12.
13.
14.
Graphitization
High-temperature hydrogen attack
Carbide precipitation
Intergranular corrosion
Embrittlement
Thermal shock
Cyclic temperature changes
Vibration
Excessive pressure surges
External loads
Cracks, bulges, distortion, and upset internal equipment are visual signs of what? (6.5)
Application of mechanical forces
15.
Many of the problems that may develop in pressure vessels are traceable to what? (6.6)
Faulty material or fabrication
API 510
16.
Poor welding, improper heat treatment, fabrication with dimensions outside tolerances
allowed by ASME Code, improper installation of internal equipment, and assembly of
flanged or threaded joints are examples of what problem? (6.7.1)
Faulty fabrication
17.
?
a.
b.
c.
d.
e.
f.
18.
(6.7.2)
Incomplete penetration
Lack of fusion
Cracking
Undercutting
Slag inclusion
Porous welds
High residual stresses near welds affecting the physical properties and corrosion
resistance of the metal is caused by what? (6.7.3)
Improper heat treatment
19.
20.
Inefficient operation
Blockage of passages
Displacement of internal equipment with pressure surges
21. Improper fitting or tightening of flanges or threaded joints may lead to what?
Leaks and possible failure
Section 8 - Methods of Inspection and Limits
22.
Before starting inspection of a pressure vessel, what are some basic things the inspector
should do? (8.1)
a.
b.
23.
Determine pressure and temperature conditions under which the vessel has
operated since last inspection
Ascertain the character of the vessel contents and the function the vessel serves in
the
process
API 510
Portable fights
Thin bladed knife
Broad chisel or scraper
Mirrors
Calipers
Page 260 of 310
f.
g.
h.
i.
j.
24.
25.
26.
27.
How do you check for lack of bond between concrete fireproofing and the protected
vessel? (8.3.3)
Light tapping with a hammer and picking with a pointed scrapper.
28.
What is the proper way to check an anchor bolt on a piece of equipment? (8.3.4)
A sideways blow with a hammer - to determine if the bolt is deteriorated below the base
plate.
29.
30.
What is one of the best methods for protecting steel structures? (8.3.6)
Galvanizing
31.
Describe how you would determine the extent of bulging or buckling on a vessel in
service. (8.3.6)
They can be inspected visually with the aid of a straightedge or plumb line.
32.
API 510
33.
34.
35.
36.
Unchecked vibrations on auxiliary equipment such as gauge connectors can cause what
type of failure? (8.3.10)
Fatigue failure
37.
What type of inspection is usually sufficient for protective coatings and insulation?
(8.3.11)
Visual
38.
39.
40.
41.
Atmospheric
Caustic Embrittlement
Hydrogen blistering
Soil corrosion
Vessels containing acidic corrodents are subject to hydrogen blistering. Where would
this be found in the vessel? (8.3.13)
Those areas below the liquid level in vessels containing acidic corrodents are more
likely than other areas to be subject to hydrogen blistering.
42.
API 510
43.
Evidence of white salts seeping through cracks will indicate what type of material?
(8.3.13)
Caustic material
44.
Unless readily visible, leaks are best found by what means? (8.3.13)
Pressure or Vacuum testing
45.
Describe how you would determine the extent of bulging or buckling on a vessel in
service. (8.3.13)
By measuring the changes in circumferences or by making profiles of the vessel wall.
Profiles are made by taking measurements from a line parallel to the vessel wall. A
surveyor's transit or a 180 degree optical plummet may also be used.
46.
The degree of surface preparation needed for internal inspection will vary with several
factors. Foremost among these are:
a.
b.
47.
48.
49.
A detailed inspection should start at one end of the vessel and work toward the other
end and include what? (8.4.4)
A systematic procedure to avoid overlooking obscure but important items.
50.
51.
Corrosion
Erosion
Hydrogen blistering
Cracking
Laminations
52.
What types of methods are used for determining the extent of cracks? (8.4.4)
a. Dye penetrant
b. Magnetic-particle (wet or dry)
c. Ultrasonic shear-wave
API 510
53.
54.
55.
How do you check for (a) small distortions, (b) bulging or buckling (c) out-of
roundness or bulging? (8.4.4)
a.
b.
57.
58.
59.
60.
Explain how the Corrosive Tab Method is used to determine the metal loss on vessel
linings. (8.4.5)
Small 1 by 2 inch tabs of lining that form a right angle are welded onto the lining with
one leg extended into the vessel. During inspections the thickness of the protruding leg
is measured, and, since both sides of the leg are exposed to corrosive action, the loss in
thickness would be twice that of the lining.
API 510
61.
What are principle methods used to inspect nonmetallic linings (glass, plastic, rubber,
concrete, and carbon block or brick). (8.4.6)
For the most part all of the above will be visually inspected for discontinuities or
physical damage. Specific: For paint, glass, plastic, & rubber lining the spark tester
method is used to locate holidays. For concrete, brick, tile, or refractory lining the
hammer testing method is used to locate lack of bond.
62.
Name at least three factors for the selection of tools for thickness measurements. (8.4.7)
a.
b.
c.
d.
e.
63.
64.
To analyze defects in welded seams that are not visible on the surface of the metal,
what two methods are used? (8.4.8)
a.
b.
65.
Radiography
Shear-wave Ultrasonics
How does the Hammer Test function in supplementing visual examination of a stayed
vessel for the inspector? (8.5.1)
Thin Locate thin sections in vessel walls, heads, and attachments.
"Tightness" Check for tightness of rivets, bolts, brackets, and the like.
"Cracks and Lack of Bond" Check for cracks in metallic linings and lack of bond in
concrete linings.
"Scale" Remove scale accumulations for spot inspections.
66.
67.
68.
Which is the preferred method, pressure or vacuum testing, and why? (8.5.2)
Pressure testing. Leaks from an internal pressure source are more easily located. With
vacuum testing you will know if there are leaks, but the location is not evident.
API 510
69.
Name the two most limits of corrosion or other deterioration that must be known by
inspection. (8.6)
a.
b.
70.
71.
Before determining the limiting or retiring thickness of parts of any pressure vessel,
what must be known? (8.6)
a.
b.
A complete record file should contain what three types of information? (10. 1)
a.
b.
c.
73.
When making reports recommending repairs, who should receive these reports? (10.2)
All management groups. This would normally include engineering, operation, and
maintenance departments. Reports should include the location, extent, and reasons for
recommended repair.
Appendix A - Exchangers
74.
Why should bundles be checked when they are first pulled from the shells? (A.9. 1)
The color, type, amount, and location of scales and deposits often help to pinpoint
corrosion problems.
75.
A distinctive Prussian Blue on bundle tubes indicates the presence of what? (A.9.2)
Ferriferro cyanide
76.
Coils in open condenser boxes and double-pipe exchanger shells should be inspected
according to what API Recommended Practice? (A.1 0)
RP574
API 510
CHAPTER 11
CONDITIONS CAUSING DETERIORATION OR FAILURES
SECOND EDITION, 1973
201 General
1.
What are the modes of failure that can be found in refinery equipment? (201.2)
a.
b.
c.
d.
e.
Fatigue Failures - is caused by stress reversals. (In machinery these cracks start at
the surface and progress with each stress reversal.)
Distortion Failures - occur when equipment is subjected to temperatures above
design temperature. At high temperatures the metal becomes weaker and
distortion occurs which may result in failure.
Brittle Fracture - carbon steels are susceptible to brittle fracture at ambient
temperatures and below. A number of tank failures have been attributed to the
brittle condition of steel at low temperatures, combined with high loads that have
been imposed by thermal stress set up rapid temperature changes.
Excessive Metal Loss - may result in failure if remaining wall thickness gets below
safety valve settings. This is a rare occurrence.
Wrong Material or Wrong Gaskets - may lead to failure.
202 - Corrosion
2.
Corrosion problems in refining operations can be, divided into three major groups.
What are these groups? (202.1)
a.
b.
c.
3.
4.
A dry hydrochloric acid (normally not corrosive in process streams). When water is
available to form hydrochloric acid.
5.
6.
Salt
What is the most active of the sulfur compounds in causing corrosion in refinery
equipment? (202.023)
Hydrogen Sulfide
API 510
7.
8.
9.
10.
11.
12.
What two forms of corrodents are formed when nitrogen is cracked in a cracking or
catalytic cracking unit? (202.027)
Ammonia & Cyanide
13.
14.
15.
When ammonia is permitted of contact copper base alloys in pH ranges of 8.0 and
above, severe corrosion in three form of general metal loss and stress corrosion
cracking will occur. How may this attack be identified? (202.037)
By the appearance of blue salt
16.
17.
As a refrigerant
For neutralization of acidic components in overhead streams, from pipe stills, and
catalytic cracking units
API 510
18.
What is chlorine used for in refinery operations and when does it become very
corrosive? (202.038)
Used for treating cooling water and for the manufacture of sodium hypochlorite for
treating oils. It becomes very corrosive in contact with small amounts of moisture
19.
Aluminum Chloride - What is it used for? What does it form in the presence of water?
How does it affect carbon steel arid stainless steels? (202.039)
Used as a catalyst in isomerization units. Forms hydrochloric acid in the presence of
water. Hydrochloric acid causes severe pitting corrosion in carbon steel and
Intergranular and stress corrosion cracking in stainless.
20.
21.
22.
At what temperature does hidden corrosion take place under insulation and fireproofing
if moisture penetrates through cracks in the insulation? (202.042)
In vessels and piping operating below approximately 250F.
23.
24.
Because the steam may be decomposed to hydrogen and oxygen, and the free oxygen may
cause severe scaling.
25.
Vanadium oxide corrosion does not take place below what temperature? (202.054)
1,100F
26.
The extent of corrosive attack by hot sulfur compounds (sulfur dioxide, hydrogen
sulfide) depends on what three things? (202.055)
Concentration, temperature, and oxidizing power of the environment.
27.
At what temperature does all gray cast iron begin to deteriorate, resulting in extreme
brittleness, loss of strength, scaling, and growth? (202.056)
800F
28.
API 510
29.
30.
In what material do you find graphitic corrosion and at what temperature does it
occur? (202.063)
In cast iron at temperatures below the dew point of water.
31.
32.
33.
34.
35.
36.
37.
38.
API 510
39.
40.
What are the most important micro-organisms that directly influence the rate of
metallic corrosion? (202.069)
Sulfate reducing bacteria found in many soils.
203 Erosion
41.
Erosion is frequently a problem in equipment utilizing the fluid and solids principle.
What is this principle? (203.02)
If a gas stream of sufficient velocity is passed through a mass of finely divided solids,
such as a powder, the mass of particles will behave very much like a true liquid.
42.
44.
45.
When austenitic stainless steels are heated or cooled in the temperature range of 750F
to 1,650F, what does this make the material susceptible to? (204.022)
Intergranular corrosion
46.
When ferritic steels are heated above a certain temperature (above 1,100F for mild
steel), how does this affect the material? (204. 022)
Leads to general lowering of the tensile strength.
47.
API 510
48.
49.
50.
51.
52.
At what temperature does hydrogen have a very destructive effect on steels? (204.035)
Above 450F
53.
What curve shows the different steel / temperature limits for hydrogen service?
(204.035)
Nelson Chart
55.
API 510
207 - Overloading
58.
Visible distortion
Change of shape
Change of position
Appendix 1
59.
Steel (ferrous alloy)is an alloy of iron and carbon. What is the carbon content range?
(App 1.A)
0.01% to 1.7% (Max. carbon content of weldable steels for Code purposes is 0.35%)
60.
Usually for refinery construction steels have less than what percent carbon? (App 1. A)
Less than 1%
61.
Steels for welding have a maximum of what percent carbon content? (App 1.A)
0.35%
62.
There are two general types of steels. What are these? (App 1. A)
a.
b.
63.
Ferritic Steel - ordinary carbon steel low and intermediate alloy steels, and high
alloy steels (straight chromium).
Austenitic - chromium - nickel stainless steels.
64.
What is the only common copper - nickel alloy and what is it used for? (App 1 B)
Monel it is used for relatively low temperature corrosion resistance.
65.
What are the major uses of commercially pure copper in refineries? (App 1 B)
Electrical conductors, gaskets, and corrosion resistance
66.
What are the major uses of aluminum and its alloys in refineries? (App 1 B)
API 510
3.
a. When must the identification markings be transferred, when cutting plate material
into two or more parts?
b.
a.
b.
API 510
4.
5.
What causes a plate when rolled and formed into a cylinder to retain its shape?
The outer fibers of the material are stretched beyond the elastic limit.
6. a. What is the permitted under tolerance for plate material in Section VIII provided the
material specification permits plate to be furnished to an under tolerance?
(Section VIII, UG-16)
b. In ordering SA-53 pipe, what is the permitted manufacturer's under tolerance,
which must be added to the calculated thickness if ordering to a nominal wall
thickness?
a. 0.01
b. The allowed manufacturing under tolerance as given in Section II of the ASME
Code
7.
Name two chemical or structural factors, which affect the hardness of steel.
a. Carbon content
b. Heat treatment
8.
API 510
9.
Define the following properties of steel and state in what units they are normally
measured:
a.
b.
c.
d.
10.
a.
b.
1.
2.
3.
Ultimate Tensile Strength: In tensile testing, the ratio of maximum load to original
cross sectional area. Measured in PSI.
Yield point: Yield Point: The first stress in a material in which there is increased
deformation under constant load. Measured in PSI. Elastic Limit: The point on the
stress-strain curve beyond which if stress is removed, the material does not return
to its original length. Measured in PSI.
Elastic limit: The point on the stress-strain curve beyond which if stress is
removed, the material does not return to its original length. Measured in PSI.
Ductility: Ability to deform plastically without fracture.
What is the maximum carbon content of carbon and low alloy steels to be used in
welded construction or to be shaped by thermal cutting process?
What objectionable qualities would excessive amount of the following impart to
steel plate?
Manganese
Phosphorous
Sulfur (Section VIII, UCS-5, API-510 5.2.7)
a. 0.35%
b. High phosphorus content causes cold shortness. High sulfur content causes
surface cracks during the rolling process, which is attributed to the hot shortness of
the metal. All three increase brittleness and decrease ductility and strength of the
metal.
11.
12.
List at least six items, which can be found on a material mill test report.
a.
b.
c.
d.
e.
f.
13.
List the material product form(s), (pipe, bar, etc.) for which a Material Test Report is
always required by Section VIII, Div. 1.
Plate
14.
Is a material supplier's (not the original material manufacturer) material test report
acceptable for Code pressure boundary plate material in lieu of the original material
manufacturer's test report? (Section VIII, UG-93)
No
API 510
2.
3.
May a FCAW welder qualified using RT, be used to weld a Section VIII, Division 1
pressure vessel using FCAW, SFA 5.20? (Section IX, QW-191.2.2)
Yes, welders and welding operators may be qualified by radiography on most materials
4.
May a welder, qualified on a 2G plate coupon with SMAW; without backing material,
make a 6 inch circumferential pipe weld in the horizontal position using the SMAW
process with a backing bar? (Assume no F or P number change.)
(Section IX, QW-461.9, QW-353)
Yes, flat and horizontal by note (2) QW-461.9. QW-363 considers addition of backing
not an essential variable for a welder.
5.
A welder is qualified in the 2G position on plate with backing using the GTAW process.
Is the welder qualified to use the following positions? (Section IX, QW-461)
Pipe groove welds in the F and H position. Yes
Plate groove welds in the H and V positions. No
6.
7.
8.
a.
b.
May a welder, qualified in the 2G position on inch -thick plate, weld a 1 inch
outside diameter pipe, 1/4 inch thick in the horizontal position without
requalification (Assume SMAW, F-1 electrode in both cases.)
Why or why not (Section IX, QW-461.9)
a.
b.
No
Not qualified for small diameter pipe, 2-7/8"and over by note (2)
a.
b.
a.
b.
API 510
9.
May a welder deviate from the parameters specified in a WPS if they are a nonessential
variable? (Section IX, QW-200.1(c))
No, the WPS would need revision.
10.
May a welder who is qualified using a double-groove weld, make a single V-groove
weld without backing on a Section VIII, Division 1 vessel without requalification?
(Section IX, QW-200.1, QW-310.2)
No, a double weld is the same as backing
11.
An SMAW WPS specifies an amperage range of 50-300 amps for E7018 electrodes.
The welder wants to use 400 amps to weld a groove weld.
(Section IX, QW-200.1(c), QW-253)
a. Must the procedure be requalified?
b. If not, what must be done as a minimum? If yes, why must it be requalified?
a.
b.
12.
a. A welder was qualified with a P-1 test coupon without backing (using SMAW E7018
electrodes). May the welder weld P-4 material using E8028 electrodes in
production? (Assume the P-4 procedure using E8028 electrodes has been qualified
with backing.)
b. Why or why not? (Section IX, QW-403.18, QW-423.1))
a.
b.
13.
a.
b.
Yes, Qualifying with a higher P-no. allows welding to a lower P-no. with
backing.
P-no.1 qualifies P1~11 and P-no. 4X
May a GTAW welder be qualified by radiography on a production weld in lieu of
bend tests? The test coupon will be P-22 material and the production welds will be
P-22 also.
If your answer is yes, what is the minimum test coupon length? If your answer is
no, why not? (Section IX, QW-304, QW-304.1)
a. Yes
b. 6
14.
a.
b.
A repair organization has a WPS which states it is qualified for P-8 to P-8 material
welds with either E308, E308L, E309, E316, electrodes (SMAW process). The
PQR, supporting this WPS, states that the weld test coupons were SA-240 Type
304L material, welded with E308 electrodes. Is the WPS properly qualified for the
base material listed?
Explain your answer. (Section IX, QW-422)
a.
b.
Yes
SA-240 is P8 material.
API 510
15.
A groove weld WPS is qualified using an 8 inch thick test coupon. The testing
equipment for tensile and bends only accommodates 1 1/2 inch wide by 1 1/2 inch thick
specimens (maximum size). Only one welding process, F-number and base material is
used.
How many and what type (i.e., side, face or root) of tests are required? (If none, put
"none". Assume the minimum number of tests will be done. Show any calculations.)
(Section IX, QW-451)
a. Number of side bends
b. Number of tensiles
6 x 4=24
6 x 2=12
8 / 6 = 1.33
Minimum number approximately equal
16.
17.
One PQR qualified with GTAW and another PQR qualified with SMAW may be
combined to qualify a WPS for GTAW and SMAW in combination. Give at least 4
items that will restrict the WPS. (Section IX, QW-200.4 (a))
a.
b.
c.
d.
18.
P-number
Base material number
Heat treatment
Weld deposit
A welder was qualified in 1972. The welder's qualifications have been maintained
since that time. The requirement for small diameter qualifications (QW-452.3) did not
appear until 1975. The welder was originally qualified on 6 inch diameter pipe. May
the welder weld 1 inch NPS pipe today without requalification? The welding will be
attaching a 1 inch sit-on fitting to the wall of a Section VIII, Division 1 pressure vessel.
(Section IX, QW-100.3)
Yes
19.
What are starting tabs and runoff tabs, how are they used and what are the advantages?
Whenever it is necessary to weld to the very end of a joint, it is necessary to provide
some means of restraining the metal so that it does not spill off the end. Run-off tabs
are the most commonly used method. They are steel tabs tacked to the ends of the weld
seam, having a joint similar to, and in alignment with the one being welded. An arc is
started on a run-off tab that is tacked to the start end of the weld and is stopped on a
second tab on the finish end of the weld. In addition to restraining the weld metal,
these tabs also minimize the discontinuities in the weld seam associated with the
starting and stopping of the welding process.
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20.
a.
b.
c.
a.
b.
c.
21. a.
b.
c.
d.
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22.
23.
Qualification on pipe for any position shall qualify for plate for the same
position.
b.
A welder who has failed the tests prescribed may be retested under the
following conditions:
1.
When an immediate retest is made, the welder shall make two
consecutive tests welds for each position which he has failed, all of which
shall pass the test requirements.
2.
When the welder has had further training or practice, a complete retest
shall be made for each position on which he failed to meet the
requirements.
c. Renewal of qualification of a performance specification is required:
1.
When a welder has not used the specific, process for a period of six
months.
2.
When there is a specific reason to question his ability to make welds
that meet the specification.
24.
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25.
Under what conditions has an Authorized Inspector the right to call for
requalification of a welding procedure, a welding operator or welder?
27.
What is the purpose of a backing strip applied to a groove weld in plate or pipe?
(Section IX, QW-492)
It is used to enable the welder to obtain complete penetration through the entire
thickness of the plate being welded from one side only.
28.
29.
Describe "Heat Affected Zone" and how can its effects be reduced?
28 (Section VIII, UW-40; Section IX, QW-492)
That portion of the base metal which has not been melted, but whose mechanical
properties or microstructures have been altered by the heart of welding or cutting.
Proper postweld heat treatment and control of heat input during the welding process
can reduce the effects.
What is meant by postweld heat treatment and how is it accomplished?
(Section VIII, UW-40)
Postweld heat treatment is the uniform heating of a structure or a portion thereof to a
temperature sufficient to relieve the major portion of the residual stresses created by the
welding process. The vessel is heated slowly to the temperature specified in Section
VIII subsection C of the ASME Code and held for a specified time. The vessel is then
allowed to cool slowly in a still atmosphere to a temperature not exceeding 800 degrees
F. The vessel shall be postweld heat treated by any of the following methods:
1.
2.
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30.
What is meant by the terms "lack of fusion", "lack of penetration" and "slag
inclusions"? How are they caused and how should such conditions be remedied?
Lack of Fusion: The failure to fuse together adjacent layers of weld metal or weld
metal and base metal.
Causes:
a.
Improper current settings
b.
Improper welding technique
c.
Failure to prepare joint properly
Remedies:
a.
Selection of proper welding current
b.
Deposit weld metal in such a manner as to insure good fusion
between the plates; in weave welding be sure weave is wide
enough to thoroughly melt the side of the joint.
c.
Ascertain that the surfaces to be welded are free of objectionable
foreign material.
Lack of Penetration: The failure of the filler metal and base metal to fuse integrally
at
the root of the weld.
Causes:
a.
Inadequate joint preparation
b.
Insufficient welding current
c.
Too fast welding speed
d.
Electrode too large
Remedies:
a.
Insure root opening and include angle of V-groove of proper
dimensions; use of a backing strip.
b.
Increase welding current for proper fusion temperature.
c.
Selection of a slower welding speed.
d.
Proper selection of a welding electrode for the welding groove.
Slag Inclusions: Non-metallic solids that are entrapped in the weld metal or between
the weld metal and base metal.
Causes:
a.
Stirring action of the arc which causes slag to be forced below
the surface of the molten metal.
b.
Slag flowing ahead of the arc causing metal to be deposited
over it.
c.
Improper joint preparation
Remedies:
a.
Proper preparation of the groove to insure full penetration of
the arc.
b.
Proper selection of electrode size.
c.
Preheat.
d.
High heat input.
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31.
When plate specification heat treatments are not performed by the mill, but by the
fabricator, what additional steps must the fabricator do in regards to the mill plate
markings? (Section VIII, UG-85)
The heat treatments shall be performed by or under the control of the fabricator who
shall then place the letter T following the letter "G" in the mill plate marking to
indicate that the material specification heat treatments have been performed.
32.
The fabricator shall also show by a supplement to the appropriate mill test report that
the specified heat treatment has been performed.
a. How does a welder performing manual arc welding create an electric arc and
maintain a circuit capable of melting a coated electrode and base metals together to
form a welded joint?
b. Name three arc welding processes. (Section IX, QW-492)
a.
b.
33.
a.
b.
c.
a.
b.
c.
34.
The electric welding machine has a positive and negative cable. One is connected
to the electrode holder and the other is attached to the part to be welded. When a
welder touches the work, he completes an electrical circuit. When he pulls the
electrode away slightly from the work the current continues to flow causing an arc
to be made between the work and the rod. This arc is the source of heat which
melts the base metal and filler metal, causing them to flow together.
GMAW - Gas Metal Arc Welding a/k/a MIG
GTAW - Gas Tungsten - Arc Welding a/k/a TIG
SAW - Submerged Arc Welding
FCAW - Flux Cored Arc Welding
SMAW - Shielded Metal - Arc Welding a/k/a stick
What is the basic difference between gas metal and gas tungsten arc welding
processes?
In submerged arc welding, what conducts the current between the electrode and the
base metal?
What is Shielded Metal Arc Welding? (Section IX, QW-492)
The basic difference is that in gas metal arc welding a consumable electrode is
used, and in gas tungsten arc welding a nonconsumable (tungsten) electrode is
used.
The flux in its molten state
An arc welding process which produces coalescence of metals by heating them
with an arc between a covered metal electrode and the work. Shielding is obtained
from decomposition of the electrode covering. Pressure is not used and filler metal
is obtained from the electrode.
What are two principal difficulties encountered in welding with heavily coated
electrodes?
Too much sidewall undercutting, slag inclusions, or excessive porosity.
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35.
36.
How must a welder identify the welding which he has performed in production and
why is this necessary? (Section VIII, UW-37)
The welder may stamp his mark adjacent to all welds made by him, or he may stamp
adjacent to a continuous weld or series of similar joints made by him at intervals of not
greater than 3 ft. or, in lieu of stamping, the manufacturer or contractor may keep a
record of welded joints and the welders making the joints. Section VIII, ASME Code
requires this identification of the welder.
37. Define distortion of a welded part and give two ways to control this distortion.
During the welding operation stresses of high magnitude may result from thermal
expansion and contraction, and remain in the weldment after the structure has cooled.
Such stresses lend to cause distortion or warpage. Rigid fixtures and careful selection
of welding sequence will minimize distortion. Peening, under controlled conditions,
has also been used to reduce distortion.
38.
a.
b.
What are "locked-in" stresses in a vessel and how are they caused?
How are these stresses relieved? (Section VIII, UW-40)
a.
"Locked up stresses" are those internal stresses remaining in the weld metal and
adjoining base metal when a weld has been made. They are caused by the fact that
the weld metal and the base metal are of considerably different temperatures when
the metal is made, and therefore do not expand and contract uniformly, thereby
setting up internal stresses.
b. Proper Postweld Heat Treatment
39. How should welded butt joints in a vessel be prepared for radiography?
(Section V, T222.2 UW-35)
The weld ripples or surface irregularities on both the inside (if accessible) and outside
shall be removed by any suitable process to such a degree that the resulting
radiographic image due to any irregularities cannot mask or be confused with the image
of any discontinuity.
40.
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41.
a.
b.
a.
Tolerance
1/4 t
1/8 in.
1/8 in.
1/8 in.
1/16 t or 3/8 in.
42.
Plates of different thickness by more than one fourth of the thickness of the
thinner plate, or by more than 1/8" required a tapered transition section having a
length not less than three times the offset between the adjoining surfaces.
Describe briefly the nature and extent of qualification tests of welders who are to be
employed in the fabrication of boilers and pressure vessels.(Section IX, QW-300, QW452)
Welders must qualify by welding a test specimen using a procedure which has been
written in accordance with Section IX of the ASME Code. The test specimen is tested
and evaluated in accordance with Section IX, and if the results are satisfactory, the
welder is "qualified" under that particular welding procedure specification.
43.
a.
b.
a.
b.
44.
What is the difference between a transverse face bend test and a transverse root
bend test, in procedure or performance qualification tests of welding?
Are tension tests required for qualification of
1. A welding procedure?
2. A manual welder? (Section IX, QW-161, QW-451, QW-452)
A face bend applies to a test specimen which is bent so that the face of the weld
becomes the convex surface of the bent specimen. A root bend applies to a
specimen which is bent so that the root of the weld becomes the convex surface of
the bent specimen.
1. Yes
2. No
What steps are necessary to qualify a welder for all position pipe welding?
(Section IX, QW-303, QW-461.9)
He must qualify in the fixed horizontal (2G) and the fixed vertical (5G), or the multiple
position (6G).
45.
What are the two methods of guided-bend tests permitted by the Code?
(Section IX, QW-162, QW-466)
a. Bottom ejection method.
b. Wrap around method.
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46.
List the various positions in which a welder may qualify for groove welds and describe
each. (Section IX, QW-120)
Plate Positions
1. Flat position (1G): Plate in a horizontal plane with the weld metal deposited from
above.
2. Horizontal position (2G): Plate in a vertical plane with the axis of the weld
horizontal.
3. Vertical position (3G): Plate in a vertical plane with the axis of the weld vertical.
4. Overhead position (4G): Plate in a horizontal plane with weld metal deposited
from underneath.
Pipe Positions
1. Position - 1G: Pipe with its axis horizontal and rolled during welding so that the
weld metal is deposited from above.
2. Position - 2G: Pipe with its axis vertical and the axis of the weld in a horizontal
plane. The pipe shall not be rotated during welding.
3. Position - 5G: Pipe with its axis horizontal and with the welding groove in a
vertical plane. Welding shall be done without rotating the pipe.
4. Position - 6G: Pipe with its axis inclined at 45 degrees to the horizontal.
Welding shall be done without rotating the pipe.
47.
In what position must the test plates be when a welder makes his test welds?
(Section IX, QW-303)
48.
Generally, the test plates should be in whatever position the welder will encounter in
actual work. But, it is possible to qualify in one position and perform production work
in other positions. For instance, for groove welds:
a. Qualification in the 2G position shall also qualify for the 1G position.
b. Qualification in the 5G position shall qualify for the 1G and 2G positions.
c. Qualification in both the 2G and 5G positions or in the 6G position shall qualify
for all positions.
What tests are required for examination of welds made for qualification of a welding
procedure? (Section IX, QW-202, QW-451)
Tension and transverse bend tests are required as followsa.
Test plate thickness less than 3/8", two reduced section tension tests, two face
bend tests and two root bend tests required. For thickness over 3/8" but less than
3/4", four side bend tests may be substituted for the face and root bend tests.
b. Plate thickness 3/4" and over, two reduced section tension tests and four side bend
tests are required.
49.
What are the type and number of tests required for Performance Qualification?
(Section IX, QW-452 (note 7))
The following guided bend tests are required for performance qualification on plate.
a. For test plate thickness less than 3/8", one face bend and one root bend are
required. For thickness over 3/8" but less then 3/4", two side bend tests may be
substituted for the required face and root bend tests.
b. For test plate thickness 3/4" and over, two side bend tests are required.
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50.
51.
52.
Name a defect that would cause you to reject a welder's test plate.(Section IX, QW-163)
Open defects exceeding 1/8" in the guided bend specimen.
53.
Who is responsible for conducting tests of welding procedures and for qualifying
welding operators? (Section IX, QW-103)
Each manufacturer or contractor is responsible for the welding and qualification tests
done by his organization.
54.
Is a welding procedure qualified under the 1965 ASME Code Section IX still
applicable? Why or why not? (QW-100.3)
Yes. Procedure and performance qualifications made in accordance with the
requirements of the 1962, or any later Edition of Section IX may be used in any
construction.
55.
56.
57.
58.
59.
a.
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What is the maximum length of slag inclusion allowed in a welded seam, as seen
on the radiograph for any thickness of plate? (App 12 Sect VIII)
Page 288 of 310
b.
What is the maximum length of crack for the same plate thickness?
(Section VIII, App 12)
a.
How long must a set of radiographs be kept on file for a pressure vessel?
(Section VIII, UW-51 (a)(1))
A complete set of radiographs and records for each vessel or part must be retained by
the manufacturer until the data report is signed by the inspector.
61.
Should a qualified welder for one certificate holder be allowed to weld for another
certificate holder? (Section VIII, QW-29 (e))
No. The performance qualification test for welders and welding operators conducted by
one certificate holder shall not qualify a welder or welding operator to do work for any
other certificate holder.
62.
Are welding operators who are to weld on ASME boiler and pressure vessels certified?
No. The welding operators are not certified by anyone under the requirements of the
ASME Code. The manufacturer certifies that the welding has been done by operators
who have passed the required test, and that the same material and techniques were used
in the tests as were employed in fabricating the boiler or vessel.
63.
Explain the difference between a guided bend test and a free bend test.
A guided bend test is made by the use of a combination male and female jig in which
the test specimen is "guided" to its Final U shape. In a free bend test the pressure is
applied to the ends of the specimen, and the test specimen is allowed to bend freely at
the weld line. Both tests are used to check ductility of the weld material.
64.
65.
66.
In performance qualification of pipe groove welds to ASME Section IX, which position
requires more than two guided bend specimens for qualification?
(Section IX, QW-452 (note 4))
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5G and 6G
67.
What precautions are made before joining together by a butt weld a 7/8" head flange
with a shell plate? Why are these precautions necessary? (Section VIII, UW-9)
A tapered transition section having a 1ength not less than three times the offset between
the adjoining surfaces shall be provided. The transition section may be formed by any
process that will provide a uniform taper. The weld may be partly or entirely in the
tapered section or adjacent to it. The transition section is necessary to reduce the stress
concentrations at the joint.
68.
What is the maximum reinforcement allowed on a welded seam? (Section VIII, UW35)
Maximum Reinforcement, in inches
Nominal Thickness,
in Pipe and Tubing
Less than 3/32
Over 3/32 to 3/16, incl.
Over 3/16 to 1/2, incl.
Over 1/2 to 1, incl.
Over 1 to 2, incl.
Over 2 to 3, incl.
Over 3 to 4, incl.
Over 4 to 5, incl.
Over 5 5/16"
69.
Circumferential
Joints
3/32
1/8
5/32
3/16
3/16
1/4
1/4
1/4
Other
Welds
1/32
1/16
3/32
3/32
1/8
5/32
7/32
1/4
5/16
A welder may qualify for fillet welding of any diameter by taking a plate groove weld
test in what position as a minimum? (Section IX, QW-303)
Welders and welding operators who pass the required tests for groove welds in the test
positions of QW-461.9 shall be qualified for the positions of the groove welds and
fillet welds shown in QW-461.9. In addition, welders and welding operators who pass
the required tests for groove welds shall also be qualified to make fillet welds in all
thickness and pipe diameters of any size within the limits of the welding variables of
QW-350 or QW-360, as applicable.
70.
Who certifies welding performed on vessels fabricated under Section VIII of the ASME
Pressure Vessel Code? (Section VIII, UW-26)
Each manufacturer (certificate of authorization holder) is responsible for the welding
done by his organization and, shall establish the procedures and conduct the tests
required in Section IX to qualify the welding procedures he uses in the construction of
the weldments built under Section VIII and the performance tests of welders who apply
these procedures.
71.
A welder has been tested in the 6G position, using an E-7018 F4 electrode, on 6"
schedule 160 (.718" nom.) SA-106B pipe. Is this welder qualified to weld a 2 300#
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ANSI schedule 80 bore flange to a 2" schedule 60 SA-106B nozzle neck? Explain your
answer. (Section IX, QW-452.3)
No. Qualification in a pipe position in a diameter greater than 2 7/8" nominal only
qualifies for groove and fillet welds in pipe 2 7/8" diameter and over.
72.
73.
You are reviewing a WPQ (QW-484) for a welder testing in the 6G position on SA-53
grade B pipe (TS 60,000 psi). The test results indicate the following:
1.
2.
1.
2.
a.
b.
a.
b.
No
The performance qualification on the 6G position required 4 transverse bend tests,
2 root and 2 face or 4 side bends. The tension tests, while satisfactory, are not
required.
Will qualification on pipe for all positions also qualify the welder to weld all
positions
on plate?
How may a welder who fails on one or more test specimens be retested
immediately? (Section IX, QW-303, QW-318)
a.
Qualification on pipe for any position shall qualify for plate for the same position.
b.
When an immediate retest is made, the welder shall make two consecutive test
welds for each position which he failed, and both of which shall pass the test
requirements.
74.
A welding electrode has the marking F-6010. Explain what each letter and number
represents.
E
Electrode
60
The minimum specified tensile strength / 1,000
1
The recommended position and coating
0
Type of coating and recommended current
75.
A welder qualified by welding in the 5G position is also qualified for what other
positions?
(Section IX, QW-469.1)
Qualification in the 5G position shall also qualify the welder in the I1G and 2G
positions.
PREVIOUS NBIC QUESTIONS ON NDE
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1.
2.
3.
4.
5.
Must the AI physically witness a Section VIII NDE procedure being qualified?
Explain.
No, but the manufacturer must satisfy the Inspector that it will work as intended.
6.
Certificate Holder
Inspector
Level III Examiner
Both a and b
7. Is Type 1 film the only one that can be used for radiographs that are to be in compliance
with Section V?
No
8.
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9.
A single film technique was used to make a radiograph using a Cobalt-60 source.
Which of the following is the minimum permitted density in the area of interest?
(Section V, T-282.1)
a.
b.
c.
d.
10.
A radiograph is made using an X-ray source, and two films in each film holder. If the
film is to be viewed, separately which of the following is the minimum permitted
density?
a.
b.
c.
d.
11.
4.0
1.8
2.0
1.3
11.0
1.8(Section V, T-282.1)
2.0
1.3
When reviewing a radiograph, a dark image of the letter B can be seen on the film.
Does this indicate an unacceptable radiograph? (Section V, T-284)
No
12.
13. A weld with a nominal thickness of 1.5 inch is to be radiographed using a film side
penetrameter. The penetrameter designation should be which of the following?
(Sect V Table T-276)
a.
b.
c.
14.
25
30
35
15.
What type of flaws can be detected by each of the following nondestructive methods?
a.
b.
c.
d.
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Surface discontinuities
Surface and slight sub-surface discontinuities
Surface and subsurface discontinuities
Surface and sub-surface discontinuities
Page 293 of 310
16.
17.
18.
19.
What is the advantage of dry type over wet type magnetic particle examination?
Dry type magnetic particle examination will give a better indication of sub-surface
discontinuities and the equipment is more portable.
20.
21.
22.
Give a brief description of the X-ray technique used in the inspection of welded joints
in shells. (Section VIII, UW-51(a)(3), Section V T-283)
All welded joints to be radiographed shall be by the X-ray or gamma-ray method in
accordance with Article 2 of Section V of the Code. The radiographic examination
shall be performed with a technique of sufficient sensitivity to display the penetrameter
image and the specified hole.
Describe the general shape of gas cavities on a radiograph and tell if these areas would
be lighter or darker in contrast with areas of defect-free material?
a.
b.
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Circular
Darker
Page 294 of 310
23.
24.
In a radiographic film of a vessel weld, how are the following characteristics measured
or judged? (Section V, T282, T283)
a.
b.
a.
b.
Penetrameter
Densitometers or step-wedge comparison films
What are penetrameters and what are they used for? (Section V, T233, T262)
A penetrameter is a small strip of material, fabricated or radiographically similar
material to the object being inspected, and having a thickness of approximately 2% of
the object being radiographed. The penetrameter has three holes in it. The sizes of
these holes are 1T, 2T and 4T where T is the thickness of the penetrameter. The 2T is
designated as the essential hole, i.e., the hole whose image must appear on the
radiograph. Penetrameter thickness and essential hole size requirements are listed in
tables in Section V of the ASME Code.
The penetrameter is identified with a number made of lead, which is attached to the
penetrameter. This number indicates the thickness of the penetrameter in thousandths
of an inch.
A penetrameter is used for evaluating radiographic technique in that it serves as an
image quality indicator; proper technique should display the penetrameter image and
the specified hole.
25.
From what type of material should shims be fabricated when they are to be used to
radiograph welds in pressure vessels? (Section V, T277.3)
A shim shall be fabricated of radiographically similar material to the object to be
inspected.
26.
a.
b.
If penetrameters are not placed adjacent to the welds, what rules apply?
For materials being radiographed other than welds, where is the penetrameter
placed? (Section V, T-277)
a.
The penetrameter should be placed on the source side of the material being
radiographed. However, where inaccessibility prevents this, the penetrameter may
be placed on the film side of the material being radiographed provided a lead
letter "F" at least as high as the identification number is placed adjacent to the
penetrameter.
For material other than weld, a source side penetrameter shall be placed in the area
of interest.
b.
27.
Under ASME Code Section VIII, what are the upper and lower densities acceptable for
viewing if the density through the body of the penetrameter is 2.7? Assume single film
viewing. (Section VIII, T-282.2)
-15% = 2.295
+30% = 3.510
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28.
29.
Give two ways radiography fails to give complete inspection information, even though
properly performed.
a.
b.
30.
The penetrameter should be placed on the source side of the material being
radiographed. However, where inaccessibility prevents this, the penetrameter may
be placed on the film side of the material being radiographed.
In accordance with Section V Table T-276, the next smaller penetrameter would be
used.
In lead letter F at least as high as the identification number shall be placed
adjacent to the penetrameter.
Very tight cracks and/or discontinuities which are less than 2% of the material
thickness may not be detected by radiographic methods.
Radiography may not detect discontinuities that are perpendicular to the lines of
radiation (laminar type discontinuities).
What is a radiograph?
A radiograph is a shadow picture produced by the passage of X-rays or gamma rays
through an object onto a film. When the rays pass through the object, part of the
radiation penetrates the material and part is absorbed. The amount of radiation
absorbed and the amount which penetrates are a function of the thickness of the
material. Where a void or discontinuity exists, there is essentially less material to
absorb the radiation. Therefore, more radiation will pass through this section and a
dark spot corresponding to the projected position of the void will appear on the film.
31.
Name two radiation sources permitted for radiographic examination in the ASME
Boiler and Pressure Vessel Code. (Section V, T-272)
The two common radiographic sources in industrial use today are X-ray machines and
artificially produced radioactive isotopes certain metallic elements.
32.
For Section VIII vessels, to what guidelines are UT requirements for examination of
welds performed? (Section VIII, UW-53)
Appendix l2 and Section V, Article 5
33.
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34.
35.
36.
37.
As a radiographer is removing cassettes (film holders) from a weld seam that has just
been radiographed, you notice that there is nothing attached to the back of the cassettes.
Would these radiographs be acceptable Explain your answer. (Section V, T-223, T-284)
No, as a check on back-scattered radiation, a lead symbol "B" with minimum
dimensions of height and 1/16 thickness shall be attached to the back of each film
holder. If a light image of the "B" appears on a darker background of the radiograph,
protection from backscatter is insufficient and the radiograph shall be considered
unacceptable. A dark image on a lighter background is not cause for rejection.
38.
Give two types of lighting for visual inspecting that can be safely used in a confined
space. (NBIC)
Low voltage lighting; either a battery powered flashlight or extension lights powered by
isolation transformers at no more than 12 volts.
39.
How are ASME Code requirements for ultrasonic examination of welds properly
transmitted to individuals performing the examination? (Section V, T-150)
By the applicable procedure specification
40.
What does the Piezo material in the search unit do in the Ultrasonic testing method?
Most transducers consist of a small piezoelectric element, which have the capability of
converting the electrical signal generated in the test instrument into mechanical
vibrations (or ultrasound). These elements act reversibly on echo signals.
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41.
b.
c.
42.
The penetrameter(s) shall be placed on the source side of the part being examined,
except where inaccessibility prevents hand placing the penetrameter(s) on the
source side, it shall be placed on the film side in contact with the part being
examined.
The penetrameter(s) may be placed adjacent to or on the weld.
For materials other than welds, the penetrameter(s) with penetrameter
identification may be placed in the area of interest.
List three items that may be requirements of the referencing Code Section or Section V,
Artic1e 5, when Ultrasonic Examination is a requirement of the code. (Section V,
T-.521)
Article 1, General Requirements, and Appendix A, Glossary of Terms used in
Nondestructive Examination, apply when the use of this Article is required by a
referencing Code section.
43.
44.
45.
46.
Direct
Indirect (or remote visual examination)
Translucent
What purpose do lead intensifying screens serve in the X-ray examination process?
(Section V, Article 22-9.1, SE-94)
Lead foil intensifying screens used in the X-ray examination may be placed directly in
front of the film. The screen provides an intensifying action and, in addition, the back
one acts as a filter by preferentially absorbing back scattered radiation from the
specimen thus improving image quality.
What is the minimum allowable density through the image of the penetrameter for
radiographs made with:
a. A 2000 kv tube?
b. Cobalt 60? (Section V, T-282.1)
a.
b.
a.
b.
c.
a.
b.
c.
API 510
47.
On a set of cassettes containing film for a seam just radiographed, you notice the lead
location markers (i.e., 1 to 2, 2 to 3, etc.) are taped to the cassettes. Would these
radiographs be acceptable? (Section V, T-275, Article 22-15.2)
No. Location markers that are to appear on the radiographic film should be placed on
the part being examined and not on the cassettes.
48.
Name the four main factors governing the penetrating ability of an X-ray.
a.
b.
c.
d.
49.
50.
a.
If the density through the penetrameter is 2.50, what would the maximum
allowable density and minimum allowable be through the weld represented by this
penny?
If the density through the weld (area of interest) is uniform and measures 2.5, what
is the maximum and minimum allowable density through the penetrameter?
(Section V, T-282)
b.
a.
b.
51.
Describe how the following surfaces shall be prepared for Ultrasonic Examination.
a. Contact surfaces
b. Weld surfaces
c. Base material (Section V, T-534)
a.
b.
c.
API 510
The finished contact surfaces shall be free from weld splatter and any roughness
that would interfere with free movement of the search unit or impair the
transmission of ultrasonic vibrations
The weld surfaces shall be finished so they cannot mask or be confused with
reflections from defects, and should merge smoothly into the surfaces of the
adjacent base materials.
The volume of base material through which the sound will travel in angle beam
examination shall be completely scanned with a straight beam search unit to detect
reflectors which might affect interpretation of' angle beam results.
52.
What is the maximum elongated slag inclusion acceptance criteria for 100%
radiography of Section VIII, Division 1 vessels? The vessel is 1 inch thick carbon
steel. (Section VIII, UW-51)
1/3(t); t = 1 Therefore, 1/3"
2.
When reviewing PWHT charts, name 4 items you would review to verify compliance
with Section VIII, Division 1 heat treating requirements. The material is carbon steel
material P-1. (Section VIII, UCS-56; Appendix 10-11)
a. Heat up rate
b. Time at temperature
c. Cool down rate
d. Calibration records
e. PWHT records and signoffs
3.
4.
A vessel designed for 1000 psi is to be hydrostatically tested at l500 psi. Is the
inspector required to examine the vessel for defects at 1500 psi? (Section VIII, UG99g)
NO. Vessel should never be examined at test pressure.
5.
6.
May a 1250 psi pneumatic test be substituted for a 1500 psi hydrostatic test if it is
shown that the testing liquid weight, in the vessel, will be unsafe for the vessel design?
(Design pressure is 1000 psi). (Section VIII, UG-100b)
Yes
Where are the QC program requirements described in Section VIII, Divisions 1?
Appendix 10
7.
When fu11y radiographing a longitudinal seam in a vessel, must the weld always be
ground flush (no weld reinforcement) for Section VIII, Division 1? An efficiency of
1.0 wi11 be used. (Section VIII, UW-35)
No
8.
API 510
9.
10.
A vessel has a partial penetration, double "v" butt joint for a Category B joint. Shop
drawings indicate the vessel wall is 2 inches thick. The measured reinforcement of the
finished weld is found to be 1/8 on each face. Does this vessel comply with Section
VIII, Division 1 requirements? (Section VIII, UW-35)
No - must he full penetration.
11.
Must a vessel fabricated by welding 1 3/8 inch thick SA-335, grade P7 (5CR - 1/2 Mo
alloy) material be fully radiographed? (Section VIII, UCS-57)
Yes - P-5 material.
12.
A seamless shel1 (1 course) with two seamless elliptical heads are combined to form a
vessel. No radiography is performed. The attaching welds are all Type 2. The vessel is
constructed to the requirements of Section VIII, Division 1.
What joint
efficiency/quality factor must be used in the head and shell calculations (assume
circumferential stress governs). (Section VIII, UW-12d)
Head = .85
Shell = .85
13.
14.
A steam separator is fabricated from SA-53 seamless pipe, 3/16 inch thick. What if
any, corrosion allowance is required as a minimum? (Section VIII, UG-25 & UCS-25)
1/16"
A vessel data report has a specified corrosion allowance of inch. Does the Code
require that, means to drain the vessel be provided"? (Section VIII, UG-25)
Yes
15.
A vessel manufacturer wants to install a 3 inch diameter nozzle through a vessel wall.
The nozzle will be welded from the outside only using a full penetration weld. Is this
permitted if no fillet weld is used on the outside? (Section VIII, Figure UW-16.2)
No
16.
A carbon steel vessel is designated for lethal service. Is full radiography and postweld
heat treatment required? (Section VIII, UW-2(a))
Yes, for CS and LA steels.
API 510
17.
18.
Must an entire vessel satisfy UG-20 (f) in order to take the exemption for impact testing
per UG-84?
No, UG-20 (f) applies to vessel materials. Materials which cannot be exempted per
UG-20 (f), must be checked per UCS-66.
19.
Can the design temperature go below -20 degrees F when applying the UG-20 (f)
exemption?
Yes, per UG-20 (f) (3) occasional temperature excursions below -20 degrees F due to
seasonal weather changes are allowed.
20.
21.
22.
API 510
a.
b.
c.
29
a.
b.
c.
2.
3.
When the construction of a pressure vessel has been completed, should the hydrostatic
test be applied with no regard to water temperature? What are the rules concerning
temperature? (Section VIII, UG-99)
Any non-hazardous liquid at any temperature may be used if below its boiling point. It
is recommended that metal temperature be maintained at least 30 degrees F above the
minimum design metal temperature. Test pressure shall not be applied until the vessel
and contents are about the same temperature.
4.
When conducting a pressure test as part of a periodic inspection, what shall the shell
temperature be during the test? (API-510 4.4)
Shell temperature shall not be less than that recommended by the applicable section of
the ASME Code or 70 degrees F and not more than 120 degrees F.
5.
a.
API 510
In applying a hydrostatic test to a steam vessel, what should the temperature of the
water be?
Page 303 of 310
b.
What is the maximum that the hydrostatic test pressure may be exceeded?
(Section VIII, UG-99)
a.
b.
API 510
PART D - PROPERTIES
Table 1A
NOTES TO TABLE 1A (CONT'D)
(B)
B3:
I-8.1 (Cont'd)
(3)
These stress values include a 0.92 factor applied to structural plate quality and are based on 55.0 ksi maximum ultimate tensile
strength.
(4)
For external pressure chart references, see Tables I.14.0.
(5)
Minimum thickness after forming any section subject to pressure shall be 3/16 in,
(6)
Nonwelded
(7)
Welded.
(8)
Not permitted for service temperature below 275 F.
(9)
Thickness over 0.580 in. through 0.750 in.
(10)
Thickness over 0.375 in. through 0.580 in.
(11)
Thickness 0.375 in. and less.
(12) Material that conforms to Class 10, 13, 20, 23, 30, 33, 40, 43, 50, or 53 is not permitted when a weld efficiency factor of 1 00 is
used in accordance with Note (3) above.
(13) Material that conforms to Class 11 or 12 is not permitted.
B4: I-12.1
(1)
(2)
(3)
(4)
(C)
NOTES:
Until rules for welding this material can be added to Section III, this material is not for welded construction.
The following are the abbreviations used for product forms: (a) Wld.-Welded; (b) Smls.- Seamless.
For the maximum thickness permitted by the material specification or 2 1/2, in-, whichever is less.
For thickness greater than 2 1/2, in., but not to exceed the maximum thickness permitted by the material specification.
Section VIII, Division 1 Application
C1: UCS-23
(a)
(b)
(c)
(d)
GENERAL NOTES:
The stress values in this Table may be interpolated to determine values for intermediate temperatures.
Stress values in restricted shear such as dowel bolts or similar construction in which the shearing member is so restricted that the
section under consideration would fail without reduction of area shall be 0.80 times the values in the above Table.
Stress values in bearing shall be 1.60 times the values in the above Table.
Stress values may be for 100 F and lower if considerations are given to toughness requirements.
NOTES:
See UCS-6 (b).
These stress values are one-fourth the specified minimum tensile strength multiplied by a quality factor of 0.92, except for SA-283,
Grade D, and SA-36.
(3) See Part UCS, Nonmandatory Appendix CS.
(4) Only killed steel shall be used above 850 F.
(5) To these stress values a quality factor as specified in UG-24 shall be applied for castings.
(6) These stress values apply to normalized and drawn material only.
(7) These stress values are established from a consideration of strength only and will be satisfactory for average service. For bolted
joints, where freedom from leakage over a long period of time without retightening is required, lower stress values may be
necessary as determined from the relative flexibility of the flange and bolts, and corresponding relaxation properties.
(8) Not permitted above 450 F; allowable stress value 7000 psi.
(9) Between temperatures of 750 F and 1000 F, inclusive, the stress values for SA-515, Grade 70 may be used until high temperature
test data become available.
(10)...
(11) For temperatures below 400 F, stress values equal to 20% of the specified minimum tensile strength will be permitted.
(12) Stress values apply to normalized, or normalized and tempered or oil quenched and tempered material only, as per applicable
specification.
(13) Stress values apply to quenched and tempered material only, as per applicable specification.
(14) Welding or brazing is not permitted when Carbon content exceeds 0.35% by ladle analysis except for limited types of welding as
allowed in Part UF.
169
(1)
(2)
API 510
Table 1A
1992 SECTION II
NOTES TO TABLE 1A (CONT'D)
(C) Section VIII, Division 1 Application (Cont'd)
C1: UCS-23 (Cont'd)
(15) Maximum allowable stress values in ksi shall be as follows:
Normalized or
Normalized
Type & & Tempered, F
Liquid Quenched and Tempered, F
Grade 650
100
200
300
400
500
600
I
II
III
IV
V2
V 3&4
V5
VIII
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
15.0
18.8
22.5
26.3
15.0
18.8
22.5
26.3
30.0
30.0
30.0
33.7
15.0
18.8
22.5
25.1
29.1
30.0
30.0
32.3
650
24.6
28.5
24.6
28.3
24.6
28.2
24.6
27.8
24.6
26.8
30.0
32.1
30.0
31.9
30.0
31.6
30.0
31.4
29.8
30.0
API 510
Table 1A
1992 SECTION II
TABLE 1A (CONTD)
A92
SECTION I, SECTION III, CLASS 2 AND 3;* AND SECTION VIII, DIVISION 1
MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS
(*See Maximum Temperature Limits for Restrictions on Class)
Nominal
Composition
Product Form
Spec.
No.
C-Si
C-Si
C
C
C
Cast pipe
Cast Pipe
Bar
Bar
Bar, rod
SA-660
SA 660
SA-675
SA-675
SA-675
C-Mn
C-Mn-Si
C-Mn-Si
C-Mn-Si
C-Si
C-Si
Forgings
Plate
Plate
Plate, sheet
Plate
Plate, sheet
C-Si
C-Mn-Si
C-Mn-Si
C-Mn-Si
C-Si
A92
A92
A92
A92
Alloy
Class/
Desig./ Cond./
UNS No. Temper Size/Thickness
Group
P-No.
No.
WCA
WCA
60
60
60
1
1
1
1
1
1
1
1
1
1
SA-765
SA-442
SA-442
SA-442
SA-515
SA-515
1
60
60
60
60
60
1
1
1
1
1
1
1
1
1
1
1
1
Plate
Plate
Plate, sheet
Plate
Wld. pipe
SA-515
SA-516
SA-516
SA 516
SA-671
60
60
60
60
CB60
1
1
1
1
1
1
1
1
1
1
C-Mn-Si
C-Mn-Si
C-Si
C-Mn-Si
C-Mn-Si
Wld. pipe
Wld. pipe
Wld. pipe
Wld. pipe
Wld. pipe
SA 671
SA-671
SA-672
SA-672
SA.672
CC60
CE60
B60
C60
E60
1
1
1
1
1
1
1
1
1
1
C
C
C
C
C-Mn
C-Mn
Wld. pipe
Plate, sheet
Bar, shapes
Plate
Wld. pipe
Smls. pipe
SA-134
SA-283
SA-283
SA-283
SA-53
SA-53
A283D
D
D
D
B
B
1
1
1
1
1
1
1
1
1
1
1
1
C-Mn
C-Mn
C-Mn
C-Mn
C-Mn
C-Si
Wld. pipe
Pipe
Smls. pipe
Wld. pipe
Smls. pipe
Smls. pipe
SA-53
SA-53
SA-53
SA-53
SA-53
SA-106
B
B
B
E/B
S/B
B
1
1
1
1
1
1
1
1
1
1
1
1
C-Si
C-Si
C-Mn
C-Si
C-Si
Pipe
Smls. pipe
Pipe
Fittings
Fittings
SA-106
SA-106
SA-135
SA-234
SA-234
B
B
B
WPB
WPB
1
1
1
1
1
1
1
1
1
1
C-Si
C-Si
C-Mn-Si
C-Mn-Si
C-Mn-Si
Fittings
Wld. fittings
Pipe
Wld. & smls. pipe
Tube
SA-234
SA-234
SA-333
SA-333
SA-334
WPB
WPBW
6
6
6
1
1
1
1
1
1
1
1
1
1
C-Mn-Si
C-Mn-Si
C-Si
C-Mn
C-Mn-Si
SA-334
SA-369
SA-372
SA-414
SA-420
6
FPB
1
D
WPL6
1
1
1
1
1
1
1
1
1
1
Type/Grade
10
API 510
PART D - PROPERTIES
Table 1A
TABLE 1A (CONTD)
A92
SECTION I, SECTION III, CLASS 2 AND 3;* AND SECTION VIII, DIVISION 1
MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS
(*See Maximum Temperature Limits for Restrictions on Class)
A92
A92
A92
A92
Min.
Tensile
Strength,
ksi
Min.
Yield
Strength
ksi
External
Pressure
Chart
No.
60
60
60
60
60
30
30
30
30
30
1000
NP
850
NP
NP
NP
700
NP
650(Cl. 3 only)
700(SPT)
NP
NP
NP
900
NP
60
60
60
60
60
60
30
32
32
32
32
32
NP
850
NP
NP
1000
NP
NP
NP
700
NP
NP
NP
650
NP
NP
850
NP
1000
60
60
60
60
60
32
32
32
32
32
NP
850
NP
NP
NP
700
NP
NP
700
700
NP
NP
1000
NP
NP
60
60
60
60
60
32
32
32
32
32
NP
NP
NP
NP
NP
700
700
700
700
700
NP
NP
NP
NP
NP
60
60
60
60
60
60
33
33
33
33
35
35
NP
NP
NP
NP
NP
900
300(Cl. 3 only)
NP
NP
300(Cl. 3 only)
NP
NP
NP
650
650
NP
900
NP
60
60
60
60
60
60
35
35
35
35
35
35
900
NP
NP
NP
NP
1000
NP
NP
700(SPT)
300(Cl. 3 only)
300(Cl. 3 only)
NP
NP
900
NP
NP
NP
NP
CS-2
CS-2
60
60
60
60
60
35
35
35
35
35
NP
NP
NP
1000
NP
NP
700
NP
NP
NP
1000
NP
900
NP
1000
CS-2
60
60
60
60
60
35
35
35
35
35
NP
NP
NP
NP
NP
700
700
NP
700
NP
NP
NP
1000
NP
650
60
60
60
60
60
35
35
35
35
35
NP
1000
NP
NP
NP
700
NP
NP
NP
NP
650
NP
650
900
850
Notes Reference
III
VIII-1
A1:(1)(5)(21)(27)
B1:(4)
A1:(1)(16)(21)(27)
CS-2
CS-2
CS-2
C1:(3)(17)(27)
C1
A1:(1)(21)
B1:(13)
CS-2
CS-2
CS-2
C1:(17)
A1:(1)(21)
C1:(17)
B1:(13)
CS-2
CS-2
A1:(1)(21)
C1:(17)
B1:(13)
B1:(1)(3)(13)(16)(17)
B1:(1)(3)(13)(16)(17)
B1:(1)(3)(13)(16)(17)
B1:(1)(3)(13)(16)(17)
B1:(1)(3)(13)(16)(17)
B1:(1)(3)(13)(16)(17)
B3:(1)(2)(3)(4)
CS-2
CS-2
C1:(1)(2)
C1:(1)
B3:(3)(4)
CS-2
CS-2
C1:(3)(25)(26)@32)
A1:(1)(21)
A1:(1)(7)(21)
C1:(3)(4)(17) A.92
B4:(2)
B3:(1)(2)(4)
B3:(1)(4)
CS-2
A1:(1)(21)
C1:(17)
B1:(1)(13)
CS.2
C1:(3)(4)(26)(32)
A1:(1)(20)(21)(21)
CS-2
C1:(18)(37)
B1:(13)
B1:(1)(3)(13)
CS-2
C1:(17)
B1:(1)(3)(13)
CS.2
C1:(26)(32)
CS-2
B1:(3)(13)
C1
A1:(1)(21)(27)
CS-2
CS-2
CS-3
11
API 510
C1:(12)(15)
C1:(3)(17)
C1;(18)(37)
Table 1A
1992 SECTION II
TABLE 1A (CONTD)
SECTION I, SECTION III, CLASS 2 AND 3;* AND SECTION VIII, DIVISION 1
MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS
(*See Maximum Temperature Limits for Restrictions on Class)
A92
Maximum Allowable Stress, ksi (Multiply by 1000 to Obtain psi) for Metal Temperature, F, Not Exceeding
A92
A92
A92
A92
-20 to 100
150
300
400
500
600
650
700
750
800
850
900
950
15.0
15.0
15.0
15.0
15.0
200
15.0
15.0
15.0
15.0 15.0
15.0
250
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.4
14.3
14.4
14.4
14.4
13.0
10.8
7.8
5.0
3.0
13.0
12.9
10.8
10.8
7.8
7.8
5.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0 15.0
15.0
15.0
15.0
15.0
15.0 15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.4
14.3
14.4
14.4
14.4
13.0
10.8
7.8
13.0
13.0
13.0
10.8
10.8
10.8
8.7
7.8
8.7
5.0
6.5
3.0
4.5
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0 15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.3
14.4
14.4
14.3
14.3
13.0
13.0
10.8
10.8
7.8
8.7
6.5
4.5
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.3
14.3
14.3
14.3
14.3
12.6
12.7
12.7
12.6
12.8
15.0
12.6
12.7 12.7
12.7 12.7
12.6
12.8 12.8
15.0
12.6
12.7
12.7
12.6
12.8
15.0
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.7
12.8
15.0
12.8
15.0
12.8
15.0
12.8
15.0
12.2
14.4
11.0
13.0
9.2
10.8
7.4
7.8
5.5
5.0
12.8
15.0
15.0
15.0
15.0
15.0
12.8
15.0 15.0
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
15.0
12.8
15.0
15.0
12.8
15.0
15.0
12.8
15.0
15.0
12.8
15.0
15.0
12.2
14.4
14.3
11.0
13.0
9.2
10.8
6.7
8.7
4.3
6.5
15.0
15.0
15.0
15.0
14.4
13.0
10.8
7.8
5.0
3.0
15.0
15.0
12.8
15.0
15.0
15.0 15.0
15.0
12.8 12.8
15.0
15.0 15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
14.4
14.3
12.2
14.4
14.4
13.0
10.8
8.7
6.5
4.5
11.0
13.0
13.0
9.2
10.8
10.8
7.4
7.8
8.7
5.5
5.0
6.6
3.0
4.6
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0 15.0
15.0
12.8 12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
15.0
15.0
15.0
15.0
12.8
14.3
14.3
14.4
14.3
13.0
10.8
7.8
5.0
3.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.3
14.4
13.0
10.8
7.8
5.0
3.0
15.0
15.0
15.0 15.0
15.0 15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
15.0
14.3
14.4
12.9
13.0
10.8
10.8
8.6
8.7
6.5
12
API 510
PART D - PROPERTIES
Table IA
A92
1000
TABLE 1A (CONT'D)
SECTION I; SECTION III, CLASS 2 AND 3;* AND SECTION VIII, DIVISION 1
MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS
(*See Maximum Temperature Limits for Restrictions on Class)
1050
1.5
1.5
2.5
2.5
1.5
2.5
1.5
2.5
1.5
1.5
13
API 510
Spec.
No.
WCA
WCA
60
60
60
SA-660
SA.660
SA-675
SA-675
SA-675
1
60
60
60
60
60
SA-765
SA-442
SA-442
SA-442
SA.515
SA-515
60
60
60
60
CB60
SA-515
SA-516
SA-516
SA-516
SA-671
CC60
CE60
B60
C60
E60
SA-671
SA-671
SA-672
SA-672
SA-672
A283D
D
D
D
B
B
SA-134
SA-283
SA-283
SA-283
SA-53
SA-53
B
B
B
E/B
S/B
B
SA.53
SA-53
SA-53
SA-53
SA-53
SA-106
B
B
B
WPB
WPB
SA-106
SA-106
SA-135
SA-234
SA-234
WPB
WPBW
6
6
6
SA-234
SA.234
SA-333
SA-333
SA.334
6
FPB
I
D
WPL6
SA-334
SA-369
SA-372
SA-414
SA-420
A92
A92
A92
A92