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CC Chong (109 SlideShares) , Surveyor/ Inspector at DNV Energy

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My API ICP Self Study Notes
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1. Fion Zhang/ Charlie Chong ASME VIII Div.1 API510 2013 June. My pre-exam self-study notes
2. Fion Zhang/ Charlie Chong
3. Speaker: Fion Zhang 2013/April/15 Fion Zhang/ Charlie Chong
5. Fion Zhang/ Charlie Chong Applicable sections; UG: the G denotes general requirements. UW: the W denotes welding. UCS: the CS denotes
carbon steel. UHT: the HT denotes heat treatment. Appendix 1: supplementary design formulae. Appendix 3: definitions.
7. Fion Zhang/ Charlie Chong SUBSECTION A GENERAL REQUIREMENTS
8. Fion Zhang/ Charlie Chong PART UG GENERAL REQUIREMENTS FOR ALL METHODS OF CONSTRUCTION AND ALL MATERIALS
9. Fion Zhang/ Charlie Chong Vessel design features
10. Fion Zhang/ Charlie Chong The main ASME VIII design topics required included in the API 510 syllabus are: Internal pressure in shells and
heads (clauses UG-27 and UG-32) External pressure on shells (clause UG-28) Nozzle compensation (mainly figure UG-37.1) Nozzle weld
sizing (mainly figure UW-16)
11. Fion Zhang/ Charlie Chong About rounding answers. In the ASME Code and for the exam you must round DOWN for pressure allowed. Even if
our solution had been 1079.999 we cannot round to 1080, we still round down to 1079 psi. This is the conservative approach taken by the Codes in
general and of course is different for the normal rules of rounding. When rounding thickness required we must round UP. The most conservative
thing to do. So our example below would round to .230”. Even it had been .2291 we would still round up to .230”.
12. Fion Zhang/ Charlie Chong UG-20 DESIGN TEMPERATURE UG-20
13. Fion Zhang/ Charlie Chong UG-20 UG-20(f) lists an exemption from impact testing for materials that meet “All” of the following requirements.
1. Material is limited to P-No.1 Gr. No.1 or 2 and the thicknesses don't exceed the following: (a) 1/2 in. for materials listed in Curve A of Fig.
UCS-66; (b) 1 in for materials from Curve B, C or D of Fig. UCS-66; 2. The completed vessel shall be hydrostatically tested 3. Design temperature is
no warmer than 650°F or colder than -20°F. 4. The thermal or mechanical shock loadings are not controlling design. 5. Cyclical loading is not a
3 of 24 15-03-2015 16:31
controlling design requirement.

14. Fion Zhang/ Charlie Chong UG-20 1. Material is limited to P-No.1 Gr. No.1 or 2 and the thicknesses don't exceed the following: (a) 1/2 in. for
materials listed in Curve A of Fig. UCS-66; (b) 1 in for materials from Curve B, C or D of Fig. UCS-66; All of the conditions of UG-20(f) must be
met to take this exemption from impact testing.
15. Fion Zhang/ Charlie Chong UG-27 THICKNESS OF SHELLS UNDER INTERNAL PRESSURE. UG-27
16. Fion Zhang/ Charlie Chong UG-27
17. Fion Zhang/ Charlie Chong c) Cylindrical Shells. The minimum thickness or maximum allowable working pressure of cylindrical shells shall be
the greater thickness or lesser pressure as given by (1) or (2) below. (1) Circumferential Stress (Longitudinal Joints). When the thickness does not
exceed one-half of the inside radius, or P does not exceed 0.385SE, the following formulas shall apply: (2) Longitudinal Stress (Circumferential
Joints). When the thickness does not exceed one-half of the inside radius, or P does not exceed 1.25SE, the following formulas shall apply: UG-27
18. Fion Zhang/ Charlie Chong Shell calculations: internal pressure Shell calculations are fairly straightforward and are set out in UG-27. Figure
below shows the two main stresses existing in a thin-walled vessel shell. Hoop (circumferential) stress This is the stress trying to split the vessel open
along its length. Confusingly, this acts on the longitudinal weld seam (if there is one). For the purpose of the API 510 exam this is the governing
stress in a shell cylinder. UG-27
19. Fion Zhang/ Charlie Chong The relevant UG-27 equations are: (used when you want to find t) or, rearranging the equation to find P when t is
already known: Where: • P = maximum design pressure (or MAWP). • t = minimum required thickness to resist the stress. • S = allowable stress of
the material. • E = joint efficiency. • Ri = the internal radius of the vessel. UG-27
20. Fion Zhang/ Charlie Chong • Remarks: • S = allowable stress of the material. This is read from ASME II part D tables or, more commonly, given
in the exam question (it has to be as ASME II part D is not in the syllabus). • E = joint efficiency. This is a factor (between 0.65 and 1) used to allow
for the fact that a welded joint may be weaker than the parent material. It is either read off tables (see UW-11 and UW-12 later) or given in the exam
question. You can think of E as a safety factor if you wish. • Ri = the internal radius of the vessel. Unlike some other design codes ASME VIII Div.I
prefers to use the internal radius as its reference dimension, perhaps because it is easier to measure. UG-27
21. Fion Zhang/ Charlie Chong Figure9.4Vesselstresses UG-27
23. Fion Zhang/ Charlie Chong A key feature of Ri is that it is the radius in the corroded conditions (i.e. that anticipated at the next scheduled
inspection). Don’t get confused by this – it is just worked out in this way. If a vessel has a current Ri of 10 in and has a corrosion rate (internal) of 0.1
in./years, with the next scheduled inspection in five years, then: Current Ri = 10 in. Ri in 5 years = 10 in. + (5 x 0.1 in) = 10.5 in corroded condition.
Hence 10.5 in. is the Ri dimension to use in the UG-27 equation. UG-27
24. Fion Zhang/ Charlie Chong The thickness must not exceed one-half of the inside radius, i.e. it is not a thick cylinder. The pressure must not
exceed 0.385SE, i.e. not be high pressure. In practice this is more than about 4000 psi for most carbon steel vessels. UG-27
25. Fion Zhang/ Charlie Chong UG-27 The pressure must not exceed 0.385SE, i.e. not be high pressure. In practice this is more than about 4000 psi
for most carbon steel vessels. Example: for SA-515/Gr. 60 at 700°F where S = 14,400 psi. P must not exceed 5544 psi.
26. Fion Zhang/ Charlie Chong Shell calculation example The following information is given in the question. Ri = inside radius of 30 in . P =
pressure of 250 psi (MAWP). E = 0.85 (type 1 butt weld with spot examination as per UW-12). S = 15 800 psi. What minimum shell thickness is
necessary to resist the internal MAWP? Using thickness (t) = PR/(SE–0.6P) from UG-27 Thickness = 250x30 / [15800x0.85 – (0.6x250)] t = 0.565 in
ANSWER UG-27
27. Fion Zhang/ Charlie Chong Shell calculation example The following information is given in the question. Ri = inside radius of 30 in. t = 0.625 in.
E = 0.85 (type 1 butt weld with spot examination as per UW-12). S = 15 800 psi. What is the MAWP? Using pressure (P) = SEt/(R + 0.6t) from
UG-27 Pressure (P) = 15 800 x 0.85x 0.625 / [30 + (0.6 x 0.625)], MAWP = 276 psi ANSWER. UG-27
29. Fion Zhang/ Charlie Chong UG-27 DESIGN INFORMATION • Design Pressure = 250 psig. • Design Temperature = 700°F. • Shell and Head
Material is SA-515 Gr. 60. • Corrosion Allowance = 0.125 in. • Both Heads are Seamless • Shell and Cone Welds are Double welded. • Heads are
spun and press without welding. • Welded and will be Spot Radiographed • The Vessel is in All Vapor Service • Cylinder Dimensions Shown are
Inside Diameters
30. Fion Zhang/ Charlie Chong UW-12 Summary Maximum Weld Joint Efficiency: Joint Type 1~6
31. Fion Zhang/ Charlie Chong UG-27 The allowable stress is given in ASME II, as it is not part of API510 examination, the following should be
given: S = 14,400 psi for SA-515/Gr. 60 at 700°F
32. Fion Zhang/ Charlie Chong UG-27 If corrosion allowance is specified: (usually not in API510 exam) Rcal for 6’ = 36.125” Rcal for 4’ =24.125”
The Rcal or Dcal used in calculation shall be the vessel RDesign or DDesign plus the corrosion allowance. The required wall thickness shall be
pressure thickness + corrosion allowance tp+c c = Corrosion Allowance R design= Designed radius R calculation = R design + c, Radius used for
calculation tp = thickness required for internal pressure
33. Fion Zhang/ Charlie Chong UG-27 Lower section 2:1 ellipsoidal head Lower section 6’ID shell Middle section conical Top section 4’ID shell
Top hemispherical head Section 1.0 0.85 0.85 0.85 1.0? Required Thickness tp + cEquationE P=250psig, S=14400psi, c=0.125in. Dcal = 72 + 2 x
0.125 = 72.25 in. Rcal = 24 + 0.125 = 24.125 in. Rcal = 24 + 0.125 = 24.125 in. Rcal = 36 + 0.125 = 36.125 in.
Top hemispherical head Section 1.0 0.85 0.85 0.85 1.0? Required Thickness tp + cEquationE P=250psig, S=14400psi, c=0.125in. Dcal = 72 + 2 x
35. 35 Fion Zhang/ Charlie Chong UG-32 D = inside diameter of the head skirt; or inside length of the major axis of an ellipsoidal head; or inside
diameter of a conical head at the point under consideration, measured perpendicular to the longitudinal axis. Di = inside diameter of the conical
portion of a toriconical head at its point of tangency to the knuckle, measured perpendicular to the axis of the cone = D − 2r (1 − cos α ) E = lowest
efficiency of any joint in the head; for hemispherical heads this includes head- to-shell joint; for welded vessels, use the efficiency specified in
UW-12 L = inside spherical or crown radius. The value of L for ellipsoidal heads shall be obtained from Table UG-37. P = internal design pressure
(see UG-21) r = inside knuckle radius S = maximum allowable stress value in tension as given in the tables referenced in UG-23, except as limited in
UG-24 and (e) below. t = minimum required thickness of head after forming ts = minimum specified thickness of head after forming, in. (mm). ts
shall be ≥ t α = one-half of the included (apex) angle of the cone at the centerline of the head (see Fig. 1-4) UG-32(a)
Top hemispherical head Section 1.0 0.85 0.85 0.85 0.85 Required Thickness tp + cEquationE P=250psig, S=14400psi, c=0.125in. Dcal = 72 + 2 x
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37. Fion Zhang/ Charlie Chong UG-27 Exercise 2 Required Thickness for Internal Pressure Determine the minimum required thickness for the
cylindrical shell and heads of the following pressure vessel: Inside Diameter = 10’ 6” Design Pressure = 650 psig Design Temperature = 750°F
Shell & Head Material = SA-516 Grade 70 Corrosion Allowance = 0.125” 2:1 Semi-Elliptical heads, seamless 100% radiography of
cylindrical shell welds The vessel is in an all vapor service (i.e., no liquid loading) ---------------------------------------------------------------------------
38. Fion Zhang/ Charlie Chong UG-27 Answers: Inside diameter = 126 + 0.25 = 126.25 in. Ri= 63.125 in. S=14800psi, E=1. Calculations: Shell: tp =
(650x63.125)/(14800-0.6x650) =2.848 in. tshell = tp+c = 2.847+0.125 = 2.973 in.# Head: tp = (650x126.25)/(2x14800-0.2x650) = 2.785 in. Thead =
tp+c=2.785+0.125=2.910 in.#
39. Fion Zhang/ Charlie Chong UG-27 Appendix 1 Supplementary Design Formulas 1-1 THICKNESS OF CYLINDRICAL AND SPHERICAL
SHELLS (a) The following formulas, in terms of the outside radius, are equivalent to and may be used instead of those given in UG-27 (c) and (d).
(1) For cylindrical shells (circumferential stress),
40. Fion Zhang/ Charlie Chong UG-27 Exercise 3 Example: Given a cylindrical shell with the following variables, solve for the MAWP of the
cylinder using both formulas. P = ? , t = 0.500“, S = 15,000 psi, E = 1.0, R = 18.0“ and Routside = 18.5"
41. Fion Zhang/ Charlie Chong UG-27 Exercise 4 A cylindrical shell has been found to have a minimum thickness of .353". Its original thickness
was .375” with an original inside radius of 12.0”. S = 13,800 psi, E = .85 What is its present MAWP ? R = 12.0" + (.375-.353) = 12.022 corroded
inside radius Ro= 12.0" + 0.375 (orig. t) =12.375” original outside radius
43. Fion Zhang/ Charlie Chong UG-27 You need to consider the hemispherical head joint to shell as category A, but ellipsoidal and torispherical head
joint to shell as category B; Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in hemispherical head joint? It
is because this joint is more critical, because the thickness obtained from the formula for hemispherical head approximately would be half of the shell
thickness; It means if the shell thickness is 1 inch, the hemispherical head thickness would be 0.5 inch.
44. 44 Fion Zhang/ Charlie Chong UG-32 Example: For the same pressure, stress and, dimension values will be used for all heads. Let’s determine
which type of head will be the thickest required and which will be the thinnest allowed. Given: P = 100 psi S = 17500 PSI E = .85 for spot RT of
hemispherical head joint to shell E = 1.0 for seamless heads ( Ellipsoidal and Torispherical ) L = 48" for the inside spherical radius for the
hemispherical head L = 96" for the inside crown radius of the torispherical head D = 96" inside diameter of the ellipsoidal t = ? Required wall
thickness, inches
45. 45 Fion Zhang/ Charlie Chong UG-32 t = (100x48)/(2x17500x0.85t = (100x48)/(2x17500x0.85--0.2x100)0.2x100) t = 0.162t = 0.162””
HemisphericalHemispherical t = (0.885x100x96)/(17500x1t = (0.885x100x96)/(17500x1--0.1x100)0.1x100) T= 0.486T= 0.486””
TorisphericalTorispherical t = (100x96) / (2x17500x1t = (100x96) / (2x17500x1--0.2x100)0.2x100) t = 0.275t = 0.275”” EllipsoidalEllipsoidal
thicknessthicknessEquationEquationHeadHead
46. Fion Zhang/ Charlie Chong UG-27 Spot radiography for ellipsoidal and torispherical heads (Cat. B). Full radiography foe hemispherical head
(Cat. A).
47. Fion Zhang/ Charlie Chong UG-28 THICKNESS OF SHELLS AND TUBES UNDER EXTERNAL PRESSURE. UG-28
51. Fion Zhang/ Charlie Chong Overview. The critical pressure that causes buckling is not a simple function of the stress that is produced in the shell,
as is true with tensile loads. An allowable stress is not used to design pressure vessels that are subject to elastic instability. Instead, the design is based
on the prevention of elastic collapse under the applied external pressure. This applied external pressure is normally 15 psig for full vacuum
conditions. The maximum allowable external pressure can be increased by welding circumferential stiffening rings (i.e., stiffeners) around the vessel
shell. The addition of stiffening reduces the effective buckling length of the shell, and this length reduction increases the allowable buckling pressure.
These stiffener rings may be welded on either the inside or the outside of the shell. UG-28
53. Fion Zhang/ Charlie Chong UG-28 Basic Data (example) Temperature = 500°F t = 0.530 in. L = 120 in. Do = 10 in. 1. Calculate Do/t 2. Calculate
L/Do Find A and B using Chart Fig. G and applicable material chart in Subpart 3 of Section II, Part D. As stated in the API 510 Body of Knowledge,
these charts will be provided in the exam body, IF an external calculation is given on the examination. 3. Calculate P
54. Fion Zhang/ Charlie Chong UG-28 1. Use common chart and Find A As stated in the API 510 Body of Knowledge, these charts will be provided
in the exam body, IF an external calculation is given on the examination.
55. Fion Zhang/ Charlie Chong UG-28 2. Select applicable material chart and Find B As stated in the API 510 Body of Knowledge, these charts will
be provided in the exam body, IF an external calculation is given on the examination.
56. Fion Zhang/ Charlie Chong UG-28 3. Calculate P
57. Fion Zhang/ Charlie Chong UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example #1 The easiest way to understand the UG-28 calculations
themselves is to look at this worked example. Figure 9.14 shows the parameters for a vessel under external pressure operating at 300oF: t =
thickness of the shell = 0.25 in. L = distance between stiffeners = 90 in. Do = shell outside diameter = 180 in. The first step is to calculate the
values of the dimensional ratios (L/Do) and (Do/t): L/Do = 90/180 = ½ Do/t = 180 / 0.25 = 720 UG-28
58. Fion Zhang/ Charlie Chong In a real design situation, these ratios would then be plotted on charts to give values of A and B. In this example, the
charts would give values of A = 0.000 15 and B = 2250 (remember that you will generally be given these in an exam question). Pa = 4B/[3 (Do/t)] =
4x 2250/(3x 720) = 4.2 psi Conclusion – the vessel is not suitable for full vacuum duty (-14.5 psi ). Conclusion – the vessel is not suitable for full
vacuum duty (-14.5 psi ). Pa should be ≥14.5psi UG-28
60. Fion Zhang/ Charlie Chong UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example #1-2 Limited data for a vessel are given as: Outside
diameter Do = 60 in Length between supports L = 15 feet Factor A = 0.000 18, Factor B = 2500 These are all the data you have. How thick does the
vessel wall have to be to be suitable for use under full vacuum? t = 3PaDo/(4B) = 3x14.5x60 / (4x2500) = 0.261in. Select your answer: (a) 1/8 in. (b)
¼ in. (c) 3/8 in. (d) others. UG-28
61. Fion Zhang/ Charlie Chong UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example #2 Step 1 Assume a value for t and determine the ratios
L/Do and Do /t. Example: The cylinder has corroded to a wall thickness of 0.530”, its length is 120” and the outside diameter is 10”. It operates at
500oF So then; Temp = 500oF t = 0.530” L = 120” Do = 10” Calculate; Do/t = 10/.530 = 18.8 call it 19# (no need to be exact) L/Do = 120/10 = 12#
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UG-28
62. Fion Zhang/ Charlie Chong UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example of Calculation using graphs Normally values A & B are
given without using the ASME II graphs UG-28
63. Fion Zhang/ Charlie Chong Step 2 Enter Fig. G in Subpart 3 of Section II, Part at the value of L/Do determined in Step 1. we must go up the left
side of the Fig. G until we reach the value of L/Do of 12. •Using the chart we have the following; Do/t = 19 L/Do = 12 UG-28
64. Fion Zhang/ Charlie Chong Step 3 Move horizontally to the line for the value Do /t determined in Step 1.... Which in our case was 19, but we will
round this to 20 since these problems are not meant to be extremely precise. So now we have. From this point of intersection move ertically
downward to determine the value of factor A. Do/t = 19 L/Do = 12 UG-28
65. Fion Zhang/ Charlie Chong Do/t=19,L/Do=12 UG-28
66. Fion Zhang/ Charlie Chong Step 4 Enter the applicable material chart in Subpart 3 of Section II, Part D for the material under consideration.
Move vertically to an intersection with the material/temperature line for the design temperature. Interpolation may be made between lines for
intermediate temperatures. To use the next figure we enter at the bottom at the value Factor A = .0028 and then up to our temperature of 500oF.
UG-28
67. Fion Zhang/ Charlie Chong Do/t = 19 L/Do = 12 A=0.0028 UG-28
69. Fion Zhang/ Charlie Chong UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example #3 Problem: A vessel is operating under an external
pressure, the operating temperature is 500oF. The outside diameter of the vessel is 40 inches. Its length is 70 inches. The vessel’s wall is 1.25 inches
thick and is of SA-515-70 plate. Its specified min. yield is 38,000 psi. What is the maximum external pressure allowed? Givens: Temp = 500oF t =
1.25 in. L = 70 in. D0 = 40 in. Determine; Do/t = 40/1.25 = 32 used equation c(1). L/Do = 70/40 = 0.175. Determine value “A” UG-28
71. Fion Zhang/ Charlie Chong Step 4. Using our value of Factor A calculated in Step 3, enter the Factor B (CS-2) chart on the bottom. Move
vertically to the material temperature line given in the stated problem (in our case 500oF). A=0.0045 UG-28
72. Fion Zhang/ Charlie Chong 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: UG-28
73. Fion Zhang/ Charlie Chong UG-28 UG-28, C(1)- Cylinders having Do /t values ≥ 10: Example #3 Problem: A vessel is operating under an
external pressure, the operating temperature is 500° F. The outside diameter of the vessel is 40 inches. Its length is 70 inches. The vessel’s wall is
1.25 inches thick and is of SA-515-70 plate. Its specified min. yield is 38,000 psi. What is the maximum external pressure allowed? Givens: Mtls =
SA-515 Gr.70. Temp = 500°F. t = 1.25 inches. L = 70 inches. Do = 40 inches. Do/t = 40/1.25 = 32 L/Do = 70/40 = 1.75
77. Fion Zhang/ Charlie Chong (2) Cylinders having Do /t values <10: UG-28
78. Fion Zhang/ Charlie Chong ASME II Part D SUBPART 3 Charts and tables for determining shell thickness of components under external
pressure As stated in the API 510 Body of Knowledge, these charts will be provided in the exam body, IF an external calculation is given on the
examination. ASME II Part D for UG-28 UG-28
79. Fion Zhang/ Charlie Chong FIG.GGEOMETRICCHARTFORCOMPONENTSUNDEREXTERNAL
ORCOMPRESSIVELOADINGS(forAllMaterials) ASMEIIPartDforUG-28UG-28
80. Fion Zhang/ Charlie Chong ASMEIIPartDforUG-28UG-28
81. Fion Zhang/ Charlie Chong 2007 SECTION II, PART D (METRIC) FIG. CS-1 CHART FOR DETERMINING SHELL THICKNESS OF
COMPONENTS UNDER EXTERNAL PRESSURE WHEN CONSTRUCTED OF CARBON OR LOW ALLOY STEELS (Specified Minimum
Yield Strength 165 MPa to, but Not Including, 205 MPa) [Note (1)] ASME II Part D for UG-28 UG-28
84. Fion Zhang/ Charlie Chong UG-32 FORMED HEADS, AND SECTIONS, PRESSURE ON CONCAVE SIDE. UG-32
85. Fion Zhang/ Charlie Chong Hemispherical Conical Torispherical Ellipsoidal FormulaDisk Head Type UG-32
86. Fion Zhang/ Charlie Chong UG-32 Ellipsoidal
87. Fion Zhang/ Charlie Chong UG-32 Torispherical
88. Fion Zhang/ Charlie Chong UG-32 Hemispherical
89. Fion Zhang/ Charlie Chong UG-32 D = inside diameter of the head skirt; or inside length of the major axis of an ellipsoidal head; or inside
diameter of a conical head at the point under consideration, measured perpendicular to the longitudinal axis. Di = inside diameter of the conical
portion of a toriconical head at its point of tangency to the knuckle, measured perpendicular to the axis of the cone = D − 2r (1 − cos α ) E= lowest
efficiency of any joint in the head; for hemispherical heads this includes head-to-shell joint; for welded vessels, use the efficiency specified in UW-12
L = inside spherical or crown radius. The value of L for ellipsoidal heads shall be obtained from Table UG-37. P = internal design pressure (see UG-
21) r = inside knuckle radius S = maximum allowable stress value in tension as given in the tables referenced in UG-23, except as limited in UG-24
and (e) below. t = minimum required thickness of head after forming ts = minimum specified thickness of head after forming, in. (mm). ts shall be ≥ t
α = one-half of the included (apex) angle of the cone at the centerline of the head (see Fig. 1-4)
91. Fion Zhang/ Charlie Chong UG-32 There are three types of calculations for formed heads listed in the Body of Knowledge: (1) Ellipsoidal, (2)
Torispherical and (3) Hemispherical. A sketch and the formulae for thickness of each kind are below. (1) (2) (3)
92. Fion Zhang/ Charlie Chong UG-32 The symbols defined below are used in the formulas of this paragraph: t = minimum required thickness of
head after forming, in. P = internal design pressure (see UG-21), psi. D = inside diameter of the head skirt; or inside length of the major axis of an
ellipsoidal head; in. S = maximum allowable stress value in tension. E = lowest efficiency of any joint in the head; for hemispherical heads this
includes head-to-shell joint; for welded vessels, use the efficiency specified in UW-12. L = inside spherical or crown radius, in.
93. Fion Zhang/ Charlie Chong Ellipsoidal Heads. For pressures over 10 bar, ellipsoidal heads are often used. In cross-section, the head resembles an
ellipse, its radius varying continuously. This results in a smooth transition between the dome and the cylindrical part of the vessel. Ellipsoidal heads
are deeper than comparable torispherical heads. The shape of the ellipsoidal head is defined by the ratio of the major and minor axis. A standard
arrangement on vessels is the 2:1 elliptical head (see Figure 2). This will have a depth of head which is a quarter of the vessel’s internal diameter, D.
6 of 24 15-03-2015 16:31
The thickness of this type of head is normally equal to the thickness of the cylinder to which it is attached. UG-32
94. Fion Zhang/ Charlie Chong 2:1 Ellipsoidal head This is also called a 2:1 elliptical head. The shape of this head is more economical, because the
height of the head is just a quarter of the diameter. Its radius varies between the major and minor axis. UG-32
95. Fion Zhang/ Charlie Chong A 2:1 ellipsoidal head has one-half the minor axis, h, equal to one-fourth of the inside diameter of the head skirt, D.
SF is the skirt length required by UG−32(l). A 2:1 ellipsoidal head may be approximated with a head containing a knuckle radius of 0.17D and a
spherical radius (L) of 0.90D. UG-32
96. Fion Zhang/ Charlie Chong 2:1 ellipsoidal head: (d) Ellipsoidal Heads With ts /L ≥ 0.002. The required thickness of a dished head of semi
ellipsoidal form, in which half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the inside diameter of the head skirt,
shall be determined by NOTE: An acceptable approximation of a 2:1 ellipsoidal head is one with a knuckle radius of 0.17D and a spherical radius (L)
of 0.90D. Note: D = inside diameter of head skirt. t = minimum required thickness after forming. ts = minimum specified thickness after forming, ts
≥ t. L = inside spherical or crown radius. The value of L for ellipsoidal heads shall be obtained from Table UG-37. UG-32
97. Fion Zhang/ Charlie Chong Non-2:1 ellipsoidal head; Appendix 1−4 gives the following formulas for ellipsoidal heads with D/2h ratios other
than 2:1. Where K1D is the equivalent spherical radius UG-32
than 2:1. Where K1D is the equivalent spherical radius UG-32 2:1 ellipsoidal head: D = inside diameter of head skirt.
99. Fion Zhang/ Charlie Chong Example: Standard 2:1 ellipsoidal head; h=D/4 D/2h = 2 ,K1 = 0.90# For non 2:1 head, the radius to use in the
hemi-spherical head formula shall be the equivalent spherical radius. GENERAL NOTES: (a) Equivalent spherical radius = K1D; D/2h = axis ratio.
(b) For definitions, see 1-4(b). (c) Interpolation permitted for intermediate values. UG-32
than 2:1. Where K1D is the equivalent spherical radius UG-32 Example: Standard 2:1 ellipsoidal head; h=D/4 D/2h = 2 ,K1 = 0.90# D = inside
diameter of head skirt.
101. Fion Zhang/ Charlie Chong Ellipsoidal head calculation example Here is an example for a 2:1 ellipsoidal head, using similar figures from the
previous example. Guides: D = inside diameter of 60 in P = pressure of 250 psi (MAWP) E = 0.85 (double-sided butt weld with spot examination
(UW-12)) S = 15800 psi What thickness is required to resist the internal pressure? t = 0.56 in. ANSWER Assuming a given head thickness of 0.625
in What is the MAWP? P = 279 psi ANSWER UG-32
102. Fion Zhang/ Charlie Chong Torispherical Heads - A torispherical (or flanged and dished) head is typically somewhat flatter than an elliptical
head and can be the same thickness as an elliptical head for identical design conditions and diameter. The minimum permitted knuckle radius of a
torispherical head is 6% of the maximum inside crown radius. The maximum inside crown radius equals the outside diameter of the head. UG-32
103. Fion Zhang/ Charlie Chong (e) Torispherical Heads With ts/L ≥ 0.002. The required thickness of a torispherical head for the case in which the
knuckle radius is 6% of the inside crown radius and the inside crown radius equals the outside diameter of the skirt [see UG-32(j)] shall be
determined by NOTE: For torispherical heads with ts /L < 0.002, the rules of 1-4(f) shall also be met. Torispherical heads made of materials having a
specified minimum tensile strength exceeding 70,000 psi (500 MPa) shall be designed using a value of S equal to 20,000 psi (150 MPa) at room
temperature and reduced in proportion to the reduction in maximum allowable stress values at temperature for the material (see UG-23). UG-32
104. Fion Zhang/ Charlie Chong Knuckle radius is 6% of the inside crown radius The inside crown radius equals the outside diameter of the skirt
UG-32
105. Fion Zhang/ Charlie Chong Torispherical head example Given: L = inside spherical (crown) radius of 30 in P = pressure of 250 psi (MAWP) E
= 0.85 S = 15 800 psi Thickness required (t) t = 0.496 in ANSWER Alternatively, to find P using a given head thickness of 0.625 in.: Pressure (P) =
315 psi ANSWER UG-32
106. Fion Zhang/ Charlie Chong R=Do r = 0.06Do UG-32
107. Fion Zhang/ Charlie Chong Hemispherical Heads - The required thickness of a hemispherical head is normally one-half the thickness of an
elliptical or torispherical head for the same design conditions, material, and diameter. Hemispherical heads are normally fabricated from segmented
sections that are welded together, spun, or pressed. Hemispherical heads are an economical option to consider when expensive alloy material is used.
In carbon steel construction, hemispherical heads are generally not as economical as elliptical or torispherical heads because of higher fabrication
cost. Carbon steel hemispherical heads may be economical for thin, very large diameter vessels, or in thick, small-diameter vessels. The thickness
transition zone between the hemispherical head and shell must be contoured to minimize the effect of local stress. Figure 4.8 shows the thickness
transition requirements that are contained in the ASME Code. UG-32
108. Fion Zhang/ Charlie Chong Thickness Transition Between Hemispherical Head and Shell UG-32
109. Fion Zhang/ Charlie Chong (f) Hemispherical Heads. When the thickness of a hemispherical head does not exceed 0.356L, or P does not exceed
0.665SE, the following formulas shall apply: UG-32
110. Fion Zhang/ Charlie Chong UG-32 Hemispherical heads while they can be formed seamless are not considered seamless heads by Section VIII.
As mentioned previously they essentially form a Category “A” seam between the head and the other part. They are never seamless; their Joint E
comes from Table UW-12 based on the Type of weld and the extent of Radiography applied. E, based on the Type of weld and the extent of
Radiography applied.
111. Fion Zhang/ Charlie Chong Hemispherical head example Given: Internal pressure (P) = 200 psi Allowable stress (S) = 15 000 psi Spherical
radius (L) = 60 in Joint efficiency (E) = 1.0 Required thickness (t) t = 0.401 in. ANSWER# Alternatively, calculating the maximum allowable
pressure for a given thickness of, say, 0.5 in.: P = 250 psi ANSWER# UG-32
113. Fion Zhang/ Charlie Chong UG-32 Example: For the same pressure, stress and, dimension values will be used for all heads. Let’s determine
which type of head will be the thickest required and which will be the thinnest allowed. Given: P = 100 psi S = 17500 PSI E = .85 for spot RT of
hemispherical head joint to shell E = 1.0 for seamless heads ( Ellipsoidal and Torispherical ) L = 48" for the inside spherical radius for the
hemispherical head L = 96" for the inside crown radius of the torispherical head D = 96" inside diameter of the ellipsoidal t = ? Required wall
thickness, inches
114. Fion Zhang/ Charlie Chong UG-32 t = (100x48)/(2x17500x0.85-0.2x100) t = 0.162” Hemispherical t = (0.885x100x96)/(17500x1-0.1x100) T=
0.486” Torispherical t = (100x96) / (2x17500x1-0.2x100) t = 0.275” Ellipsoidal thicknessEquationHead
115. Fion Zhang/ Charlie Chong (g) Conical Heads and Sections (Without Transition Knuckle). The required thickness of conical heads or conical
shell sections that have a half apex-angle not greater than 30 deg shall be determined by A reinforcing ring shall be provided when required by the
rule in 1-5(d) and (e). Conical heads or sections having a half apex-angle greater than 30 deg without a transition knuckle shall comply with Formula
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(4) and 1-5(g). (h) Toriconical Heads and Sections UG-32

116. Fion Zhang/ Charlie Chong Example of conical head calculation Given: Internal pressure (P) = 300 psi Inside diameter of cone (D) = 40 in
Allowable stress (S) = 12 000 psi Joint efficiency (E) = 0.85 Cone half angle (α) = 308 Cosine of 30o = 0.866 Calculating required thickness (t): t =
0.69 in ANSWER Alternatively calculating the maximum allowable pressure for a given head thickness of, say, 0.75 in: P = 325 psi ANSWER
UG-32
117. Fion Zhang/ Charlie Chong UG-32 Torispherical head: These heads have a dish with a fixed radius (r1), the size of which depends on the type of
torispherical head. The transition between the cylinder and the dish is called the knuckle. The knuckle has a toroidal shape. Note: The inside crown
radius to which an unstayed formed head is dished shall be not greater than the outside diameter of the skirt of the head. The inside knuckle radius of
a torispherical head shall be not less than 6% of the outside diameter of the skirt of the head but in no case less than three times the head thickness.
Torispherical Heads. The required thickness and the design pressure of a torispherical head is calculated by the following formulas: The following
equations apply:
119. Fion Zhang/ Charlie Chong UG-32 http://www.engineersedge.com/calculators/Torispherical-Heads/pressure-vessel-torispherical-heads..htm
120. Fion Zhang/ Charlie Chong UG-36 OPENINGS IN PRESSURE VESSELS. UG-36
121. Fion Zhang/ Charlie Chong UG-36 The main things of interests in this paragraph to the API 510 inspector are the following: 1. All references to
dimensions apply to the finished construction after deduction for material added as corrosion allowance. 2. Openings not subject to rapid fluctuations
in pressure do not require reinforcement other than that inherent in the construction under the following conditions: (a) The finished opening is not
larger than: • 3 ½ in. diameter in vessel shells or heads 3/8 in. or less in thickness • 2 3/8 in. diameter in vessel shells or heads over 3/8 in. in
thickness (c) No two isolated un-reinforced openings, in accordance with the above shall have their centers closer to each other than the sum of their
diameters
122. Fion Zhang/ Charlie Chong UG-36 (c) No two isolated un-reinforced openings, in accordance with the above shall have their centers closer to
each other than the sum of their diameters Radius R1 Radius R2 Center to center > 2R1+2R2
123. Fion Zhang/ Charlie Chong UG-37 REINFORCEMENT REQUIRED FOR OPENINGS IN SHELLS AND FORMED HEADS. UG-37
124. Fion Zhang/ Charlie Chong The ASME Code uses simplified rules to ensure that the membrane stresses are kept within acceptable limits when
an opening is made in a vessel shell or head When the opening is made, a volume of material is removed from the pressure vessel. This metal is no
longer available to absorb the applied loads. The ASME Code simplifies the design calculations by viewing the nozzle-to-vessel junction area in
cross section. This simplification permits the nozzle reinforcement calculations to be made in terms of metal cross-sectional area rather than metal
volume. The ASME Code requires that the metal area that is removed for the opening must be replaced by an equivalent metal area in order for the
opening to be adequately reinforced. The replacement metal must be located adjacent to the opening within defined geometric limits. The
replacement metal area may come from two sources: Excess metal that is available in the shell or nozzle neck that is not required for pressure or to
absorb other loads. Reinforcement that is added to the shell or nozzle neck. UG-37
125. Fion Zhang/ Charlie Chong If a reinforcement pad is used, its material should have an allowable stress that is at least equal to that of the
pressure vessel shell or head material to which it is attached. No credit can be taken for the additional strength of any reinforcement that has a higher
allowable stress. If reinforcement material with a lower allowable stress is used, the reinforcement area must be increased to compensate for this.
UG-37
126. Fion Zhang/ Charlie Chong ASME VIII, UG-37 Is the nozzle sufficiently reinforced ASME VIII, UW-16 Are the nozzle welds of adequate
sizes. UG-37
127. Fion Zhang/ Charlie Chong ASME VIII, UG-37 The code uses the principle of the area replacement method http://www.wermac.org/specials
/branch_reinforced.html UG-37
128. Fion Zhang/ Charlie Chong (a)Nomenclature. The symbols used in this paragraph are defined as follows: • A = total cross-sectional area of
reinforcement required in the plane under consideration (see Fig. UG-37.1) (includes consideration of nozzle area through shell if Sn /Sv<1.0) •
A1=area in excess thickness in the vessel wall available for reinforcement (see Fig. UG-37.1) (includes consideration of nozzle area through shell if
Sn /Sv<1.0) • A2=area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-37.1) • A3=area available for reinforcement
when the nozzle extends inside the vessel wall (see Fig. UG-37.1) (Not in the exam) • A5=cross-sectional area of material added as reinforcement
(see Fig. UG-37.1) • A41, A42, A43=cross-sectional area of various welds available for reinforcement (see Fig. UG-37.1) UG-37
129. Fion Zhang/ Charlie Chong FIG. UG-37.1 NOMENCLATURE AND FORMULAS FOR REINFORCED OPENINGS UG-37
130. Fion Zhang/ Charlie Chong The left-hand side shows the configuration in which the nozzle is ‘set through’ the shell. You can ignore this as the
set-through configuration is specifically excluded from the API syllabus. set on to the shells – abuts. UG-37
133. Fion Zhang/ Charlie Chong If A1+A2+A41+A5≥A Opening is adequately reinforced UG-37
134. Fion Zhang/ Charlie Chong UG-40 LIMITS OF REINFORCEMENT An opening is adequately reinforced if: A1 + A2 + A3 + A41 + A42 + A5
> A UG-40
135. Fion Zhang/ Charlie Chong tn trn tr t te Smaller of 2.5t or 2.5tn+te Larger of d or Rn+tn+t A1 A2 A5 A4 UG-40
137. Fion Zhang/ Charlie Chong Larger of d or Rn+tn+t Shell plate remove area (A) Spare area available in nozzle A2 Material available in weld A4
Material available in pad A5 Spare material available in shell A1 Smaller of 2.5t or 2.5tn+te t tn te UG-40
139. Fion Zhang/ Charlie Chong UG-84 UG-84 CHARPY IMPACT TESTS
140. Fion Zhang/ Charlie Chong CHARPY IMPACT TESTS UG-84
141. Fion Zhang/ Charlie Chong UG-84(a) General. Charpy impact tests in accordance with the provisions of this paragraph shall be made on
weldments and all materials for shells, heads, nozzles, for which impact tests are required by the rules in Subsection C. UG-84(b) Test Procedures.
UG-84(b)(1) Impact test procedures and apparatus shall conform to the applicable paragraphs of SA-370. SA-370 is a document that describes in
great detail the actual procedure for breaking specimens. UG-84(c) Test Specimens. UG-84(c)(1) Each set of impact test specimens shall consist of
three specimens. UG-84
142. Fion Zhang/ Charlie Chong UG-84(g) Location, Orientation, Temperature, and Values of Weld Impact Tests. All weld impact tests shall comply
with the following: UG-84(g)(1) Each set of weld metal impact specimens shall be taken across the weld with the notch in the weld metal. Each
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specimen shall be oriented so the notch is normal to the surface of the material and one face of the specimen shall be within 1/16 in. (1.6 mm) of the
surface of the material. UG-84(g)(2) Each set of heat affected zone impact specimens shall be taken across the weld and of sufficient length to locate,
after etching, the notch in the heat affected zone. The notch shall be cut approximately normal to the material surface in such a manner as to include
as much heat affected zone material as possible in the resulting fracture. UG-84
143. Fion Zhang/ Charlie Chong UG-84 UG-84(h) Impact Tests of Welding Procedure Qualifications • UG-84(h)(1) General. For steel vessels of
welded construction, the impact toughness of the welds and heat affected zones of the procedure qualification test plates shall be…...UG-84(h)(2)
When Required. Welding procedure impact tests shall be made when required by UCS-67, UHT-82, or UHA-51. For vessels constructed to the rules
of Part UCS, the test plate material shall satisfy all of the following requirements…… a) be of the same P-Number and Group Number; b) be in the
same heat treated condition; and c) meet the minimum notch toughness requirements of UG-84(c)(4) for the thickest material of the range of base
material qualified by the procedure. • (UG-84(h)(3) Material Over 1 ½ in. Thick. When procedure tests are made on material over 1 ½ in. (38 mm)
thick, three sets of impact specimens are required.
144. Fion Zhang/ Charlie Chong UG-84 • (UG-84(h)(3) Material Over 1 ½ in. Thick. When procedure tests are made on material over 1 ½ in. (38
mm) thick, three sets of impact specimens are required. Base material = 1 set of 3 Welding procedure t ≤ 1 ½ “ = 2 sets of 3 (HAZ & Weld) Welding
procedure t > 1 ½ “ = 3 sets of 3 (HAZ & 2 sets of Weld)
145. Fion Zhang/ Charlie Chong UG-84 UG-84(g3): One set of heat affected zone specimens shall be taken as described in (g)(2). Two sets of impact
specimens shall be taken from the weld with one located within 1/16” the surface of one side of the material and one set taken as near as practical
midway between the surface and the center of thickness of the opposite side as described in (g)(1) above.
148. Fion Zhang/ Charlie Chong UG-84 GENERAL NOTES: a) Interpolation between yield strengths shown is permitted. b) The minimum impact
energy for one specimen shall not be less than 2⁄3 of the average energy required for three specimens. The average impact energy value of the three
specimens may be rounded to the nearest ft-lb. c) Material produced and impact tested in accordance with SA-320, SA-333, SA- 334, SA-350,
SA-352, SA-420, impact tested SA/AS 1548 (L impact designations), SA-437, SA-540 (except for materials produced under Table 2, Note 4 in
SA-540), and SA-765 do not have to satisfy these energy values. See UCS-66(g). d) For materials having a specified minimum tensile strength of 95
ksi or more, see UG-84(c)(4)(b).
149. Fion Zhang/ Charlie Chong UG-84 Criteria for Acceptance & Retest. Figure UG-84.1. 1. The average energy of 3 specimen shall equal or
exceed FIG. UG- 84.1 CHARPY V-NOTCH IMPACT TEST REQUIREMENTS 2. The minimum impact energy for one specimen shall not be less
than 2⁄3 of the average energy required for three specimens. Note: For acceptance, average of 3 shall equal or exceed the specified value and one
(only one) may be below but shall exceed 2/3 the specified value.
150. Fion Zhang/ Charlie Chong UG-84 Criteria for Retest. UG-84(c)(6) When the average value of the three specimens equals or exceeds the
minimum value permitted for a single specimen (2/3 specified average) and (1) the value for more than one specimen is below the required average
value, or (2) when the value for one specimen is below the minimum value permitted for a single specimen, a retest of three additional specimens
shall be made. The value for each of these retest specimens shall equal or exceed the required average value. Example: SMYS=50ksi, t=2 in. average
value of the three specimens ≥18f-lb. Minimum impact energy for one specimen 2/3 x 18 = 12 ft-lb. 1st Criteria for retest, 3 specimen average ≥ 12
ft-lb.
151. Fion Zhang/ Charlie Chong UG-84 UG-84 Testing FIG. UG-84.1 & General Notes. Accept Satisfy UG-84(c)(6) Retest allowed with stringent
requirement. Reject
152. Fion Zhang/ Charlie Chong UG-84 Example: Average required is 15 ft-lb (joules 20.4) Minimum value permitted for single specimen is 10 ft-lb.
•15 + 16 + 14 = 45/3 = 15 Passed. •18 + 14 + 13 = 45/3 = 15 Failed, more than one below 15 (retest allowed) •15 + 14 + 13 = 42/3 = 14 Failed, more
than one below 15 (retest allowed) •18 + 18 + 9 = 45/3 = 15 Failed, one below 2/3 of 15 = 10 (retest allowed)
153. Fion Zhang/ Charlie Chong UG-99 STANDARD HYDROSTATIC TEST UG-99
154. Fion Zhang/ Charlie Chong STANDARD HYDROSTATIC TEST UG-99
155. Fion Zhang/ Charlie Chong UG-99 STANDARD HYDROSTATIC TEST 1999 addendum and later: Test Pressure in psi (MPa) = 1.3 MAWP ×
(Stest temp /Sdesign temp) Prior to 1999 addendum: Test Pressure in psi (MPa) = 1.5 MAWP × (Stest temp /Sdesign temp) Lowest stress ratio (LSR)
for the materials of which the vessel is constructed. The stress ratio for each material is the stress value S at its test temperature to the stress value S at
its design temperature (Stest temp /Sdesign temp) UG-99
156. Fion Zhang/ Charlie Chong Note that where a vessel is constructed of different materials that have different allowable stress values, the lowest
ratio of stress values is used. You will see this used later in ASME VIII worked examples. Loweststress ratio (LSR) for the materials of which the
vessel is constructed. The stress ratio for each material is the stress value S at its test temperature to the stress value S at its design temperature (S test
temp / S design temp) UG-99
157. Fion Zhang/ Charlie Chong UG-99(g): The visual inspection of joints and connections for leaks at the test pressure divided by 1.3 may be
waived provided: ( Visual inspection at MAWP) 1. a suitable gas leak test is applied; 2. substitution of the gas leak test is by agreement reached
between Manufacturer and Inspector; 3. all welded seams which will be hidden by assembly be given a visual examination for workmanship prior to
assembly; 4. the vessel will not contain a “lethal” substance. UG-99
158. Fion Zhang/ Charlie Chong Testing Medium. Any nonhazardous liquid at any temperature may be used for the hydrostatic test if below its
boiling point. Combustible liquids having a flash point less than 110ºF (43 ºC), such as petroleum distillates, may be used only for near atmospheric
temperature tests. Metal temperature. It is recommended that the metal temperature during hydrostatic test be maintained at least 30 ºF (17 ºC)
above the minimum design metal temperature, but need not exceed 120 ºF (48 ºC), to minimize the risk of brittle fracture. [See UG-20 and General
Note (6) to Fig. UCS-66.2.] The test pressure shall not be applied until the vessel and its contents are at about the same temperature. If the test
temperature exceeds 120 ºF (48 ºC), it is recommended that inspection of the vessel required by (g) above be delayed until the temperature is reduced
to 120 º F (48 ºC) or less. UG-99
boiling point. Combustible liquids having a flash point less than 110°F (43 °C), such as petroleum distillates, may be used only for near
atmospheric temperature tests. Metal temperature. It is recommended that the metal temperature during hydrostatic test be maintained at least 30°F
(17°C) above the minimum design metal temperature, but need not exceed 120°F (48°C), to minimize the risk of brittle fracture. [See UG-20 and
General Note (6) to Fig. UCS-66.2.]. The test pressure shall not be applied until the vessel and its contents are at about the same temperature. If
the test temperature exceeds 120°F (48°C), it is recommended that inspection of the vessel required by UG-99(g) above be delayed until the
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temperature is reduced to 120°F (48°C) or less. UG-99

160. Fion Zhang/ Charlie Chong Metal temperature API 510 has a different rule for this, it recommends that the temperature be 10°F above for 2 in.
(≤50mm) thickness and under and 30°F above for over 2 in. (>50mm). UG-99
boiling point. Combustible liquids having a flash point less than 110°F (43°C), such as petroleum distillates, may be used only for near atmospheric
temperature tests. UG-99
162. Fion Zhang/ Charlie Chong Example: Hydrostatic testing pressure Design pressure (MAWP) = 250 psi Design temperature = 750°F Material:
carbon steel SA516-60 . S room = 15 000 psi . S 750°F = 13 000 psi Ratio of stress values = 15 000/13 000 = 1.154 Test pressure = 1.3x 250x 1.154
Test pressure = 375 psi. ANSWER# UG-99
163. CAUTION: A small liquid relief valve set to 1⅓ (1.33) times the test pressure is recommended for the pressure test system, in case a vessel,
while under test, is likely to be warmed up materially with personnel absent. likely to be; warmed up materially with personnel absent. Fion Zhang/
Charlie Chong UG-99
164. UG-99(k) Vessels, except for those in lethal service, may be painted or otherwise coated either internally or externally, and may be lined
internally, prior to the pressure test. However, the user is cautioned that such painting / coating / lining may mask leaks that would otherwise have
been detected during the pressure test. Fion Zhang/ Charlie Chong UG-99
165. Fion Zhang/ Charlie Chong UG-100 PNEUMATIC TEST. UG-100
166. Fion Zhang/ Charlie Chong UG-100 • UG-100 (d) The pressure in the vessel shall be gradually increased to not more than one-half of the test
pressure. Thereafter, the test pressure shall be increased in steps of approximately one-tenth of the test pressure until the required test pressure has
been reached. Then the pressure shall be reduced to a value equal to the test pressure divided by 1.1 and held for a sufficient time to permit inspection
of the vessel. Except for leakage that might occur at temporary test closures for those openings intended for welded connections, leakage is not
allowed at the time of the required visual inspection. Leakage from temporary seals shall be directed away so as to avoid masking leaks from other
joints. The visual inspection of the vessel at the required test pressure divided by 1.1 may be waived provided: 1. a suitable gas leak test is applied; 2.
substitution of the gas leak test is by agreement reached between Manufacturer and Inspector; 3. all welded seams which will be hidden by assembly
be given a visual examination for workmanship prior to assembly; 4. the vessel will not contain a “lethal” substance.
167. Fion Zhang/ Charlie Chong UG-100 1. a suitable gas leak test is applied; 2. substitution of the gas leak test is by agreement reached between
Manufacturer and Inspector; 3. all welded seams which will be hidden by assembly be given a visual examination for workmanship prior to
assembly; 4. the vessel will not contain a “lethal” substance.
169. Fion Zhang/ Charlie Chong the pneumatic test pressure at every point in the vessel shall be at least equal to 1.1 times the maximum allowable
working pressure multiplied by the lowest stress ratio (LSR) for the materials of which the vessel is constructed. The pressure in the vessel shall be
gradually increased to not more than one-half of the test pressure. Thereafter, the test pressure shall be increased in steps of approximately one-tenth
of the test pressure until the required test pressure has been reached. Then the pressure shall be reduced to a value equal to the test pressure divided
by 1.1 and held for a sufficient time to permit inspection of the vessel. Pneumatic test pressure = 1.1 x MAWP x LSR UG-100
170. Fion Zhang/ Charlie Chong Test pressure divided by 1.1 and held for a sufficient time to permit inspection of the vessel. Pneumatic test pressure
= 1.1 x MAWP x LSR UG-100
171. Fion Zhang/ Charlie Chong “Test pressure divided by 1.1” is not MAWP! There is a LSR factor. Pneumatic test pressure = 1.1 x MAWP x LSR
UG-100
172. UG-100 (e) Vessels, except for those in lethal service, may be painted or otherwise coated either internally or externally, and may be lined
internally, prior to the pressure test. However, the user is cautioned that such painting / coating /lining may mask leaks that would otherwise have
been detected during the pressure test. Fion Zhang/ Charlie Chong UG-100
173. Fion Zhang/ Charlie Chong UW-50 NONDESTRUCTIVE EXAMINATION OF WELDS ON PNEUMATICALLY TESTED VESSELS On
welded pressure vessels to be pneumatically tested in accordance with UG-100, the full length of the following welds shall be examined7 for the
purpose of detecting cracks: a) all welds around openings; b) all attachment welds, including welds attaching non-pressure parts to pressure parts,
having a throat thickness greater than 1⁄4 in. (6 mm). Note: 7 Examination shall be by magnetic particle or liquid penetrant methods when the
material is ferromagnetic, or by the liquid penetrant method when the material is nonmagnetic. UG-100
174. Fion Zhang/ Charlie Chong a) all welds around openings; b) all attachment welds, including welds attaching non-pressure parts to pressure
parts, having a throat thickness greater than 1⁄4 in. (6 mm). UG-100
175. Fion Zhang/ Charlie Chong Q8. ASME VIII UG-100 (d): pneumatic test What are the increments used to increase the pressure up to pneumatic
test pressure? (a) Increase gradually to 50 % design pressure followed by 10 % increments (b) Increase gradually by 10 % increments (c) Increase
gradually to 50 % test pressure followed by 10 % increments (d) Increase gradually to 1.3x design pressure followed by 10 % increments UG-100
176. Fion Zhang/ Charlie Chong UW-102 UG-102 TEST GAGES
177. Fion Zhang/ Charlie Chong UG-102: (b) Dial indicating pressure gages used in testing shall be graduated over a range of about double the
intended maximum test pressure, but in no case shall the range be less than 1 ½ nor more than 4 times that pressure. Digital reading pressure gages
having a wider range of pressure may be used provided the readings give the same or greater degree of accuracy as obtained with dial pressure gages.
Applicable testing range 40psi~107psi UG-102
178. Fion Zhang/ Charlie Chong UG-102: the gauge range be within 1½ and 4 times that of test pressure. Applicable test pressure range: 37.7
~100psi UG-102
179. Fion Zhang/ Charlie Chong API576-5.4.5 Incorrect calibration of pressure gauges is a frequent cause of improper valve setting. To ensure
accuracy, gauges should be calibrated frequently on a regularly calibrated dead weight tester. The pressure range of the gauge should be chosen so
that the required set pressure of the pressure-relief valve falls within the middle third of the gauge pressure range. Snubbers on pressure gauges are
not generally recommended since they tend to clog and produce pressure lag. Applicable test range: 50~100psi UG-102 middle third
180. Fion Zhang/ Charlie Chong Snubbers on pressure gauges are not generally recommended since they tend to clog and produce pressure lag.
UG-102 A snubber is a device used to suppress ("snub") some phenomenon, such as: • Voltage transients in electrical systems. • Pressure transients in
fluid systems. • Excess force or rapid movement in mechanical systems.
181. Fion Zhang/ Charlie Chong a) An indicating gage shall be connected directly to the vessel. If the indicating gage is not readily visible to the
operator controlling the pressure applied, an additional indicating gage shall be provided where it will be visible to the operator throughout the
duration of the test. For large vessels, it is recommended that a recording gage be used in addition to indicating gages. b) Dial indicating pressure
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gages used in testing shall be graduated over a range of about double (2X) the intended maximum test pressure, but in no case shall the range be less
than 1 ½ nor more than 4 times that pressure. Digital reading pressure gages having a wider range of pressure may be used provided the readings give
the same or greater degree of accuracy as obtained with dial pressure gages. c) All gages shall be calibrated against a standard deadweight tester or a
calibrated master gage. Gages shall be recalibrated at any time that there is reason to believe that they are in error. UW-102
182. Fion Zhang/ Charlie Chong c) All gages shall be calibrated against a standard deadweight tester or a calibrated master gage. Gages shall be
recalibrated at any time that there is reason to believe that they are in error. UW-102
183. Fion Zhang/ Charlie Chong UW-116 UG-116 REQUIRED MARKING.
184. Fion Zhang/ Charlie Chong UW-116 UG-116(e4) “RT 4” when only part of the complete vessel has satisfied the radiographic requirements of
UW-11(a) or where none of the markings “RT 1,” “RT 2,” or “RT 3” are applicable. RT 4 UG-116(e3) “RT 3” when the complete vessel satisfies the
spot radiography requirements of UW-11(b); or RT 3 UG-116(e2) “RT 2” when the complete vessel satisfies the requirements of UW-11(a)(5) and
when the spot radiography requirements of UW-11(a)(5)(b) have been applied; or RT 2 UG-116(e1) “RT 1” when all pressure-retaining butt welds,
other than Category B and C butt welds associated with nozzles and communicating chambers that neither exceed NPS 10 (DN 250) nor 1 1⁄8 in. (29
mm) wall thickness [except as required by UHT-57(a)], satisfy the full radiography requirements of UW- 11(a) for their full length; full radiography
of the above exempted Category B and C butt welds, if performed, may be recorded on the Manufacturer’s Data Report; or RT 1
185. Fion Zhang/ Charlie Chong UW-116 UW-11 RADIOGRAPHIC AND ULTRASONIC EXAMINATION (a) Full Radiography. The following
welded joints shall be examined radiographically for their full length in the manner prescribed in UW-51: (5) all Category A and D butt welds in
vessel sections and heads where the design of the joint or part is based on a joint efficiency permitted by UW-12(a), in which case: (a) Category A
and B welds connecting the vessel sections or heads shall be of Type No. (1) or Type No.(2) of Table UW-12; (b) Category B or C butt welds [but not
including those in nozzles or communicating chambers except as required in (2) above] which intersect the Category A butt welds in vessel sections
or heads or connect seamless vessel sections or heads shall, as a minimum, meet the requirements for spot radiography in accordance with UW-52.
Spot radiographs required by this paragraph shall not be used to satisfy the spot radiography rules as applied to any other weld increment.
186. Fion Zhang/ Charlie Chong UW-116
189. Fion Zhang/ Charlie Chong UW-116 Required Marking • The marking applied to a vessel's nameplate or directly to its shell are described in this
paragraph. It is important information. Often a vessel's Data Report is lost and the only information that is available is that found on the Name Plate
or the shell itself. In some cases the Name Plate is missing or sand blasted and not readable. The following is a listing of what is required by the Code
to be present on the Name Plate. 1. 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. Name of the manufacturer preceded by the words "Certified by". 3. Maximum allowable working pressure ____psi at __°F. 4.
Minimum design metal temperature __°F at ____ psi. 5. Manufacturer's serial number. 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.
190. Fion Zhang/ Charlie Chong UW-116 8. If a vessel is built using more than one type of construction all shall be indicated. 9. If a vessel is in a
special service the lettering as shown below must be applied. a. a. Lethal Service L. b. b. Unfired Steam Boiler UB. c. c. Direct Firing DF. 11.10. The
MAWP must be based on the most restrictive part of the vessel.
191. Fion Zhang/ Charlie Chong UW-116 11.When a complete vessel or parts of a vessel of welded construction have been radiographed in
accordance with UW-11, the marking must be as follows: a. "RT 1" when all pressure retaining butt welds, other than B and C associated with
nozzles and communication chambers that neither exceed NPS 10 nor 1 1/8 inch 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. b. "RT 2"
Complete vessel satisfies UW-11(a)(5) and UW- 11(a)(5)(b) has been applied. c. "RT 3" Complete vessel satisfies spot radiography of UW-11(b). d.
"RT 4" When only part of the vessel satisfies any of the above.
192. Fion Zhang/ Charlie Chong UW-116 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 received partial Postweld heat treatment. 14.Code symbol must be applied after hydro or pneumatic test. 15.Parts of
vessels for which Partial Data Report are required shall be marked by the parts manufacturer with the following: a. "PART“. b. Name of the
Manufacturer. c. The manufacturer's serial number.
193. Fion Zhang/ Charlie Chong UW-116 "RT 2" Complete vessel satisfies UW-11(a)(5) and UW- 11(a)(5)(b) has been applied. UW-11
RADIOGRAPHIC AND ULTRASONIC EXAMINATION (a) Full Radiography. The following welded joints shall be examined radiographically for
their full length in the manner prescribed in UW-51: (5) all Category A and D butt welds in vessel sections and heads where the design of the joint or
part is based on a joint efficiency permitted by UW-12(a), in which case: (b) Category B or C butt welds [but not including those in nozzles or
communicating chambers except as required in (2) above] which intersect the Category A butt welds in vessel sections or heads or connect seamless
vessel sections or heads shall, as a minimum, meet the requirements for spot radiography in accordance with UW-52. Spot radiographs required by
this paragraph shall not be used to satisfy the spot radiography rules as applied to any other weld increment.
196. Fion Zhang/ Charlie Chong UW-116 When and where is there a code requirement for full radiography? Item 1: All butt welds in vessels used to
contain a lethal substance (UW-11(a)). Lethal substances have specific definitions in ASME Code in UW-2 and it is the responsibility of the end user
to determine if they ordered a vessel that contains lethal substances. Item 2: All butt welds in vessels in which the nominal thickness exceeds
specified values (UW-11(a)). You can find these values in subsection C, in UCS-57, UNF-57, etc. For example, this value for P-No.1 in UCS-57 is 1
¼ inch. Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UW- 11(a)). Item 4: All category “A” and “D” butt welds in
vessel when “Full Radiography” optionally selected from table UW-12(column (a) in this table is selected); and categories B and C which intersect
Category “A” shall meet the spot radiography requirement (UW-11(a) (5) (b)).
197. Fion Zhang/ Charlie Chong UW-116 Item 4: All category “A” and “D” butt welds in vessel when “Full Radiography” optionally selected from
table UW-12(column (a) in this table is selected); and categories “B” and “C” which intersect Category A shall meet the spot radiography
requirement (UW-11(a) (5) (b)).
198. Fion Zhang/ Charlie Chong UW-116 The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is
mandated by code; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) in UW-12 table. But
in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table UW-12 for full radiography. So here
there is a concession or bonus to manufacturers for joint categories B and C. What is concept behind this concession or bonus in pressure vessel RT
11 of 24 15-03-2015 16:31
test? If you review item 1, 2 and 3 one more time, you will see that the pressure vessel RT tests are related to the type of welds and services. You can
see the pressure vessels in these items are critical from a safety point of view, one contains a lethal substance, the other one has a high thickness,
which implicates high pressure, and the last one is an unfired steam boiler. But item 4 has no criticality like the other items have. But you should note
all 4 items have been categorized in full radiography clause( U-11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT symbols (RT1 / RT2) are
used in Code (UG-116).
199. Fion Zhang/ Charlie Chong UW-116 Lethal service / thickness / unfired steam boiler. RT 1 All butt welds in vessels. (categories A, B, C, D) RT
2 All category “A” and “D” butt welds in vessel and categories “B” and “C” which intersect Category “A” shall meet the spot radiography
requirement (UW-11(a) (5) (b)). Optionally selected “E” from table UW-12(column a).
200. Fion Zhang/ Charlie Chong UW-116 RT 1: Items 1, 2 and 3, (E=1), All butt welds-full length radiography RT 2: Item 4 (E=1), Category A and
D butt welds full length radiography and category B and C butt welds spot Radiography RT 3: (E=0.85), Spot radiography butt welds RT 4: (E=0.7),
Partial / No radiography http://www.inspection-for-industry.com/asme-pressure-vessel-joint-efficiencies.html
201. Fion Zhang/ Charlie Chong UW-116 http://www.nationalboard.org/PrintPage.aspx?NewsPageID=144 Q. What is the difference between an
RT-1 and an RT-2 vessel? A. The definitions for the RT-1 and RT-2 are provided in paragraph UG- 116(e) and, by reference, UW-11(a). Paragraph
UW-11(a) defines both plans as full radiography. The RT-1 plan requires all butt-welded joints be fully radiographed over their entire length using the
criteria in paragraph UW-51. The RT-2 plan requires all category A and D butt- welded joints be radiographed over their entire length using the
criteria in paragraph UW-51. All category B and C butt-welded joints must be spot radiographed per UW-11(a)(5)(b) using the criteria in paragraph
UW-52. Depending on the welded joint type employed for welded components, the efficiency will normally be established by a category A or D butt-
welded joint (UG-27 footnote 15). A vessel complying with either plan will be 100 percent efficient for both components having type 1 welded joints
(Table UW-12 column [a]) and seamless head or shell sections (UW-12[d]).
202. Fion Zhang/ Charlie Chong UW-119 UG-119 Nameplates
203. Fion Zhang/ Charlie Chong UW-119 UG-119 Nameplates. In this paragraph are the details of nameplates, including such things as the size and
methods of markings allowed. The nameplate must be located within 30 in. of the vessel and must be thick enough to resist distortion when stamping
is applied. The types of acceptable attachment types include welding, brazing, and tamper resistant mechanical fasteners of metal construction.
Adhesive attachments may be used if the provisions of Appendix 18 are met. An additional nameplate may be used if it is marked with the words
"DUPLICATE". On previous tests some questions have come from this paragraph.
204. Fion Zhang/ Charlie Chong UG-120 Data Reports UW-120
205. Fion Zhang/ Charlie Chong UW-120 UG-120 Data Reports Data Reports must prepared on form U-1 or U-1A for all vessels that the Code
Symbol will be applied to. The Manufacturer and the Inspector must sign them. A single Data Report may represent all vessel made in the same day
production run if they meet all of the requirements listed in UG-120. A copy of the Manufacturer's Data Report must be furnished to the User and
upon request the Inspector. The manufacturer must either keep a copy of the Data Report on file for 5 years or register the vessel and file the Data
Report with the National Board of Boiler and Pressure Vessel Inspectors.
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CC Chong (109 SlideShares) , Surveyor/ Inspector at DNV Energy

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