PREPARATION CLASS

API 510
PRESSURE VESSEL
INSPECTOR
CERTIFICATION EXAMINATION

5TH

PUSPATRI
JOHOR BAHRU
-9TH NOVEMBER 2007

Course Outlines
DAY 1 - 5th November 2007
Introduction to API 510 Certification
Module 1: ASME Section VIII Rules For Construction Of
Pressure Vessel
Module 2: Static Head, MAWP & Stress Calculations
DAY 2 - 6th November 2007
Module 3: Joint Efficiencies & Internal Pressure
Module 4: Pressure Testing, MDMT, Impact Testing
Module 5: External Pressure

Course Outline
DAY 3 7th November 2007
Introduction to API 510 Pressure Vessel Inspection Code
Section
Section
Section
Section

1
2
3
4

: Scope
: References
: Definitions
:Owner User Inspection Organization

Section 5 - : Inspection Practices

5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

Preparatory Work
Modes of Deterioration and Failure
Corrosion Rate Determination
Maximum Allowable Working Pressure Determination
Defect Inspection
Inspection of Parts
Corrosion & Minimum Thickness Evaluation
Fitness for Service Evaluation

Course Outline
DAY 4 8th November 2007
Section 6: Inspection and Testing of Pressure Vessels and
Pressure
Relieving Devices
6.1
6.2
6.3
6.4
6.5
6.6
6.7

General
Risk Based Inspection
External Inspection
Internal and On Stream Inspection
Pressure Test
Pressure Relieving Devices
Records

Section 7: Repairs, Alterations and Re-rating of Pressure Vessels

7.1 General
7.2 Welding
7.3 Rerating

Course Outline
Day 5 9th November 2007
API 572: Inspection of Pressure Vessel (Towers, Drum, Reactors
Heat
Exchanger & Condensers)
API 576: Inspection of Pressure Relieving Devices
Trial Examination

Why Are You Here?

Why API Certification?
- Significant milestone in inspectors career
- Additional job opportunities & salary increase
- Widen employment doors resume with API certificates
- Oil & Gas industry is booming
- Middle East offers USD 500 - 700 per day

Life is too short to be ordinary

What Will Be Asked?

API Publications
1. API 510, Pressure Vessel Inspection Code
2. API RP 571, Damage Mechanisms Affecting Equipment in
Refining Industry
3. API RP 572, Inspection of Pressure Vessels
4. API RP 576, Inspection of Pressure Relieving Devices
5. API RP 577, Welding Inspection and Metallurgy

ASME Publications
1. Section V, Nondestructive Examination
2. Section VIII, Division 1, Rules for Constructing Pressure
Vessels
3. Section IX, Welding and Brazing Qualifications

Dont Worry About The Exam

The API Examination
- 150 multiple choices with four possible answers
- Exam divided into 2 Parts
(a) Open Book 50 questions for 4 hours durations
(b) Closed Book 100 questions for 4 hours durations
-The examination handle by Professional Examination Services (PES)
-Result approximately 3 months after the examination
-API grants three consecutive attempts within 18 months periods
- 1st attempt : Applications forms and exam fees USD 800
- 2nd attempt : re-scheduling fees is USD 50
- 3rd attempt : USD 50 plus updated Employment Reference Form
Note: Failed after three attempts - New applications with new
applications fees

What To Bring To Exam

1.
2.
3.

4.
5.
6.
7.

API Examination Confirmation Letter

Identification Card
API & ASME reference publications. Note: highlighting,
underlining, page tabs, written notes on the codes book is
acceptable. Loose pages inserted into the codes book is not
acceptable.
Non-programmable calculator. Make sure enough battery.
2B pencil, eraser and other stationery
Jacket some classroom is uncomfortably cool
Earplugs you never know who might be seat next to you

Module 1:
ASME Section VIII Rules For
Construction Of Pressure
Vessel

ASME SECTION VIII

RULES FOR CONSTRUCTION OF
PRESSURE VESSEL

ASME
Boiler & Pressure Vessel Code
Sections
I Rules for Construction of Power Boilers
II Materials-Ferrous, Nonferrous, Welding Rods, Electrodes
III Nuclear Power Plant
IV Rules of Construction of Heating Boilers
V Nondestructive Examination
VI Rules for Operation of Heating Boilers
VII- Guidelines for Operations of Power Boilers
VIII- Rules for Construction of Pressure Vessel
IX-Welding & Brazing Qualifications
X-Fiber Reinforced Plastic Pressure Vessel
XI-Rules for In-Service Inspection of Nuclear Power Plant
XII-Rules for Construction and Continued Service of Transport Tank

Settings Rules!
Is What The Code Is All About
Important factors during fabrication that affect vessel safety
and
reliability seem almost endless.
(a)
(b)
(c)
(d)
(e)

Design thickness formulas, welding processes

Material Known physical & chemical properties
Fabrication qualified welding procedure, NDT
Pressure Testing hydro or pneumatic
Documentation nameplate, design calculation data

Scope of the Code

U-1(a) For the scope of the division pressure vessels are containers for
the containment of pressure either internal or external.
U-1(c)(2) The following classes of vessels are not considered to be
within the scope of the division:
(a) Within cope of other division
(b) Fired process tubular heaters
(c) PV of integral parts/component of pumps, turbines, compressor
(d) Pipe and piping component
(e) PV for water under pressure in which P d<300 psi or Td<2100F
(f) Tank hot water in which heat input<200,000 BTU, T<2100F,
capacity <120 gallon
(g) PV having internal/external pressure <15 psi; no size limit
(h) PV having inside diameter <6 inches
(i) PV for human occupancy

Scope of the Code

continued

Vessel Boundary Limits

U-1(e)1
(a) 1st circumferential weld
(b) 1st threaded joint for screwed connection
(c) face of 1st flange for bolted connection
(d) 1st sealing surface for proprietary connection/fitting
U-1(e) 2 Non-pressure part that are welded directly to the
vessel
U-1(e) 3 Pressure retaining cover i.e. manhole and hand hole
covers

Shhhhh!!!!!
During API exam you will be asked to find specific information in
Section VIII. In order to accomplish this quickly and successfully
you
must know:
(1) How information is organized in the code
(2) How to use the organization tools of the code
If you know these 2 secret, every answer can be found with
minimum
effort. Thats much better than paging through 700 pages of the
codes!

Organization of Code
Section VIII- Rules for Construction of Pressure Vessel consists
of 2 division;
(a) Division 1 Routine Vessel
(b)Division 2 Alternate Rules for special vessel
Section VIII Division 1
Introduction
3 Subsections

Subsection A General
Subsection B Fabrication Method
Subsection C - Material

2 Appendix

Mandatory
Non-Mandatory

Organization of Code

continued

Each Subsection is further divided into Parts

Subsection A General
Part UG applies to all vessels

Subsection B Fabrication
Part UW applies to all vessels that are welded

Subsection C Materials
Part UCS applies to all vessel made of CS or LA steel
Part UHT applies to ferritic vessel that use Heat Treatment

Every Part is divided into Paragraphs

UG-1, UW-1, UCS-1

Organization of Code

continued

Mandatory Appendices
U-1(b) address specific subject not covered elsewhere in this
division
Alternate formulae
QC Manual
NDE Standards
Non-mandatory Appendices
U-1(b) provides information and suggested good practices
Completed Sample Problems

Example 1-1 Finding the Right Answer

At what base metal temperature is welding not
allowed on routine pressure vessel?

Example 1-1 Finding the Right Answer

At what base metal temperature is welding not allowed on
routine
pressure vessel?
ASME Code
Section 1
Boilers

Section II
Materials

Section VIII
Pressure Vessel

Division 1
Routine
Sub A
General
Part UF
Forge

Section V
NDT

Section IX
Welding

Division 2
Other

Sub B
Fabrication

Sub C
Materials

Part UW
Welding

Part UB
Brazing

Design
Materials
Fabrication
Inspect
Marking

Exercise 1-2
A vessel is welded with Carbon Steel components.
Which part in the Code would you find:
(a) Design Requirements
:
(b) Hydrotest Pressure
:
(c) RT Acceptance Standards
____________________
(d) Nameplate Data
:
(e) Limits of Carbon % in Materials
____________________
(f) Material ID Traceability
:
(g) Inspection Requirements
____________________
(h) PWHT Requirements
:

____________________
____________________
:
____________________
:
____________________
:
____________________

Exercise 1-2

answer.

A vessel is welded with Carbon Steel components.

Which part in the Code would you find:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)

Design Requirements : UG, UW, UCS

Hydrotest Pressure
: UG
RT Acceptance Standards
: UW
Nameplate Data : UG
Limits of Carbon % in Materials
: UCS
Material ID Traceability : UG
Inspection Requirements
: UG, UW, UCS
PWHT Requirements
: UW, UCS

Hint:
If its applicable to all vessel UG.
If its only applicable because its welded UW
If its based on metallurgy - UCS

Codes Purpose
Establish Rules for Construction of Pressure Vessel

To ensure the construction of pressure vessels will be carried

out in a
safe and reliable manner.
One way the Code achieves this is by setting requirements for
critical
work assignment. This will involved:
(1) User
(2) Manufacturer
(3) Authorized Inspector
(4) Welder
(5) NDE Technician

Setting The Rules

User Roles & Responsibilities
U-2(a) : The user or his designated agent shall establish the
requirements for pressure vessel
- Specify size and shape
- Specify vessel internals; type, spacing
- Determine design pressure and temperature
- Specify the Corrosion Allowance
- Determine whether the PV be classified as Lethal Service
- Specify PWHT if needed for process conditions

Setting The Rules

Manufacturer Roles & Responsibilities
U-2(b)(1) The manufacturer of any vesselhas the responsibility
of
complying with all of the applicable requirements of this
Division ..
UG-90(b) The Manufacturer shall perform his specified duties.

Obtain Certificate of Authorization from ASME

Perform design calculations & develop fabrications drawings

Identify all material used during fabrication

Examine materials before fabrication: thickness, ID, defects

Qualify welding procedures & welders

Perform NDE test and records result

Perform vessel hydro or pneumatic test

Apply the Code Stamp

Prepare Manufacturers Data Report

Setting The Rules

Authorized Inspector

Roles &

Responsibilities
Section VIII requires that all vessels be inspected by a qualified thirdparty inspector which is employed by An Authorized Inspection
Agency.
U-2(e) It is the duty of the Inspector to make all of the inspections
specified by the rules of this Division, and of monitoring the quality
control and the examinations made by the Manufacturer..
U-2(f) The rules of this Division shall serve as the basis for the
inspector to:
1. Perform required duties
2. Authorize the application of the Code Symbol
3. Sign the Certificate of Shop Inspection

Setting The Rules continued

Authorized Inspector Roles &
Responsibilities
UG-90(c)(1) The inspector shall

Verify the Manufacturer has a current Certificate of

Authorization

Verify Manufacturer is working to the QC system

Verify design calculations are available

Verify materials meet Codes

Verify weld procedures and welders are qualified

Verify NDE tests have been performed & are acceptable

Perform internal & external inspections

Verify nameplate is attached and has the right markings

Witness the hydrotest

Sign the Manufacturers Data Report

Setting The Rules

Welders & NDE Techs

Roles &

Welder
Responsibilities

UW-29(a) The welders ..used in welding pressure partsshall be

qualified in accordance with Section IX
NDE Technician
UW-51(a)(2) RT Qualified and certified in accordance with employers
written practice. SNT-TC-1A used as a guidelines
App 12-2 UT Qualified and certified in accordance with employers
written practice. SNT-TC-1A used as a guidelines
App 6-2 (a&b) MT He has vision ..read a Jaeger Type No. 2 Chart ..
And is competent in the techniques of the magnetic particle
examination method
App 8-2 (a&b) MT He has vision ..read a Jaeger Type No. 2 Chart ..
And is competent in the techniques of the magnetic particle
examination method

CODE-OLOGY
Code Stamp
When the manufacturer uses the Code
Stamps, they are saying We met all
the applicable requirement of the
Code:
UG-116(a&b) Each pressure vessel
shall be marked with official Code U
symbol or the official UM Symbol
UG-116 (g) The Manufacturer shall
have a valid Certificate of
Authorization, and with the
acceptance
of Inspector shall apply the Code
Symbol to the vessel.

Note: The Code

Symbol shall be
applied after
hydrostatic or
pneumatic test

CODE-OLOGY
Certificate of Authorization
What driving license does for the driver, the Certificate of
Authorization (CoA) does for the Manufacturer!
CoA - authorizes Manufacturer to design & build a Section
VII vessel.
CoA -authorizes Manufacturer to stamp the vessel with
the Code Stamp.
UG-117(a&b)
A Certificate of Authorization to use the Code U, UM, & UV
symbolswill be granted by the Society Each applicant must
agree
that each Certificate of Authorization and each Code Symbol
Stamp are
at all times the property of the Society

CODE-OLOGY
Quality Control System
UG-117(e) Any Manufacturer shall have and demonstrate a
Quality
Control System to establish all Code requirementwill be met.
The
Quality Control System shall be in accordance with Appendix
10.
The Code tells the Manufacturer what must be done when
building a
vessel. The Manufacturers Quality Control System tells ASME
and the
AI how things will be done in the shop to meet the code.

CODE-OLOGY
Data Reports
UG-120(a) A Data Report shall be filled out on Form U-1..by
the
Manufacturer and shall be signed by the Manufacturer and
Inspector
for each pressure vessel marked with the Code U symbol.
For UM vessel the Form U-3
For vessel parts the Form U-2

CODE-OLOGY
UM Vessel Mini Vessel
If a vessel

Is not covered by U-1 (c), (g), (h) & (i)

Is not required to be fully radiographed

Does not have a quick actuating device

Does not exceed either the following limit

5 ft3 and 250 psi

1.5 ft3 and 600 psi

U-1(j) The vessel may be exempted from inspection by

Inspectors
Vessel fabricated .. With this rule shall be marked with the
UM
symbol

Exercise 1-3
1) Full radiography is performed on a vessel shell with a wall
thickness
of . What is the maximum allowed length for a slag inclusion?
2) A P-1 material (carbon steel) 2 thick is being PWHT. What is
the
a. Normal Holding Temperature
b. Minimum Holding Time
3) A relief device is required on a vessel so that the pressure
does not
rise more than _____% or ______ psi above MAWP (whichever
greater)

Exercise 1-3
1) Full radiography is performed on a vessel shell with a wall
thickness
of . What is the maximum allowed length for a slag inclusion?
Subsection B Fabrication Part UW Inspection UW51(b)2
2) A P-1 material (carbon steel) 2 thick is being PWHT. What is the
a. Normal Holding Temperature
b. Minimum Holding Time
Subsection C Materials Part UCS Design UCS56
3) A relief device is required on a vessel so that the pressure does
not
rise more than _____% or ______ psi above MAWP (whichever
greater)
Subsection A General Part UG Pressure Relief Devices UG125(c)

I have learned that success is to be measured not so much by the position that
one has reached in life as by the obstacles which he has overcome while trying
to succeed.
-Booker T. Washington

Module 2: Static Head, MAWP

& Internal Pressure

Module 2.1
Static Head

What is Static Head?

The weight of liquid applied a force (lbs) & a pressure
(psi). The higher the liquid height, the greater the
pressure. The pressure resulting from liquid height is
called, Static Head!
12
12

Box is 1
cubic ft

1 cubic foot of water

weighs 62.4 lbs.

12

1) How much force (weight) is on the bottom of this

container?______________
2) How much force on each square inch of the boxs
bottom?________ Whats this pressure? _______

Static Head Factor?

Water, 1 foot high will exert 0.433 psi at the bottom of the
container?
62.4 lbs/144 sq inch = 0.433 psi per foot of water
What is the pressure at the bottom of 10 of water?

PSHead = 0.433 x liquid height

Exercise 2-1
Static Head Pressure
1)

2)

A deep diving submarine cruising at a depth of 854 feet.

What is the static head pressure on this submarine?
(external pressure)
A vessel is 50 high. The vessel will be hydrotested
a. When filled with water what is the pressure at the bottom of
the vessel?
b. When the hydrotest pressure at the top of the vessel 100 psi,
what is
total pressure at the bottom?

3)

100 psig

0
0
A 60 vessel
is filled
with water. The pressure
at the ?? psig
psig
bottom is 210 psi. What is the pressure at the top?
2a

50

2b

??
psig

?? psig
50

210 psig
60

Exercise 2-1
Answer 1
A deep diving submarine cruising at a depth of 854 feet.
What is the static head pressure on this submarine?
(external pressure)

845 ft x 0.433 psi/ft = 369.8

psig

854 ft

1)

Exercise 2-1
Answer 2a
2) A vessel is 50 high. The vessel will be hydrotested
a. When filled with water what is the pressure at the
bottom of the vessel?

Pbtm = 0.433 psi/ft x 50 ft

0
psig

= 21.7 psig
2a

50

??
psig

Exercise 2-1
Answer 2b
2) A vessel is 50 high. The vessel will be hydrotested
b. When the hydrotest pressure at the top of the vessel
100 psi, what is total pressure at the bottom?
100 psig

Pbtm = Ptop + Psh

= 100 + (0.433x50)

2b

= 121.7 psig
?? psig
50

Exercise 2-1
Answer 3
3) A 60 vessel is filled with water. The pressure at
the
bottom is 210 psi. What is the pressure at the
top?
0

?? psig

Ptop = Pbtm - Psh

= 210 - (0.433x60)

= 184 psig
210 psig
60

Module 2.2
Design Pressure

Design Pressure
The pressure used in the design of a vessel component
together with
the coincident design metal temperature for the purposes of
determining the minimum permissible thicknessstatic head
shall be
added to the design pressure App 3-2

Exercise 2-2
Design Pressure
A 50 high vessel has a design pressure of 100 psig. The
elevations are
shown in the sketch below.
a.
b.
c.

The shell should be designed for

_________
psig
The top head should be designed for _________ psig
The bottom head should be designed for
_________
0
100 psig
psig
2

?? psig

48

?? psig

50

?? psig

Exercise 2-2
Design Pressure
a.

b.

c.

Pshell = Ptop +Psh

0
= 100 psig + (0.433 psi/ft x 48 ft)
= 120.8 psig
2
Ptop head = Ptop + Psh
= 100 psig + (0.433 psi/ft x 2 ft)
= 100.9 psig
48
Pbtm head
= Ptop + Psh
= 100 psig + (0.433 psi/ft x 50 ft)
50
= 121.7 psig

100 psig

?? psig

?? psig

?? psig

Note: Each component should be designed for the highest pressure

it will see at conditions. The highest pressure is at the bottom of the
part

Module 2.3
MAWP Calculations

MAWP
Vessel & Vessel Part
UG98(b) The maximum MAWP for a vessel part is the maximum
pressure including static head(based) upon rules and formulae in
this Divisionexcluding any metal thickness specified as corrosion
allowance
UG98(a) The maximum MAWP for a vessel is the maximum pressure
permissible at the top of the vessel in its normal operating position...
It is the least of the values found for maximum allowable working
pressure for any of the part of the vesseland adjusted for any
difference in static head

How much can he

lift?

MAWP
Vessel & Vessel Part
To determine Vessel MAWP:
Step 1: Determine each part MAWP (based on code formulas)
Step 2: For each part subtract appropriate static head
Step 3: Pick smallest pressure at top, the weakest link
0
12

Part B:
MAWP
336

Part B: 336 -0.433(12) = 330.8 psig

Thus, vessel MAWP = 328.3 psig

34

Part A: 343 0.433(34) = 328.3

psig

Part A:
MAWP
343

Exercise 2-3
Determining Vessel MAWP
The maximum MAWP this vessel can be rated is ______psig.
0 ft
1 ft
3 ft

24 ft
40 ft
42 ft

Exercise 2-3
Determining Vessel MAWP
The maximum MAWP this vessel can be rated is ______psig.
0 ft
1 ft
3 ft

24 ft
40 ft
42 ft

Design Pressure vs. MAWP

Design Pressure pressure from the system (process + static
head)
MAWP pressure part of the vessel is good for
Design
Pressure

MAWP

To meet Code
Requirement:
MAWP > Design Pressure

If MAWP < Design

Pressure

Exercise 2-3
More MAWP & Static Head calculation
1)

2)

The MAWP of a vessel is 100 psig. Each head depth is 2

and the cylindrical portion of the shell is 32. The shell
should be designed for a pressure of ______ psig.
A vessels MAWP is limited by the lower shell portion. This
shell part has a MAWP of 87.5 psig. What is the maximum
allowed MAWP for this vessel?
0 ft
1 ft

3)

A 80 tall pressure vessel is being hydrotested. A pressure

gauge 20 up from the bottom reads 136 psig. What is the
50 ft
pressure at the top of the vessel.
100
ft

Exercise 2-3
More MAWP & Static Head calculation
1)

The MAWP of a vessel is 100 psig. Each head depth is 2

and the cylindrical portion of the shell is 32. The shell
should be designed for a pressure of ______ psig.
0 ft

Pshell = Ptop + Psh

= 100 + 0.433(34)
= 114.7 psig

2 ft

34 ft

100 psig

Exercise 2-3
More MAWP & Static Head calculation
2)

A vessels MAWP is limited by the lower shell portion. This

shell part has a MAWP of 87.5 psig. What is the maximum
allowed MAWP for this vessel?
0 ft

Ptop = Pshell Psh

= 87.5 (0.433 x100)
= 44.2 psig

1 ft

50 ft

100
ft

Exercise 2-3
More MAWP & Static Head calculation
3)

A 80 tall pressure vessel is being hydrotested. A pressure

gauge 20 up from the bottom reads 136 psig. What is the
pressure at the top of the vessel.

Ptop = Pgauge Psh

= 136 (0.433 x 60)
= 110.0 psig

0 ft

60 ft
80 ft

136 psig

Module 2.4
Calculating Stress

Stress on Welds

Circumferential
Weld

Longitudinal Weld

Circumferential Stress affects: ___________ welds

Longitudinal Stress affects: __________ welds

Stress on Welds

Circumferential
Weld

Longitudinal Weld

Circumferential Stress affects: Longitudinal

welds
Longitudinal Stress affects: Circumferential
welds

Calculating Stress
A weld specimen that is 0.250 thick and 1.0 wide.
The
specimen breaks with 12,500 lbs. of load. What is
the
ultimate tensile strength of this specimen?

Calculating Stress
A weld specimen that is 0.250 thick and 1.0 wide.
The
specimen breaks with 12,500 lbs. of load. What is
the
ultimate tensile strength of this specimen?
S = Load/Area
S = 12,500/(0.25 x 1.0)
S = 50,000 psi

Exercise 2.5
Calculating Stress
1)
2)

A tension specimen is 0.5 thick and 0.75 wide. It breaks

with a load of 21,500 lbs. The failure stress is _______ psi.
A vessel is 10 in diameter and has pressure of 100 psi.
The force (load) trying to launch a vessel head into space
is 1,100,000 lbs. The circumference of the shell is about
400. The head and shell are thick, not including
corrosion allowance.
What is the actual longitudinal stress on the shell-to-head
weld?

Exercise 2.5
Calculating Stress
1)

2)

A tension specimen is 0.5 thick and 0.75 wide. It breaks with

a load of 21,500 lbs. The failure stress is _______ psi.
S = Load/Area
S = 21,500/(0.5)(0.75)
S = 57,333 psi
A vessel is 10 in diameter and has pressure of 100 psi. The
force (load) trying to launch a vessel head into space is
1,100,000 lbs. The circumference of the shell is about 400.
The head and shell are thick, not including corrosion
allowance.
What is the actual longitudinal stress on the shell-to-head
weld?
S = Load/Area
S = 1,100,000/(400)(0.5)
S = 5,500 psi

What is Allowable Stress?

Stress level that the designer is allowed to used.

The allowable stress is generally determined by dividing the

Ultimate
Tensile Strength by Codes safety Factor.
Allowable Stress = Ultimate Tensile Strength / Safety Factor

The Allowable Stresses for Section VIII Pressure Vessel are

provided in
the B&PV Code Section II.
The Safety Factor for Section VIII vessel is:

Pre 2000
Factor

4.0 to 1.0 Safety

Post 2000

3.5 to 1.0 Safety

Exercise 2-6
Allowable Stress
A material has an ultimate tensile strength of 70,000 psi at
ambient
temperature
a) What is the allowable stress for this material at ambient
conditions if used in a pressure vessel today?
b) What is the allowable stress for this material at ambient
conditions if used in a 1977 pressure vessel ?

Exercise 2-6
Allowable Stress
A material has an ultimate tensile strength of 70,000 psi
at ambient temperature
a) What is the allowable stress for this material at ambient
conditions if used in a pressure vessel today?
Allowable Stress = UTS/S.F
Allowable Stress = 70,000/3.5
Allowable Stress = 20,000 psi
b) What is the allowable stress for this material at ambient
conditions if used in a 1977 pressure vessel ?
Allowable Stress = UTS/S.F
Allowable Stress = 70,000/4.0
Allowable Stress = 17,500 psi

You may be disappointed if you fail, but you are doomed

if you dont try
-Beverly Sills

Module 3.1
Joint Efficiencies

E The Basic
What is Joint Efficiency E?
What factors that affect E?
How does Joint Efficiency affect E?
How is Joint Efficiency determined?

E The Basic
What is Joint Efficiency E?
- A safety factor for welds
- Compensation for possible weld defects
What factors that affect E?
- Type of Joint, Location of Joint, Amount of RT
How does Joint Efficiency affect t?
- As E decreases, required thickness increases
How is Joint Efficiency determined?
- The Code, Section VIII Table UW-12
- (also few exception listed in UW-12)

Exercise 2.7
Joint Efficiencies
1)
2)
3)

A shell is made with Type 2 joints and spot RT was performed.

What is E? _________.
A shell is made with Type 1 joints and Full RT was performed.
What is E? _________.
A shell is made with Type 3 joints and no RT was performed.
What is E? _________.

Exercise 2.7
Joint Efficiencies
1)
2)
3)

A shell is made with Type 2 joints and spot RT was performed.

What is E? 0.8 .
A shell is made with Type 1 joints and Full RT was performed.
What is E? 1.0.
A shell is made with Type 3 joints and no RT was performed.
What is E? 0.6.

Weld Joint Categories

The term Category as used herein defines the location of
a joint in a vessel, but not the type of joint.

Category A: Longitudinal welded joints

within the main shell, communicating
chambers,2 transitions in diameter, or
nozzles; any welded joint within a
sphere, within a formed or flat head, or
within the side plates3 of a flat-sided
vessel; circumferential welded joints
connecting hemispherical heads to main
shells, to transitions in diameters, to
nozzles, or to communicating chambers.
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 shells, to
transitions in diameter, to nozzles, or to
communicating chambers. UW-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 to
communicating chambers,any welded joint
connecting one side plate to another side
plate of a flat sided vessel.
Category D: Welded joints connecting
communicating chambers or nozzles to
main shells, 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).

Degree of Radiography
Type of Radiography
Full Generally 100% of welds, some exception
Spot On RT for each 50 ft of weld
None Send the RT techs home
Amount specified by Code for some vessels
Based on Service, Thickness or Welding Process (UW-11)
Amount specified by Users/Designer for others
The User or his designated agent shall establish the type of joint and
the degree of examination when the rules of this Division do not
mandate specific requirements (UW-12)

Full RT Required by Code

Full RT is required by the Code, when:
1.
Vessels in Lethal Service 100% RT Butt Welds
2.
Butt Welds > 1-1/2- 100% RT
3.
Unfired Boilers > 50 psig 100% RT Butt Welds
4.
Butt Welds of nozzles for 1&3 100% RT
5.
Butt Welds made using Electrogas & Electroslag Process
-100% RT
UW-11(a)

Full RT Required by User

Full RT can be specified by the User:
- If full RT is not required by the Code
- Selected to increase E and lower t
- Full RT does not mean 100% RT
- The following RT must be performed
- Category A welds -100% RT
- Category A&B welds Type 1 or 2
- Category B welds Spot RT
UW-11(a)(5)

The RT Factors
Describe the amount of RT performed
- RT 1&2: Full Radiography
- RT-3: Spot Radiography
- RT-4: Combo Radiography
The RT Factor is located on Nameplate
They are described in UG-116(e)

Seamless Parts E
For seamless vessel sections or head, where circumferential stresses
govern:
E = 1.0
When the category B and C butt welds are spot RT
And the welds connecting seamless vessel sections or heads are
either Type 1 or 2.
E = 0.85
When the butt welds are either not spot RT
Or when the welds connecting seamless vessel sections or heads are
type 3,4,5 or 6.
UW-12(d)

Example Finding E
1)

A pressure vessel has butt welds which are single welded. No RT has
been performed.
1)
2)

2)

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-3
1)
2)

3)

E for welded shell? _______

E for the seamless head? ________

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-2.
1)
2)

4)

E for welded shell? _______

E for the seamless head? _______

E for welded shell? _______

E for the seamless head? _______

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-1
1)
2)

E for welded shell? _______

E for the seamless head? _______

Example Finding E
1)

A pressure vessel has butt welds which are single welded. No RT has
been performed.
1)
2)

2)

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-3
1)
2)

3)

E for welded shell? 0.85

E for the seamless head? 1.00

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-2.
1)
2)

4)

E for welded shell? 0.6

E for the seamless head? 0.85

E for welded shell? 1.00

E for the seamless head? 1.00

A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-1
1)
2)

E for welded shell? 1.00

E for the seamless head? 1.00

Exercise 2-8
More Joint Efficiencies
1)

A pressure vessel has lap welds which are single welded. The
vessel is stamped RT-3
1)
2)

2)

A pressure vessel has lap welds which are double fillet welded
1)
2)

3)

E for welded shell? _____

E for the seamless head? ______
E for welded shell? ______
E for the seamless head? ______

A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
1)
2)

E for welded shell? ______

E for the welded head? _______

Exercise 2-8
More Joint Efficiencies
1)

A pressure vessel has lap welds which are single welded. The
vessel is stamped RT-3
1)
2)

2)

A pressure vessel has lap welds which are double fillet welded
1)
2)

3)

E for welded shell? 0.45

E for the seamless head? 0.85
E for welded shell? 0.55
E for the seamless head? 0.85

A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
1)
2)

E for welded shell? 0.99

E for the welded head? 0.99

Module 3.2
Tmin Calculations

Successful Calculations
The 5 steps to calculating Success
1) Always write the formula. Leave space above the formula for step
2 data
2) Write the Givens above formula. Put these in the same order as
the formula.
3) Plug-in the values directly below the formula
4) Solve the problem
5) When complete shows the appropriate units e.g. inches, mpy, years

Shell tmin Calculations

The formula UG-27(c)(1) Internal Pressure
t = PR/SE-0.6P
R is the inside radius of diameter
P is the Design Pressure: Pressure on the part includes Static Head

The P formula calcs the shell MAWP

P = SEt/R + 0.6t
The part MAWP The shells good for pressure
This is not vessel MAWP

Example
A vessel has an internal radius of 36. At the design temperature the
materials allowable stress is 15,000 psi. The pressure on the shell is 158 psi
(static head included). The joint efficiency is 1.0. Determine the minimum
required thickness

___________________________________________________________

The Givens: P=158 psi, R= 36, S=15,000 psi, E=1.0

___________________________________________________________
2)
The formula: t = PR/SE-0.6P
___________________________________________________________
3)
The plug-in: t = 158 x 36 / (15,000 x 1) (0.6 x 158)
___________________________________________________________
4)
The solutions with Units t = 0.382
___________________________________________________________

Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24. At the design
temperatures the materials allowable stress is 20,000 psi. The
pressure on the shell is 250 psi (static head is included). The joint
efficiency is 1.0. Determine the minimum required thickness?
___________________________________________________________

The Givens: P= , R= , S=, E=

___________________________________________________________
2)
The formula: t = PR/SE-0.6P
___________________________________________________________
3)
The plug-in: t =
___________________________________________________________
4)
The solutions with Units t =
___________________________________________________________

Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24. At the design
temperatures the materials allowable stress is 20,000 psi. The
pressure on the shell is 250 psi (static head is included). The joint
efficiency is 1.0. Determine the minimum required thickness?
___________________________________________________________

The Givens: P= 250 psi , R= 24 , S= 20,000 psi, E= 1.0

___________________________________________________________
2)
The formula: t = PR/SE-0.6P
___________________________________________________________
3)
The plug-in: t = (250)(24)/(20,000 x 1.0) (0.6 x 250)
___________________________________________________________
4)
The solutions with Units t = 0.302
___________________________________________________________

Exercise 2-10
Shell Minimum Required Thickness
1)
A vertical vessel has an internal radius of 48. The material
allowable stress is 12,500 psi. The MAWP of the vessel is 120 psi. The
welds are double-welded and the nameplate says RT-3. The top of
this shell section is 4 ft from the top of the vessel and the bottom of
this shell section is 52 ft from the top of the vessel. Determine the
minimum required thickness.
2) A horizontal vessel has an internal diameter of 10 ft. The materials
allowable stress is 14,000 psi. The MAWP of the vessel is 120 psi.
The welds are all Type 1 and full RT was performed. Determine
the minimum required thickness.

Exercise 2-10
Shell Minimum Required Thickness
1)
A vertical vessel has an internal radius of 48. The material
allowable stress is 12,500 psi. The MAWP of the vessel is 120 psi. The
welds are double-welded and the nameplate says RT-3. The top of
this shell section is 4 ft from the top of the vessel and the bottom of
this shell section is 52 ft from the top of the vessel. Determine the
minimum required thickness.
___________________________________________________________
1)
The Givens: P= ? , R= 48 , S= 12,500 psi, E= 0.85 (Table UW-12)
Pshell = Ptop + Psh = 120 + (0.433x52) = 142.5 psi
___________________________________________________________
2)
The formula: t = PR/SE-0.6P
___________________________________________________________
3)
The plug-in: t = (142.5)(48)/(12,500 x 0.85) (0.6 x 142.5)
___________________________________________________________
4)
The solutions with Units
t = 0.649
___________________________________________________________

Exercise 2-10
Shell Minimum Required Thickness
2) A horizontal vessel has an internal diameter of 10 ft. The
materials allowable stress is 14,000 psi. The MAWP of the vessel is
120 psi. The welds are all Type 1 and full RT was performed.
Determine the minimum required thickness.
___________________________________________________________

The Givens: P= ? , R= 5=60 , S= 14,000 psi, E= 1.00 (Table UW-12)

Pshell = Ptop + Psh = 120 + (0.433x10) = 124.33 psi
___________________________________________________________
2)
The formula: t = PR/SE-0.6P
___________________________________________________________
3)
The plug-in: t = (124.33)(60)/(14,000 x 1.00) (0.6 x 124.33)
___________________________________________________________
4)
The solutions with Units
t=
___________________________________________________________

Rounded Head tmin Calculations

Ellipsoidal Head UG-32 (d)
t = PD/2SE-0.2P
P = 2SEt/D + 0.2t
Torispherical Head UG-32 (e)
t = 0.885PL/SE-0.1P
P = SEt/0.885L + 0.1t

L = outside diameter

Hemispherical Head UG-32 (f)

t = PL/2SE-0.2P
P = 2SEt/L + 0.2t

L = inside radius

Head Calculations Example

The design pressure (with static head) on a 2:1 seamless elliptical head is 200
psi. The vessel ID is 60. The allowable stress is 15,000 psi. Welds are Type 1
with Spot RT. Find heads minimum required thickness?
___________________________________________________________

The Givens: P= , R= , S= , E=
___________________________________________________________
2)
The formula: t = PD/2SE-0.2P
___________________________________________________________
3)
The plug-in: t =
___________________________________________________________
4)
The solutions with Units
t=
___________________________________________________________

Head Calculations Example

The design pressure (with static head) on a 2:1 seamless elliptical head is 200
psi. The vessel ID is 60. The allowable stress is 15,000 psi. Welds are Type 1
with Spot RT. Find heads minimum required thickness?
___________________________________________________________

The Givens: P= 200, R=60 , S= 15,000 psi, E= 1.00 (Table UW-12(d))

___________________________________________________________
2)
The formula: t = PD/2SE-0.2P
___________________________________________________________
3)
The plug-in: t = (200)(60)/2(15,000 x 1.00) (0.2 x 200)
___________________________________________________________
4)
The solutions with Units
t = 0.401
___________________________________________________________

Exercise 2-11
Formed Head Minimum Thickness
1)

2)

A vertical vessel has an internal diameter of 84. The heads are

hemispherical and made in segments. The head material has n
allowable stress of 8,700 psi at the design temperature. The
MAWP of the vessel is 48 psi. The overall vessel height is 38.
The welds are double welded and Spot RT was performed.
Determined the minimum required thickness for the bottom
head.
A horizontal vessel with seamless torispherical heads has an
outside diameter of 96 inches. The materials allowable stress is
20,000 psi. The MAWP of the vessel is 120 psi. The joint
efficiency is 1.0. Determine the minimum required thickness for
the heads.

Exercise 2-11
Formed Head Minimum Thickness
A vertical vessel has an internal diameter of 84. The heads are
hemispherical and made in segments. The head material has n allowable
stress of 8,700 psi at the design temperature. The MAWP of the vessel is 48
psi. The overall vessel height is 38. The welds are double welded and Spot
RT was performed. Determined the minimum required thickness for the
bottom head.

___________________________________________________________
1)
The Givens: P= ?, L=R =42 , S= 8,700 psi, E= 0.85 (Table UW-12)
Pshell = Ptop + Psh = 48 + (0.433 x 38) = 64.5 psi
___________________________________________________________
2)
The formula: t = PL/2SE-0.2P
___________________________________________________________
3)
The plug-in: t = (64.5)(42)/2(8,700 x 0.85) (0.2 x 64.5)
___________________________________________________________
4)
The solutions with Units
t = 0.183
___________________________________________________________

Exercise 2-11
Formed Head Minimum Thickness
A horizontal vessel with seamless torispherical heads has an outside diameter
of 96 inches. The materials allowable stress is 20,000 psi. The MAWP of the
vessel is 120 psi. The joint efficiency is 1.0. Determine the minimum required
thickness for the heads.
___________________________________________________________
1)
The Givens: P= ?, L=OD =96=8 , S= 20,000 psi, E= 1.0 (Seamless)
Pshell = Ptop + Psh = 120 + (0.433 x 8) = 123.46 psi
___________________________________________________________
2)
The formula: t = 0.885PL/SE-0.1P
___________________________________________________________
3)
The plug-in: t = 0.885(123.46)(96)/(20,000 x 1.00) (0.1 x 123.46)
___________________________________________________________
4)
The solutions with Units
t = 0.52
___________________________________________________________

Flat Head tmin Calculations

The code allows for many different types of flat head designs. See
figure UG-34 for illustrations.
You are responsible for welded flat heads, not bolted heads
From UG-34(c)(2) equation (1)
t = d CP/SE

d generally inside diameter

C a factor based on head design concept similar to E
E joint efficiency normally 1.0. Only needs to be determined if the
flat head is made with multiple plates. This does not apply to
head-to-shell weld

Exercise 2-12
Flat Head tmin
A flat circular head is made from seamless A-285 Grade B plate with a
corner design illustrated in Figure UG-34 (e). The allowable stress is
12,500 psi. The vessel MAWP is 300 psi. The horizontal vessel is
stamped RT-3. Assume m=1.0. The vessel inside diameter is 60.
t = d CP/SE

Exercise 2-12
Flat Head tmin
A flat circular head is made from seamless A-285 Grade B plate with a
corner design illustrated in Figure UG-34 (e). The allowable stress is
12,500 psi. The vessel MAWP is 300 psi. The horizontal vessel is
stamped RT-3. Assume m=1.0. The vessel inside diameter is 60.
___________________________________________________________
1)
The Givens: P= ?, D = 60 = 5, C= 0.33m = 0.33 x 1 =0.33 , S= 12,500
psi, E= 1.0 (Seamless)
Pshell = Ptop + Psh = 300 + (0.433 x 5) = 302.165 psi
___________________________________________________________
2)
The formula: t = d CP/SE
___________________________________________________________
3)
The plug-in: t = 60 C(0.33)(302.165)/(12,500)(1.0)
___________________________________________________________
4)
The solutions with Units
t = 5.359
___________________________________________________________

Part MAWP
Part MAWP is the pressure a part is good for
Based on knowing the thickness (dont include the CA)
The a typically used in re-rate calculations
This is not vessel MAWP. Vessel MAWP is based on the weakest
link after subtracting Static Head.
Part MAWP formulas are given in the same paragraphs as the tmin
formulas.
No P formula for flat heads
Symbols are the same as used in the tmin formulas
t = PD/2SE-0.2P
P = 2SEt/D + 0.2t

Exercise 2-13
Lets Calculate Part MAWP
1) The thickness of each part is 0.5. The allowable stress ofte
materials is 15,000 psi. The joint efficiency is 1.0. The inside
diameter is 60. Calculate the maximum pressure each part is good
for.
P = 2SEt/D + 0.2t
2:1 Ellipsoidal Head: _______ psi
P = SEt/0.885L + 0.1t
Torispherical Head: _______ psi
P = 2SEt/L + 0.2t
Hemispherical Head: _______ psi
Cylinder: ________ psi
P = SEt/R + 0.6t
Flat Head: ________ psi
2) Which shape is the best for containing pressure? __________
3) Which shape is the worst for containing pressure? _________

Exercise 2-13
Lets Calculate Part MAWP
1) The thickness of each part is 0.5. The allowable stress ofte
materials is 15,000 psi. The joint efficiency is 1.0. The inside
diameter is 60. Calculate the maximum pressure each part is good
for.
P = 2SEt/D + 0.2t
2:1 Ellipsoidal Head: 249.6 psig
P = SEt/0.885L + 0.1t
Torispherical Head: 138.8 psig
P = 2SEt/L + 0.2t
Hemispherical Head: 498.3 psig
Cylinder: 247.5 psig
P = SEt/R + 0.6t
Flat Head: 5.2 psig For info only
2) Which shape is the best for containing pressure? Hemispherical
3) Which shape is the worst for containing pressure? Flat Head

Destiny is no matter of chance. It is a matter of choice. It is not a thing to

be waited for, it is thing to be achieved
-William Jennings Bryan

Module 4: Pressure
Testing, MDMT, Impact
Testing

Hydrostatic Testing
Hydro test Requirements in UG-99
The test pressure formula:
Pt = 1.3 x MAWP x (St/Sd)
Pt = Test Pressure
St = Allowable stress at temperature
of hydrotest
Sd = Allowable stress at design
temperature
Note: St/Sd always > 1
What is (???)x MAWP x (St/Sd)
Corrected for Temperature As the temperature increases, materials get weaker.
Since vessel designed for hot temperatures are hydro tested at ambient conditions
(where materials are stronger) the test pressure needs to be compensated (increased)

Hydrotest Procedure
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

Complete all pre-hydrotest work & testing

Assure vessel & support structure is designed for weight of hydrotest liquid
Select hydrotest fluid any non-hazardous liquid below its boiling point
Disconnect or blind off appurtenances not to be tested
Vent of high points to remove possible air-pockets
Test fluid should be 300F above MDMT
Pressure gauges must be acceptable range. About 2 times test pressure.
(Acceptable range is 1.5 to 4 times Test Pressure)
Pressure gauge should be calibrated
Pressure gauge should be connected directly to vessel. If not visible, another
should be connected near operator.
Check tightness of test equipment
Perform pressure test at 1.3 times MAWP corrected for temperature.
Back pressure down to Test Pressure divided by 1.3
After vessel temperature is below 1200F, perform close visual inspection of joints
and connections.

Hydrotest Calculation
A vessel is constructed of a P-1 material. The vessel is stamped MAWP
is 300 psi at 8000F. Material allowable stress S is:
1000F = 20,000 psi
8000F = 13,500 psi
Determine the a) hydrostatic test pressure b) minimum inspection
test pressure

Hydrotest Calculation
a) Calculate Test Pressure
MAWP = 300 psi, St = 20,000 psi, Sd = 13,500 psi
Formula: Pt = 1.3 (MAWP) x (St/Sd)
= 1.3 (300) x (20,000)/(13,500)
= 390 x 1.481
= 577.7 psi
Hydrotest pressure is 577.7 psi at the top of vessel
b) Calculate the min Inspection Test Pressure
Pinsp = Pt/1.3
= 577.7/1.3
= 444.4 psi

Exercise 3-1
Hydrotest Solution
A vessel is constructed of a P-1 material. The vessel MAWP is 600 psi
at 6500F. Allowable stress S is @ 1000F = 17,000 psi, @ 6500F=17,000
psi. Determine the Hydrostatic Test Pressure and the Minimum
Inspection Test Pressure.

Exercise 3-1
Hydrotest Solution
A vessel is constructed of a P-1 material. The vessel MAWP is 600 psi
at 6500F. Allowable stress S is @ 100 0F = 17,000 psi, @ 6500F=17,000
psi. Determine the Hydrostatic Test Pressure and the Minimum
Inspection Test Pressure.
Calculate Test Pressure
MAWP=600 psi, St=17,000 psi
Pt= 1.3 (600)(17,000/17,000)
= 780 psi
Minimum Inspection Test Pressure
Pinsp = Pt/1.3
= 780/1.3
= 600 psi

Sd=17,000 psi

Pneumatic Testing
Pneumatic Test Requirements UG 100
Safety Issues Compressed Air
The Test Pressure formula
Pt = 1.1 x MAWP x (St/Sd)
Pressure increased in steps
0.5Pt 1st step
0.6Pt 2nd step
0.7Pt 3rd step
0.8Pt 4th step
0.9Pt 5th step
1.0Pt at test pressure
Pinsp = Pt/1.1

Exercise 3-2
Hydrotest Solution
A vessel is constructed of a P-1 material. The vessel MAWP is 100 psi
at 7500F. Material allowable stress S is:
1000F = 18,000 psi
7500F = 17,000 psi
Determine the:

Pneumatic Test Pressure

Each of the Test Pressure Steps

Inspection Test Pressure

Exercise 3-2
Hydrotest Solution
a)
Pneumatic Test Pressure
Pt = 1.1(MAWP) x (St/Sd) = 1.1x100(18,000/17,000) = 116.5 psi
b) Each of the Test Pressure Steps
0.5Pt 1st step = 0.5(116.5) = 58.2 psi
0.6Pt 2nd step = 0.6(116.5) = 69.9 psi
0.7Pt 3rd step = 0.7(116.5) = 81.5 psi
0.8Pt 4th step = 0.8(116.5) = 93.2 psi
0.9Pt 5th step = 0.9(116.5) = 104.8 psi
1.0Pt at test pressure = 1.0(116.5) = 116.5
c)
Inspection Test Pressure
Pinsp = Pt/1.1 = 105.9 psi

Minimum
Design Metal
Temperature
(MDMT)

Why MDMT?
- The code is very concerned about the lower operating temperature.
It is so important that it is one of the few pieces of information that
is required on the nameplate.
UG-116(a)(4)
- The reason for all the concern? Generally as the temperature of a
material is lowered the material become brittle
- A Brittle Fracture can be instantaneous and thus Catastrophic.
This must be avoided!

Factors Affecting Brittleness

(a)
(b)
(c)
(d)
(e)

Material
Temperature
Thickness
Stress Loading
Residual Stress

The material property that is opposite brittleness is called

Toughness.
Toughness describes the ability of a material to absorb an impact
and is measured in ft-lb. One tests to determine a materials
toughness is called Charpy impact test.

The Code Controls Toughness

The Code control brittle fracture by:
1. Controls Material Selection only certain material can be used
in a pressure vessel.
2. Provides method to calculate a vessels allowable MDMT.
3. Specifies impact testing for materials that operate below the
temperature limits determined in item 1 & 2.

Our goal: Determine the lowest allowable MDMT without impact

testing.

MDMT 4 EASY STEPS

1. Table UCS-66 or Fig. UCS-66 Initial MDMT (Factor thickness,
temperature, material type)
Determine Material curve
Determine Initial MDMT from table base on nominal thickness and
material type A,B,C,D
2. Fig. UCS-66.1 MDMT reduction (factor-maximum operation stress
compare to max. material stress loading.
Ratio will be given determine temperature reduction
Subtract temperature reduction from initial MDMT
3. UCS-68 ( c ) - Further reduction
Has vessel has been PWHT when not required by UCS-56
If yes subtract an addition 30 F from MDMT
4. Check Limits- UCS-66(b)(2) (cannot exceed these limits)

Example 3-2
Calculate MDMT
Example :
A horizontal vessel is made from SA 516 gr 70
plates that are not normalized. The vessel is
rated at 250 psig at 700 F. The wall thickness
is 0.500 and has a corrosion allowance of
0.100. The nameplate is stamped RT-3 and
HT.
Find : The lowest possible MDMT for this
vessel. Reduction ratio is 0.90.

Example 3-2
Calculate MDMT
Step 1: Initial MDMT: Table UCS-66
Material : Curve B
Initial MDMT: -70F
Step 2: MDMT Reduction: Figure UCS 66-1
Reduction ration: 0.90
Reduction: 100F
New MDMT = Initial Reduction = -70F - 100F = -170F
Step 3: PWHT Reduction UCS 68(c)
PWHT: Yes
Required by Code: No
Additional Reduction: 300F
Final MDMT: Step 2 PWHT reduction = -170F - 300F = -470F
Step 4: Check limits: UCS 66(b)(2)
No restriction as UCS-68 (c) allows for temperatures below these limits

Example 3-2
Calculate MDMT
Step 1: Initial MDMT: Table UCS-66
Material : Curve B
Initial MDMT: -70F

Example 3-2
Calculate MDMT

Step 2: MDMT Reduction: Figure UCS 66-1

Reduction ration: 0.90
Reduction: 100F
New MDMT = Initial Reduction
= -70F - 100F = -170F

Example 3-2
Calculate MDMT
Step 3: PWHT Reduction UCS 68(c)
PWHT: Yes
Required by Code: No
Additional Reduction: 300F
Final MDMT: Step 2 PWHT reduction
= -170F - 300F = -470F

Example 3-2
Calculate MDMT

Step 4: Check limits: UCS 66(b)(2)

No restriction as UCS-68 (c) allows
for temperatures below these limits

Exercise 3-3
Determine MDMT
1)
2)
3)

Material is SA-516 Gr. 60. Nominal thickness is 2.0. Renewal thickness

is 1.750. Nameplate stamped HT
Material normalized SA-612. Thickness is 0.750. Reduction ration is
0.85. Vessel was not PWHT.
Material SA-516 Gr. 70, material retirement thickness 0.875. New
thickness 1.0. Vessel is PWHT for environmental cracking. The reduction
ratio is 0.88.

Exercise 3-3
Determine MDMT
1) Material is SA-516 Gr. 60. Nominal thickness is 2.0. Renewal thickness is
1.750. Nameplate stamped HT.
Material Curve C
Initial MDMT
Ratio Reduction
PWHT Reduction
Final MDMT

260F [SA-516 Gr. 60 as it is not mentioned as normalized]

00F [no reduction ratio given assume no reduction]
00F [no reduction as 2 plate required PWHT by Codes]
260F

Exercise 3-3
Determine MDMT
2) Material normalized SA-612. Thickness is 0.750. Reduction ration is 0.85.
vessel was not PWHT.
Material Curve D for SA-612 normalized.
Initial MDMT
-420F [Either figure UCS-66 or Table UCS-66 for tabular values]
Ratio reduction -150F [from figure UCS-66.1]
PWHT reduction -00F [as no PWHT carried out]
Final MDMT
-570F
UCS-66(b)(2) limits the MDMT to -550F otherwise impact testing is required.

Exercise 3-3
Determine MDMT
3)

Material SA-516 Gr. 70, material retirement thickness 0.875. New thickness
1.0. Vessel is PWHT for environmental cracking. The reduction ratio is 0.88.

Curve B
Initial MDMT

31 0F [Either figure UCS-66 or Table UCS-66 for tabular values]

Ratio reduction
PWHT reduction
Final MDMT

-12 0F [from figure UCS-66.1]

-30 0F [P-1 material <1 not required PWHT as per UCS-56]
-11 0F

Impact Testing UG-84

Impact testing of material is required
when minimum operating temperature
is lower than allowed by the UCS-66
MDMT calculations.
(a)
(b)
(c)

Test procedure SA-370

Each set of specimens 3
specimens
Acceptance criteria Figure UG84.1
* Average value from the chart
* Minimum value 2/3 chart

Note: 1 ksi = 1,000 psi

Exercise 3-4
Impact Testing
1) Impact testing is performed on a 3 thick plate that has yield
strength of 55,000 psi. To be acceptable, the average for the set
must be at or above ________ ft-lbs
2) Impact testing is performed on a 1 thick plate that has yield
strength of 45,000 psi.
a) To be acceptable, the average for the set must be > ____ft-lbs
b) To be acceptable each specimen must be > _____ft-lbs

Exercise 3-4
Impact Testing
1)

Impact testing is performed on a 3 thick plate that has yield

strength of 55,000 psi. To be acceptable, the average for the set
must be at or above 30 ft-lbs

2) Impact testing is performed on a 1 thick plate that has yield

strength of 45,000 psi.
a) To be acceptable, the average for the set must be > 15 ft-lbs
b) To be acceptable each specimen must be > 10 ft-lbs

More Exercise
Impact Testing
A welding procedure requires impact testing for a thickness range
3/16 2. The specimen is 1 having 45 ksi yield strength. What is
the minimum acceptable impact test values for the three specimens?
1)
2)
3)
4)

18-19-12
17-12-25
17-16-17
18-17-12

More Exercise
Impact Testing
A welding procedure requires impact testing for a thickness range
3/16 2. The specimen is 1 having 45 ksi yield strength. What is
the minimum acceptable impact test values for the three specimens?
From figure UG-84.1 find value required for average of 3 specimen using 2
the thickest range.
Average = 17 ft-lbs
Min value = 2/3 (17) = 11.3
1)
2)
3)
4)

18-19-12
17-12-25
17-16-17
18-17-12

[Average
[Average
[Average
[Average

16.3, Min value 12]

18, Min value 12]
16.67, Min value 16]
15.67, Min value 12]

External Pressure
Thickness of shells and tubes under external pressure (UG28)
Shells or tubes under external
pressure are required to resist
collapse by buckling. Methods for
calculating minimum thickness
are primarily based on factors
influencing stiffness rather than
material strength
Codes provides a series of charts
in section II Part-D to eliminates
tedious calculation.
Shells of pressure vessel that fails
the external pressure design may
be stiffened using stiffening rings.

External Pressure
Steps for calculations
D0 = Outside diameter
P =4B/3(Do/t)

L = Length between supports (inches)

Factors A & B numbers from graph

Step 1 : Calculate L/Do & Do/t

Step 2 & 3 : Determine Factor A (from Fig. G graph)
Step 4/5 : Determine Factor B (from Matl chart Fig. CS-2)
Step 6 : Calculate P Max All External Pressure

External Pressure
Sample of calculations
A tube has an outside diameter of 6.625. The distance between
supports is 20. The wall thickness is 0.120. Tube material is SA 516
Gr. 70. The tube is rated for 125 psi at 700 0F. Determine the
maximum allowed external pressure.

External Pressure
Sample of calculations
A tube has an outside diameter of 6.625. The
distance between supports is 20. The wall
thickness is 0.120. Tube material is SA 516
Gr. 70. The tube is rated for 125 psi at 700 0F.
Determine the maximum allowed external
pressure.
Step 1: Calculate L/D0 & D0/t
L/D0 = (12x20)/6.625 = 36.23
D0/t = 6.625/0.120 = 55.2
Step 2&3: Determine Factor A from figure G
Find D0/t curve 55.2
Find intersection with the L/D0 line of 36.23
At intersection drop line straight down to
bottom of graph & read factor A 0.000375

External Pressure
Sample of calculations
A tube has an outside diameter of 6.625.
The distance between supports is 20.
The wall thickness is 0.120. Tube
material is SA 516 Gr. 70. The tube is
rated for 125 psi at 700 0F.
Determine the maximum allowed
external pressure.
Steps 4&5: Determine factor B from Fig CS-2
Find temperature curve (700 0F)
Find intersection with Factor A line
0.000375
At intersection move horizontally to side of
graph and read factor B = 4500
Step 6: Calculate P Max All External Pressure
P =4B/3(Do/t) = 4(4500)/3(55.2) = 108.7 psi.

Exercise 3-5
External Pressure
A tube has length of 30 and outside diameter of 10. The nominal
thickness is 0.375 and the renewal thickness is 0.20. The design
temperature is 5000F. Use material chart Fig CS-2.
Determine the maximum allowed external pressure.

Exercise 3-5
External Pressure
A tube has length of 30 and outside diameter
of 10. The nominal
thickness is 0.375 and the renewal thickness is
0.20. The design
temperature is 5000F. Use material chart Fig CS2.
Determine the maximum allowed external
pressure.
Step 1: Calculate L/D0 & D0/t
L/D0 = 30/10 = 3
D0/t = 10/0.20 = 50
Step 2 & 3: Determine Factor A from figure G
Find D0/t curve 50
Find intersection with the L/D0 line of 3
At intersection drop line straight down to
bottom of graph & read factor A = 0.0012

Exercise 3-5
External Pressure
A tube has length of 30 and outside diameter
of 10. The nominal thickness is 0.375 and the
renewal thickness is 0.20. The design
temperature is 5000F. Use material chart Fig
CS-2.
Determine the maximum allowed external
pressure.
Steps 4&5: Determine factor B from Fig CS-2
Find temperature curve (500 0F)
Find intersection with Factor A line =

0.0012
At intersection move horizontally to side of
graph and read factor B = 10,500
Step 6: Calculate P Max All External Pressure
P =4B/3(Do/t) = 4(10,500)/3(50) = 280 psi.

Question 12
Sample of API Question
The inner wall of a jacketed vessel is 0.635 wall, the cylinder is 45
outside diameter, the unsupported length is 120 and is made of SA516 Gr.70 material. Factor A is 0.0008 and Factor B is 11,600. What is
the maximum pressure permitted on the inner wall of the jacket with
temperature rating of 3000F.

Question 12
Sample of API Question
The inner wall of a jacketed vessel is 0.635 wall, the cylinder is 45
outside diameter, the unsupported length is 120 and is made of SA516 Gr.70 material. Factor A is 0.0008 and Factor B is 11,600. What is
the maximum pressure permitted on the inner wall of the jacket with
temperature rating of 3000F.
t= 0.635
D0=45

B=11,600
A=0.0008

P =4B/3(Do/t)
= 4(11,600)/3(45/0.635)
= 218 psi

We must sail sometimes with the wind and sometimes against it-but
we must sail, and not drift, nor lie at anchor.
-Oliver Wendell Holmes

To

People are always blaming their circumstances for what they are. I
dont believe in circumstances. The people who get on in this world
are the people who get up and look for the circumstances they want,
and if they cant find them, make them.
-George Bernard Shaw

If we dont change, we dont grow. If we dont grow, we arent really

living.
-Beverly Sills