Welcome to

TRAINING PROGRAM ON

API 510 PRESSURE VESSEL INSPECTOR

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Agenda - session 1

• This session will provide:

– An introduction to Codes and
Standards
– Objectives of Codes/ Standards.
– ASME Code System.
– Introduction To ASME Sec. VIII-1
• Approximate duration – 1.5 hours
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 ASME Codes
IIssued by : American society of mechanical Engineers, New York.

Issue freq. : New edition every 3 years, on 1st July

latest edition was on 1st July 07.

Addenda : In-between revisions, issued yearly

also on 1st July.

2004 Edition. --- 1st July '04

2005 Addenda --- 1st July '05
2006 Addenda --- 1st July '06
ANew edition issued in- 2007 (1st July)
NNext edition on: 1 July 2010.

Applicability : Edition & Addendas effective 6 months from date of issue

(i.e. 1st Jan of next year)
 ASME SEC. VIII DIV. 1

Pressure vessels within scope:

• Ve s s e l s d e s i g n e d f o r p r e s s u r e s a b o v e 1 5
psig and not exceeding 3000 psi.

• Vessels having inside diameter above 6 in.

• Unfired steam boilers, evaporators,

Heat exchangers
A S M E S e c . V I I I d i v. 1 - - E x c l u d e d f r o m s c o p e

• Ve s s e l s c o v e r e d b y o t h e r s e c t i o n s

• Pressure containers which are integral

p a r t o f r o t a t i n g m a c h i n e r y.

• Piping system & components beyond

battery limits.

• Ve s s e l s f o r h u m a n o c c u p a n c y
 ASME Boiler & Pressure Vessel
Codes
ASME Codes give stipulations and guidelines for the
design, materials, manufacture and testing of
pressure vessels. These are issued by the American
Society of Mechanical Engineers, New York.

The codes were first issued in 1915. Since then,

many changes have been made and new sections
added to the code as need arose. It is a LIVE code
and is revised and updated periodically. It keeps
pace with time and is responsive to its users.
 APPLICABILITY

The editions and addenda become

applicable after six months from date of
issue. Thus, 1 st Jan. 2000, the
construction of Pressure Vessels shall be
as per 1998 edition and 1999 addenda.
However, for old contracts spilling over
b e y o n d 1 st J a n 2 0 0 0 , t h e o l d a p p l i c a b l e
edition and addenda are valid.
ASME Sec. VIII Div. 1 has five different parts

Part 1 : UG – General requirements (Design requirements)

Part 2 : Material Specific Requirements

UCS – Carbon steel & low alloy steel
UHA – High alloy steels
UNF – Non ferrous metallurgy

Part 3 : Fabrication method specific requirements

UW – Welded construction
UF – Forging construction

Part 4 : Mandatory Appendices &

Part 5 : Non mandatory Appendices

 Types of vessels

• Cylindrical – Horizontal or Vertical

• Spherical
 Steps in design -1
• Find service conditions & metallurgy.
• Ensure ductility at service conditions
• Calculate thickness required (TR).
 Steps in design -2
• Design thickness = TR + Corr Allow
• Roundup to commercially available thickness
to get nominal thickness
• Find MAWP from nominal thickness
Solve a problem
Calculate the minimum thickness of a cylindrical shell of inside diameter
4000mm, tan to tan length of 8300mm and a design pr. of 100 Kg/sq cmg.

Design temperature of the vessel is 343 C

Material of construction – ASTM A 516 Gr 70

Allowable stress of vessel at 343 C = 16500 psi

Corrosion allowance = 3.0 mm

Efficiency of the weld joint – 1.0

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UW – 3 : WELD JOINTS CATEGORIES.
 UW – 3 : WELD JOINTS CATEGORIES.

Category A :

1 Longitudinal weld joints in main shell or

nozzles.
2 Any welded joints in spherical shell.
3. Any welded joints in Dished Head.
4. Circumferential Seam , Hemisph. head to
shell.
 UW – 3 : WELD JOINTS CATEGORIES.

Category B :

1 Circumferential seam in main shell, or

nozzle
2 Circumferential seam connecting formed
head (other than hemi-spherical head) to
shell.
UW – 3 : WELD JOINTS CATEGORIES .
Contd.
Category C :

• Weld joints connecting flanges, tube sheets, flat

head to main shell or Nozzles
(Flange Welds)

Category D:

• Welds joining communicating chamber or nozzle

to the main shell / heads.
(Attachment Welds).
 Types of ends
FLAT HEADS :
– For low pressures up to 5 kg/sqcm
FORMED HEADS :
– Torispherical
• Generally used up to 15 kg/sqcm
– Ellipsoidal
• Generally used between 15 to 25 kg/sqcm
– Hemispherical
• Generally used above 25 kg/sqcm.
CONICAL HEADS : for Special purposes.
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 FORMED HEADS
For spherical shells / head :
t = P x R / (2SE - 0.2P) ….for Thickness
P = 2SEt / (R + 0.2t)….for MAWP

For Ellipsoidal Heads : ( 2 : 1 type)

t = P x D / (2SE - 0.2P) ….for Thickness
P = 2SEt / (D + 0.2t) ….for MAWP

For Torisph. Heads : (L = Crown Rad., r = 0.06 x L)

t, = 0.885 x P x L / (SE - 0.1P)… for Thickness
P = SEt / ( 0.885L + 0.1 t ) … for MAWP
UW-11 :RT and UT EXAMINATIONS
Full Radiography is required in following cases :

• All butt welds of vessels for lethal substances

• If thickness exceeds given in table UCS -57, UHA - 33,

• Butt welds of unfired boilers, with design pr. > 50 psi.

• For all other vessels, All cat. A welds full radiography .

Cat. B & C welds which intersect the Cat. A welds shall be
spot radiographed.

• Radiography is not required of category B and C butt

welds in nozzles less than NPS 10 or 1 1/8 in. thick.
 UW-11 :RT and UT
EXAMINATIONS…contd.
1 Spot Radiography : Spot RT of Butt joints if
design efficiency is selected for spot
radiography.

2 No Radiography : No RT of weld joints if design

efficiency is selected for no radiography or
vessel is designed for external pressure

3 Ultrasonic examination : May be substituted

for RT only for the final closure seam of a
pressure vessel.
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UW – 12 :WELDED JOINT TYPES
UW – 12 :WELDED JOINT EFFICIENCY

RT – 1 : Full Radiography ( E=1) :

Full length radiography of all butt welds
RT – 2 : Full Radiography ( E=1):
Cat – A: Full length radiography
Cat – B: Spot RT per [UW – 11 (a) 5 (b)]

RT – 3 : Spot radiography ( E= 0.85)

RT – 4 : No radiography ( E= 0.7)
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Out of roundness of Shell

Difference between the maximum and minimum inside diameter measured at

any cross section of the vessel shall not exceed 1% of the nominal diameter at
that cross section under consideration.
The diameter can be measured from either inside or outside. If measured from
outside shall be corrected for the thickness at that cross section.
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 NOZZLE REINFORCEMENT
Required area of Reinforcement = d X tr

d= Diameter of finished opening

tr = Required thickness of shell or head.

Reinforcement is waived off for single openings if:

1. finished opening size is 3 1/2" or less diameter

in shell or head of thickness 3/8" or less; or

2. finished opening size 2 3/8" or less diameter

in shell or head of thickness over 3/8";
 UCS-66 : IMPACT TESTING
1 MDMT - Thickness point falls on or above the
relevant curve. Impact test is not required
(Curve UCS – 66 )

2 Impact test is must, if MDMT < 120 deg F, and:

Thickness Of welded part > 4”
Thickness for Non-welded part > 6”

3 Test normally required for MDMT < -55 deg. F

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IMPACT TESTING EXEMPTION -- UG-20 (f) :
Impact test exempt for if,
Materials are P No 1, Gr. No. 1 and 2
1. Materials of curve A : thickness < 0.5 inch
2. Materials curve B, C, D : thickness < 1.0
inch
3. Hydrostatic test performed as required
4. Design temp = -20 deg F to 650deg.F
5. No cyclic or thermal shock loading
 IMPACT TESTING EXEMPTION…….contd.

1 UCS-68 (c) : If PWHT is performed when not a

C o d e r e q u i r e m e n t , r e d u c t i o n o f 3 0 d e g . F ( 1 7 0C )
in impact testing exemption temp.(from Fig UCS -
66) may be given for P No. 1 materials

2 If coincident ratio is < 1, Reduction to

exemption temperature may be given as per
UCS-66.1
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UW-40 : POST-WELD HEAT TREATMENT
• PWHT is Code Requirement if thickness exceeds
those given in tables for respective materials .

• Furnace PWHT method is preferred .

• Min. Overlap for PWHT in multiple heats = 5 ft.

• Local PWHT : Min Soak Band = weld width + Lesser of

2’’ or t. and it shall extend full 360 deg for circ. Joint

• PWHT temperature is higher of the two for dissimilar

metal joints
 UCS-56: POST -WELD HEAT TREATMENT

· Max. Loading temp in furnace = 800 deg .F

· Max. heating rate 400 deg F/hr/inch of thickness.

· Soaking period as per UCS-56 tables.

· Te m p d i f f e r e n c e b e t w e e n h o t t e s t a n d c o l d e s t
parts of vessel shall not exceed 150 deg .F

· Max. cooling rate = 500 deg .F /hr/inch of thk.

· Max. offloading temp = 800 deg. F

· Still air cooling permitted below 800 deg .F.

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Summary of NDT
 NDE OF PRESSURE VESSELS
Selection of a particular NDT technique :

Applicable NDT methods / Welding Discontinuities

Applicable NDT Methods

Discontinuities
RT T PT MT VT ET
Porosity  * a *b a *

Slag Inclusion   NA *b NA *

Incomplete fusion *  NA *b NA *

Incomplete Penetration   NA * NA *

Undercut  * * *  *

Overlap *   * *
NA
Cracks *  a b a 

Laminations 
NA a,c b,c a,c NA
 Applicable NDT methods for Weld joint types

NDT Methods
Joints

RT UT PT MT VT ET

Butt      

Corner *     *

T *     *

Lap * *    *
Note to NDT Table

a. Surface

b. Surface and slightly subsurface

c. Weld preparation or edge of base metal

 Applicable method

* Marginal applicability depending on other factors.

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 UG-99 : HYDROSTATIC TEST
• H y d r o s t a t i c Te s t p r. = 1 . 3 X M A W P X s t r e s s r a t i o
Stress ratio = Stress at test temp./Stress at design temp.

• M i n . I n s p e c t i o n p r e s s u r e = Te s t p r e s s u r e / 1 . 3

• Any non-hazardous liquid may be used for the test.

• M i n . Te s t t e m p = M D M T + 3 0 d e g . F ( 1 7 C )

• I n s p e c t i o n t e m p e r a t u r e < = 1 2 0 d e g . F.

• T h e M A W P m a y b e s a m e a s D e s i g n p r.

• Te s t g a u g e r a n g e = 1 . 5 t o 4 t i m e s t e s t p r.
 UG-100 : PNEUMATIC TESTS

• Pneumatic test is used instead of hydro when:

• Ve s s e l s c a n n o t b e s a fe l y f i l l e d w i t h w a t e r

• Ve s s e l s i n s e r v i c e i n w h i c h t ra c e s o f
testing liquid cannot be tolerated

• Te s t p r = 1 . 1 X M A W P X s t r e s s r a t i o .

• Te s t t e m p s h a l l e x c e e d M D M T b y 3 0 d e g F.

• P r. G a u g e r a n g e = 1 . 5 t o 4 t i m e s t e s t p r e s s u r e
 Safety precautions for Pneumatic Test

• All welds around openings and attachment welds

with throat >= 6mm ( 0.25”) to be MT or PT tested

• T h e p r. s h a l l b e f i r s t r a i s e d t o 5 0 % o f t h e t e s t p r.

• Then the pressure shall be raised in steps of

1 0 % o f t e s t p r. To r e a c h f u l l t e s t p r e s s u r e

• The pressure then shall be reduced to a value of

test pressure /1.1 , to permit inspection.
 CODE STAMPING

Each pressure vessel shall be marked with the following :

1) The official Code U Symbol or the official UM Symbol.

2) Name of the Manufacturer of the pressure vessel
preceded by the words "certified by";
3) Max. allowable working pressure ---- psi at ---- 0F .

4) Minimum design metal temperature ---- 0F ----psi

5) Manufacturer's serial number;
6) Year built.
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 Thank You for
your
Time and Attention