Welcome to ASME ASME BPVC.VIII.

1-2021
SECTION VIII
Rules for Construction of Pressure Vessels
 ASME VIII (BOK) 2

I. THICKNESS MEASUREMENTS, INSPECTION INTERVALS AND VESSEL INTEGRITY

The following categories describe the minimum necessary knowledge and skills:

JOINT EFFICIENCIES STATIC HEAD INTERNAL PRESSURE

EXTERNAL PRESSURE PRESSURE TESTING IMPACT TESTING

WELD SIZE FOR ATTACHMENT WELDS AT OPENINGS NOZZLE REINFORCEMENT

 ASME VIII (BOK) 3

II. WELDING PROCEDURE AND QUALIFICATION EVALUATION BASED ON ASME BOILER AND
PRESSURE VESSEL CODE, SECTION IX
The inspector should be familiar with and understand the general rules for welding in ASME Section VIII, Div. 1, Parts UW
and UCS such as:

Typical joints and definitions Weld sizes Restrictions on joints

Maximum allowable reinforcement Inspection requirements Heat treatment

 ASME VIII (BOK) 4

III. NONDESTRUCTIVE EXAMINATION

The inspector should be familiar with and understand the general rules for NDE (UG, UW, Appendices 4, 6, 8, and 12)
 Introduction 5

There are several “Fabrication” codes that provide the requirements for design,
material selection, fabrication, testing, identification and documentation for boilers
and pressure vessels.

These codes are:

• Section I, Power Boilers.
• Section III, Div. 1-3, The Nuclear Codes.
• Section IV(4), Heating Boilers.
• Section VIII, Div.1 and 2, Pressure Vessels.
• Section X(10), Fiberglass Reinforced Vessels.
 Introduction 6

The reference codes were issued to support the “book codes” “Fabrication codes”.
• These reference codes provide information that is common to all the construction
codes.

These reference codes are:

• Section II, Materials, which was issued in 1924 and now consists of four parts:
- Part A, Ferrous Materials
- Part B, Non-Ferrous Materials
- Part C, Welding Materials
- Part D, Material Properties

• Section IX, Welding Qualifications, was issued in 1937.

• Section V, Non-Destructive Examination

 Introduction 7

ASME Section VIII Division-1

• Applicable for pressure between 15 psig and 3000 psig.
• Division 1 is used most often since it contains sufficient requirements for majority of pressure vessels.

ASME Section VIII Division-2

• Scope of division 2 is identical to that of division 1, however there is no limitation on higher pressure.
• Allowable stress values are higher for division 2 that division 1, hence division 2 vessels are thinner
• Vessels constructed with division 2 are economical over division 1 when saving in material cost is higher
than the additional cost required to meet stringent requirements of division 2.
• Economical for higher pressure applications and for more expensive alloy materials.

ASME Section VIII Division-3

• Applied to vessels operating at internal or external design pressure is generally above 10000 psig.
• Material and NDE requirements more stringent than division 1 and 2
 U-1 Scope 8

Pressure Vessels subject to internal or external Pressure :

- Over 15 psi MAWP (100 kPa), internal or external pressure.

- The rules of this Division have been formulated based on design principles and
construction practices applicable to vessels designed for pressures not exceeding
3,000 psi (20 MPa).

The following classes of vessels are not considered to be within the scope of the
division

API 510
 U-2 General 9

Para. (a), The user or his designated agent shall establish the design requirements
which shall include as a minimum:

• The need for corrosion allowances;

• Definition of lethal services;
• The need for PWHT beyond requirement of this Division and service dependent;
• The degree of nondestructive examination(s) and the selection of applicable
acceptance standards when such examinations are beyond the requirements of this
Division.
 UG & UCS Material 10

UG-4(a) is the general paragraph that says that material used for pressure parts must comply with a
specification given in Section II, Part D, and that are permitted in Subsection C.

USE OF NON-CODE MATERIALS

• It is often assumed that only Code acceptable material may be used in Code construction.
• UG-4(b) allows the use of Non-Code material if used for non-pressure parts.
• If this material is welded to the vessel, it must be of proven weldable quality per UW-5(b).

USER'S RESPONSIBILITIES
• UG-4(f) states that the user or his designated agent assures that the material used is acceptable for the
intended services.

CARBON OR LOWALLOY S TEELS

• UCS-5(b) states Carbon or low alloy steel having a carbon content of more than 0.35% by heat analysis shall
not be used in welded construction
 UG Design 11

UG-16(b) Minimum Thickness of Pressure Retaining Components

For shells and heads, after forming and regardless of product form and material, minimum thickness
shall be 1/16 in. (1.5 mm) exclusive of any corrosion allowance. Exceptions are:

(1) does not apply to heat transfer plates of plate-type heat exchangers;
(2) does not apply to the inner pipe of double pipe heat exchangers nor to pipes and tubes that are enclosed
and protected from mechanical damage by a shell, casing, or ducting, where such pipes or tubes are NPS 6
(DN 150) and less.
(3) The minimum thickness of shells and heads of unfired steam boilers shall be1/4 in. (6 mm) exclusive of
any corrosion allowance;
(4) The minimum thickness of shells and heads used in compressed air service, steam service, and
water service, made from materials listed in Table UCS-23, shall be 3/32 in. (2.5 mm) exclusive of any
corrosion allowance.
(5) This minimum thickness does not apply to the tubes in air cooled and cooling tower heat exchangers.
 UG Design 12

UG-16(c) Mill Under-tolerance

• It state that plate material shall be ordered not thinner than the design thickness.
• However, it is also acceptable that an under-tolerance of < smaller value of 0.01 in. (0.3 mm) or 6%
of the ordered thickness may be used at the full design pressure for the thickness ordered.

UG-20 DESIGN TEMPERATURE

The maximum design temperature shall be equal to or greater than the mean metal temperature (through the
thickness) expected during operation.
• The minimum design metal temperature shall be the lowest temperature expected in service.
• The lowest metal temperature shall be the mean temperature of the metal .
• If necessary, the metal temperature shall be determined by
- computation or
- by measurement from equipment in service under equivalent operating conditions
 UG Design 13

UG-22 Loadings
• Internal or external design pressure,
• Weight of vessel plus normal and test contents including static head,
• Weights of attachments,
• Internal attachments,
• Vessel support attachments,
• Cyclic and dynamic reactions due to pressure, thermal, or mechanical loads,
• Wind, snow, and seismic loads,
• Impact reactions such as those due to fluid shock, and
• Temperature gradients and differential thermal expansion.
 UG Design 14

Markings and Nameplates (UG-116)

All pressure equipment built in accordance with Section VIII, Division 1 by an ASME certified
fabricator must be permanently marked in accordance with the requirements of UG-115,UG-
116,UG-118, UG-119, UG-129, and UG-130 as applicable.

UG-116(a) requires that each pressure vessel are marked with the following:
• The official Code U Symbol
• Name of the Manufacturer of the pressure vessel preceded by the words "certified by";
• Maximum allowable working pressure at temperature;
• Minimum design metal temperature
• Manufacturer's serial number;
• Year built.
 UG Design 15

UG-116(e) Markings for Radiographic Examination

UG-116(e) specifies that when radiographic or ultrasonic examination has been performed on
a vessel in accordance with UW-11, marking shall be applied under the Code Symbol as
follows:
• RT 1
• RT 2
• RT 3
• RT 4

UG-116(f) Markings for Heat Treatment

• UG-116(f)(1) specifies that the letters HT shall be applied under the Code Symbol when the
complete vessel has been post-weld heat treated as provided in UW-10.

• The letters PHT shall be applied under the Code Symbol when only part of the complete
vessel has been post-weld heat treated as provided in UW-10 (see UG-116(f)(2)).
 UG Design 16

UG-119 Nameplates
specifies that nameplates are to be used on vessels, except when markings are directly
applied on the vessel wall according to UG-118.

Nameplates must be made from a metal suitable for the intended service with the markings
specified in UG-116.

Nameplates must also be located in an obvious location on the vessel to allow for easy
reading.

UG-119(b) Nameplate Thickness

• The nameplate thickness must be sufficient to:

• Resist distortion from being marked
• Resist distortion from the method of attachment
• The nominal thickness shall not be less than 0.020 in.
 UG Design 17

UG-120(a) requires the vessel Manufacturer to fill out a data report on Form U-
1 or Form U-1A. It must
also be signed by the Manufacturer and the Inspector for each pressure vessel
marked with the Code U
Symbol.

UG-120(a)(3) Manufacturer's Responsibilities for Data Reports

UG-120(a)(3) requires the vessel Manufacturer to:

(a) Furnish a copy of the Manufacturer's Data Report to the user and, upon
request, to the Inspector;

(b) Submit a copy of the Manufacturer's Data Report to the appropriate

enforcement authority in the jurisdiction in which the vessel is to be installed,
where required by law;

(c) Keep a copy of the Manufacturer's Data Report on file in a safe repository
for at least 3 years.
UW-3 weld joint category 18
 UW-3 weld joint category 19

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

Category D Category C Category B Category A

Category A - Longitudinal and spiral welded joints within the main shell, communicating
chambers, transitions in diameter, or nozzles;
- Any welded joint within a sphere, within a formed or flat head, or within
the side plates of a flat-sided vessel;
- Circumferential welded joints connecting hemispherical heads to main
shells, to transitions in diameters, to nozzles, or to communicating chambers.
 UW-3 weld joint category 20

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

Category D Category C Category B Category A

- Circumferential welded joints within the main shell, communicating

chambers, nozzles, or transitions in diameter including joints between the
Category B
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 weld joint category 21

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

Category D Category C Category B Category A

Welded joints connecting flanges, tube sheets, or flat heads to main shell, to
Category C 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.
 UW-3 weld joint category 22

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

Category D Category C Category B Category A

Welded joints connecting communicating chambers or nozzles to main shells,

Category D 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)
 UW-3 weld joint category 23

Hemispherical heads from category A joint between themselves and

the other part , shell another hemispherical head etc.

Hemispherical heads are NEVER considered seamless by code rules. The

category A weld made by attaching the hemispherical head to shell is
considered part of the head for calculation purposes.
UW-3 weld joint category 24
 UW-2 25

UW-2 (Service Restriction)

UW-2 (d) UW-2 (c) UW-2 (b) UW-2 (a)

Vessels Subject Unfired Low temp. Lethal

to Direct Firing Steam boiler Service Service
 SERVICE RESTRICTIONS UW-2 26

Lethal Service When the substance in the vessel is designated as lethal, all butt welds used to
manufacture the vessel shall be fully examined using radiographic techniques,

Some other important liquid or restricts weld types listed in table UW-12 that
gaseous lethal service restrictions are designated for lethal service as follows:
listed in UW2(a) are as follows: - Category A shall be Type No. (1)
- ERW pipe or tube is not permitted to - Categories B and C shall be Type No. (1) or
be used as a shell or nozzle. No. (2)
- When fabricated of carbon or low - Category D shall be full penetration welds
alloy steel, post-weld heat treated is extending through the entire thickness of the
required vessel wall or nozzle wall
ERW >> Electric Resistance Welded
 Joint type (UW-12) 27

Joint Type

Type (6) Type (5) Type (4) Type (3) Type (2) Type (1)
 Joint type (UW-12) & Service Restrictions (UW-2) 28

Type (1) Butt joints as attained by double welding or by other means which will obtain
the same quality of deposited weld metal on the inside and outside weld
surfaces to agree with the requirements of UW 35.
Welds using metal backing strips which remain in place are excluded.
 Joint type (UW-12) & Service Restrictions (UW-2) 29

Type (2) Single welded butt joint with backing strip other than those included under (1)

Type (3) Butt joints welded from one side only without a permanent backing strip that
cannot be verified as having achieved full penetration and fusion
 Joint type (UW-12) & Service Restrictions (UW-2) 30

Type (4) Double full fillet lap joint

Type (5) Single full fillet lap joints with plug welds

Type (6) Single full fillet lap joints without plug welds
 RADIOGRAPHIC AND ULTRASONIC EXAMINATION UW-11 31

RT Radiography

None Spot Radiography Full Radiography

UW-11 c UW-11 b UW-11 a

UW-52 UW-51
 RADIOGRAPHIC AND ULTRASONIC EXAMINATION UW-11 32

Full Radiography

(1) All butt welds in the shell and heads of vessels used to contain lethal substances

(2) All butt welds in the shell and heads of vessels in

which the nominal thickness at the welded joint exceeds 11/2 in. (38 mm), or exceeds the
lesser thicknesses prescribed in UCS-57
 33

(4) All butt welds in nozzles, communicating

chambers, etc., with the nominal thickness at the
welded joint that exceeds the thickness in (2) above
or attached to the shell or heads of vessels under
(1) or (3) above that are required to be fully
radiographed;
however, Category B and C butt welds in nozzles
and communicating chambers that neither exceed
NPS 10 (DN 250) nor 11/8 in. (29 mm) wall
thickness do not require any radiographic
examination;
 RADIOGRAPHIC AND ULTRASONIC EXAMINATION UW-11 34

Full Radiography
(5) (desired by the designer to improve E) (3 items if applied >> full RT)

(a) Category A and B welds connecting the shell or heads of vessels 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 and communicating
chambers except as required in (4) above] which intersect the Category A butt welds in the
shell or heads of vessels or connect seamless vessel shell or heads shall, as a minimum, meet
the requirements for spot radiography in accordance with UW-52.
 UW-3 weld joint category 35

Spot radiographs required by this paragraph shall not be used to satisfy the spot radiography
rules as applied to any other weld increment.
 36

- This paragraph is only mandatory when it is desired by the designer to use the highest joint efficiency possible for
calculations of thickness required or pressure allowed.
- It is a choice the designer makes when there are no mandatory requirements based on service or material as found in UW-
11 (a) (1)*Lethal Service, (2)*Thickness exceeded
 RADIOGRAPHIC AND ULTRASONIC EXAMINATION UW-11 37

Full Radiography
(6)
- All butt welds joined by electro-gas welding with any single pass greater than 11/2 in. (38
mm)
- All butt welds joined by electroslag welding.

(7) All Category A welds in a tube-sheet shall be of Type (1) of Table UW-12
 RADIOGRAPHIC EXAMINATION OF WELDED JOINTS UW-51 38

Full Radiography
UW-51 (a) (4)

As an alternative to the radiographic examination requirements above, all welds in material

1/4 in. (6 mm) and greater in thickness may be examined using the ultrasonic (UT) method

per the requirements of 7.5.5 of Section VIII, Division 2.

 RADIOGRAPHIC EXAMINATION OF WELDED JOINTS UW-51 39

Full Radiography
UW-51 (b)
- Defects shall be repaired as provided in UW-38, and the repaired area shall be reexamined.
- In lieu of reexamination by radiography, the repaired weld may be ultrasonically examined
in accordance with Mandatory Appendix 12 at the Manufacturer’s option.

- This ultrasonic examination shall be noted under Remarks on the Manufacturer’s Data
Report Form
 RADIOGRAPHIC EXAMINATION OF WELDED JOINTS UW-51 40

Full Radiography t = the thickness of the weld excluding any allowable

reinforcement. For a butt weld joining two members
having different thicknesses at the weld, t is the thinner
UW-51 (b) of these two thicknesses
Degree of RT
Examination
Unacceptable imperfection (Defect)

Indication characterized as a crack or zone of incomplete fusion or penetration

For t up to (19 mm) >> (1:19) Greater than 6 mm

Full RT Linear For t from (19 mm) to (57 mm) >> (19 : 57) Greater than ⅓ t
(Depend on t)
t over (57 mm) Greater than 19 mm
Rounded indications in excess of that specified by the acceptance
Round standards given in Mandatory Appendix 4.

Cracks – IF – IP – Linear - Round Linear : L > 3 w , Round : L ≤ 3 w

 SPOT EXAMINATION OF WELDED JOINTS UW-52 41

Spot Radiography
Minimum Extent of Spot Radiographic Examination
(1) One spot shall be examined on each vessel for each 50 ft (15 m) increment of weld or
fraction thereof for which a joint efficiency from column (b) of Table UW-12 is selected.
- However, for identical vessels or parts, each with less than 50 ft (15 m) of weld for which a
joint efficiency from column (b) of Table UW-12 is selected, 50 ft (15 m) increments of weld
may be represented by one spot examination
50' 25' fraction
increment
The minimum length of spot
radiograph shall be 6 in. (150 mm).
 SPOT EXAMINATION OF WELDED JOINTS UW-52 42

Spot Radiography
Minimum Extent of Spot Radiographic Examination
(2) For each increment of weld to be examined, a sufficient number of spot radiographs shall be taken
to examine the welding of each welder or welding operator.
Under conditions where two or more welders or welding operators make weld layers in a joint, or on
the two sides of a double‐welded butt joint, one spot may represent the work of all welders or welding
operators.

Welder A
Alone
 SPOT EXAMINATION OF WELDED JOINTS UW-52 43

Spot Radiography
Minimum Extent of Spot Radiographic Examination
(3) Each spot examination shall be made as soon as practicable after completion of the increment of
weld to be examined. The location of the spot shall be chosen by the Inspector after completion of the
increment of welding to be examined, except that when the Inspector has been notified in advance and
cannot be present or otherwise make the selection, the Manufacturer may exercise his own judgment
in selecting the spots.
 SPOT EXAMINATION OF WELDED JOINTS UW-52 44

UW-52 (b)(4) Spot Radiography

Radiographs required at specific locations to satisfy the rules of other paragraphs, such as UW-9(d),
UW-11(a)(5)(-b), and UW-14(b), shall not be used to satisfy the requirements for spot radiography
UW-9(d)
Vessels made up of two or more courses shall have the centers of the welded longitudinal joints of
adjacent courses staggered or separated by a distance of at least five times the thickness of the
thicker plate.

Exception (Welded intersection):

The longitudinal joints are radiographed 4 in. (100
mm) each side of each circumferential welded
intersection.
 SPOT EXAMINATION OF WELDED JOINTS UW-52 45

Spot Radiography
UW-14(b)
Single openings meeting the requirements given in UG-36(c)(3) may be located in head-to-shell or
Category B or C butt welded joints, provided the weld meets the radiographic requirements in UW-51
for a length equal to three times the diameter of the opening with the center of the hole at mid-
length.
 SPOT EXAMINATION OF WELDED JOINTS UW-52 46

Spot Radiography
UW-52 (d) Evaluation and Retests
When a spot, radiographed as required in (b)(1) or (b)(2) above has been examined and the radiograph
discloses welding which does not comply……..two additional spots shall be examined in the same weld
increment at locations away from the original spot..
 SPOT EXAMINATION OF WELDED JOINTS UW-52 47

Spot Radiography
Evaluation and Retests
The locations shall be determined by the Inspector… if the two additional pass, repair the failed spot, if
either of the two additional spots fail ,the entire rejected weld shall be removed and the joint
rewelded or the entire increment completely radiographed and all defects corrected

First Additional Radiograph

Failed.

Original Radiograph Repair all defects in the 50' or

Rejected 50' increment Or Second Additional Entire 50' remove all 50' then weld and
50' increment
Radiograph Failed. apply spot radiography again.
 Joint Efficiencies based on RT Marking 48

Shell and Heads

RT 1 MW-1

Lethal E= 1.0

Shell and Heads

RT 2 MW-1
Desire
for E=1.0
E= 1.0
Joint Efficiencies based on RT Marking 49
Thickness of Shells Under Internal Pressure UG-27 50
 Thickness of Shells Under Internal Pressure UG-27 51

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.

E = joint efficiency
P = internal design pressure (see UG-21)
R = inside radius of the shell course under consideration,
S = maximum allowable stress value (see UG-23 and
t = minimum required thickness of shell
 Thickness of Shells Under Internal Pressure UG-27 52

Spherical Shells
When the thickness of the shell of a wholly spherical vessel does not exceed 0.356R, or P does
not exceed 0.665SE, the following formulas shall apply:

E = joint efficiency
P = internal design pressure (see UG-21)
R = inside radius of the shell course under consideration,
S = maximum allowable stress value (see UG-23 and
t = minimum required thickness of shell
 Thickness of Shells Under Internal Pressure UG-27 53

Appendix 1 Supplementary Design Formulas

The following equations, in terms of the outside radius, are equivalent to and may be used
instead of those given in UG-27(c) and UG-27(d):
(1) For cylindrical shells (circumferential stress),

PRo where , Ro = outside

t= OR SEt
P= radius of the shell course
SE + 0.4 P Ro - 0.4 t under consideration

(2) For spherical shells

 Internal pressure on formed head UG-32 54

Ellipsoidal Torispherical Hemispherical

Unreal point

Half oval shape Part of Hemispherical

 Internal pressure on formed head UG-32 55

t = minimum required thickness of head after forming, in. (mm)

P = internal design pressure (see UG-21), psi (kPa)
D = inside diameter of the head skirt; or inside length of the major axis of an ellipsoidal
head; in. (mm)
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. (mm)
 Internal pressure on formed head UG-32 56

Example
Givens: 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.
P = 100 psi
S = 17500 PSI
E = 0.85 for spot RT of Hemi-head joint to shell
E = 1.0 for seamless heads ( Ellipsoidal and Torispherical )
L = 48" for the inside spherical radius for the hemi-head
L = 96" for the inside crown radius of the torispherical head
D = 96" inside diameter of the ellipsoidal
t = ? Required wall thickness, inches
 Internal pressure on formed head UG-32 57

Example

Given the above data find the required thickness of a seamless ellipsoidal head

PD
t=
2SE - 0.2 P

100 x 96 9600
t= = .2744 "
(2 x 17,500 x 1.0) - (0.2 x 100) 34980
 Internal pressure on formed head UG-32 58

Example

Using the same data, calculate the required thickness of a hemispherical head

PL
t=
2SE - 0.2P

100 x 48 4800
t= = = 0.1614 "
( 2 x 17,500 x 0.85) − (0.2 x 100) 29730
 Internal pressure on formed head UG-32 59

Example
Determine the required t of this tori-spherical head

0.885PL
t=
SE - 0.1P

0.885 x 100 x 96 8496

t= = = .4857 "
(17,500 x 1.0) - (0.1 x 100) 17490
 Internal pressure on formed head UG-32 60

Remember
So we have from thickest to thinnest, all things equal:

Torispherical = 0.4857” (Rounds to 0.486”)

Ellipsoidal = 0.2744 (Rounds up to 0.275”)

Hemispherical = 0.1614 (Rounds to 0.162”)

There have been several exams where the question was asked, “ Which is required to be
thickest” or “ Which can be the thinnest” Remember this.
 Hydrostatic test UG-99 61

UG-99 Standard Hydrostatic Test

A hydrostatic test shall be conducted on all vessels after:
(1) all fabrication has been completed
(2) all examinations have been performed

- A hydrostatic test based on a calculated pressure may be used by agreement between the user and the
manufacturer .
The hydrostatic test pressure at the top of the vessel shall be the minimum of the test pressures calculated by
multiplying the basis for calculated test pressure
- If the vessel is subjected to visible permanent distortion, the Inspector shall reserve the right to reject the
vessel.
 Hydrostatic test UG-99 62

UG-99 Standard Hydrostatic Test

UG-99(g) Visual Inspection at MAWP

(The visual inspection of joints and connections for leaks at the test pressure divided by 1.3
may be waived provided:-

- A suitable gas leak test is applied;

- Substitution of the gas leak test is by agreement reached between Manufacturer and
Inspector;
- All welded seams which will be hidden by assembly be given a visual examination for
workmanship prior to assembly;
- The vessel will not contain a “lethal” substance.
 Hydrostatic test UG-99 63

UG-99 Standard Hydrostatic Test

UG-99(g) Visual Inspection at MAWP
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°F
above the minimum design metal temperature, but need not exceed 120°F, to minimize the risk of
brittle fracture.
- 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).
 Hydrostatic test UG-99 64

UG-99 Standard Hydrostatic Test

UG-99(g) Visual Inspection at MAWP

Metal 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 temperature is reduced to 120°F (48°C) or less.

- Caution: A small liquid relief valve set to 1-1/3 (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.
 Hydrostatic test UG-99 65

Static Head
- The inspector must be able to compensate for the pressure resulting from static head.
- All static head will be based upon a specific gravity of 1.0.

- The inspector should be able to:

a) list the static head/pressure conversion factor (0.433 psi/ft);

P static head = 0.433 x liquid height

a) know the difference between vessel MAWP and vessel part MAWP (UG-98);
b) calculate total pressure (MAWP + static head) on any vessel part;
 Hydrostatic test UG-99 66

- The purpose of a pressure test is to detect gross defects in design or fabrication.

- The minimum test pressure shall be:

Stest temperature
Ptest = 1.3 ( MAWP)
Sdesign temperature

(MAWP): Maximum Allowable Working Pressures

 Hydrostatic test UG-99 67

UG-98(a) The maximum allowable working pressure for a vessel is the maximum pressure
permissible at the top of the vessel in its normal operating position at the designated
coincident temperature specified for that pressure.
Min. MAWP Calculated
 Hydrostatic test UG-99 68

What would be the pressure at the bottom if an pressure of 235 psi were applied ?
235 235
psi psi
The hydrostatic head of water is equal to 0.433 psi per vertical foot
above the point where the pressure will measured. For example,
the hydrostatic head of water at a point in a vessel with 10 feet of
water above it is calculated by multiplying 10 x 0.433 psi.

10 x 0.433 = 4.33 psi

100 Feet 100 Feet
100 x 0.433 = 43.3 psi 0.433 ̴ Density x g

235 + 43.3 = 278.3 psi

? 278.3
psi
Hydrostatic test UG-99 69
 Hydrostatic test UG-99 70

Depth of a Hemi and Ellipsoidal and Hydrostatic Head of Water

Hemispherical Head

For this example, we will use a hemispherical head that has an inside diameter of 48 inches
which means it has a radius of 24 inches. The radius is the depth of the hemispherical head
 Hydrostatic test UG-99 71

Depth of a Hemi and Ellipsoidal and Hydrostatic Head of Water

Standard 2 to 1 Ellipsoidal Head

- An ellipsoidal head's I. D. will be the same as the shell's.
- The inside diameter of an ellipsoidal head is also its major axis.
- The 2 to 1 refers to the ratio of the Major Axis to the Minor Axis of an ellipse which is used to
form the head.
 Hydrostatic test UG-99 72

Depth of a Hemi and Ellipsoidal and Hydrostatic Head of Water

Standard 2 to 1 Ellipsoidal Head

Of course: only half of the Minor Axis or ¼ Major Axis is used for the
head

Now add the 2 inch flange to the dish

 Pneumatic test UG-100 73

- Wherever possible, pneumatic test should be avoided because the expansive nature of a
gas could maintain stress on a leak and cause it to grow, thus creating the potential for an
explosive failure during the test.

- Specifically, UG-100(a) only gives two possible reasons for performing a pneumatic test in
lieu of hydrostatic testing for vessels:

* UG-100(a)(1) that are so designed and/or supported that they cannot safely be filled with
water;
* UG-100(a)(2) not readily dried, that are to be used in services where traces of the testing
liquid cannot be tolerated and the parts of which have, where possible, been previously tested
by hydrostatic pressure to the pressure required in UG-99.
 Pneumatic test UG-100 74

UG-l00(b) Pneumatic Test Pressure

‐ 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.

where: PT = minimum pneumatic test pressure

ST = permitted stress value at the test temperature
SD = permitted stress value at the design temperature
MAWP =maximum allowable working pressure
 Pneumatic test UG-100 75

UG-l00(c) Pneumatic Test Temperature.

UG-100(c) does specify that the metal temperature during pneumatic test shall be maintained
at least 30°F (17°C) above the minimum design metal temperature to minimize the risk of
brittle fracture. [See UG-20 and Figure UCS-66.2, Note (6).]

UG-l00(d) the pneumatic test procedure

The steps are:
- Pressurize to 50 % test pressure.
- Increase in steps of approximately 10 % of test pressure until the required pressure is
reached.
- Reduce to test pressure/1.1 and held for a sufficient time to permit visual inspection of the
vessel
Pneumatic test UG-100 76

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– 6th step
Pinsp = Pt/1.1
 Pneumatic test UG-100 77

UG-102 TEST GAGES:

- Dial type indicating gages shall have a range
of about double the maximum test pressure,
but in no case shall the range of the gage be
less than 1 1/2 times nor more than 4 times the
maximum test pressure.

- Digital gages having a wider range may be

used as long as they provide the same or
greater accuracy of the dial type.
 Pneumatic test UG-100 78

Ug-102 (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.
 Procedures for PWHT UW-40 79

In accordance with UW-40(a) the PWHT soak band must contain:

- The weld , heat affected zone
‐ A portion of base metal adjacent to the weld being heat treated for a minimum distance of the
widest width of weld plus 1 t or 2 in. (50 mm), whichever is less, on each side or end of the weld.

The term t = the nominal

thickness of the weld at the
point of attachment
 Procedures for PWHT UW-40 80

UW-40(a)(1) PWHT vessel as a whole :

heating the vessel as a whole in an enclosed furnace, This procedure is preferable and should be used
whenever practicable

UW-40(a)(2) PWHT with Multiple Heats:

When heating the vessel in more than one heat in a furnace,

- the overlap of the heated sections of the vessel must be at least 5 ft (1.5 m).

- The vessel portion outside of the furnace must be shielded prevent any harmful temperature
gradient.
 UCS-56 Requirements for Post-weld Heat Treatment 81

UCS-56 (a)

There are 3 situations where PWHT are required

- Thickness controls. (table UCS-56 & Table UCS-56.1)

- Process service requirements (Lethal Service). (UCS-56(a))

- Welding methods (High input) (Laser welding process – electroslag welding

(course grain)) . (UCS-56(a)).

 UW-40 Procedures for PWHT 82

UW-40( f ) The term nominal thickness ( t ):

For pressure vessels or parts of pressure vessels being PWHT in a furnace charge, it is the
greatest weld thickness for all weld types as defined in (1) through (6) below in any vessel or
vessel part that has not previously been post-weld heat treated.
(1) Same thickness, using a full penetration butt weld, the nominal thickness is the total depth of the
weld exclusive of any permitted weld reinforcement.
(2) For groove welds, the nominal thickness is the depth of the groove.
 UW-40 Procedures for PWHT 83

UW-40( f ) The term nominal thickness ( t ):

(3) fillet welds, the nominal thickness is the throat dimension.

 UW-40 Procedures for PWHT 84

UW-40( f ) The term nominal thickness ( t ):

(4) If a fillet weld is used in conjunction with a groove weld, the nominal thickness is the depth of the
groove or the fillet throat dimension, whichever is greater.
(5) When a welded joint connects parts of unequal thicknesses
- the thinner of two adjacent butt-welded parts including head to shell connections;
 UW-40 Procedures for PWHT 85

UW-40( f ) The term nominal thickness ( t ):

(6) For repairs, the nominal thickness is the depth of the repair weld
 UCS-56 Requirements for Post-weld Heat Treatment 86

UCS-56 (d)
- The temperature of the furnace shall not exceed 800°F (427°C) at the time the vessel or part
is placed in it.

- Above 800°F (427°C), the rate of heating shall be not more than 400°F/hr (222°C/ hr) divided
by the maximum metal thickness of the shell or head plate in inches, but in no case more than
400°F/hr (222°C/hr).
Max. heating
- The rates of heating and rate = 400 F / t
cooling need not be less
than 100°F/hr (56°C).
Min. heating
T = 0.5 inch rate = 100/hr F
Max. = 400 / 0.5 = 800
>> 400 F
 UCS-56 Requirements for Post-weld Heat Treatment 87

UCS-56 (d) (2)

During the heating period there shall not be a greater variation in temperature throughout
the portion of the vessel being heated than 250°F (140°C) within any 15 ft (4.6 m) interval of
length.
 UCS-56 Requirements for Post-weld Heat Treatment 88

UCS-56 (d) (3) (Holding Time)

The vessel or vessel part shall be held at or above the temperature specified in Table UCS‐56
or Table UCS‐56.1 for the period of time specified in the Tables.

During the holding period, there shall not be a greater difference than 150°F (83°C) between
the highest and lowest temperature throughout the portion of the vessel being heated,
except where the range is further limited in Table UCS‐56.

UCS-56 (d) (4)

‐ During the heating and holding periods, the furnace atmosphere shall be so controlled as to
avoid excessive oxidation of the surface of the vessel.
‐ The furnace shall be of such design as to prevent direct impingement of the flame on the
vessel.
 UCS-56 Requirements for Post-weld Heat Treatment 89

UCS-56 (d)(5)
Above 800°F (425°C), cooling shall be done in a closed furnace or cooling chamber at a rate
not greater than 500°F/hr (280°C/hr) divided by the maximum metal thickness of the shell or
head plate in inches, but in no case more than 500°F/hr (280°C/hr).
- From 800°F (425°C) the vessel may be cooled in still air.

- The rates of heating and cooling need not be less than 100°F/hr (56°C). However, in all cases
consideration of closed chambers and complex structures may indicate reduced rates of
heating and cooling to avoid structural damage due to excessive thermal gradients.
 UCS-56 Requirements for Post-weld Heat Treatment 90

The rates of heating and cooling need not be less than 100°F/hr (56°C).
UCS-56 Requirements for Post-weld Heat Treatment 91
 UCS-56 Requirements for Post-weld Heat Treatment 92

Alternative Post-weld Heat Treatment Requirements For Carbon and Low Alloy Steels (Table
UCS-S6.1)

Table UCS-56.1 presents alternative lower temperatures with corresponding longer times at
temperature (see Table UCS-56.1 Note (1)).

Post-weld heat treatment temperatures of 150°F or 200°F lower than permitted in Tables
UCS-56 are only permitted for P-No. 1 Gr. Nos. 1 and 2 materials (see Table UCS-56.1 Note
(2)).
UCS-56 Requirements for Post-weld Heat Treatment 93
 Design Temperature UG-20 94

UG-20(a) Maximum Design Temperature

The maximum temperature used in design shall be not less than the mean metal temperature (through
the thickness) expected under operating conditions.

UG-20(b) Minimum Design Temperature

‐ The minimum design metal temperature shall be the lowest temperature expected in service.
‐ The lowest metal temperature shall be the mean temperature of the metal and must consider the
lowest operating temperature, operational upsets, auto‐refrigeration, atmospheric temperature, and
other sources of cooling.
‐ The MDMT marked on the nameplate shall correspond to a coincident pressure equal to the MAWP.
When there are multiple MAWP’s, the largest value shall be used to establish the MDMT marked on the
nameplate.
Additional MDMT’s corresponding with other MAWP’s may also be marked on the nameplate .
 Design Temperature UG-20 95

UG-20(f) Material Exemption to Impact Testing

Impact testing per UG-84 is not mandatory for pressure vessel materials that satisfy all of the following:

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. (13 mm) for materials listed in Curve A of Fig. UCS-66;
(b) 1 in (25 mm) for materials from Curve B, C or D of Fig. UCS-66;

2. The completed vessel shall be hydrostatically tested per UG-99(b) or (c) or 27-4.

3. Design temperature is no warmer than 650°F (345°C) or colder than -20°F (−29°C).

4. The thermal or mechanical shock loadings are not controlling design. (See UG-22.)

5. Cyclical loading is not a controlling design requirement. (See UG-22.)

 Design Temperature UG-20 96

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 the conditions of UG-20(f)

must be met to take this
exemption from impact
testing.
 Design Temperature UG-20 97

When coincident
ratio are defined :-
 Charpy Impact Tests UG-84 98

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.
 Charpy Impact Tests UG-84 99

UG-84(c) Test Specimens.

UG-84(c)(1) Each set of impact test specimens shall consist of three specimens.
UG-84(c)(2) The impact test specimens shall be of the Charpy V-notch type and shall conform in all
respects to Fig. UG-84 .

- The standard (10 mm ×10 mm) specimens, when obtainable, shall be used for nominal thicknesses
of 0.438 in. (11.13 mm) or greater, except as otherwise permitted…

- Subsize (10 mm × 6.7 mm) specimens may be used in lieu of full-size specimens for materials that
normally have absorbed energy in excess of 75 ft‐lbf (100 J) minimum for each specimen and the
lateral expansion in mils (mm) shall be reported
Charpy Impact Tests UG-84 100

UG-84(c) Test Specimens

depth of the notch is shown in Fig.

UG-84 to be 2 mm
 Charpy Impact Tests UG-84 101

UG-84(c) Test Specimens

 Charpy Impact Tests UG-84 102

UG-84(h) Impact Tests of Welding Procedure Qualifications

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.

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.
 Charpy Impact Tests UG-84 103

Criteria for Acceptance & Retest

Figure UG-84.1.
(1) The average energy of 3 specimen shall ≥ FIG. UG- 84.1 Charpy v-notch impact test requirements
(2) The minimum impact energy for one specimen shall not be > 2⁄3 of the average energy required for
three specimens.

Note: For acceptance,

- average of 3 shall ≥ specified value and
- one (only one) may be below but shall < 2/3 the specified value.
 Charpy Impact Tests UG-84 104

Criteria for Acceptance & Retest

UG-84(c)(6) Criteria for Retest

When the average value of the three specimens ≥ the minimum value permitted for a single specimen
(2/3 specified average) and.
- the value for more than one specimen is below the required average value, or
- 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 ≥ the required average value.
 Charpy Impact Tests UG-84 105

A high energy
value for a notch
toughness test
indicates The
material is ductile

A low energy
value for a notch
toughness test
indicates The
material is brittle
 Charpy Impact Tests UG-84 106

UG-84 (c)(5) Charpy Impact Test Temperature:

UG-84(c)(5)(a) specifies that for full size Charpy impact specimens,

i.e., the width along the notch is at least 0.315 in. (8 mm), the Charpy test is conducted at a temperature
not warmer than the minimum design metal temperature.

When subsize Charpy impact specimens are used,

i.e., the width along the notch less than 0.315 in. (8 mm),
the test is conducted at a temperature lower than the minimum design metal temperature as shown in
Table UG-84.2 for that specimen width, except when UG-84(c)(2)(a) applies for materials that normally
have absorbed energy in excess of 180 ft-lbf (240 J).
Charpy Impact Tests UG-84 107
 LOW TEMPERATURE OPERATION 108

Rules for Determining Lowest (MDMT) Without Impact Testing

Step 1. Determine appropriate Curve for the material, including the Notes in Fig. UCS-66.

Step 2. Determine the governing thickness (tg) from UCS-66(a)(1) through (a)(5).
The governing thickness to be used in Fig. UCS-66 is determined from paragraph UCS-66(a)(1) through
(a)(5) based upon if the component under consideration is a welded part, casting, flat non-welded part, or
a dished non-welded part.

Step 3. Using the Curve and tg, determine the MDMT from Tabular Values in Fig. UCS-66.
 LOW TEMPERATURE OPERATION 109

Rules for Determining Lowest (MDMT) Without Impact Testing

Step 4. Determine additional exemption values for the MDMT by checking:

a) Based on the design loading conditions at the MDMT , Fig. UCS-66.1 (coincident ratio)
b) UCS-68(c) Has vessel has been PWHT when not required by UCS-56 ? If yes subtract an addition 30 F
from MDMT

Step 5. UCS-68(b)(2) For MDMT colder than −55°F (−48°C), impact testing is required for all materials
except as allowed in (3) below and in UCS-68(c).
 UW-33 Welding Alignment Tolerance 110

UW‐33(a) Alignment of sections at edges to be butt welded shall be such that the maximum
offset is not greater than the applicable amount for the welded joint category (see UW‐3)
under consideration, as listed in Table UW‐33. The section thickness t is the nominal
thickness of the thinner section at the joint.
 Thank You For Your Attention

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