Pressure Vessel Inspector Certification - by Puspatri

PREPARATION CLASS
API 510
PRESSURE VESSEL INSPECTOR
CERTIFICATION EXAMINATION
PUSPATRI
JOHOR BAHRU
5TH -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 1 : Scope
Section 2 : References
Section 3 : Definitions
Section 4 :Owner User Inspection Organization
Section 5 - : Inspection Practices

5.1 Preparatory Work
5.2 Modes of Deterioration and Failure
5.3 Corrosion Rate Determination
5.4 Maximum Allowable Working Pressure Determination
5.5 Defect Inspection
5.6 Inspection of Parts
5.7 Corrosion & Minimum Thickness Evaluation
5.8 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 General
6.2 Risk Based Inspection
6.3 External Inspection
6.4 Internal and On Stream Inspection
6.5 Pressure Test
6.6 Pressure Relieving Devices
6.7 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
Don’t 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. API Examination Confirmation Letter
2. Identification Card
3. 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.
4. Non-programmable calculator. Make sure enough battery.
5. 2B pencil, eraser and other stationery
6. Jacket – some classroom is uncomfortably cool
7. 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) Design – thickness formulas, welding processes

(b) Material – Known physical & chemical properties
(c) Fabrication – qualified welding procedure, NDT
(d) Pressure Testing – hydro or pneumatic
(e) 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 Pd<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. That’s 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 Section II Section VIII Section V Section IX

Boilers Materials Pressure Vessel NDT Welding
Division 1 Division 2
Routine Other
Sub A Sub B Sub C

General Fabrication Materials
Part UF Part UW Part UB Design

Forge Welding Brazing
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) Design Requirements : UG, UW, UCS

(b) Hydrotest Pressure : UG
(c) RT Acceptance Standards : UW
(d) Nameplate Data : UG
(e) Limits of Carbon % in Materials : UCS
(f) Material ID Traceability : UG
(g) Inspection Requirements : UG, UW, UCS
(h) PWHT Requirements : UW, UCS
Hint:
If it’s applicable to all vessel –UG.
If it’s only applicable because it’s welded – UW
If it’s based on metallurgy - UCS
Code’s 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 vessel…has 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 Manufacturer’s Data Report
Setting The Rules
Authorized Inspector Roles & Responsibilities
Section VIII requires that all vessels be inspected by a qualified third-

party 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 Manufacturer’s Data Report
Setting The Rules
Welders & NDE Techs Roles & Responsibilities
Welder
UW-29(a) “ The welders ..used in welding pressure parts…shall be
qualified in accordance with Section IX”
NDE Technician
UW-51(a)(2) RT “Qualified and certified in accordance with employer’s
written practice. SNT-TC-1A used as a guidelines”
App 12-2 UT “Qualified and certified in accordance with employer’s
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 Note: The Code Symbol

have a valid Certificate of shall be applied after
hydrostatic or pneumatic
Authorization, and with the acceptance
test
of Inspector shall apply the Code
Symbol to the vessel.”
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
symbols…will 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 requirement…will 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 Manufacturer’s 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 ½”. 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 ½”. 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” Box is 1 1 cubic foot of water weighs

cubic ft 62.4 lbs.
12”
12”
1) How much force (weight) is on the bottom of this

container?______________
2) How much force on each square inch of the box’s
bottom?________ What’s 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) A deep diving submarine cruising at a depth of 854 feet. What is
the static head pressure on this submarine? (external pressure)
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?
b. When the hydrotest pressure at the top of the vessel 100 psi, what is
total pressure at the bottom?
3) A 60’ vessel is filled with water. The pressure at the bottom is
210 psi. What is the pressure at the top?
0’ 0 psig 100 psig
0’ 0’ ?? psig
2a 2b 3
?? ?? psig 210 psig

50’ psig 50’ 60’
Exercise 2-1
Answer 1
1) A deep diving submarine cruising at a depth of 854 feet. What is
the static head pressure on this submarine? (external pressure)
854 ft
845 ft x 0.433 psi/ft = 369.8 psig
Exercise 2-1
Answer 2a
a. When filled with water what is the pressure at the bottom of
the vessel?
0’ 0 psig
Pbtm = 0.433 psi/ft x 50 ft
= 21.7 psig
2a
??
50’ psig
Exercise 2-1
Answer 2b
b. When the hydrotest pressure at the top of the vessel 100 psi,
what is total pressure at the bottom?
100 psig
0’
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) 3
= 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 thickness…static 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. The shell should be designed for _________ psig

b. The top head should be designed for _________ psig
c. The bottom head should be designed for _________ psig
0’ 100 psig
2’
?? psig
48’ ?? psig
50’ ?? psig
Exercise 2-2
Design Pressure
a. Pshell = Ptop +Psh
= 100 psig + (0.433 psi/ft x 48 ft) 0’ 100 psig
= 120.8 psig 2’
?? psig
b. Ptop head = Ptop + Psh
= 100 psig + (0.433 psi/ft x 2 ft)
= 100.9 psig
c. Pbtm head = Ptop + Psh 48’ ?? psig
= 100 psig + (0.433 psi/ft x 50 ft)

= 121.7 psig 50’ ?? 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 Division…excluding 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 vessel…and 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’ B
Part A: 343 – 0.433(34) = 328.3 psig
Part B:
MAWP 336 Part B: 336 -0.433(12) = 330.8 psig
Thus, vessel MAWP = 328.3 psig
A
Part A:
MAWP 343
34’
Exercise 2-3
Determining Vessel MAWP
The maximum MAWP this vessel can be rated is ______psig.
0 ft
1 ft Part Part MAWP Static Head Pressure @ Top

3 ft Top Nozzle 342 psig
Side Nozzle 426 psig
Top Head 329 psig
24 ft
40 ft
Bottom Head 336 psig
42 ft
Shell 337 psig
Exercise 2-3
Determining Vessel MAWP
The maximum MAWP this vessel can be rated is ______psig.
0 ft
1 ft Part Part MAWP Static Head Pressure @ Top
3 ft
Top Nozzle 342 psig 0.433 341.6
Side Nozzle 426 psig 10.4 415.6
Top Head 329 psig 1.3 327.7
24 ft
40 ft
Bottom Head 336 psig 18.2 317.8
42 ft
Shell 337 psig 17.3 319.7
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
If MAWP < Design Pressure
To meet Code Requirement:

MAWP > Design Pressure
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.
2) A vessel’s 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 pressure at
50 ft
the top of the vessel.
100 ft
Exercise 2-3
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.
100 psig
0 ft
Pshell = Ptop + Psh

2 ft
= 100 + 0.433(34)
= 114.7 psig
34 ft
Exercise 2-3
2) A vessel’s 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
1 ft
= 87.5 – (0.433 x100)
= 44.2 psig
50 ft
100 ft
Exercise 2-3
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.
0 ft
Ptop = Pgauge – Psh
= 136 – (0.433 x 60)
= 110.0 psig
60 ft 136 psig
80 ft
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) 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.
2) 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 ½” thick, not including corrosion allowance.
What is the actual longitudinal stress on the shell-to-head weld?
Exercise 2.5
Calculating Stress
1) 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
2) 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 ½” 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 4.0 to 1.0 Safety Factor

Post 2000 3.5 to 1.0 Safety Factor
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 don’t
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) A shell is made with Type 2 joints and spot RT was performed.
What is “E”? _________.
2) A shell is made with Type 1 joints and Full RT was performed.
What is “E”? _________.
3) A shell is made with Type 3 joints and no RT was performed.
What is “E”? _________.
Exercise 2.7
Joint Efficiencies
1) A shell is made with Type 2 joints and spot RT was performed.
What is “E”? 0.8 .
2) A shell is made with Type 1 joints and Full RT was performed.
What is “E”? 1.0.
3) 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) “E” for welded shell? _______
2) “E” for the seamless head? _______
2) A pressure vessel has butt welds which are double welded. The vessel
is stamped as RT-3
2) “E” for the seamless head? ________
is stamped as RT-2.
2) “E for the seamless head? _______
is stamped as RT-1
2) “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) “E” for welded shell? 0.6
2) “E” for the seamless head? 0.85
is stamped as RT-3
is stamped as RT-2.
2) “E for the seamless head? 1.00
is stamped as RT-1
Exercise 2-8
More Joint Efficiencies
1) A pressure vessel has lap welds which are single welded. The
vessel is stamped RT-3
1) “E” for welded shell? _____
2) “E” for the seamless head? ______
2) A pressure vessel has lap welds which are double fillet welded
1) “E” for welded shell? ______
2) “E” for the seamless head? ______
3) A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
1) “E” for welded shell? ______
2) “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
2) A pressure vessel has lap welds which are double fillet welded
3) A pressure vessel has butt welds which are single welded with
backing strips.The vessel is stamped as RT-2
2) “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 – ½ of diameter

– “P” is the Design Pressure: Pressure on the part includes Static Head
• The “P” formula calc’s the shell MAWP
P = SEt/R + 0.6t
– The part MAWP – The shell’s “good for” pressure

– This is not vessel MAWP
Example
A vessel has an internal radius of 36”. At the design temperature the
material’s 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 material’s 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=
___________________________________________________________
___________________________________________________________
3) The plug-in: t =
___________________________________________________________
4) The solutions with Units t =
___________________________________________________________
Exercise 2-9
A vessel shell has an internal radius of 24”. At the design
temperatures the material’s 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
___________________________________________________________
___________________________________________________________
3) The plug-in: t = (250)(24)/(20,000 x 1.0) – (0.6 x 250)
___________________________________________________________
___________________________________________________________
Exercise 2-10
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 material’s

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
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
___________________________________________________________
___________________________________________________________
3) The plug-in: t = (142.5)(48)/(12,500 x 0.85) – (0.6 x 142.5)
___________________________________________________________
___________________________________________________________
Exercise 2-10
2) A horizontal vessel has an internal diameter of 10 ft. The
material’s 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
___________________________________________________________
___________________________________________________________
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 head’s 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 head’s 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)
___________________________________________________________
___________________________________________________________
Exercise 2-11
Formed Head Minimum Thickness
1) 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.
2) A horizontal vessel with seamless torispherical heads has an
outside diameter of 96 inches. The material’s 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
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)
___________________________________________________________
___________________________________________________________
Exercise 2-11
A horizontal vessel with seamless torispherical heads has an outside diameter
of 96 inches. The material’s 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)
___________________________________________________________
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)
___________________________________________________________
___________________________________________________________
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)
___________________________________________________________
2) The formula: t = d √CP/SE
___________________________________________________________
3) The plug-in: t = 60 √C(0.33)(302.165)/(12,500)(1.0)
___________________________________________________________
___________________________________________________________
Part MAWP
Part MAWP is the pressure a part is “good for”
Based on knowing the thickness (don’t 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
Let’s 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
Torispherical Head: _______ psi P = SEt/0.885L + 0.1t
Hemispherical Head: _______ psi P = 2SEt/L + 0.2t

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
Let’s 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
Torispherical Head: 138.8 psig P = SEt/0.885L + 0.1t
Hemispherical Head: 498.3 psig P = 2SEt/L + 0.2t

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) Complete all pre-hydrotest work & testing
2) Assure vessel & support structure is designed for weight of hydrotest liquid
3) Select hydrotest fluid – any non-hazardous liquid below its boiling point
4) Disconnect or “ blind off” appurtenances not to be tested
5) Vent of high points to remove possible air-pockets
6) Test fluid should be 300F above MDMT
7) Pressure gauges must be acceptable range. About 2 times test pressure.
(Acceptable range is 1.5 to 4 times Test Pressure)
8) Pressure gauge should be calibrated
9) Pressure gauge should be connected directly to vessel. If not visible, another
should be connected near operator.
10) Check tightness of test equipment
11) Perform pressure test at 1.3 times MAWP corrected for temperature.
12) Back pressure down to Test Pressure divided by 1.3
13) 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
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.
Calculate Test Pressure

MAWP=600 psi, St=17,000 psi Sd=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
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
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) Material
(b) Temperature
(c) Thickness
(d) Stress Loading
(e) 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 material’s
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
= -7 F - 100F = -170F
0
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) Material is SA-516 Gr. 60. Nominal thickness is 2.0”. Renewal thickness
is 1.750”. Nameplate stamped “HT”
2) Material normalized SA-612. Thickness is 0.750”. Reduction ration is
0.85. Vessel was not PWHT.
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.
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 260F [SA-516 Gr. 60 as it is not mentioned as normalized]
Ratio Reduction 00F [no reduction ratio given assume no reduction]
PWHT Reduction 00F [no reduction as 2” plate required PWHT by Codes]
Final MDMT 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 -12 0F [from figure UCS-66.1]
PWHT reduction -30 0F [P-1 material <1 ½” not required PWHT as per UCS-56]
Final MDMT -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) Test procedure – SA-370

(b) Each set of specimens – 3
specimens
(c) Acceptance criteria – Figure UG-
84.1
* 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
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
strength of 55,000 psi. To be acceptable, the average for the set
must be at or above 30 ft-lbs

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) 18-19-12
2) 17-12-25
3) 17-16-17
4) 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) 18-19-12 [Average 16.3, Min value 12]

2) 17-12-25 [Average 18, Min value 12]
External Pressure
Thickness of shells and tubes under external pressure
(UG-28)
• 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 Mat’l 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
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
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 CS-
2.
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.
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 SA-
516 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 SA-
516 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” B=11,600
D0=45” 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 don’t 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 can’t find them, make them.
-George Bernard Shaw
If we don’t change, we don’t grow. If we don’t grow, we aren’t really living.
-Beverly Sills

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PREPARATION CLASS

DAY 2 - 6th November 2007

Introduction to API 510 Pressure Vessel Inspection Code

Section 5 - : Inspection Practices

Section 6: Inspection and Testing of Pressure Vessels and Pressure

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

API 572: Inspection of Pressure Vessel (Towers, Drum, Reactors Heat

“ Life is too short to be ordinary”

-The examination handle by Professional Examination Services (PES)

Important factors during fabrication that affect vessel safety and

(a) Design – thickness formulas, welding processes

Vessel Boundary Limits

U-1(e) 2 Non-pressure part that are welded directly to the vessel

(1) How information is organized in the code

Section VIII Division 1

Each “Subsection” is further divided into “Parts”

Every “Part” is divided into “ Paragraphs”

Section 1 Section II Section VIII Section V Section IX

Sub A Sub B Sub C

Part UF Part UW Part UB Design

(a) Design Requirements : ____________________

(a) Design Requirements : UG, UW, UCS

To ensure the construction of pressure vessels will be carried out in a

Section VIII requires that all vessels be inspected by a qualified third-

U-2(e) “ It is the duty of the Inspector to make all of the inspections

When the manufacturer uses the Code

UG-116(a&b) “Each pressure vessel

UG-116 (g) “The Manufacturer shall Note: The Code Symbol

What driving license does for the driver, the Certificate of

UG-117(e) “ Any Manufacturer shall have and demonstrate a Quality

UG-120(a) “A Data Report shall be filled out on Form U-1..by the

For UM vessel – the Form U-3

U-1(j) “The vessel may be exempted from inspection by Inspectors…”

1) Full radiography is performed on a vessel shell with a wall thickness

2) A P-1 material (carbon steel) 2” thick is being PWHT. What is the

3) A relief device is required on a vessel so that the pressure does not

2) A P-1 material (carbon steel) 2” thick is being PWHT. What is the

3) A relief device is required on a vessel so that the pressure does not

12” Box is 1 1 cubic foot of water weighs

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

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

?? ?? psig 210 psig

Ptop = Pbtm - Psh

a. The shell should be designed for _________ psig

= 100 psig + (0.433 psi/ft x 50 ft)

UG98(a) “The maximum MAWP for a vessel is the maximum pressure

It is the least of the values found for maximum allowable working

How much can he lift?

To determine Vessel MAWP:

The maximum MAWP this vessel can be rated is ______psig.

1 ft Part Part MAWP Static Head Pressure @ Top

The maximum MAWP this vessel can be rated is ______psig.

If MAWP < Design Pressure

To meet Code Requirement:

3) A 80’ tall pressure vessel is being hydrotested. A pressure gauge

Pshell = Ptop + Psh

2) A vessel’s MAWP is limited by the lower shell portion. This shell

Circumferential Weld Longitudinal Weld

Circumferential Stress affects: ___________ welds

Circumferential Weld Longitudinal Weld

Circumferential Stress affects: Longitudinal welds