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

Dont Worry About The Exam

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

What To Bring To Exam

1. 2. 3. API Examination Confirmation Letter Identification Card API & ASME reference publications. Note: highlighting, underlining, page tabs, written notes on the codes book is acceptable. Loose pages inserted into the codes book is not acceptable. Non-programmable calculator. Make sure enough battery. 2B pencil, eraser and other stationery Jacket some classroom is uncomfortably cool Earplugs you never know who might be seat next to you

4. 5. 6. 7.

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

ASME SECTION VIII RULES FOR CONSTRUCTION OF PRESSURE VESSEL

ASME Boiler & Pressure Vessel Code

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

Settings Rules!
Is What The Code Is All About
Important factors during fabrication that affect vessel safety and reliability seem almost endless. (a) (b) (c) (d) (e) Design thickness formulas, welding processes Material Known physical & chemical properties Fabrication qualified welding procedure, NDT Pressure Testing hydro or pneumatic Documentation nameplate, design calculation data

Scope of the Code

U-1(a) For the scope of the division pressure vessels are containers for the containment of pressure either internal or external. U-1(c)(2) The following classes of vessels are not considered to be within the scope of the division: (a) Within cope of other division (b) Fired process tubular heaters (c) PV of integral parts/component of pumps, turbines, compressor (d) Pipe and piping component (e) PV for water under pressure in which 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) (2) How information is organized in the code How to use the organization tools of the code

If you know these 2 secret, every answer can be found with minimum effort. Thats much better than paging through 7:: 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 Mandatory Non-Mandatory

2 Appendix

Organization of Code continued

Each Subsection is further divided into Parts Subsection A General
Part UG applies to all vessels

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

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

Every Part is divided into Paragraphs UG-1, UW-1, UCS-1

Organization of Code continued

Mandatory Appendices U-1(b) address specific subject not covered elsewhere in this division Alternate formulae QC Manual NDE Standards

Non-mandatory Appendices U-1(b) provides information and suggested good practices Completed Sample Problems

Example 1-1 Finding the Right Answer

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

Example 1-1 Finding the Right Answer

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

Section 1 Boilers

Section II Materials

Section VIII Pressure Vessel

Section V NDT

Section IX Welding

Division 1 Routine Sub A General Part UF Forge Sub B Fabrication Sub C Materials Part UB Brazing

Division 2 Other

Part UW Welding

Design Materials Fabrication Inspect

Marking

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

Exercise 1-2

answer.

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

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

Codes Purpose
Establish Rules for Construction of Pressure Vessel To ensure the construction of pressure vessels will be carried out in a safe and reliable manner. One way the Code achieves this is by setting requirements for critical work assignment. This will involved: (1) User (2) Manufacturer (3) Authorized Inspector (4) Welder (5) NDE Technician

Setting The Rules User Roles & Responsibilities

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

Setting The Rules Manufacturer Roles & Responsibilities

U-2(b)(1) The manufacturer of any vesselhas the responsibility of complying with all of the applicable requirements of this Division .. UG-90(b) The Manufacturer shall perform his specified duties. Obtain Certificate of Authorization from ASME Perform design calculations & develop fabrications drawings Identify all material used during fabrication Examine materials before fabrication: thickness, ID, defects Qualify welding procedures & welders Perform NDE test and records result Perform vessel hydro or pneumatic test Apply the Code Stamp Prepare Manufacturers Data Report

Setting The Rules Authorized Inspector

Roles & Responsibilities

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

Setting The Rules continued Authorized Inspector Roles & Responsibilities

UG-9:(c)(1) The inspector shall Verify the Manufacturer has a current Certificate of Authorization Verify Manufacturer is working to the QC system Verify design calculations are available Verify materials meet Codes Verify weld procedures and welders are qualified Verify NDE tests have been performed & are acceptable Perform internal & external inspections Verify nameplate is attached and has the right markings Witness the hydrotest Sign the Manufacturers Data Report

Setting The Rules Welders & NDE Techs

Roles & Responsibilities

Welder UW-29(a) The welders ..used in welding pressure partsshall be qualified in accordance with Section IX NDE Technician UW-51(a)(2) RT Qualified and certified in accordance with employers written practice. SNT-TC-1A used as a guidelines App 12-2 UT Qualified and certified in accordance with employers written practice. SNT-TC-1A used as a guidelines App 6-2 (a&b) MT He has vision ..read a Jaeger Type No. 2 Chart .. And is competent in the techniques of the magnetic particle examination method App 8-2 (a&b) MT He has vision ..read a Jaeger Type No. 2 Chart .. And is competent in the techniques of the magnetic particle examination method

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

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

CODE-OLOGY
Quality Control System
UG-117(e) Any Manufacturer shall have and demonstrate a Quality Control System to establish all Code requirementwill be met. The Quality Control System shall be in accordance with Appendix 1:. The Code tells the Manufacturer what must be done when building a vessel. The Manufacturers Quality Control System tells ASME and the AI how things will be done in the shop to meet the code.

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

CODE-OLOGY
UM Vessel Mini Vessel
If a vessel Is not covered by U-1 (c), (g), (h) & (i) Is not required to be fully radiographed Does not have a quick actuating device Does not exceed either the following limit

5 ft3 and 250 psi 1.5 ft3 and 600 psi

U-1(j) The vessel may be exempted from inspection by Inspectors Vessel fabricated .. With this rule shall be marked with the UM symbol

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

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

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

Module 2: Static Head, MAWP & Internal Pressure

Module 2.1 Static Head

What is Static Head?

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

Box is 1 cubic ft

1 cubic foot of water weighs 62.4 lbs.

12

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

Static Head Factor?

Water, 1 foot high will exert 0.433 psi at the bottom of the container? 62.4 lbs/144 sq inch = 0.433 psi per foot of water What is the pressure at the bottom of 1: 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) A vessel is 5: 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?

2)

3)
:

A 6: vessel is filled with water. The pressure at the bottom is 210 psi. What is the pressure at the top?
0 psig : 100 psig : ?? psig

2a

2b

5:

?? psig

?? psig 5: 6:

210 psig

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)

845 ft x 0.433 psi/ft = 369.8 psig

854 ft

Exercise 2-1
Answer 2a
2) A vessel is 5: high. The vessel will be hydrotested a. When filled with water what is the pressure at the bottom of the vessel?

Pbtm = 0.433 psi/ft x 50 ft

0 psig

= 21.7 psig
2a

5:

?? psig

Exercise 2-1
Answer 2b
2) A vessel is 5: high. The vessel will be hydrotested b. When the hydrotest pressure at the top of the vessel 100 psi, what is total pressure at the bottom?

100 psig

Pbtm = Ptop + Psh

= 100 + (0.433x50)
= 121.7 psig

2b

?? psig 5:

Exercise 2-1
Answer 3
3) A 6: vessel is filled with water. The pressure at the bottom is 210 psi. What is the pressure at the top?

?? psig

Ptop = Pbtm - Psh

= 210 - (0.433x60)
= 184 psig

210 psig 6:

Module 2.2 Design Pressure

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

Exercise 2-2
Design Pressure
A 50 high vessel has a design pressure of 100 psig. The elevations are shown in the sketch below. a. b. c. The shell should be designed for The top head should be designed for The bottom head should be designed for _________ psig _________ psig _________ psig

: 2

100 psig ?? psig

48

?? psig

5:

?? psig

Exercise 2-2
Design Pressure
a. Pshell = Ptop +Psh = 100 psig + (0.433 psi/ft x 48 ft) = 120.8 psig Ptop head = Ptop + Psh = 100 psig + (0.433 psi/ft x 2 ft) = 100.9 psig Pbtm head = Ptop + Psh = 100 psig + (0.433 psi/ft x 50 ft) = 121.7 psig
: 2 100 psig

b.

?? psig

c.

48

?? psig

5:

?? psig

Note: Each component should be designed for the highest pressure it will see at conditions. The highest pressure is at the bottom of the part

Module 2.3 MAWP Calculations

MAWP
Vessel & Vessel Part
UG98(b) The maximum MAWP for a vessel part is the maximum pressure including static head(based) upon rules and formulae in this Divisionexcluding any metal thickness specified as corrosion allowance

UG98(a) The maximum MAWP for a vessel is the maximum pressure permissible at the top of the vessel in its normal operating position...
It is the least of the values found for maximum allowable working pressure for any of the part of the vesseland adjusted for any difference in static head
How much can he lift?

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

3 ft

24 ft 40 ft 42 ft

Part Top Nozzle Side Nozzle Top Head Bottom Head Shell

Part MAWP Static Head Pressure @ Top 342 psig 426 psig 329 psig 336 psig 337 psig

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

24 ft 40 ft 42 ft

Part Top Nozzle Side Nozzle Top Head Bottom Head Shell

Part MAWP Static Head Pressure @ Top 342 psig 0.433 341.6 426 psig 10.4 415.6 329 psig 1.3 327.7 336 psig 18.2 317.8 337 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 1:: psig. Each head depth is 2 and the cylindrical portion of the shell is 32. The shell should be designed for a pressure of ______ psig. A vessels MAWP is limited by the lower shell portion. This shell part has a MAWP of 87.5 psig. What is the maximum allowed MAWP for this vessel?
0 ft 1 ft

2)

3)

A 8: tall pressure vessel is being hydrotested. A pressure gauge 2: up from the bottom reads 136 psig. What is the pressure at 50 ft the top of the vessel.
100 ft

Exercise 2-3
More MAWP & Static Head calculation
1) The MAWP of a vessel is 1:: psig. Each head depth is 2 and the cylindrical portion of the shell is 32. The shell should be designed for a pressure of ______ psig.
0 ft 100 psig

Pshell = Ptop + Psh = 100 + 0.433(34) = 114.7 psig

2 ft

34 ft

Exercise 2-3
More MAWP & Static Head calculation
2) A vessels MAWP is limited by the lower shell portion. This shell part has a MAWP of 87.5 psig. What is the maximum allowed MAWP for this vessel?
0 ft

Ptop = Pshell Psh = 87.5 (0.433 x100) = 44.2 psig

1 ft

50 ft

100 ft

Exercise 2-3
More MAWP & Static Head calculation
3) A 8: tall pressure vessel is being hydrotested. A pressure gauge 2: 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
80 ft

136 psig

Module 2.4 Calculating Stress

Stress on Welds

Circumferential Weld

Longitudinal Weld

Circumferential Stress affects: ___________ welds Longitudinal Stress affects: __________ welds

Stress on Welds

Circumferential Weld

Longitudinal Weld

Circumferential Stress affects: Longitudinal welds Longitudinal Stress affects: Circumferential welds

Calculating Stress
A weld specimen that is :.25: thick and 1.: 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 :.25: thick and 1.: wide. The specimen breaks with 12,500 lbs. of load. What is the ultimate tensile strength of this specimen? S = Load/Area S = 12,500/(0.25 x 1.0) S = 50,000 psi

Exercise 2.5 Calculating Stress

1) 2) A tension specimen is :.5 thick and :.75 wide. It breaks with a load of 21,500 lbs. The failure stress is _______ psi. A vessel is 1: in diameter and has pressure of 1:: psi. The force (load) trying to launch a vessel head into space is 1,1::,::: lbs. The circumference of the shell is about 4::. The head and shell are thick, not including corrosion allowance. What is the actual longitudinal stress on the shell-to-head weld?

Exercise 2.5 Calculating Stress

1) A tension specimen is :.5 thick and :.75 wide. It breaks with a load of 21,500 lbs. The failure stress is _______ psi. S = Load/Area S = 21,500/(0.5)(0.75) S = 57,333 psi A vessel is 1: in diameter and has pressure of 1:: psi. The force (load) trying to launch a vessel head into space is 1,1::,::: lbs. The circumference of the shell is about 4::. The head and shell are thick, not including corrosion allowance. What is the actual longitudinal stress on the shell-to-head weld? S = Load/Area S = 1,100,000/(400)(0.5) S = 5,500 psi

2)

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 Post 2000

4.0 to 1.0 Safety Factor 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 dont try -Beverly Sills

Module 3.1 Joint Efficiencies

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

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

Exercise 2.7
Joint Efficiencies
1) 2) 3) A shell is made with Type 2 joints and spot RT was performed. What is E? _________. A shell is made with Type 1 joints and Full RT was performed. What is E? _________. A shell is made with Type 3 joints and no RT was performed. What is E? _________.

Exercise 2.7
Joint Efficiencies
1) 2) 3) A shell is made with Type 2 joints and spot RT was performed. What is E? 0.8 . A shell is made with Type 1 joints and Full RT was performed. What is E? 1.0. A shell is made with Type 3 joints and no RT was performed. What is E? 0.6.

Weld Joint Categories

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

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

Category B: Circumferential welded joints within the main shell, communicating chambers, nozzles, or transitions in diameter including joints between the transition and a cylinder at either the large or small end; circumferential welded joints connecting formed heads other than hemispherical to main shells, to transitions in diameter, to nozzles, or to communicating chambers. UW-3

Category C: Welded joints connecting flanges, Van Stone laps, tubesheets, or flat heads to main shell, to formed heads, to transitions in diameter, to nozzles, or to communicating chambers,any welded joint connecting one side plate to another side plate of a flat sided vessel. Category D: Welded joints connecting communicating chambers or nozzles to main shells, to spheres, to transitions in diameter, to heads, or to flat-sided vessels, and those joints connecting nozzles to Communicating chambers (for nozzles at the small end of a transition in diameter, see Category B).

Degree of Radiography
Type of Radiography Full Generally 100% of welds, some exception Spot On RT for each 50 ft of weld None Send the RT techs home

Amount specified by Code for some vessels Based on Service, Thickness or Welding Process (UW-11)
Amount specified by Users/Designer for others The User or his designated agent shall establish the type of joint and the degree of examination when the rules of this Division do not mandate specific requirements (UW-12)

Full RT Required by Code

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

Full RT Required by User

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

The RT Factors
Describe the amount of RT performed - RT 1&2: Full Radiography - RT-3: Spot Radiography - RT-4: Combo Radiography

The RT Factor is located on Nameplate They are described in UG-116(e)

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

Example Finding E
1) A pressure vessel has butt welds which are single welded. No RT has been performed.
1) 2) E for welded shell? _______ E for the seamless head? _______

2)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-3
1) 2) E for welded shell? _______ E for the seamless head? ________

3)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-2.
1) 2) E for welded shell? _______ E for the seamless head? _______

4)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-1
1) 2) E for welded shell? _______ E for the seamless head? _______

Example Finding E
1) A pressure vessel has butt welds which are single welded. No RT has been performed.
1) 2) E for welded shell? 0.6 E for the seamless head? 0.85

2)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-3
1) 2) E for welded shell? 0.85 E for the seamless head? 1.00

3)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-2.
1) 2) E for welded shell? 1.00 E for the seamless head? 1.00

4)

A pressure vessel has butt welds which are double welded. The vessel is stamped as RT-1
1) 2) E for welded shell? 1.00 E for the seamless head? 1.00

Exercise 2-8 More Joint Efficiencies

1) A pressure vessel has lap welds which are single welded. The vessel is stamped RT-3
1) 2) E for welded shell? _____ E for the seamless head? ______ E for welded shell? ______ E for the seamless head? ______

2)

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

3)

A pressure vessel has butt welds which are single welded with backing strips.The vessel is stamped as RT-2
1) 2) E for welded shell? ______ E for the welded head? _______

Exercise 2-8 More Joint Efficiencies

1) A pressure vessel has lap welds which are single welded. The vessel is stamped RT-3
1) 2) E for welded shell? 0.45 E for the seamless head? 0.85 E for welded shell? 0.55 E for the seamless head? 0.85

2)

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

3)

A pressure vessel has butt welds which are single welded with backing strips.The vessel is stamped as RT-2
1) 2) E for welded shell? 0.99 E for the welded head? 0.99

Module 3.2 Tmin Calculations

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

Shell tmin Calculations

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

The P formula calcs the shell MAWP

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

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

___________________________________________________________ The Givens: P=158 psi, R= 36, S=15,000 psi, E=1.0 ___________________________________________________________ 2) The formula: t = PR/SE-0.6P ___________________________________________________________ 3) The plug-in: t = 158 x 36 / (15,000 x 1) (0.6 x 158) ___________________________________________________________ 4) The solutions with Units t = 0.382 ___________________________________________________________

Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24. At the design temperatures the materials allowable stress is 20,000 psi. The pressure on the shell is 250 psi (static head is included). The joint efficiency is 1.0. Determine the minimum required thickness? ___________________________________________________________ The Givens: P= , R= , S=, E= ___________________________________________________________ 2) The formula: t = PR/SE-0.6P ___________________________________________________________ 3) The plug-in: t = ___________________________________________________________ 4) The solutions with Units t = ___________________________________________________________

Exercise 2-9
Shell Minimum Required Thickness
A vessel shell has an internal radius of 24. At the design temperatures the materials allowable stress is 20,000 psi. The pressure on the shell is 250 psi (static head is included). The joint efficiency is 1.0. Determine the minimum required thickness? ___________________________________________________________ The Givens: P= 250 psi , R= 24 , S= 20,000 psi, E= 1.0 ___________________________________________________________ 2) The formula: t = PR/SE-0.6P ___________________________________________________________ 3) The plug-in: t = (250)(24)/(20,000 x 1.0) (0.6 x 250) ___________________________________________________________ 4) The solutions with Units t = 0.302 ___________________________________________________________

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

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

Exercise 2-10
Shell Minimum Required Thickness
2) A horizontal vessel has an internal diameter of 10 ft. The materials allowable stress is 14,000 psi. The MAWP of the vessel is 120 psi. The welds are all Type 1 and full RT was performed. Determine the minimum required thickness. ___________________________________________________________ The Givens: P= ? , R= 5=60 , S= 14,000 psi, E= 1.00 (Table UW-12) Pshell = Ptop + Psh = 120 + (0.433x10) = 124.33 psi ___________________________________________________________ 2) The formula: t = PR/SE-0.6P ___________________________________________________________ 3) The plug-in: t = (124.33)(60)/(14,000 x 1.00) (0.6 x 124.33) ___________________________________________________________ 4) The solutions with Units t= ___________________________________________________________

Rounded Head tmin Calculations

Ellipsoidal Head UG-32 (d)

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

Hemispherical Head UG-32 (f)

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

Head Calculations Example

The design pressure (with static head) on a 2:1 seamless elliptical head is 200 psi. The vessel ID is 60. The allowable stress is 15,000 psi. Welds are Type 1 with Spot RT. Find heads minimum required thickness? ___________________________________________________________ The Givens: P= , R= , S= , E= ___________________________________________________________ 2) The formula: t = PD/2SE-0.2P ___________________________________________________________ 3) The plug-in: t = ___________________________________________________________ 4) The solutions with Units t= ___________________________________________________________

Head Calculations Example

The design pressure (with static head) on a 2:1 seamless elliptical head is 200 psi. The vessel ID is 60. The allowable stress is 15,000 psi. Welds are Type 1 with Spot RT. Find heads minimum required thickness? ___________________________________________________________ The Givens: P= 200, R=60 , S= 15,000 psi, E= 1.00 (Table UW-12(d)) ___________________________________________________________ 2) The formula: t = PD/2SE-0.2P ___________________________________________________________ 3) The plug-in: t = (200)(60)/2(15,000 x 1.00) (0.2 x 200) ___________________________________________________________ 4) The solutions with Units t = 0.401 ___________________________________________________________

Exercise 2-11
Formed Head Minimum Thickness
1) A vertical vessel has an internal diameter of 84. The heads are hemispherical and made in segments. The head material has n allowable stress of 8,700 psi at the design temperature. The MAWP of the vessel is 48 psi. The overall vessel height is 38. The welds are double welded and Spot RT was performed. Determined the minimum required thickness for the bottom head. A horizontal vessel with seamless torispherical heads has an outside diameter of 96 inches. The materials allowable stress is 20,000 psi. The MAWP of the vessel is 120 psi. The joint efficiency is 1.0. Determine the minimum required thickness for the heads.

2)

Exercise 2-11
Formed Head Minimum Thickness
A vertical vessel has an internal diameter of 84. The heads are hemispherical and made in segments. The head material has n allowable stress of 8,700 psi at the design temperature. The MAWP of the vessel is 48 psi. The overall vessel height is 38. The welds are double welded and Spot RT was performed. Determined the minimum required thickness for the bottom head. ___________________________________________________________ 1) The Givens: P= ?, L=R =42 , S= 8,700 psi, E= 0.85 (Table UW-12) Pshell = Ptop + Psh = 48 + (0.433 x 38) = 64.5 psi ___________________________________________________________ 2) The formula: t = PL/2SE-0.2P ___________________________________________________________ 3) The plug-in: t = (64.5)(42)/2(8,700 x 0.85) (0.2 x 64.5) ___________________________________________________________ 4) The solutions with Units t = 0.183 ___________________________________________________________

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

Flat Head tmin Calculations

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

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

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

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

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

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

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

Destiny is no matter of chance. It is a matter of choice. It is not a thing to be waited for, it is thing to be achieved -William Jennings Bryan

Module 4: Pressure Testing, MDMT, Impact Testing

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

Hydrotest Procedure
1) 2) 3) 4) 5) 6) 7) Complete all pre-hydrotest work & testing Assure vessel & support structure is designed for weight of hydrotest liquid Select hydrotest fluid any non-hazardous liquid below its boiling point Disconnect or blind off appurtenances not to be tested Vent of high points to remove possible air-pockets Test fluid should be 300F above MDMT Pressure gauges must be acceptable range. About 2 times test pressure. (Acceptable range is 1.5 to 4 times Test Pressure) Pressure gauge should be calibrated Pressure gauge should be connected directly to vessel. If not visible, another should be connected near operator. Check tightness of test equipment Perform pressure test at 1.3 times MAWP corrected for temperature. Back pressure down to Test Pressure divided by 1.3 After vessel temperature is below 1200F, perform close visual inspection of joints and connections.

8) 9)
10) 11) 12) 13)

Hydrotest Calculation
A vessel is constructed of a P-1 material. The vessel is stamped MAWP is 300 psi at 8000F. Material allowable stress S is: 1000F = 20,000 psi 8000F = 13,500 psi

Determine the a) hydrostatic test pressure b) minimum inspection test pressure

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

Exercise 3-1 Hydrotest Solution

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

Exercise 3-1 Hydrotest Solution

A vessel is constructed of a P-1 material. The vessel MAWP is 600 psi at 6500F. Allowable stress S is @ 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 Pt= 1.3 (600)(17,000/17,000) = 780 psi

Sd=17,000 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

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

Determine the: Pneumatic Test Pressure Each of the Test Pressure Steps Inspection Test Pressure

Exercise 3-2 Hydrotest Solution

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

Minimum Design Metal Temperature (MDMT)

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

Factors Affecting Brittleness

(a) (b) (c) (d) (e) Material Temperature Thickness Stress Loading Residual Stress

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

The Code Controls Toughness

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

Our goal: Determine the lowest allowable MDMT without impact testing.

MDMT 4 EASY STEPS

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

Example 3-2 Calculate MDMT

Example : A horizontal vessel is made from SA 516 gr 70 plates that are not normalized. The vessel is rated at 250 psig at 700 F. The wall thickness is 0.500 and has a corrosion allowance of 0.100. The nameplate is stamped RT-3 and HT.

Find : The lowest possible MDMT for this vessel. Reduction ratio is 0.90.

Example 3-2 Calculate MDMT

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

Example 3-2 Calculate MDMT

Step 1: Initial MDMT: Table UCS-66 Material : Curve B Initial MDMT: -70F

Example 3-2 Calculate MDMT

Step 2: MDMT Reduction: Figure UCS 66-1 Reduction ration: 0.90 Reduction: 100F New MDMT = Initial Reduction 0 = -7 F - 100F = -170F

Example 3-2 Calculate MDMT

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

Example 3-2 Calculate MDMT

Step 4: Check limits: UCS 66(b)(2) No restriction as UCS-68 (c) allows for temperatures below these limits

Exercise 3-3 Determine MDMT

1) 2) 3) Material is SA-516 Gr. 60. Nominal thickness is 2.0. Renewal thickness is 1.750. Nameplate stamped HT Material normalized SA-612. Thickness is 0.750. Reduction ration is 0.85. Vessel was not PWHT. Material SA-516 Gr. 70, material retirement thickness 0.875. New thickness 1.0. Vessel is PWHT for environmental cracking. The reduction ratio is 0.88.

Exercise 3-3 Determine MDMT

1) Material is SA-516 Gr. 60. Nominal thickness is 2.0. Renewal thickness is 1.750. Nameplate stamped HT. Material Curve C Initial MDMT Ratio Reduction PWHT Reduction Final MDMT 260F [SA-516 Gr. 60 as it is not mentioned as normalized] 00F [no reduction ratio given assume no reduction] 00F [no reduction as 2 plate required PWHT by Codes] 260F

Exercise 3-3 Determine MDMT

2) Material normalized SA-612. Thickness is 0.750. Reduction ration is 0.85. vessel was not PWHT. Material Curve D Initial MDMT Ratio reduction PWHT reduction Final MDMT for SA-612 normalized. -420F [Either figure UCS-66 or Table UCS-66 for tabular values] -150F [from figure UCS-66.1] -00F [as no PWHT carried out] -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 Ratio reduction PWHT reduction Final MDMT

31 0F [Either figure UCS-66 or Table UCS-66 for tabular values] -12 0F [from figure UCS-66.1] -30 0F [P-1 material <1 not required PWHT as per UCS-56] -11 0F

Impact Testing UG-84

Impact testing of material is required when minimum operating temperature is lower than allowed by the UCS-66 MDMT calculations. (a) (b) (c) Test procedure SA-370 Each set of specimens 3 specimens Acceptance criteria Figure UG84.1
* Average value from the chart * Minimum value 2/3 chart

Note: 1 ksi = 1,000 psi

Exercise 3-4 Impact Testing

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

Exercise 3-4 Impact Testing

1) Impact testing is performed on a 3 thick plate that has yield strength of 55,000 psi. To be acceptable, the average for the set must be at or above 30 ft-lbs

2) Impact testing is performed on a 1 thick plate that has yield strength of 45,000 psi. a) To be acceptable, the average for the set must be > 15 ft-lbs b) To be acceptable each specimen must be > 10 ft-lbs

More Exercise Impact Testing

A welding procedure requires impact testing for a thickness range 3/16 2. The specimen is 1 having 45 ksi yield strength. What is the minimum acceptable impact test values for the three specimens? 1) 2) 3) 4) 18-19-12 17-12-25 17-16-17 18-17-12

More Exercise Impact Testing

A welding procedure requires impact testing for a thickness range 3/16 2. The specimen is 1 having 45 ksi yield strength. What is the minimum acceptable impact test values for the three specimens? From figure UG-84.1 find value required for average of 3 specimen using 2 the thickest range. Average = 17 ft-lbs Min value = 2/3 (17) = 11.3 1) 2) 3) 4) 18-19-12 17-12-25 17-16-17 18-17-12 [Average [Average [Average [Average 16.3, Min value 12] 18, Min value 12] 16.67, Min value 16] 15.67, Min value 12]

External Pressure
Thickness of shells and tubes under external pressure (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 Matl chart Fig. CS-2) Step 6 : Calculate P Max All External Pressure

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

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

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

Exercise 3-5 External Pressure

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

Exercise 3-5 External Pressure

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

Exercise 3-5 External Pressure

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

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

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

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

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

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

To

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

If we dont change, we dont grow. If we dont grow, we arent really living. -Beverly Sills