Lethal Service

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Lethal Service - Quick Guide

File:PVE-3856, Date:Oct 7, 2011, By:LRB, Last updated June 17 2015

Introductions
Requirements for lethal service are scattered through VIII-1, the code cases and the interpretations.
ASME VIII-1 section UW-2 has most of the requirements for lethal service. Two definitions of lethal
service are provided in UW-2. The second definition is also duplicated in the end notes:
[A] vessel is to contain fluids of such a nature that a very small amount mixed or unmixed
with air is dangerous to life when inhaled[.]
By "lethal substances" are meant poisonous gases or liquids of such a nature that a very small
amount of the gas or of the vapour of the liquid mixed or unmixed with air is dangerous to-life
when inhaled. For purposes of this Division, this class includes substances of this nature which
are stored under pressure or may generate a pressure if stored in a closed vessel.
It is up to the user to determine if a service is lethal. We at Pressure Vessel Engineering do not
determine if the vessel service is lethal (but we might have opinions based on previous jobs).
ASME VIII-1 Lethal Service Code References
UW-2 Service Restrictions is a very important section for lethal service vessels and must be read in
its entirety. A few brief points from UW-2:

UW-2(a) and UW-11(a)(1) - All butt welds shall be 100% radiographed

UW-2(a) - ERW pipe (like some grades of SA-53) is not permitted but interpretation VIII1-01-118 says it is acceptable if the long seam is fully radiographed
UW-2(a) - Post weld heat treatment is required for CS and Low Alloy
UW-2(a)(1)(a) - Category A welds shall be type 1 only (butt welded with no permanent
backing strip)
UW-2(a)(1)(b&c) &Interpretation VIII-1 92-211 - Category B & C welds shall be
type 1 or 2 only (butt welded). No slip on flanges! No Figure UW-13.2 Flange or Head to
Shell attachments
Interpretation VIII-I-98-23 - Category D welds (typically nozzles) shall be full
penetration.
UW-2(a)(1)(c) - Category C joints for stub ends have a long list of requirements
UW-2(a)(2 and 3) - Heat exchangers have a long list of requirements
Read all of UW-2 for more restrictions...

When it has been determined that a vessel is in Lethal Service, some of the following code sections will
apply. Other code sections might also be required. (List last updated June 16 2015 based on the ASME
2013 VIII-1 code edition.)

U-2(a)(2) - The user determines if the service is lethal.

UG-16(5)(a) - Air cooled and cooling tower heat exchanger tube walls to be 1/16" min.
UG-24(6) - Casting RT requirements.
UG-25(e) - No telltale holes.
UG-99(g),(k) - Hydro test visual leak inspection cannot be waived. Do not paint prior to
the hydro test.
UG-100(d)(4) - Pneumatic tests cannot be used for lethal service vessels, but also see
code cases 2046-2, 2055-2, 2407 regarding pneumatic instead of hydrostatic testing
UG-116(c) - "L" stamping must be added to the nameplate.
UG-120(d)(1) - "lethal service" is added to the data report
UW-2 - Service Restrictions - main source of info on Lethal Service (see lots more from
UW-2 below)
UW-11(a)(1) - All shell and head butt welds to be 100% RT
Fig UW-13.5 - One possible lap joint stub end configuration - see also interpretation BC79-680 / VIII-80-111
UB-3 - Brazed vessels shall not be used
UCS-6 - Do not use SA-36, 38W or SA-283
UCS-79 - PWHT and extreme fiber elongation - read for rules when heat treatment is
required
UCI-2, UCD-2 Cast iron and ductile cast iron vessels are not allowed.
UIG-2(c) - Metal parts for graphite vessels are to be designed to UIG requirements

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UIG-23(b) - Factor of safety for lethal service

UIG-60 - Lethal service
UIG-99 - Lethal service pressure tests
ULW-1 & ULW-26(b)(4) - Layered vessels lethal restrictions apply to the inner shell and
heads only
UHX-19.1(b) - Heat exchanger markings
Appendix 2-5(d) & 2-6 - Maximum Flange Bolt Spacing
Appendix 2-14(a) - Mandatory flange flexibility
Appendix 7-1, 7-5 - Steel casting examination for 100% quality factor
Appendix 9-8 - if the jacket does not carry lethal substances, lethal service restrictions
do not apply to it
Appendix 17-2(a) - Dimple jackets will not contain lethal substances
Appendix 35-3(c) & 35-7(d) - Mass production rules
Appendix W Table W-3 - Filing out the U forms
Appendix KK (note 12) - Filling out User Design Requirements forms
Appendix NN Table NN-6-5 - User or designated again determines if the contents are
lethal
End notes 65 - Definition of lethal service

Weld restrictions by category

Special lap joint stub end for lethal

service - see also Fig UW-13.3 and Fig
2-4(5) and (6)

All partial penetration nozzles are

prohibited

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All figure UW-13.2 corner welds are

prohibited

No slip on flanges

Code Cases
The following Code Cases refer to lethal service for VIII-1 vessels (2013 edition)

1750-20(g) - A126 not to be used for prvs, or rupture disks.

2249 - Furnace Brazing
2318 - slip on flanges in lethal service
2321-1 PWHT of P4 and P5A materials
2324 - Ultrasonic inspection
2334 - single fillet lap joint tubesheet to shell connection
2346-1 & 2537 - Alternative rules for SE and F&D head to shell attachment
2369 - Testing of covers separate from vessels
2377 - RT of SA-612 steel
2421 - Single fillet joints in Heat exchanger tubes
2437 - Diffusion bonded heat exchangers
2527 Pneumatic testing of UM vessels
2537 alternative F&D and SE head to shell attachment is not for lethal service
2621 Diffusion bonding
2751 alternative spherical head to shell attachment is not for lethal service

Interpretations
With interpretations now available on line at cstools.asme.org/Interpretation/SearchInterpretation.cfm it
is now easier to find relevant and up to date interpretations. A search for "BPV Section VIII Div 1"
keyword: "lethal" returns 44 records. The comments on the most interesting lethal service
interpretations are listed below. Refer to the actual interpretations for the actual text.

VIII-1-01-118 and VIII-1-83-77R - ERW pipe may only be used if the long seam is
radiographed
VIII-82-65 - volumetric examination of category D joints is not always required
VIII-1-01-42 and VIII-1-04-48 - cone >30 and and corner joints not permitted
VIII-1-86-84 and VIII-1-95-138 - prohibited flange attachments - Fig UW-13.2(m)
and Fig 2-4 sketches (7), (8), (8a), (8b), and (9)
VIII-1-92-112 - full radiography of category C and D butt welds is required except for
UW-11(a)(4)
VIII-1-92-194 - full penetration angle joints are not permitted
VIII-1-92-211 - Fig UW-13.2 attachments are not permissible
VIII-1-98-113 - permissible repad and flange pad arrangements
VIII-1-98-23 - Fig UW-16.1 (a) and (c) are permissible nozzle attachments, others are
not discussed
VIII-77-62 - "It is the intent of Section VIII, Division 1 that Category B and C butt welds
in nozzles and communicating chambers that neither exceed 10 in. nominal pipe size or
1-1/8 wall thickness are excluded from the provisions of radiography, even though the
vessel is in lethal service. This overrides the provisions of UW-2(a)."
VIII-80-02 - do not use corner joints from Fig UW-13.2 - redesign to create butt joints
that can be radiographed
VIII-80-111 - acceptable lap joint flanges include Fig. 2-4(1) and Fig. UW-13.3 and Fig.
2-4(5) and (6)

Disclaimer: This material is provided for educational uses only. Only ASME can make code
interpretations.
2016 Pressure Vessel Engineering Ltd.

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