ADVANCED MATERIAL 11/03 REV 12 Fast Track Technical Training 167 281-482-2253 — www.apiexams.orgAPI510 MODULES Static Head of Water ‘The static head of water is equal 1o 0.433 psi per vertical foot above the point where the pressure will measured. For example the static head of water at a point in a vessel with 10 feet of water above it is calculated by multiplying 10 x 0.433 psi. 10 x 0.433 = 4.33psi ‘The 4,33 psi is being exerted totally by the weight of the water. No other external pressure having. ‘been applied. If an external source of pressure is applied it would be added to the static head pressure of the water at any given point in the vessel ‘Suppose an extemal pressure from a pump of 100 psi is applied to the above vessel.. ‘This pressure ‘would be added to the 4.33 psi that already exists from the static head for a total pressure at that point of 104.33 psi, From this simple principle the following concepts must be understood. ‘+ Case 1. How do you determine static head based on a given elevation? ‘© Case 2. When do you add the static head pressure in vessel calculations? '* Case 3. When do you subtract the static head in vessel calculations? * Case 4. How do you calculate static head on ellipsoidal and hemi heads? 168 11/03 REV 12 FastTrack Technical Training 281-482-2253 — www.apiexams.org,Case 1. To determine static head based on an elevation fiom a stated problem it must be understood that clevations are normally taken from the ground level for an existing vessel including any base the vessel is on. You must subtract the GIVEN elevation form the TOTAL elevation to determine vertical feet of static head above the given elevation. Example: A vessel has an elevation of 18 feet and is mounted on a 3 foot base. What is the static head pressure of water at the 11 foot elevation which is located at the bottom of the top shell course? aw 18" a ‘You must realize itis the number of vertical feet above the GIVEN elevation in question wich causes the static head at that point. To find the static head you must suburact the elevation of the GIVEN point from the TOTAL elevation given forthe vessel, 18° feet total -L1 desired point 7 total static head Static head pressure at 11’ elevation is: 7 x 0.433psi = 3.08 psi 11/03 REV 12 Fast Track Technical Training 169 281-482-2253 — www.apiexams.orgCase 2. Static head st a point in a vessel must be added to the pressure used (normally vessel MAWP) ‘when calculating the required thickness of the vessel component at that elevation. Example: Determine the required thickness of the shell course in Case 1. ‘The vessels MAWP (Always measured at the top in the normal operating position) is 100 psi. ‘The following variables apply: Givens: Circumferential stress FromUG-27(c)(1) P= 100 psi + Static Head eee SE-06P 5 = 15,000 psi E=10 R=20" Since the bottom ofthis shell course is at the 11 foot elevation the pressure it will see is 100 psi + the static head, Or 100 + 3.03 = 103.08 psi 103.03x20 20606 (G5,000%1.0)—(0.62103.03) 1493818 379" 170 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.aplexams.orgCase 3. You must subtract static head pressure when determining the MAWP ofa vessel. If given a vessel ‘of multiple parts and the MAWP for each of the parts, the MAWP of the entire vessel is determined by subtracting the static head pressure atthe bottom of each part to find the part which limits the MAWP of the vessel Example: A vessel has an elevation of 40 feet including a 4 foot base. ‘The engineer has calculated the {following part MAWP'S to the bottom of each part based on each par's minimum thickness and corroded diameter. Determine the MAWP of the vessel. Design pressure at the bottom of *Top Shell Course 28' Elev. 406.5 psi fiddle Shell Course 16.5' Elev. 410.3 psi *Bottom Shell Course 4’ Elev. 422.8 psi 408.5 psi 20" . Bottom of top shell course: 40.0" elev. -28.0'elev. 12.0' head. 12'x 0.433 psi = 5.196 psi of Static Head 11/03 REV 12 Fast Track Technical Training im 281-482-2253 — www.apiexams.org406.5 psi 20 410.3 psi Bottom of the middle shell course: 40.0' elev. 216.5'elev. 23.5' head 23.5' x 0.433 psi = 10.175 psi of Static Head 406.5 psi 28" 410.3 psi 16.5 422.8 psi Bottom of bottom shell course: 40.0' elev. 4.0’ elev. 36.0 bead 36 x 0.433 psi = 15.588 psi of Static Head 172 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.aplexams.org,‘The final step in determining the MAWP of the vessel a its top is to subtract the static head of water from the calculated MAWP'S at each given point, The lowest calculated pressure will be the maximum ‘gage pressure permitted at the top of the vessel Bottom of top shell course 406.5 - 5.196= 401.3 psi Bottom of mid shell course 410.3 - 10.17: Bottom of btm, shell course 422.8 - 15.58% ‘Therefore the bottom of the middle shell course MAWP determines the MAWP of the entire vessel. 400.125 psi Static Head 10.175 psi 410.3 psi 16.5" ‘The MAWP of the vessel is 400.125 psi 11/03 REV 12 Fast Track Technical Training 173 281-482-2253 — www.apiexams.orgCase 4, As part of calculating hydrostatichead on a vessel you will be required to determine the depth of two types of heads, 2 to I ellipsoidal and hemispherical. You will be given only the diameter of the vessel and using this you must calculate the head's depth which in tum is used to find the hydrostatic head at the bottom of the head Example: A vessel has an inside diameter of 48 inches. Determine the depth of a hemispherical and 2 2 to 1 ellipsoidal head with a 2 inch straight flange. The approach here is based on the fact that the hheads diameters will match the vessels diameter and therefore will be the same. In this case 48 inches. Hemispherical Head Our hemispherical head has an inside diameter of 48 inches which means it has a radius of 24 inches. ‘The radius fs the depth of the hemispherical head Shell I.D. 48" a Radius 24" Depth 24" 174 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.org2 to 1 Ellipsoidal Head ‘An ellipsoidal head's LD. will be the same as the shell's. The inside diameter ofan ellipsoidal head is also its major axis. This fact i the basis of finding the depth of a2 to 1 ellipsoidal head. Notice that ‘we are strictly talking about 2 to 1 ellipsoidal heads. The 2to 1 refers tothe ratio of the Major Axis to the Minor Axis ofa ellipse which is used to form the head. Ofcourse only half of the Minor 201 Se | Minor Axis. 12" Major Axis ag 1103 REV 12 Fast Track Technical Training us 281-482-2253 — www.apiexams.orgNow add the 2 inch flange to the dish. 2to1 jepth ‘Therefore our 2 to | Ellipsoidal head has a depth of 14 inches. Example; Calculate the hydrostatic head of water for the following heads on a vessel with a Total Elevation of 70°. The vessel's I. D. is 64 inches. The top head is a 2 to 1 ellipsoidal and has a 2 inch flange. The bottom head is a hemispterical and is welded to the shell at the 8 foot elevation. 2 70 176 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www apiexams.org,Step 1. Caleulae the depth ofthe 2 to 1 ellipsoidal head ontop. The LD. ofthe head equals the Major Axis therefore: 64" isthe Major Axis and the Minor axis equals 1/2 the Major Axis, 64" divided by 2 equals 32" which equals the entre Minor Axis However an ellipsoidal head uses only half the Minor Axis forts dished portion. 32” divided by 2 equals 16". To this you must add the length of the straight flange 2" So the depth of our ellipsoidal head is 18 inches, Step 2. Calculate the depth of the hemispherical head. ‘The LD. of the hemi head equals the LD. of the vessel therefore: 64" equals the diameter and the radius is one-half of the diameter. 64 divided by 2 equals 32" which equals the radius ofthis head ‘The Radius is equal to the Depth ofthe hemi head or 32 inches. Step 3. Calculate the static head pressure on each head. Depth of head x 0.433 psi = Static head pressure. Ellpsoidal Converting to fee: 18" divided by 12 = 1.5'x 0.433 psi= 0.6895 psi Homispherieal Converting to feet. 32" divided by 12 =2.666' x 0.433 psi = 1.1543 psi 11/03 REV 12 Fast Track Technical Training a 281-482-2253 — www.apiexams.org‘To find the total hydrostatic head on the hemispherical head at its bottom you must add all of the head ‘hat exists above it including the shell and the ellipsoidal head. We calculate as follows. 70’ total elevation +8! to the top of hemi head 62 hydrostatic head 2.6661 depth of hemi head 64.666 total feet head 64.666 x 0.433 psi 8.0 psi to the bottom of the hemi head. om 0.6495 psi 70 ANS: Statie head for the: soidal head equals 0.649 psi Hemispherical head equals 28.0 psi 178 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.orgQuiz Static Head /UG-99 A. A 100 foot tall columm is being hydrostatically tested. The vessel's MAWP is 100 PSI at 750°F, The vessel's material has an allowable stress of 13,500 PSI at MAWP, its material allowable stress at 70°F, the test temperature is 15,000 PSI What is the required hydrostatic test pressure? B. The vessel above is under full hydrostatic test pressure in an operating unit during the summer. A plant ‘wide evacuation alarm sounds and all test personnel leave, Four hours later, upon the all clear, the test crew finds thatthe gauge pressure on vessel has risen to an unacceptable pressure. How could this have been avoided? C. The test gauge for the test above is located at the 30’ elevation of the vessel, what will be its gauge pressure during the test and at what pressure shall the visual inspection take place as zead from the gage at the 30’ elevation? 11/03 REV 12 Fast Track Technical Training 19 281-482-2253 — www.aplexams.orgANSIUG-99 Solution A: Hydrostatic Test Pressure Per UG-99(b) 15,000PSI ROOST «1.31 00=144.44 PST 13,500PSI Solution B: Per UG-99(h), a relief valve set at 1 1/3 the pressure could have been installed. Solution C: test pressure/I.3 plus static head at 30’elevation. Per UG-99(2) ‘Test pressure at the top 144.44 Hydrostatichead = +.30, Test pressure at30° 174.75 144.44/1.3 = 111.11 + 30.31 = 141.42 psi (inspection psi as read at 30' elev.) Drawing: asses ae eS ee Of LL enn wi Le 180 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.orgCorrosion Example Problems A 60 foot tower consisting of four (4) shell courses was found to have varying corrosion rates in each course. Minimum wal thickness readings were taken after 4 years and 6 months of service. All original ‘wall thicknesses included a 1/8" corrosion allowance. The top course's original thickness was 3125". The present thickness is 3000". The second course downward had an original thickness of 375". During the inspection it was found to have a minimum wall thickness of 349", The third course was measured at 440" its original thickness was .500". The bottom course had an original thickness of .625" and measured to be 595" Determine the metal loss for the top course the corrosion rate forthe second course, the corrosion allowance remaining in the third course, the retirement date for the bottom course. 200) 349 60-0" 440 11/03 REV 12 Fast Track Technical Training 181 281-482-2253 — www.apiexams.orgSolution A: ‘TOP COURSE. ‘Metal loss equals the previous thickness minus the present thickness. Previous 3125" Present 3000" 0125" Metal Loss SECOND COURSE. Corrosion rate equals metal loss per given unit of time. Previous .3750" Present -.3490" (0260" Metal Loss —Loss=0.260" 996") Per Year Time—4.Syears ‘THIRD COURSE. Remaining Corrosion Allowance equals the actual thickness minus the required thickness. Origiral Thickness 500" Original C. A.=125" Required Wall Thickness 375" Actual Wall Thickness .440" Required Wall 375" Remaining C.A. 065" 182 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.org,BOTTOM COURSE. ‘Remaining life equals the remaining corrosion allowance divided by the corrosion rate.**#** 1 Required Thickness Original Thickness .625" Original C. A.2125" Required Thickness 500" 2.Remaining Corrosion Allowance 3.Comosion Rate 4.Remaining Life ‘Remaining Corrosion Allowance .095' Actual Wall Thickness 595" Required Thickness -.500" Original Thickness .625" Present Thickness -.595" Metal Loss 030" feral Loss_.030" ime 45 Years, Corrosion Rate = .0067"/Yr. Rem. Corrosion Allowance,095" Corrosion Rate .0067"/Yr. 11/03 REV 12 Remaining Life = 14.2 Years Fast Track Technical Training 281-482-2253 — www.apiexams.org 183,6.7 Corrosion and Minimum Thickness Evaluation Fora corroded area of considerable size in which the Circumferential Stress Govern, the least thickness along the most critical element of the area may be averaged over a length not exceeding the following: 1, For vessels with the inside diameters less than or equal to 60 inches (150 centimeters) one half the vessel diameter or 20 inches (50 centimeters) whichever is less. 2 For vessels withthe inside diameters greater than 60 inches (150 centimeters) one third ‘the vessel diameter or 40 inches (100 centimeters) whichever is less. When the area contains an opening the distance on either side of the opening within which the thicknesses ‘are averaged shall not extend beyond the limits of the reinforcement as defined in the ASME Code. See Fig. UG-37 and refer to reinforcement calculations for determining the limits of renforcement. 184 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.org,Widelv scattered pits may be ignored as long as the following are true: oe Pit#1 0.334 Pit#2 0278" 2 oe Pit#3 0.402" Sy _ 7 Pit#a, 0302" ee 1. No pit depth is greater than one half the vessel wall thickness exclusive of the corrosion allowance. 1.0” — 0,125" = 0.875" Therefore no pit deeper the 0.875/2 = 0.4375" Pit#3 > 0.402 <0.4375" OK! 2. The total area of the pits does not exceed 7 square inches (45 sq. centimeters) within any 8 inch (20 centimeter) diameter rele. We will assume the pits to be circles and use the formula Phi x Radius Squared to determine the area of each pit, Bit#One 3.141 x(0.170/2)?= 0.085? =0,0226 sq, inch Pit#Two 3.141 x( 0.330/2)?= 0.165? = 0.0855 sq. inch Pit# Three 3.141 x (0.250/2)*= 0.125? = 0.0490 sq. inch Pit#Four 3.141 x (0.377/2)* = 0.1185" = 0.1116 sq, inch Total 0.2678 sq. inch < than 7 sq. inches OK! 3. The sum of their dimensions along any straight line within the cirele does not exceed 2 inches (S centimeters) Straight line for pits 1-3-4 #1. 070" 8. 05 #4. 9377" Total 0.797" <2 inches OK! 1103 REV 12 Fast Track Technical Training 185 281-482-2253 — www.aplexams.org,When the surface at a weld with a joint factor of other than 1.0 as well as the surfaces remote from the weld is corroded, an independent calculation using the appropriate weld joint factor must be made to determine ifthe thickness at the weld or remote from the weld governs the allowable working pressure. For this calculation the surface at a weld includes 1 inch (2.5 centimeters) on either side of the weld ‘or twice the minimum thickness on either side of the weld, whichever is great E= 25 Shell t min = 2.0" ive ————— Use E=.85 ‘When measuring the corroded thickness of ellipsoidal and torispherical heads the governing thickness may be as follows: 1, The thickness of the knuckle region with the head rating calculated by the appropriate head formula, 2. The thickness of the central portion of the dished region in which case the dished region may be considered to be a spherical segment whose allowable pressure is calculated by the Code formula for spherical shells 3. For calculating the spherical portion using the spherical formula the following applies to find the spherical radius Li a, L=the OD of the Torispherieal head bb, L=the BD of the shell times 90% for 2 to 1 Elipsoidal heads '\ Spherical Portion Shell. D.60" | | | 80% x60" = 48" Use UG-27 Spherical 1} Shell formula —l Knuckle Portion Use UG-32 formula for head 186 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.aplexams.org,Cylinder Under Internal Pressure Problem #1 Calculate the required thickness of a 60 inch LD. cylindrical shell. Itis constructed of SA-S16-70 rolled steel plate, The vessel's Category A&D Type I joins are fully radiographed. All Category B joints are Type | also and have been spot radiographed per UW-11(a)(5)(b). The vessel MAWP must be 350 PSI at 450°F, The shell wil see 11 psi of static head at its bottom. SOLUTION: DRAWING: Tyee! cara rou ar od \ ones fear 77 spoTRT Givens 0.0" R=30" P= 350+ Lipsi static head $= 17,500 from stress table E= 1.0 per UW-12(a) UG-27(¢)(1) CIRCUMFERENTIAL STRESS tok 3E-0.6P 361%30 eae (@7,500%1.0) - (0.6361) ANSWER t = 6266" 1103 REV 12 Fast Track Technical Training 187 281-482-2253 — www.apiexams.org(Cylinder Under Internal Pressure Problem #2 A vessel is constructed using two courses of rolled and welded SA-515-60 plate. The maximum design temperature is 750°F. All joints used in shell courses are Type 1 those used to join heads are Type 2. The vessel's name plate is stamped with the following: HT, W, RT 3. The vessel is 48 inches O.D. and has a thickness of 500 inch. What would be the vessel's MAW based on the MAWP of the shell? DRAWING: Givens: t=.500" Pe? = 13,000 from stress table E=.85 RT3 for Type 1 OD =48.0" Ry =24.0" APPENDIX | SEt Ro-0.4t SOLUTION: 188 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.org,Heads Under Internal Pressure Problem #1 ‘A hemispherical head formed from solid plate is 48.0 inches in inside diameter and has a thickness of 500 inch, This head will be attached to a seamless shell which has not had radiography on the Category A Type | weld that attaches the head to the shell. The vessel is horizontal and operates at 500 PSI water pressure ‘with an allowable stress on the head's material of 15,000 PSI. Does the head's thickness meet Code? Show calculations. SOLUTION: DRAWING: HEMISPHERICAL Givens: 500" D=48.0" L=24.0" P = 500 PSI ~ (0.433 psi x 4’) = 1.732 501.732 $= 15,000 E=.70 UG-32() oo 2SE-0.2P ne $01.732%24.0 (2x15,000% 0.7) —(0.2x501.732) Answer: NO. 11/03 REV 12 Fast Track Technical Training 189 281-482-2283 - www.aplexams.org‘Heads Under Internal Pressure Problem #2 ‘An Bllipsoidal head of seamless construction is welded to a seamless shell. The weld joint was spot radiogcaphed per UW-11(@)(5)(b). The head's inside diameter was originally 36 inches. Uniform corrosion hhas occurred on the internal surfaces of the head leaving a wall thickness of 240". The original thickness of the head was 375". The MAWP of the vessel is 175 PSIG at 450°F and the static head at the bottom of the head is 5.3 psi... The stress allowable om the head's material is 13,500 PSL. Does this meet Code? SOLUTION: DRAWING: original head dimensions Givens: 240" D=36.0" + [(.375-.240) x 2] = 36.0 + 270 + 36.270" adjusted for corrosion! P=175 PSI + 5.3 psi static head = 180.3 psi $= 13,500 E= 1.0 from UW-12(4) UG-32(4) PD coe 2SE-0.2P ne 1803x3627 (@x13,500%1.0)- (0.21803) 240" <,.242" 190 11/03 REV 12 Fast Track Technical Training 281-482-2253 ~ www.apiexams.orgHeads Under Internal Pressure Problem #3 ‘A seamless circular flat head is attached to 2 36 inch LD. shell similar to Figure UG-34(e). The shells required tis 375 inch. The shell’s actual fis 500 inch. The flat head is .750 inch in thickness. The vessel {s to operate at 300 PSIG. The head's material has a stress allowance of 15,000 PSI. The fillet welds are 0.7 tg. Is the head's thickness in compliance with the Code? SOLUTION: DRAWING: se Givens: 750 1.0 Because the flat head is seamless C=.33 xm=.33x,375 =.33 x.750 = 247 500 UG-34(6)2) 360 [287300 SY 15,00041.0 f 1=360X | 129.53 15,000 Answer: NO. 11/03 REV 12 Fast Track Technical Training 191 281-482-2253 - www.apiexams.orgHeads Under Internal Pressure Problem #4 ‘While pulling exchanger bundles, a contractor backed against a torispherical head on a vessel. As a result of the bump, a circular flt spot is left on the formed head. ‘This head is 375 inch thick and the flat spot is 6 inches in diameter. The vessel has a MAWP of 150 PSI and the head's material has an allowable stress of 15,000 PSI. Dees this head require repair? Per Formed Heads UG-32(0) AND UG-34(6)(2) Drawing: so | Givens: t= 375 (formed head) P= 150 $= 15,000 1.0 Seamless, Flat Head C=0.25 per UG-32(0) 4% [enor (C2550) aa (25,000)(1.0) 0.375">0,300" 300° Answer: No repairs are required. The flat spot meets t required for an equivalent flat head. See UG-32 (0), found near the end of UG-32. 192 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.orgAPI S10 MODULES UG-84 WPS. Problem #1 Please evaluate the following Charpy Impact Test results for a SMAW procedure. The plate is SA-516 grade 70 normalized, 1 3/4" thick. The WPS is being qualified for a range from 3/16" to 8” in thickness. ‘The max weld pass ¢= 1/2". The plate's specified minimum yield normalized is 38 KSI. Do the test results qualify this procedure for impact testing? Specimen Noteh Notch Test Location Type Temp. Wel WELD ¥ 250 2 WELD ¥ “250 20 ‘WELD Vv 250 5 WELD Vv 259 2 WELD ¥ 250 2 WELD ¥ 25°F @ HAZ Vv 250 19 HAZ Vv 25°F 19 HAZ v “25°F 20 1103 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.org 193,UG-84 WPS SOLUTION: Step (1) Determine the minimum impact eneray forthe test coupon Per UG-84(1)(2)(c) the test spocimens must meet or exceed the values for the thickness ofthe range qualified in the welding procedure. Per QW-451.1 Section IX. This procedure willbe qualified from 3/16 inch to 8 inches. Therefore: T qualified = 8.0 inches. Going to Table UG-84.1 and entering on the bottom line st any value greater than 3 inches, then roving upto the <38 KSI curve, then across tothe minimum impact values on the lft, we finda minimum impact value of 18 f/bs. Step (2) Check tes results (a) Average impact value required per Figure UG-84.1 is 18 ft/ Ibs. (b) Calculate averages wa 21 w4 2 HA 19 w2 20 ws 2 H2 19 wa +15 Ws +14 HS +20 56+3~186 58436193 193 (©) Note (b) of Figure UG-84.1 states that one specimen shall not be less than 2/3 the average energy required for three specimens. Only one (1) specimen is allowed to fall below the min avg. of tree per UG-84(0\(6. ‘The minimum acceptable value ofa single specimen i a follows ‘Acceptance values = 2/3 x 18 = 12 minimum Answer: All values meet minimums and the procedure's impact tests pass. 194 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www-apiexams.org,ADVANCED EXERCISE PROBLEMS INTERNAL PRESSURE (CYLINDERS) 1).A cylindrical shell has been discovered to have uniform external corrosion. The shells original thickness ‘was 7/8 inch, it is presently .745 inch in thickness. The original O.D. of the shell was 30 inches. The ‘vessel operates at 650 OF with a stress allowable on the material of 15,000 psi. All joints were fully radiographed. All joints are type 1. What isthe vessel's present MAWP? 2). A vessel is fabricated ftom SA-S16 gr.70 plate material to operate at 600 OF with an allowable stress of 17,500 psi. The vessel has an inside diameter of 36 inches end operates at 375 psi. The type 2 long seam. has had full RT. The circumferential joints have met UW-12(4) and UW-11(a)(5)(b)requirements. What is its required thickness? 3.) A shell course is being replaced with the new course being 60 inches in inside diameter and 7/8 inches ‘thick, The vessel course material is SA-S15 gr. 60 plate at a design temperature of 650 OF with an allowable stress of 13,000 psi, The vessel joints are all type 2 and the vessel is stamped RT-3. What is the MAWP of this shell course? 4.) What is the minimum required thickness of a vessel shell operating at 650 psi and 500 °F. The vessel shell is fabricated of SA-516 gr. 60 plate, allowable stress of 15,000 psi. The inside diameter ofthe vessel shell is 50 inches. The vessel has received FULL RT on Category A joints. All ofits category A joints are ‘ype 1. The category B joints are type 2 and have met the requirements of UW-12(d) and UW-11(a)(5)(b). 5). A vessel shell is made from SA-515 - Grade 70. It has a design operating pressure of 200 psi at 750 OF, allowable stress is 14,800 psi. The inside diameter is 14 feet, All joint efficiencies are 1.0 The shell has corroded down to 1.28 inches. Its original t was 1.375". May this vessel shell remain in service in accordance with rules of Section VIII Division 1? 11/03 REV 12 Fast Track Technical Training 195 281-482-2253 — www.aplexams.orgINTERNAL PRESSURE (HEADS) 1) A seamless torispherical head made of SA-S15 gr. 70 material with an allowable stress of 14,800 at 750 ©F is to operate at 250 psi. The knuckle radius is 6% ofthe outside diameter of the head skirt and the inside crown radins is equal to the outside diameter of the skirt. The outside diameter of the skirt is SO inches. ‘The vessel itis attached to meets the requizements of UW-12(4) and UW-11(a)(5)(b). What is the ‘minimum required thickness of the head? 2.) A seamless ellipsoidal head with ato 1 ratio of the major to the minor axis isto operate at 750 OF ‘with an intemal pressure of 250 psi. The material has an allowable stress of 14,800 and the skirt has an inside diameter of 50 inches. All category B butt welds do not meet UW-11(a)(5)(b). What is the ‘minimum required thickness for the head? 3.) A seamless hemispherical head is fabricated from a material with a calculated stress of 14,800 psi at ‘operating temperature. All category B but joints in the vessel meet UW-11(a)(5)(b) and all category A joints are type 1 and have had spot radiogmphy. The vessel's design requires an maximum operating pressure of 250 psi. The corroded thickness of this head is 295", It has a corroded LD. of 72.230". May this head continue in service ? 4.) During the inspection of a horizontal 36 inch ID vessel in gas service e seamless circular flat head attached similar to Fig UG-34(e) was found to have corroded to a thickness of 1.948 inch minimum. The shell's required thickness was calculated based on 100% joint efficiency and an allowable stress of 17,500 psi. ‘The shell’s actual thickness is .50S inch and the vessel operates at 250 psi. The flat head's allowable stress is 15,500 psi. The fillet weld throat sizes are still in excess of .7 ty. May this flat head remain in service? 196 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.orgSolutions for Internal Pressure Cylinders SEt Ro-04t 1. From: Appendix 1-1 Givens: original =.875" tpresent =.745” P=? S= 15,000 psi E=10 5875-745) 30 Rw 1487" 5.0.13 = 14.87 * this adjusts the o.d.. wall loss x1. Ox.745 1487 (044.745) 766.88psi ‘The trick here is knowing to adjust the outside radius for corrosion, remember it will decrease ‘when there is extemal corrosion. The opposite is true for internal corrosion. PR 2. From: UG-27 (¢) (1) a 375218 a (€7,5005.90) ~ (0.62375) In order to take .90 for the E on the category A joint, it must have fall RT and the circumferential joint must meet the spot RT requited by UW-12(a. 1103 REV 12 Fast Track Technieal Training 197 281-482-2253 — www.apiexams.org3, From: UG-27(¢)( 1) 4, From: UG-27 (¢) (1) t=? P= 650 psi S= 15,000 psi B= 10 n~ 30 25 : R+ 060 13,000x.80x.875 30+ (0.6.75) PR i SE-0.6P 650225 {(15.00021.0) — (0.6650) = 298.1 psi ‘Here you must remember that UW-12(a) will not allow the use ofa joint E from column A unless the requirements of UW-1] (a)(5) have been applied. Ifthe spot RT had not been performed the E would be taken from column B and have a value of 85. 198 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www-apiexams.orgPR SEt a SE-06P ROG 5, From: UG-27 (¢) (1) Givens: t = 128" P= 200psi Sm 14,800 psi E=10 1 R= Sf = 7x 12 = 84" Inside radius comoded = 847(1.375-1.28) = 84.085 200x84,095 (C4R0021.0) — (0.6200) 14,800x1.0x1.28 84.095 +(0.6x1.28) 145"or 223.23 pst ‘The answer to the question is YES it may remain in service ‘Notice that since both pressure and thickness are known that either calculation can be made. It does not ‘matter which is used, 1103 REV12 Fast Track Technical Training 281-482-2253 — www.apiexams.org 199Solutions for Internal Pressure Heads o.885PL 1, From: UG-32 (e) Spon yp (Torispherical Formula rom: UG-32 (¢) r= SESE (Tors ) Givens: = 14,800 psi 0 L= 50” crown radius 0.885%250x50 (G48002.0) ~ (0.12250) PD 2. From: UG-32(é) 1=_*P 258 -0.2P Givens: 50” inside diameter ____250x50 op (@214,800x.85) (0.25250) 3. From: UG32() = 25E-0.2P Givens: t P= 250 psi S= 14,800 psi 88 36.115" inside spherical radius 250x36.115 . (214,800.85) — (022250) — ANS: NO 200 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.aplexams.org,7 [er -afZ2 4 From UG34(e)(2) red Givens: t=? t= 505” actual thickness ofthe shell 250 psi for head material 15,500 psi for shell material 17,500 psi for head 36” shell 36” inside 1.0 fora seamless head ‘Step 1. Caloulate the Shell’s required thickness Ombenang From: UG 27 (¢) (1) we use the t= formula to find thatthe shell’s required which is .259” remember to use the shell’s material stress in this ealeulation. ‘Step 2. Using the actual thickness of shell and its calculated reg. thickness find “m” From: The definitions of variables in and fig. UG-34 (e) m=" = 252 6 505 Step 3. Caleulate the value of C ‘From: Fig. UG-34 (¢) C= 33 xm= 33 x 51 =.1683 ‘Since the minimum that C is allowed to be in this geometry is 20 use C= 20 to solve. Step 4. Calculate the required t of the flat head ———— ag [202250 =36 [Fe egos g ” 36¥ 0082258 = 36%.0567961= 2.048" Answer No: 1.984” <2.044” 11/03 REV 12 Fast Track Technical Training 201 281-482-2253 — www.apiexams.orgAPPENDIX, 202 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.orgSolutions for ASME Modules Exercises ow. 1. ans. D (it depends on the location inthe vessel) 2. ans. B (itis category C weld) 3. : iP ee ‘ rl 281-482-2253 — www.apiexams.orguw Category A joints in nozzles and communicating chambers and category B joints in nozzles and chambers which exceed either 10“ NPS or 1-1/8 wall thickness, 2. The category A joint must be fally radiographed and the spot radiography of UW-11 (a)(5)(b) must be applied per UW-12(2) 3, Full radiography for all butt joints, which exceed the specified thickness, excluding the category Bs that do not exceed the 10” NPS or 1-1/8 inch thickness. 4, emay not be assumed that all Joints nave been rediographed. The thickness of some joints may not exceed the limit fr the material used, Remember iis the least nominal thickness at the welded joint ‘which determines the requirement 5, Both joints must be radiographed by the requirement that all A AND D butt welds shall be shot. uw.2#1 B= 1.0 per UW-12 (@) E = .80 based on the joint E from column B of the welded joint used for the head E = 85 based on the joint E from column B of the welded joint used for the head E=1.0 per UW-12 (@) E= 85 no spot RT. per UW-12 (4) 85 no spot RT. per UW-12 (@) E=.65 based on the joint E from column B of the welded joint used for the head uw.2#2 1, E=1.0 based on full RT of all category A and D joints and the spot RT applied to the category B joint attaching the Ellipsoidal head (see UW-12(a) }. 2, E= 80 based on the joint E from column B of the welded joint used for the Ellipsoidal head 3. E= 1.0 Full RT on the category A joint in the hemispherical head. 4. B= 1.0 per UW-12 (@) 5. E=1.0per UW-12 (6) 6. E=1.0per UW-12 (6) 7. E=.80 based on the joint E from column B of the welded joint used for the head and spot RT. 204 11/03 REV 12 Fast Track Technical Training 281-482-2253 ~ www.apiexams.org500 psi 15,000 psi E= 1.0 per UW-12(4) pow 1275 5375" 2. From: UG-27(¢)( 1) Givens: t = 850" P=? S= 15,000 psi E= 10 R=52" 1103 REV 12 po PRO “SE +0AP 300%6.37: (G5,000x1.0) + (0.4500) ~ 15,000x1.0x.850 52+ (0.6x.850) =242.8ipsi ANS: MAWP is 242.81 psi Fast Track Technical Training 281-482-2283 — www.apiexams.org 205ue32 1, From UG-32( ¢=5—* 2SB-02P Givens: 350 psi $= 15,000 psi 1.0 fall RT per UW-11 (a) (1) in but joints in shells and heads D= 48” inside diameter 35048 __ a s613" (2x15,000x1.0) = (0.24350) ANS: required t = 3613” 2. From:UG-32(e) + Givens: 353 100 psi 3,800 psi 10 56” crown radius 0.8853100256 = 3593" (5,800x1.0)= (0.1x100) ANS: No the head may not remain in service. 206 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.org,PL 3. FromUG32(9 r= PL © '33e-0a8 Givens: 100 psi 7,500 psi £85 Spot RT per UW-12(d) 32,0" inside spherical radius (D/2) 200332.0, 20033200 ___ aa sge Gxd7500%.85) (025200) ANS: the required thickness = 2154" 4, From: UG-32(@) r=- 72 — 25E-02P Givens: 85 No spot RT per UW-12(8) 64.0" 200x64 sos" (217,500.85) — ©2200) — 11/03 REV 12 Fast Track Technical Training 207 281-482-2253 — www.apiexams.orguG-34 ce Larmeussaier(a) —eaaf® Givens: t=? 1=.500” actual thickness of the shell P75 psi SS for head material 13,800 psi ‘S= for shell material 15,000 psi = for head 42" D=for shell 42” inside E= 1.0 for shell calculation (Shell E is always 1.0 for a flat head calculation) E= 1.0 per UW 12 (d), this isa forged head but is treated like a formed head. Read the paragraph for the Fig UG-34 (b-2) C= 033xm=? ‘Step 1. Calculate the Shell's required thickness ‘From: UG 27 (¢) (1) we use the t= formula to find thatthe shell’s required which is 1053” remember to ‘use the shell's material stress in this calculation Step 2. Using the actual thickness of shell and its calculated req, thickness find mr _ 1083 From: The definitions of variables and fig. UG-34 (e) in UG-34 m = =" = 2106 Step 3. Calculate the value of C From: Fig. UG-34 (6) C= .33 xm=.33x.2106=.0694 Since the minimum that C is allowed to be in this geometry is 20 use C= 20 to solve. Step 4. Caleulate the required t of the flat head 20x75 aii 2,| 2075 __ 49 00108 iiaoon0* ‘Ans. thickness required = 1.3846” 2x.0329681 = 1.3846" 208 11/03 REV 12 FastTrack Technical Training 281-482-2253 — www.aplexams.org(one ie a1 Tesi ti is agp apes Des =" ans 4.123 Step 1. Our value of Dg is 54 inches and Lis 98 inches, We will use these to determine the ratio of 2-38-18) Ds 34 Step 2. Enter the Factor A chart at the value of 1.8 determined above. Step 3. Then move across horizontally to the curve at approximately Doj, =48. Then down from this point to find the value of Factor A which is approximately 0022 Step 4, Using our value of Factor A calculated in Step 3, enter the Factor B (CS-2) chart on the bottom, then vertically up to the material temperature line given in the stated problem (in our case 300 °F). Step 5, Next step is across to find the value of Factor B. We find that Factor B is approximately 15000. Note due to the variance in the reading of the charts answers and values may vary, but should be within aS % range of the solution, Step 6. Using this value of Factor B, calculate the value of the maximum allowable external pressure Py using the following formal: 3 30%) 60,000 3(48) 144 16.66 psi 416.66 psi > 350 psi ANSWER: YES it may remain in service, your numbers may be slightly different +or- 5% due to the variation in reading the factor A and B charts. This is acceptable. 1103 REV 12 Fast Track Technical Training 209 281-482-2253 - www-apiexams.orgUG-99/100 1. Hydrostatic Test A B, 16,700 414,700 13x25»: 332.295 13 C. Mininum gage range 1.5 x 332.295 = 498.4 ( use 500 psi) 255.61psi 32.295 psi ‘Maxinum gage range 4 x 332.295 =1329.18 (use 1000 psi) Of course the gage pressure at the 4X range would be rounded down to closest standard range! 2, Pneumatic Test Step 1. Raise the pressure to % the test pressure, % x 310psi = 155 psi then raise in 1/10 steps to full test pressure, Step 2. Step 3. Step 4. Step 5. Step 6. Last find the inspection pressure 310/1. 155431=186 psi 186131=217 psi 217431248 psi 248+31=279 psi 279431=310 psi 210 11/03 REV 12 FastTrack Technical Training 281-482-2253 — www.aplexams.org, 181.8 psi and lower for visual inspection.6 ‘Throat = Leg Size x.707 Throat Leg Size uv 707 1, 1.125 x.707 = .7953” = throat size 2, tap sine= = 5186 ttt 16 ab 7 ch 13/16<,8486<7/8 (14/16) or .8125<.8486<.875 uceamauins 100 1, Ratio= =1.0135 therefore use 1.0 credit cannot be taken for the higher strength of the pad’s 14800 material, only the reverse is true, tha is you must reduce the area that the pad provides ifit is of a lower strength than the shel 2. The centers can be no closer than the sum of their diameters and still be considered isolated openings, in this case 64 =10 inches, The answer is: their centers can be no closer than 10 inches with out the areas of reinforcement overlapping. 3. The area of reinforcement must that of hole which would contain all of the nozzles with in it. Itis treated as if it were on large hole for reinforcement calculation, UG-37 Reinforcement 1. Corrosion allowance must be deducted from all surfaces in contact withthe corrosive substance. 2. Aq dt, F +2; t,F(L-y) Area required 3. Answer: 4 points for the reinforcement and 4 points for the hydrostatic calculations. Which one takes ‘the most study time? Which one of these ate you most likely to do in actual practice? Which one of these is the most likely to be on the exam? 11/03 REV 12 Fast Track Technical Training 21 281-482-2253 — www.apiexams.orguG-84 SA-370 ( second paragraph of UG-84) Charpy V-notch(only one mentioned in UG-84, first paragraph UG-84 Charpy impact tests shall be performed) 3. 165" long x 0.394"thick see Fig UG-84 4, Three make a set 5, Three seis, two fiom the weld metal and one set of heat affected zone specimens. 6 1. ‘The P No, and the Group No, must be the same as will welded in production, Weld Metal and Heat Affected Zone. UG-20/0C366/68 1, Step 1. UG 20), Step 2. UCS-66(a) , Step 3. UCS-66 (b) , Step 4. UCS-68 (c). 2, When the Welded thickness exceeds 4 inches and the MDMT is below 120 °F. 3, When the governing thickness exceeds 6 inches and the MDMT is below 120 °F 4, 88 °F SA-S1S gr. 70 is @ curve A material 5, 48°F a coincident Ratio of 0.6 will reduce any materials MDMT by 40 °F from that inthe curvesttables, Solutions for Internal Pressure Cylinders 1, From: Appendix 1-1 Givens: ‘original =.875" present =.745" P=? S= 15,000 psi Bots nos try = $2 2 15.(975.745 18019- 187 isan od wll \Ox1.0x.745 1487—(0.4x.745) 66.88psi “The trick here is knowing to adjust the outside radius for corrosion, remember it will decrease ‘when there is external corrosion. The opposite is true for internal corrosion, eee ‘SE-0.6P 2. From: UG-27(¢) (1) Givens: te 27 Pe 375 psi S= 17,500 psi E= 90 36 _igu R= D=18 375x18 (17500%.90) - (0.65375) 347" In order to take 90 for the E on the category A joint, it must have full RT and the circumferential joint must meet the spot RT required by UW-12(a). 212 11/03 REV 12 Fast Track Technical Training 281-482-2253 - www.apiexams.org3, From UG-27(¢) (1) com Givens: P=? S= 13,000 psi re = Bars el 1300530585 5p seit a sem VOoT(e)() t= PR (cy SE-06P be ops 3 hep oan 125; (G5, 00031.0) — (0.62650) Here you must remember that UW-12(a) will not allow the use of a joint E from column A unless the requirements of UW-11 (a)(5) have been applied. Ifthe spot RT had not been performed the E would be taken from column B and have a value of £85. , ow $ Hom U627(2)(1 oe +0.6t Give P= 200psi So ket Bie «HE pct2 ners corde (1578128) - 8008 200%84.095 ss gong pa _14.800x1.031.28 (@4800x1.0)— (0.67200) 84.095-+ (0.6x1.28) 223.23psi ‘The answer to the question is YES it may remain in service, ‘Notice that since both pressure and thickness are known that either calculation can be made. It does not ‘matter which is used, 11/03 REV 12 Fast Track Technical Training 213, 281-482-2253 — www.apiexams.orgSolutions for Internal Pressure Heads 0.88sPL Sen ap (Totispherical Formula) 1, From: UG-32 (e) Givens: P=250 psi S= 14,800 psi B=10 L= 50” crown radius 885x250x50 t= 08852250850 __ = 747" (1480021.0) — (0.12250) PD 2. From UG32(6) t=-—PP 258 -02P Givens: 50” inside diameter 250x50 —__25050__. agg (@x14 8002.85) - (021250) 3. FomUG32() te 2SE -02P 36.115" inside spherical radius 250536115 ayy (Gel, 8002.85) - (025250) ANS: NO 214 11/03 REV 12 Fast Track Techinfea! Training 281-482-2253 - www.apiexams.org4, From: UG-34(¢) (2) t Givens: =? 505” actual thickness of the shell P= 250 psi 'S= for head material 15,500 psi S= for shell material 17,500 psi d= for head 36” D= for shell 36” inside E= 1.0 fora seamless head c=? Step 1. Calculate the Shell’s required thickness From: UG 27 (c)(1) we use the t= formula to find that the shell’s required which is 259” remember to use the shell’s material stress in this calculation. ‘Step 2. Using the actual thickness of shell and its calculated req. thickness find “m” From: Th dfsitons of ashes in and fig. UG-34 (@) m= = 22 ts 505 Step 3. Calculate the value of C From: Fig. UG-34 (e) C= 33 xm=.33x.51=.1683, ‘Since the minimum that C is allowed to be in this geometry is .20 use C = 20 to solve. Step 4, Calculate the required t of the flat head [aaa | Ure" = 360032258 = 36x.0567961=2.044" '\15,500x0.0 6, Answer No: 1.984” < 2,044” 11/03 REV 12 Fast Track Technical Training m5 281-482-2253 — www.apiexams.orgTHIS PAGE INTENTIONALLY BLANK 26 11/03 REV 12 Fast Track Technical Training 281-482-2253 — www.apiexams.org