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Part 8
Assessment of Weld
Misalignment and Shell Distortion

Quest Integrity
October 2015

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Weld misalignment and shell distortion YOUR LOGO

• Weld misalignment:
– Centerline offset
– Angular misalignment

• Shell distortion:
– General shell distortion
– Out-of-roundness

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Centerline offset YOUR LOGO
Flat plates

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Centerline offset YOUR LOGO
Pipe girth welds

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Angular misalignment YOUR LOGO

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Weld peaking YOUR LOGO

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Angular misalignment in a YOUR LOGO
circumferential seam

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Global out-of-roundness YOUR LOGO

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Measurement of out-of-roundness YOUR LOGO
in a cylinder

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Guidelines in BS7910 YOUR LOGO

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 YOUR LOGO

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Pipe axial misalignment YOUR LOGO

Example
12 mm welded to 16 mm with 5mm
misalignment

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Level 1 Assessment YOUR LOGO

• The Level 1 assessment procedures are based on the fabrication tolerances

in the original construction code. API 579 gives an overview of these
tolerances for the following codes:
– ASME B&PV Code, Section VIII, Div. 1&2 - Table 8.3
– ASME B31.3 Piping Code - Table 8.4
– API 620 Standard - Table 8.5
– API 650 Standard - Table 8.6
– API 653 Standard - Table 8.7

• If the component does not meet Level 1 requirements, a Level 2 or Level 3

assessment may be performed

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Pressure Vessel Fabrication Tolerances YOUR LOGO

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Pressure Vessel Fabrication Tolerances YOUR LOGO
(cont.)

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Piping Fabrication Tolerances YOUR LOGO

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Piping Fabrication Tolerances (cont.) YOUR LOGO

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API 620 Tank Fabrication Tolerances YOUR LOGO

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API 620 Tank Fabrication Tolerances (cont) YOUR LOGO

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API 650 Tank Fabrication Tolerances YOUR LOGO

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API 650 Tank Fabrication Tolerances (cont) YOUR LOGO

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API 653 Tank Fabrication Tolerances YOUR LOGO

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API 653 Tank Fabrication Tolerances (cont) YOUR LOGO

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Level 1 weld misalignment example YOUR LOGO

A NPS 36 long seam welded pipe is to be used in a refinery project. Inspection

of this pipe indicates peaking at the long seam weld. The pipe was constructed
to ASME B31.3

Determine if the pipe is suitable for service using the API 579 Level 1
methodology

Pipe Data:
• Material = ASTM A-691 Grade 1-1/4Cr 1990
• Design Conditions = 315 psig @ 800oF
• Outside Diameter = 36 in
• Wall Thickness = 0.5 in
• Future Corrosion Allowance = 0.05 in
• Weld Joint Efficiency = 100%

Inspection Data:
• Peaking Distortion δ = 0.31 in

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Level 1 weld misalignment example (cont.) YOUR LOGO

• Assess weld misalignment using Level 1 per Part 8, paragraph 8.4.2.1

Limitations for weld peaking misalignment are not specified in ASME B31.3 (see Part 8,
Table 8.4). Typically, the rules for out-of- roundness are applied to this type of
misalignment

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Level 1 weld misalignment example (cont.) YOUR LOGO

(Dmax-Dmin)=(36.31 in – 36 in) = 0.31 in ≤ (1%D=0.36 in)

True

The Level 1 Assessment Criteria are

Satisfied

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Level 2 Assessment YOUR LOGO

• Equations are provided to assess the effect of various types of weld

misalignment and shell distortion. These equations vary depending on the
type of structural irregularity being assessed

• Acceptance criteria are based on the RSF concept

• The computed RSF can be used to rerate a component that does not meet
the Level 2 acceptance criteria

• A fatigue assessment is required if the component is in cyclic service

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Weld macros YOUR LOGO

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Weld macros (cont.) YOUR LOGO

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Weld macros (cont.) YOUR LOGO

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3D Finite element model YOUR LOGO
Weld Simulation
V1
L10

Z X

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