Calculations

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(Calculations– InternalandExternalInspectionIntervals)
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API510Ͳ Calculations Section7,par
7.1.1
ShortTermCorrosionRate LongTermCorrosionRate
tprevious Ͳ tactual tinitial Ͳ tactual
CRST = #ofyearsbetweentprevious &tactual CRLT = #ofyearsbetweentprevious &tactual
Intial
Remaining Life InternalInspectionInterval
tactual Ͳ trequired ,QWHUYDO= /HVVHU RIòRI5/RU \HDUV

RL =
CorrosionͲRate
ExternalInspectionInterval
,QWHUYDO= /HVVHU RI\HDUVRU,QWHUQDO,QWHUYDO

RequiredThickness Minimum
Thickness InternalorOnstream Interval
35
Ͳ Lesserof10yrs or½Remaininglife
W=
>6( 3@ WP = WF Ͳ ifremaininglifeislessthan4yrs,fulllife
upto2years
Ͳ Remaininglifeis2yearsorless,interval
isFULLLIFE
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ShortTermCorrosionRate LongTermCorrosionRate
tprevious Ͳ tactual_LAST tinitial Ͳ tactual_LAST

CRST = CRLT = #ofyearsbetweentInitial &tactual_LAST
#ofyearsbetweentprevious &tactual_LAST
Variables forThicknessCalcs
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Section7,par
6KRUWWHUPFRUURVLRQUDWH 7.1.1
tprevious Ͳ tlast
CorrosionͲrate =
#ofyearsbetweentprevious&tlast
/RQJWHUPFRUURVLRQUDWH
/RQJ7HUP tinitial Ͳ tlast

=
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#ofyearsbetweentinitial &tlast
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Section7,par
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Section7,par
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tprevious Ͳ tlast
CorrosionͲrate = tprevious = 0.875
#ofyearsbetweentprevious&tlast
tlast = 0.865
0.875 Ͳ 0.865
=
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Determined by SHORT term or Long Term Calculations

(API 510, par 7.1.1.2)
Newly installed or Change in Service (API 510, par 7.1.2)

1. Calculated from data of vessels in similar service.
2. Estimated from Owner-User experience
3. Published Data
4. On-stream determination after 1000 hrs of service.
May have different corrosion-rates for large vessels with

multiple zones. (API 510, par 6.5.3)
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5HPDLQLQJ/LIHHTXDWLRQ Section7,par
7.2.1
Remaining Life
tactual_Last Ͳ trequired
RL =
CorrosionͲRate
Variables forRemainingLifeCalcs
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Section7,par
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25
Section7,par
:KDWLV.QRZQ"
/RRNLQJDWWKHIRUPXODIRU³5HPDLQLQJ/LIH´ZKDWLV81.2:1"
tprevious 0.625
tlast Ͳ trequired
5HPDLQLQJ/LIH = tlast
CorrosionͲrate 0.600
8QNQRZQ"
CorrosionͲrate = ?????
Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe
CorrosionͲrate.
26
3UDFWLFH4XHVWLRQ
tlast Ͳ trequired
5HPDLQLQJ/LIH =
CorrosionͲrate
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tprevious 0.625
tprevious Ͳ tlast
&RUURVLRQUDWH =
#ofyearsbetweentprevious&tlast tlast 0.600
0.625 Ͳ 0.600
=
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= 0.003
27
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tlast Ͳ trequired :KDWLV.QRZQ"

5HPDLQLQJ/LIH =
CorrosionͲrate
trequired = 0.575
0.600 Ͳ 0.575
= tlast = 0.600
0.003
= 8 yrs CorrosionͲrate = 0.003
28
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Section6,par
,QWHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1) 6.5.1v
Internal or on-stream inspections shall not exceed one half the remaining life of the
vessel or 10 years, whichever is less.
Whenever the remaining life is less than four years, the inspection interval may be the
full remaining life up to a maximum of two years. 4 = or > RLT> or = 2----IT=2 , ex (RLT=3---IT=2)
([WHUQDO,QVSHFWLRQ,QWHUYDOV(API 510 par 6.5.1.1) RLT<2--------IT=FRLT , ex ( RLT=1.5 -- IT=1.5)
Interval not exceed the lesser of 5 years or the internal/on-stream interval..
ThicknessInspectionIntervals
Should be part of the inspection plan, but no interval requirements mentioned in API-
510 (API 510 par 5.5.1)
Section5,par
CUIInspectionIntervals 5.5.1
Should be part of the inspection plan, but no interval requirements mentioned in API-
510 (API 510 par 5.5.1)
“SHALL” be considered for insulated vessels in “intermittent” service or operates
between;
10oF and 350oF for carbon steel and alloy steels
140oF and 400oF for austenitic stainless steels
31
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Section6,par
3UDFWLFH4XHVWLRQ 6.5.1v
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tprevious 0.625
tlast Ͳ trequired
5HPDLQLQJ/LIH = tlast
CorrosionͲrate 0.600
Section7,par
7.2.1
8QNQRZQ"
CorrosionͲrate = ?????
Sincethe“CORROSIONͲRATEisunknown,the1st Stepistodeterminethe
CorrosionͲrate.
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tprevious 0.625
tprevious Ͳ tlast
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#ofyearsbetweentprevious&tlast tlast 0.600
0.625 Ͳ 0.600
=
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Section7,par \HDUV
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= 0.003 7.1.1
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Section7,par
7.2.1
6WHS± &DOFXODWHWKH5(0$,1,1*/,)(
tlast Ͳ trequired :KDWLV.QRZQ"

5HPDLQLQJ/LIH =
CorrosionͲrate
trequired = 0.575
0.600 Ͳ 0.575
= tlast = 0.600
0.003
= 8 yrs CorrosionͲrate = 0.003
35
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InternalInspectionInterval=4years
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Section6,par
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Section7,par
Widely scattered pits can be ignored, if; 7.4.3
Rule#1
Remaining Thickness below pit is
greater than ½ the Required Thickness
Vessel Thickness = 2.0”

Depth of Pit = 1.06”
Corrosion Allowance = 0.250
Retirement Thickness = 1.75”
45
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Section7,par
Rule#2
Areaofthepittingbelowthe
corrosionallowancehasan
arealessthan7in2withinan
8”diametercircle.
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Section7,par
Rule#3
Sumofthelengthofpitswithinany8”line,mustbelessthan2”
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“Minimum allowed remaining thickness below the pit is ½ the required thickness”,
Therefore, the minimum thickness allowed at the deepest pit is;
( ½ required thickness = 1.250”/2 = 0.625”)
Corrosionallowance
Required
Thickness
Remainingthickness ½ ofRequired
belowpit Thickness
49
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Section7,par
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a. Pitscanbeignored
b. Pitsareunacceptablebasedonsumofthepitdimensionsalonga8”straightline.
c. Pitsareunacceptableduetototalareaofpittingwithinan8”diametercircle.
d. Pitsareunacceptableduetoinsufficientremainingthicknessbelowthedeepestpit.
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Section7,par
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58
,QVSHFWLRQ3ODQV Section5,par
5.1
A. Inspection plan must be established for all

pressure vessels and pressure-relieving devices.
B. Inspection plan developed by inspector or
engineer.
C. Corrosion-specialist must be consulted for
inspection plan for vessels operating above 750oF.
D. Inspection plan shall be evaluated based on
present or possible types of damage mechanisms.
E. Methods and extent of NDE shall be evaluated to
assure they can adequately identify the damage
mechanism and severity of damage.
59
,QVSHFWLRQ3ODQV Section5,par
5.1
F. Examinations must be scheduled at intervals that consider;
A. Type of damage
B. Rate of damage
C. Tolerance of equipment to the damage
D. Probability of the NDE methods to detect the damage
E. Maximum intervals as defined in API 510
G. Minimum Contents of Inspection Plan

A. Type of inspection needed
B. Next inspection date for each type inspection (internal,
external, etc)
C. Describe inspection and NDE techniques
D. Describe extent and locations of inspection and NDE
E. Describe the cleaning requirements
F. Describe the requirements of any needed pressure test
G. Describe any required repairs
60
7\SHVRI,QVSHFWLRQ Section5
A. General
Inspections should be conducted in accordance with the inspection
plan
Prior to performing an inspection, the inspector should be familiar
with;
Thorough understanding of the inspection plan
Operating conditions since the last inspection (API 572 par 9.1)
Applicable damage mechanisms
Prior history
New inspection intervals shall be established if operating temp
increases, operating pressure increases or process fluid changes. (API
510 par. 6.2.2)
61
7\SHVRI,QVSHFWLRQ
% ,QWHUQDO,QVSHFWLRQ
Interval is lesser of ½ remaining life or 10 years. If remaining life is LESS than 4
years, interval can be the full remaining life up to max of 2 years. (API 510 par 6.5.1.1).
SHALL be conducted by the inspector (API 510 par 5.5.2.1)
Primary reason for internal inspection is to find damage that cannot be found by
external CML’s (API 510 par 5.5.2.1)
Internal inspection performed inside the vessel (API 510 par 5.5.2.1)
Internals may need to be removed to facilitate the internal inspection. Likely will
not need to remove 100% of the internals. (API 510 par 5.5.2.2)
Inspector should consult with Corrosion Specialist to determine if it is necessary

to remove any linings and/or deposits (API 510 par 5.5.2.3)
Vessels in non-continuous service, the interval is based on number of years of

actual service, instead of calendar years, provided the vessel when idled is
separated from process stream & not exposed to corrosive streams.
62
7\SHVRI,QVSHFWLRQ $3,SDUSDJH
C. On-stream Inspection
Interval same as INTERNAL inspection.
Should be conducted by either an inspector or examiner. (API 510 par
5.5.3.1)
On-stream inspections performed by examiners shall be

authorized/approved by the inspector (API 510 par 5.5.3.1)
Inside of vessel inspected from outside vessel. (API 510 par 5.5.3.2)
63
D. External Inspection
Performed by inspector or qualified others (qualified

with appropriate training). (API 510 par 5.5.4.1.1)
Interval is lesser of 5 years or the internal interval.
External inspections check; (API 510 par 5.5.4.1.2)
Condition of Outside surface of vessel
Condition of Insulation system
Condition of Coating system
Condition of Supports
For leaks
Hot spots
Vibration damage
Allowance for expansion
Bulging, misalignment, distortion, etc
Conditions discovered by others, must be reported to

inspector. (API 510 par 5.5.4.1.3)
64
E. Thickness Inspection
Performed by inspector or examiner. (API 510 par 5.5.5.1)
No required interval.
Inspector should consult with corrosion-specialist when short term
corrosion-rate changes significantly. (API 510 par 5.5.5.3)
Owner-user is responsible for assuring individuals taking thickness
readings are trained and qualified (API 510 par 5.5.5.4)
F. CUI Inspection
Performed by inspector or other qualified personnel (i.e. same as external)
Shall be considered for; (API 510 par 5.5.6.1)
Carbon steel and low alloy operating between 10oF and 350oF.
Stainless steel operating between 140oF and 400oF.
Usually causes localized corrosion damage (API 510 par 5.5.6.2)
Susceptible locations include; (API 510 par 5.5.6.2)
Insulation or stiffening rings
Nozzles and manways
Structural penetrations (ladder clips, pipe supports, etc)
Damage insulation
Insulation with failed caulking
Top and bottom heads
CUI inspection may require some or all insulation (API 510 par 5.5.6.3)
Insulation may not need to be removed if; (API 510 par 5.5.6.3)
Insulation is in good condition and there is no reason to suspect damage behind
the insulation;
CUI inspection can be performed with UT from ID of vessel.
66
:HOG-RLQW&DWHJRULHV $60(9,,,8:D E
WeldJointCATERGORY isthe”location”ofa“joint”inapressurevessel
SubͲSectionB,
UW,General,
UWͲ3
Category A:
Alllongitudinalweldsinshellandnozzles
Allweldsinheads,HemiͲheadtoshellweldjoint
Category B:
Allcircumferentialweldsinshellandnozzles
Headtoshelljoint(otherthanHemispherical.)
Category C and D are flange welds and nozzle attachment welds respectively
Longitudinal welds (Category A) are more critical than Circumferential welds (Category B)
because they are under double stress.
This the reason why in different part of ASME code we have stringent rules in category A
joint compared to category B joint.
67
:HOG-RLQW7\SHV SubͲSectionB,
UW,Design,
UWͲ12
Weld Joint Types

7\SH± 'RXEOHZHOGHGEXWWMRLQWV
7\SH± 6LQJOHZHOGHGZLWKEDFNLQJ
7\SH 6LQJOHZHOGHGZLWKRXWEDFNLQJ
68
:HOG-RLQW7\SHV SubͲSectionB,
UW,Design,
UWͲ12
Weld Joint Types

7\SH± 'RXEOH)XOO)LOOHW/DS-RLQW
7\SH± 6LQJOH)XOO)LOOHW/DS-RLQW
ZLWKSOXJZHOG
7\SH 6LQJOH)XOO)LOOHW/DS-RLQW
ZLWKRXWSOXJZHOG
69
5DGLRJUDSK\ SubͲSectionB,
UW,Design,
UWͲ11
SubͲSectionC,
CCS,Design,
TypeofRadiography UCSͲ57
Full– asrequiredbytheCode(seeUWͲ11(a)),andUCS57
Spot– CategoryBandCweldsthatarenotrequiredtobe
radiographedbyUWͲ11(a)(5)(b).
None
CodeRequiredRT(UWͲ11(a)andUWͲ11(b)
BasedonService,ThicknessorWeldingProcess
UserSpecifiedRT
Theusercanestablishthetypeofjointanddegreeofexaminationwhen
therulesofCodedoesnotrequireradiography(seeUWͲ12)
70
UW,Design,
UWͲ11a
FULLRT– RequiredbyCODE
FULLRT
Allbuttweldsinshell&headsinlethalservice
Allbuttweldsinshell&headswiththickness>11/2orperUCSͲ57
Allbuttweldsinshell&headsofunfiredboilerswith;
Pressureexceeding50psigorthickness>11/2orperUCS57
Buttweldsinnozzles>10NPSor>11/8”thickness
Category“A”and“D”weldsinshellsandheads,wherejoint
efficiencyisbasedonTableUWͲ12
ButtweldsmadeusingElectroͲgas&ElectroͲslagprocess
SpotRT
CategoryBandCbuttweldsintersectingCatAweldsinshellsandheads
CategoryBandCbuttweldsconnectingseamlessheadsorshells
127(&DWHJRU\ $ %ZHOGVPXVWEH7\SHRU7\SHZHOGVVHH7DEOH8:
71
UW,Design,
When and where is there a code requirement for full radiography? UWͲ11
Item 1: Allbuttweldsinvesselsusedtocontainalethalsubstance(UWͲ11(a)).Lethalsubstanceshavespecific
definitionsinASMECodeinUWͲ2anditistheresponsibilityoftheendusertodetermineiftheyordered
avesselthatcontainslethalsubstances.
Item 2: All butt welds in vessels in which the nominal thickness exceeds specified values (UWͲ11(a). You can find
these values in subsection C, in UCSͲ57. For example, this value for PͲNo.1 in UCSͲ57 is 1 ¼ inch. Nozzles
larger than 10 NPS or thickness greater than 1 1/8”. SubͲSectionC,
UCS,Design,
Item 3: All butt welds in an unfired steam boiler with design pressure > 50 psi (UWͲ11(a)). UCSͲ57
Item 4: All category A and D butt welds in vessel when “Full Radiography” optionally selected from table UWͲ
12(column (a) in this table is selected); and categories B and C which intersect Category A shall meet the
spot radiography requirement (UWͲ11(a) (5) (b)).
The point is this: items 1, 2 and 3 are similar, but item 4 is completely different. In items 1, 2 and 3 it is mandated by
code; to do full radiography in all butt welds in vessel so it means it is mandatory for designer to select column (a) in
UWͲ12 table.
But in item 4, there is no mandating rule. A manufacturer with its own decision has chosen to use column (a) in table
UWͲ12 for full radiography.
72
5DGLRJUDSK\ $60(6HF9,,,8:
7KHUH LV D FRQFHVVLRQ RU ERQXV WR PDQXIDFWXUHUV IRU FDWHJRULHV % DQG &
:KDW LV FRQFHSW EHKLQG WKLV FRQFHVVLRQ RU ERQXV LQ SUHVVXUH YHVVHO 57 WHVW"
a. Items 1, 2 and 3 from the previous slide; RT is related to the type of welds and
services.
b. Pressure vessels in these items are critical from a safety point of view, one
contains a lethal substance, the other one has a high thickness, which
implicates high pressure, and the last one is an unfired steam boiler
c. Item 4 has no criticality like the other items have.
d. But you should note all 4 items have been categorized in full radiography
clause( UͲ11(a)), so to differentiate item 1, 2 and 3 from item 4, the RT
symbols are used in Code (UGͲ116).
73
5DGLRJUDSK\ SubͲSection
A,UG,Design,
UGͲ116
RT1: Items1,2and3,(E=1),AllbuttweldsͲfulllengthradiography
RT2: Item4(E=1),CategoryAandDbuttweldsfulllengthradiography
andcategoryBandCbuttweldsspotRadiography
RT3: (E=0.85),Spotradiographybuttwelds
RT4: (E=0.7),Partial/Noradiography
You need to consider the hemispherical head joint to shell as category A, but ellipsoidal
and torispherical head joint to shell as category B;
Do you know why? Why ASME considered the stringent rule for pressure vessel RT test in
hemispherical head joint?
It is because this joint is more critical, because the thickness obtained from the
formula for hemispherical head approximately would be half of the shell thickness;
It means if the shell thickness is 1 inch, the hemispherical head thickness would be
0.5 inch. 74
SubͲSectionB,
5DGLRJUDSK\ UW,Design,
UWͲ11
SpotRT– RequiredbyCODE
B and C welds that are not required to be radiographed by UW-
11(a)(5)(b)
Type 1 and Type 2 butt welds that are not required to be
radiographed by UW-11(a).
RTMarkings
RT 1 and RT 2 - FULL Radiography
RT 3 - Spot Radiography SubͲSection
RT 4 - Combo Radiography A,UG,Design,
UGͲ116
RTmarkingsarelocatedonNameplate
75
HEAD
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SubͲSectionB,
-RLQW(IILFLHQF\ UW,Design,
TableUWͲ12
Joint Efficiency is based on;

:HOG-RLQW7\SH7\SHV
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5DGLRJUDSK\575757DQG57
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80
5DGLRJUDSK\ -RLQW(IILFLHQF\
SubͲSection
A,UG,Design,
UGͲ116
RTͲ1 E=1 RTͲ3 E=0.85

E=1
RTͲ2 E=1 E=1 RTͲ4 E=0.70

E=0.85
81
-RLQW(IILFLHQF\ SubͲSection
A,UG,Design,
UGͲ116
JointEfficiencybasedonRadiography SubͲSectionB,
RTͲ1– FullRTperUWͲ11(a),exceptUW(a)(5) UW,Design,
UseColumn“a”ofTableUWͲ12 TableUWͲ12
ForSeamlessheads&shellsE=1
RTͲ2Ͳ FullRTperUWͲ11(a)(5)
UseColumn“a”ofTableUWͲ12
ForseamlessheadsandshellsE=1
RTͲ3Ͳ SpotradiographyperUWͲ11(b)
UseColumn“b”ofTableUWͲ12
Forseamlessheads&shellsE=1
RTͲ4Ͳ CombinationofRTͲ1,RTͲ2andRTͲ3
NoRTͲ noradiographyatall
UseColumn“c”ofTableUWͲ12
ForseamlessshellsandheadsE=0.85
RTStamping
82
$60(6HF9,,,8: -RLQW(IILFLHQF\
RT1
or
RT2 RT3 RT4
SubͲSectionB,
UW,Design,
TableUWͲ12
NOTE:ForWeldtypes3,4,5,and6,RTcannotbeusedtoincreasethejointefficiency. 83
-RLQW(IILFLHQF\
Joint Efficiency For Seamless Parts SubͲSectionB,

UW,Design,
ParUWͲ
WeldType Spot RT NoRT 11(a)(5)(a)&(b)
1 1.0 0.85
SubͲSectionB,
2 1.0 0.85 UW,Design,Par
3 0.85 0.85 UWͲ12d
4 0.85 0.85
5 0.85 0.85
6 0.85 0.85
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SubͲSectionB,UW,
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Design,ParUWͲ
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TableUWͲ12
SubͲSectionB,
UW,Design,Par
UWͲ12d
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UGͲ98(a)(b)
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(atbottomofthewatercolumn)
5
ASMESectionVIII
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
, 3DUW6WDWLF+HDG 2ft
6 ft
WhatisMAWPofeachcomponentfora48ft tall N1
verticalvesselwithellipsoidalheadsandaMAWP
of500psig? 44ft
8ft 36ft
VesselMAWP=500psig
N2
VesselMAWPisthegagepressureatthe“TOP”of
thevessel,includingStaticheadpressure.Reference 6 ft
UGͲ98(a)(b) 2ft
MAWPofN1=________
MAWPofN2=_________
MAWPofTophead=_________
MAWPofBtm head=_________
MAWPoftheshell=_________
6
ASMESectionVIII
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
, 3DUW6WDWLF+HDG 2ft
6 ft
WhatisMAWPofeachcomponentfora48ft tall N1
verticalvesselwithellipsoidalheadsandaMAWP
of500psig? 44ft
8ft 36ft
VesselMAWP=500psig
N2
VesselMAWPisthegagepressureatthe“TOP”of
thevessel,includingStaticheadpressure.Reference 6 ft
UGͲ98(a)(b) 2ft
MAWPofN1=________
500psig+(6x0.433)=500+2.6=502.60psig
MAWPofN2=_________
500psig+(42x0.433)=500+18.19=518.19psig
MAWPofTophead=_________
500psig+(2x0.433)=500+0.87=500.87psig
MAWPofBtm head=_________
500psig+(48x0.433)=500+20.78=520.78psig
MAWPoftheshell=_________
500psig+(46x0.433)=500+19.92=519.92psig
7
ASMESectionVIII
UGͲ98(a)(b)
ASMESecVIII,UGͲ98
, 3DUW6WDWLF+HDG
WhatisMAWPofthisvessel?
0ft
Part Part Static Pressureat 2ft
MAWP Head Topof N1
8ft
Vessel
Top 10ft
510psig
head
N2
N1 500psig 42ft
48ft
N2 495psig 50ft
Shell 510psig
Btm
507psig
Head
8
9HVVHO0$:3YV 3DUW0$:3
ASMESectionVIII
, 9HVVHO 3DUW0$:3 SubsectionA,UG,
UGͲ98(a)(b)
PracticeQuestion#1
2ft
Ifthisvesselisbeinghydrostaticallytestedat200 6 ft
psig,whatisthepressureatthebottomofthe N1
vessel?
66ft
8ft 58ft
PracticeQuestion#2 N2
IftheMAWPofthevesselis550psig,whatisthe
MAWPofN2? 6 ft
2ft
PracticeQuestion#3
IftheMAWPoftheshellofthevesselis564psig,
whatistheMAWPofN1?
Usethisvesseltoanswer
thesepracticequestions
9
ASMESectionVIII
7RWDO3UHVVXUH SubsectionA,UG,
UGͲ98(a)(b)
, 7RWDO3UHVVXUH
PracticeQuestion#4 2ft
6 ft
Ifavesselisbeinghydrostaticallytestedat400 N1
psig,whatisthepressureatN2?
66ft
8ft 58ft
PracticeQuestion#5
N2
Duringahydrotest ofavessel,ifthepressureatthe
bottomofthevesselis635psig,whatisthe 6 ft
2ft
pressureatN1?
PracticeQuestion#6
Duringahydrotest ofavessel,ifthepressureatN2
is528psig,whatisthepressureatthetopofthe
vessel? Usethisvesseltoanswer
thesepracticequestions
10
NOTE:PerASMESectionVIII,UGͲ99(c.),thehydrotest pressureisthepressureatthetopofthevessel.
ASMESectionVIII
,QWHUQDO3UHVVXUH SubsectionA,UG,
UGͲ98(a)(b)
ASMESecVIII,UGͲ21andAppendix3(par3Ͳ2)
, 'HVLJQ3UHVVXUH
Designpressureisthepressureusedinthedesignofavesselcomponent
togetherwithcoincidenttemperatureforthepurposeofdeterminingthe
minimumpermissiblethicknessforeachcomponent.Designpressure
includesstaticheadpressure.
NOTE:Designpressureistheminimumpressureusedtodesignthevessel(i.e.usedtodeterminethe“required
thickness”ofeachcomponent.
,, 0$:3
Maximumallowableworkingpressure(MAWP)isthemaximumpressure
permissibleatthetopofthevesselinitsnormaloperatingposition.MAWPis
adjustedforthedifferenceinstaticheadthatmayexistbetweenforthepart
consideredandthetopofthevessel.
,,, 'HVLJQ3UHVVXUHYV 0$:3
Designpressureisthepressurefortheprocess(processpressureplus
statichead).MAWPisthemaximumpressureratingforeachpart
and/orvessel.
11
6KHOO0LQLPXP5HTXLUHG7KLFNQHVV
ASMESecVIII,UGͲ27(c.)(1)
, 7KHUHTXLUHGWKLFNQHVVRIDF\OLQGULFDOVKHOO
EDVHGRQFLUFXPIHUHQWLDOVWUHVVJLYHQD
SUHVVXUH8*F
Variables
t=PR/(SE)Ͳ(0.6P) t=requiredthickness inches
P=DesignPressure psi
R=InsideRadius ofshell inches
S=AllowableStress psi
E=JointEfficiency
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
12
ASMESectionVIII
SubsectionA,UG,
PracticeQuestion#7 Design,UGͲ27(c.)(1)
A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?
13
ASMESectionVIII
SubsectionA,UG,
A60’tallverticalvesselhasaninsidediameterof8’anddesignedfor300psig@450deg
F.Allowablestressofthematerialofconstructionis17,500psiandthejointefficiencyis
0.85.Whatistheminimumrequiredthickness?
PR
t =
(SE)Ͳ(0.6P)
300 x 48
t =
Variables
( 17500 x 0.85 ) Ͳ ( 0.6 x 300 )
t=requiredthickness inches
14400 P=DesignPressure psi
t =
( 14875 ) Ͳ ( 180 ) R=InsideRadius ofshell inches
14400 E=JointEfficiency
t =
14695
t = 0.980 inches
14
ASMESectionVIII
SubsectionA,UG,
Avesselhasaninsidediameterof60”anddesignedfor150psig@350deg F.
Allowablestressofthematerialofconstructionis18,000psiandthejoint
efficiencyis1.0Whatistheminimumrequiredthickness?
15
ASMESectionVIII
SubsectionA,UG,
Avesselhasaninsideradiusof48”anddesignedfor250psig@500deg F.
Allowablestressofthematerialofconstructionis17,000psiandthejoint
efficiencyis.90Whatistheminimumrequiredthickness?
16
6SKHUH0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
, 7KHUHTXLUHGWKLFNQHVVRID6SKHUHLVJLYHQE\8*G
PR Variables
t = t=requiredthickness inches
(2SE)Ͳ(0.2P) P=DesignPressure psi
R=InsideRadius ofshell inches
E=JointEfficiency
17
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
PracticeQuestion#10
Aspherehasaninsideradiusof12ft anddesignedfor250psig@500deg F.
Allowablestressofthematerialofconstructionis17,000psiandtheweldsare
singlebuttweldedwithbackingandvesselisstampedRTͲ2.Whatisthe
minimumrequiredthickness?
18
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(d)
PracticeQuestion#11
AspherehasanIDof36ft anddesignedfor30psig@400deg F.Allowable
stressofthematerialofconstructionis15,000psiandthejointefficiencyis0.80
Whatistheminimumrequiredthickness?
19
9HVVHO+HDGV
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(d)
h=1/4D
D=Insidediameter
LongAxis
Ellipsoidalheadsareknownas2to1heads.2to1comes Short
fromthefactthatanellipsoidalheadis1/2ofaellipse.An Axis
ellipsehasalongaxisthatis2xtheshortaxis.
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
L=insideradius
D=Insidediameter
20
+HDGV0LQLPXP5HTXLUHG7KLFNQHVV
ASMESectionVIII
SubsectionA,UG,
MinimumRequiredThicknessofanEllipsoidalHead Design,UGͲ32(d)
Px D t=minimumrequiredthickness
t = P=DesignPressure
2 [( S x E ) Ͳ ( 0.2 X P )] D=InsideDiameter
S=AllowableStress
E=JointEfficiency
ASMESectionVIII
SubsectionA,UG,
MinimumRequiredThicknessofaHemisphericalHead Design,UGͲ32(f)
t=minimumrequiredthickness
P x L P=DesignPressure
t = L=InsideRadius
2 [( S x E ) Ͳ ( 0.2 X P )]
S=AllowableStress
E=JointEfficiency
21
ASMESectionVIII
SubsectionA,UG,
PracticeQuestion#12 Design,UGͲ32(d)
Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel
withellipsoidalheads,insidediameterof72”,allowablestressof16,500psi,
MAWPof120psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?
22
ASMESectionVIII
PracticeQuestion#13 SubsectionA,UG,
Design,UGͲ32(d)
Whatistheminimumrequiredthicknessfortheheadofaseamlesshorizontalvessel
withellipsoidalheads,insidediameterof96”,allowablestressof18,000psi,MAWP
of200psig,andweldsthataredoubleͲfullfilletweldedlapjointsandRTͲ1?
23
ASMESectionVIII
Design,UGͲ32(f)
Whatistheminimumrequiredthicknessfortheheadofa30’tallverticalvessel
withhemisphericalheads,insidediameterof72”,allowablestressof16,500psi,
MAWPof320psig,andweldsthataredoubleͲweldedbuttweldsandSpotRT’d?
24
ASMESectionVIII
Design,UGͲ32(f)
Whatistheminimumrequiredthicknessfortheheadsofahorizontalvesselwith
hemisphericalheads,insidediameterof96”,allowablestressof18,000psi,MAWPof
200psig,andweldsthataredoubleͲfullfilletweldedlapjointsandRTͲ1?
25
HEAD
BANGER
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FUDFNLQJDIWHUZHOGLQJVWDLQOHVVVWHHOFODGGLQJ"
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ASMESectionVIII
I. MAWPofEllipsoidalHeads SubsectionA,UG,
Design,UGͲ32(d)
2 SEt t=minimumrequiredthickness
P = D=InsideDiameter
( D + 0.2t) S=AllowableStress
E=JointEfficiency
ASMESectionVIII
II. MAWPofHemisphericalHeads SubsectionA,UG,
Design,UGͲ32(f)
t=minimumrequiredthickness
2Set L=InsideRadius
P = S=AllowableStress
( L + 0.2t)
E=JointEfficiency
29
0$:3
ASMESectionVIII
Design,UGͲ32(d)
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRTͲ1.Whatis
themaximumallowableworkingpressureforthisseamlessellipsoidalhead?
30
0$:3
ASMESectionVIII
Design,UGͲ32(d)
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottomellipsoidal
headwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowablestressis17,000
psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstampedRTͲ1.Whatis
themaximumallowableworkingpressureforthisseamlessellipsoidalhead?
2 SEt
P =
( D + 0.2t)
t=0.785”
2 ( 17000 x 1 x 0.785 ) D=96”
P =
( 96 + ( 0.2 x 0.79 ) S=17,000
E=1
2 x 13345
P =
96 + 0.157
Note:
Readthequestionclosely,inthisquestionthereisnomention
26690 ifthevesselhaslongseamsornot.Therefore,assumethevessel
P =
96.157 haslongseams.YougotoTableUWͲ12andfindthejointefficiency
tobe“1”for“doubleͲweldedbuttwelds”.The“seamless”head,
P = 277.57 doesnotchangethejointefficiency.
31
0$:3
ASMESectionVIII
Design,UGͲ32(f)
Ahorizontalvesselwithanoutsidediameterof72”andellipsoidalheads.Shellthicknessis
0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis
0.125”.Whatisthemaximumallowableworkingpressurefortheellipsoidalhead?
32
0$:3
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ32(f)
PracticeQuestion#18
Duringaninspectionofaverticalvesselthicknessmeasurementstakenonthebottom
hemisphericalheadwasfoundtobe0.785.Theinsidediameterofthevesselis96”,allowable
stressis17,000psi,andweldsthataredoubleweldedbuttweldjointsandthevesselisstamped
RTͲ1.Whatisthemaximumallowableworkingpressureforthishemisphericalhead?
33
0$:3
ASMESectionVIII
SubsectionA,UG,
PracticeQuestion#19 Design,UGͲ32(f)
Ahorizontalvesselwithanoutsidediameterof72”andhemisphericalheads.Shellthicknessis
0.750”andtheheadsare0.500”thick. Theallowablestressis16,000psi.Weldsaredoublefull
filletlapjointsandthevesselisstampedRTͲ1.Thecorrosionallowancefortheentirevesselis
0.125”.WhatisthemaximumallowableworkingpressurefortheHemisphericalhead?
34
0$:3 ASMESectionVIII
SubsectionA,UG,
Design,UGͲ27(c.)(1)
9HVVHOLQ&RUURVLYH6HUYLFH
API510,Section7,SubͲ
PracticeQuestion#20 par7.3.3
Duringarecentinspectionofahorizontalvesselwithaninsidediameterof72”
andhemisphericalheads,shellthicknesswasrecordedas0.625”.Theallowable
stressis16,000psi.Weldsaredoublefullfilletlapjointsandthevesselis
stampedRTͲ1.ThecorrosionͲrateis0.006”/yr.Requiredthicknessis0.588”.
Vesselisincorrosiveservice.Nextinspectionisin5years.Whatisthe
maximumallowableworkingpressureforthisvessel?
35
([WHUQDO3UHVVXUH
ASMESectionVIII
SubsectionA,UG,
Design,UGͲ28(c.)
Therearethreefactorsthatcaneffecttheresistanceof
crushingdueexternalpressure.
1. Stiffeners
2. Thickness– thickermaterialsresistcrushing
3. Diameter– increasingdiameter,increasessusceptibilityofcrushing
36
([WHUQDO3UHVVXUH&DOFXODWLRQV
ASMESectionVIII
I. Formulaandvariables SubsectionA,UG,
Design,UGͲ28(c.)
4B
Pa =
[ 3 ( Do / t )]
A=FactorbasedonratioofL/DoandDo/t.(GetitfromASMESecII,PartD,FigG.)
B=Factorbasedon“A”FactoranddesignTemperature(GetiffromASMESecII,
PartD,TablesCSͲ1orCSͲ2)
Do =OutsideDiameter
t=Minimumrequiredthickness
“B”factorwillbegiventoyouinthequestion.
37
ASMESectionVIII
Design,UGͲ28(c.)
Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween
supportsis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ
516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@
500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure
forthisvessel?
38
ASMESectionVIII
Design,UGͲ28(c.)
Ahorizontalvesselhasanoutsidediameterof60”.Thedistancebetween
supportsis15’ft.Thewallthicknessis0.625”.MaterialofconstructionisSAͲ
516Gr70.Thisvesselhasa“B”factorof3500andisdesignedfor250psig@
500deg F.Allowablestressis16,500.Whatisthemaximumexternalpressure
forthisvessel?
4B
Pa =
[ 3 ( Do / t )]
B=3500
Do =60”
t=0.625
4 x 3500
Pa =
[ 3x ( 60 / 0.625 ) ]
14000
Pa = 3x ( 96 )
Pa = 48.611 psi 39
ASMESectionVIII
Design,UGͲ28(c.)
Duringanexternalinspectionofavesselwithanoutsidediameterof48”
uniformcorrosiondamagewasdiscovered.Thethicknessinthisareaofshell
wasfoundtobe0.425”.Thisvesselisdesignedfor35psiexternalpressureand
hasaBfactorof1800.Canthisvesseloperateat35psiexternalpressureor
doesitneedtobererated?
40
ASMESectionVIII
Design,UGͲ28(c.)
A20ft longexchangertubehasanoutsidediameterof2”andnominal
thicknessof0.083”.MaterialofconstructionisSAͲ283GrDanddesign
temperatureis600deg F.The“B”factorforthetubeis1500.Whatisthe
maximumallowedexternalpressureforthistube?
41
/HVVRQ3ODQ,,,
(Calculations– ImpactTesting,WeldSizeandNozzle
Reinforcement)
1
/HVVRQ3ODQ,,,
(Calculations– ImpactTesting,WeldSizeandNozzleReinforcement)
I. Impact Testing
A. Theinspectorshouldunderstandimpacttestingrequirementsandimpacttestingprocedure(UGͲ84)
B. Theinspectorshouldbeabletodeterminetheminimummetaltemperatureofamaterialwhichisexemptfromimpacttesting(UGͲ20(f),UCSͲ66,
UCSͲ68(c).)
II. WELD SIZE FOR ATTACHMENT WELDS AT OPENING

MustbeabletodetermineiftheweldsizemeetsCoderequirements.
A. Convertafilletweldthroatdimensiontolegdimensionorvisaversa,usingconversionfactor(0.707);
B. Determinetherequiredsizeofweldsatopenings(UW-16)
III. Nozzle Reinforcement

A. Understandthekeyconceptsofreinforcement,suchasreplacementofstrengthremovedandlimitsofreinforcement.
Creditcanbetakenforextrametalinshellandnozzle
B. Beabletocalculatetherequiredareasforreinforcementorchecktoensurethatadesignedpadislargeenough.To
simplifytheproblem:
Allfr =1.0
AllF=1.0
AllE=1.0
C. Therewillbenonozzleprojectinginsidetheshell
D. Beabletocompensateforcorrosionallowances
E. Weldstrengthcalculationsareexcluded
2
,PSDFW7HVWLQJ0'07
(ASMEVIIIUGͲ20(f),UGͲ84UCSͲ66,UCSͲ68(c).)
I. WhatdoesImpactTestingDetermine?
II. WhatisMDMT?
III. WhydoestheCodeworryaboutMDMT?
IV. Whataresomefactorsthataffectbrittlenessofmaterials?
V. Whatistheoppositeofbrittleness?
.
3
ASMEVIII,
0'07 6XEVHFWLRQ$3DUW8*'HVLJQ8*
6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6DE 8&6F
I. HowdoesASMESectionVIIImanageBrittleFracture
ASMEVIII,
a. ByMaterialSelection(P1Group1and2Ͳ seeFig.UCSͲ66) 6XEVHFWLRQ&3DUW8&6/RZ7HPSHUDWXUH
2SHUDWLRQ8&6SDJHGRZQWLPHV
b. ProvidesamethodfordeterminingMDMT
1. Curvesformaterialgroupings(Fig.UCSͲ66)
2. Initialimpacttestingexempttemperaturebasedonmaterial(curve
letter)andthickness(TableUCSͲ66Ͳ1)
3. StressReductionRatiofactor[(tr xE)/(tnͲc)].(FigUCSͲ66.1)
Note:Thisratiowillbeprovidedonthetest.
4. PWHTReduction(residualstressreductionallowedwhenPWHTisperformedandisnotrequired
bytheCode)see(par.UCSͲ68(c.))
c. TemperaturelimitedbyUCSͲ66(b)(2)&(3)andUCSͲ68(c.)
a) UCSͲ66(b)(2)– nocolderthanͲ55oF,unless ;
1) Stressreductionratiois0.35orless,thentemperaturecanbe
betweenͲ55oFandͲ155oF.(UCSͲ66(b)(3)
2) PWHTperformedwhennotrequiredbyCode,temperaturecan
bebelowͲ55oF.(UCSͲ68(c.)
4
0'07
PracticeQuestion#1
A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for
350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction
ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for
this vessel?
5
0'07
PracticeQuestion#1
A horizontal vessel constructed from SA-516 Gr 65 plate (not normalized). Designed for
350 psig @ 650oF. Wall thickness is 1.5”, with a 1/16” corrosion allowance and reduction
ratio is .80. Nameplate is stamped RT-1 and HT. What is the lowest possible MDMT for
this vessel?
ASMEVIII,
Step1:FindmaterialCurveLetter; 2SHUDWLRQ8&6SDJHGRZQWLPHV
Curveletteris“B”fromFig.UCSͲ66
ASMEVIII,
Step2:InitialMDMT; 2SHUDWLRQ8&6SDJHGRZQWLPHV
51oF fromTableUCSͲ66
Step3:MDMTreduction(stressratioreduction); ASMEVIII,
20oF reductionallowed,therefore 2SHUDWLRQ8&6SDJHGRZQWLPHV
ReducedMDMT=51oFͲ 20oF=+31oF (fromFig.UCSͲ66.1)
Step4:PWHTreduction(notallowed)
PWHTreductionisnotallowedbecausePWHTwasrequired
byCode(i.e.nameplatestamped“HT”)seePar.UCSͲ68(c.)
ASMEVIII,
LowestMDMT=+31oF 2SHUDWLRQ8&6SDJHGRZQWLPHV
6
0'07
PracticeQuestion#2
A horizontal vessel constructed from SA-516 Gr 50N plate. Designed for 300 psig @ 600oF.
Wall thickness is 0.25”, with a 1/32” corrosion allowance and reduction ratio is .80.
Nameplate is stamped RT-1. Vessel was PWHT’d. What is the lowest possible MDMT for
this vessel?
7
0'07
PracticeQuestion#3
AhorizontalvesselconstructedfromSAͲ178GrAplate.Designedfor200
psig@500oF.Wallthicknessis0.500”,witha1/8”corrosionallowance
andreductionratiois.80.VesselwasPWHT’d.NameplateisstampedRTͲ
2.WhatisthelowestpossibleMDMTforthisvessel?
0'07
PracticeQuestion#4
A horizontal vessel constructed from SA-516 Gr 60 plate. Designed for 200 psig @ 500oF.
Wall thickness is 0.750”, with a 1/8” corrosion allowance and reduction ratio is .88.
Nameplate is stamped RT-2 and vessel was PWHT’d for environment cracking. What is
the lowest possible MDMT for this vessel?
&KDUS\,PSDFWV
CharpyImpactTest ASMEVIII,
6XEVHFWLRQ$3DUW8*)DEULFDWLRQ8*
EachSpecimenshallconsistofthreespecimensASMEVIIIUGͲ84
Specimenthicknessis0.394”Fig.UGͲ84
10
&KDUS\,PSDFWV
CharpyImpactTest ASMEVIII,
SDJHGRZQWLPHV
(a)Interpolationbetweenyieldstrengthsshownispermitted.
(b)Theminimumimpactenergyforonespecimenshallnotbelessthan2Ш3oftheaverageenergyrequired
forthreespecimens.Theaverageimpactenergyvalueofthethreespecimensmayberoundedtothe 11
nearestftͲlb.
&KDUS\,PSDFWV
ASMEVIII,
SDJHGRZQWLPHV
PracticeQuestion#5
Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith50ksi
MSYSandis1.0thick?
12
&KDUS\,PSDFWV (ASMEVIIIUGͲ84
ANSWER:
Average=15ft lbs
Min.Value=2/3x15=10ft lbs
50Ksi
15ft lbs
1.0thickness 13
PracticeQuestion#6
Whatistherequiredaverageandminimumcharpy impactvaluesforamaterialwith55ksi
MSYSandis2.0thick?
14
PracticeQuestion#7
Duringimpacttestingofa1½”thickmaterialwithaMSYSof45,000psi,theimpact
testingvaluesforthespecimenswere17,12,and11?Aretheresultsoftheseimpact
testsacceptable?
15
ASMEVIII,
)LOOHW:HOGV 6XEVHFWLRQ%3DUW8:'HVLJQ8:E
DQGSDJHGRZQRQFHIRU)LJ8:
Filletweldsizeisnormallydescribedbythe“leg”size.
Calculatingfilletweldsize;
Throatsize=0.707xlegsize
Legsize=throatsize/0.707 Throat
Leg
PerFig.UWͲ16.1;
Throatsize=½tmin
or Leg
Throatsize=tc
or
Throatsize=tw
16
ASMEVIII,
)LOOHW:HOGV 6XEVHFWLRQ%3DUW8:'HVLJQ8:E
Calculatingthesizeoffilletwelds;
Throat
Leg
PracticeQuestion#5
Anequallegfilletweldhasathroatof0.375”. Leg
Whatislegsizeforthisfilletweld?
Legsize=throatsize/0.707
=0.375/0.707
= 0.530”
PracticeQuestion#7
PracticeQuestion#6
A45o filletweldhasalegsizeof0.125”.
Afilletweldwithalegsizeof0.250”.
Whatisthroatsizeforthisfilletweld?
Whatisthroatsizeforthisfilletweld?
17
)LOOHW:HOG6L]H ASMEVIII,
6XEVHFWLRQ%3DUW8:'HVLJQ8:E
Perpar.UWͲ16(b);
Filletweldsize,mustbeconvertedfromthroatsize(½tmin ortc)tolegsize.
tmin =lesserof¾”ormembersjoined
tn
Assume,therepadis0.375”thick,thevessel
d
shellis0.500”thickandthenozzleis0.432”.
Whatistherequiredfilletweldsizeattaching tc
therepadtothevesselshell? te
t
Step1: Gotothesketch(UWͲ16.1(aͲ1).
1/2tmin
aͲ1
Step2: Calculatethroatsize(½tmin)
½tmin =½x(less
=½x(lesserof(0.75”,_____,_____,____)
=½x(lesserof(0.75”,0.375”,0.500”,0.423”)
=½x0.375”
=0.1875”
Step3:Calculateweldsize(FilletweldLegsize);
Leg=½tmin /0.707=0.1875/0.707=0.265”,roundedtonext1/16”=0.3125”
18
)LOOHW:HOG6L]H
Perpar.UWͲ16(b);
Fillet weld size for nozzles without repads must be
calculated by converting throat size (tc), to leg size.
tc = not less than smaller of ¼” or 0.707 x tmin tn

d
Assume, the vessel shell is 0.500” thick and the
nozzle is 0.432”. What is the required fillet weld tc
size for this branch connection?
Step1: Find correct sketch (UW-16.1(a). t
Step2: Calculate the throat size (tc) a

tc = lesser of ¼” or 0.707 x tmin
= lesser of ¼” or 0.707 x (lesser of 0.750, 0.423, 0.500)
= lesser of ¼” or (0.707 x 0.432)
= lesser of ¼” or 0.305”
= 0.250”
Step 3: Calculate weld size (Fillet weld Leg size);

Leg = tc / 0.707 = 0.250 / 0.707 = 0.357”, rounded to next 1/16” = 0.375”
19
tc =
0.375”
0.3125”
0.250”
20
)LOOHW:HOG6L]H ASMEVIIIpar.UWͲ16(b);
PracticeQuestion#8
Abranchconnectionisbeinginstalledwithoutareinforcementpad.
Thenozzlethicknessis0.625”andthevesselshellis0.875”thick.Whatsize
filletweldshouldbeusedforthisbranchconnection?
tn
d
tc
21
)LOOHW:HOG6L]H ASMEVIIIpar.UWͲ16(b);
PracticeQuestion#9
Abranchconnectionisbeinginstalledwithareinforcementpad.
Thenozzlethicknessis0.625”,repadis0.750”thickandthe
vesselshellis0.875”thick.Whatsizefilletweldshouldbe
usedtoattachtherepad tothevesselshell?
tn
d
tc
te
t
1/2tmin
aͲ1
22
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)
Practice Question # 10
AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness
is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet
WeldsizeforthenozzleͲtoͲshellfilletweld?
tn
d
tc
23
)LOOHW:HOG6L]H
ASMEVIIIpar.UWͲ16(b),Fig.UWͲ16.1(a)
AnozzleisinstalledinavesselperFig.UWͲ16.1(a).Thevesselwallthickness
is0.325”andthenozzlewallthicknessis0.375”.Whatistheminimumfillet
weldsizeforthenozzleͲtoͲshellfilletweld?
tn
d
tc
24
)LOOHW:HOG6L]H
ASMEVIIIpar.UGͲ37
Anew8NPSnozzleisinstalledinavesselperFig.UWͲ16.1(h).Shellrequiredthicknessis
1.125”.Nominalshellthicknessis1.250”.Nominalthicknessforthenozzleis0.875”.
Therepadthicknessis0.500”.
1) WhatistheminimumfilletweldsizeforthenozzleͲtoͲrepadfilletweld?
2) WhatistheminimumfilletweldsizefortheshellͲtoͲrepadfilletweld?
tn
d
tw=0.7tmin
tc
t
tc
Fig.UWͲ16Ͳ1(h)
25
HEAD
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ASMEVIIIpar.UGͲ37
I. Nozzle Reinforcement
Replacingarealostbycuttingholeinvessel(crossͲsectionalarea)
Strengthofthemateriallost,mustbereplaced
Strengthlost=diameterofholexshelltmin
Limitsofreinforcement
Extrametalmustbenearthenozzle
Strengthofreinforcement
Reinforcementmustbeequaltothestrengthremoved
Additionalreinforcementmustbeadded
Reinforcementcancomefrommultiplesources
Shell,nozzle,repadandfilletwelds
Corrosionallowancecannotbeused
29
1R]]OH5HLQIRUFHPHQW
ASMEVIII,SubsectionA,PartUG,UGͲ37
Nozzle Reinforcement Variables
6XEVHFWLRQ%3DUW8:'HVLJQ8:EDQGSDJH
GRZQRQFHIRU)LJ8:
Variables for nozzles without repads tn

Variables for nozzles with repads tn
d
d
tc
tc te
t
A = d x tr t
A = d x tr 1/2tmin
aͲ1
a
A1 = d (t-tr) or 2(t + tn)(t-tr) , extra shell area, larger A1 = d (t-tr) or 2(t + tn)(t-tr) , larger of these two
of these two A2 = 5t(tn-trn) or 5tn (tn-trn) , smaller of these two
A2 = 5t(tn-trn) or 5tn (tn-trn) , extra nozzle area, A41 = Leg2
smaller of these two
A42 = Leg2
A41 = leg2
A5 = (Dp – d – 2tn)te
d = diameter of nozzle in corroded condition
t = shell thickness in the corroded condition
tr = shell required thickness
tn = nozzle thickness in the corroded condition
Notes:
trn = nozzle required thickness
Dp =outsidediameterofrepad A. Therewillbenonozzleprojectinginsidetheshell
te = repad thickness B. Beabletocompensateforcorrosionallowances
Limits of reinforcement = greater of d or Rn+tn_t
C. Weldstrengthcalculationsareexcluded
30
1R]]OH5HLQIRUFHPHQW
Practice Question # 13 GRZQRQFHIRU)LJ8:
A12NPSnozzleisbeinginstalledonavessel.ThecorrodedIDofthenozzleis
12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness
fortheshellis0.625”.Theareathatmustbereplacedis;
tn
d
tc
31
1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UGͲ37
12.0”.Shellthicknessis0.750”.Corrosionallowanceis1/16”.Requiredthickness
fortheshellis0.625”.Theareathatmustbereplacedis;
tn
d
tc
GRZQRQFHIRU)LJ8:
32
1R]]OH5HLQIRUFHPHQW
ASMEVIIIpar.UGͲ37
8.0”.Nozzlethicknessis0.250”.Requiredthicknessforthenozzleis0.100”
Shellthicknessis0.450”.Requiredthicknessfortheshellis0.400”.
Filletweldsizeis0.375”.
tn
1.Whatisthearealost? d
tc
2.Whatisthelimitsofreinforcement? t
3.Whatistheextraareaprovidedbyshell? a
4.Whatistheextraareaprovidedbythenozzle?
33
1R]]OH5HLQIRUFHPHQW
A12NPSnozzleisbeinginstalledinavesselasindicatedbyFig.UWͲ16.1(aͲ1).Thevessel
wallthicknessis0.825”thick.Vesselrequiredthicknessis0.625”.Thenozzlewall
thicknessis0.500”.Requirednozzlethicknessis0.375”.Therepadis0.375”thick.
Corrosionallowanceis0.125”.
1) What is the limits of reinforcement (edge to edge)? tn
d
2) What is the area lost?
tc
te
t
1/2tmin
Fig.UWͲ16.1(aͲ1)
/HVVRQ3ODQ,9
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:36345:34
1
ExamRestrictions/Exclusions:
1. No more than one process (SMAW, GTAW or SAW).
2. One filler metal per process
3. PQR will be the supporting PQR for the WPS (only one WPS and one PQR).
4. Base metal limited to P1, P3, P4, P5 and P8
5. Dissimilar metals and/or thicknesses are excluded from exam
6. Corrosion-resistant weld overlay, hard-facing overlay, and dissimilar metal welds with
buttering of ferritic member is excluded from exam
7. P1, P3, P4 & P5 lower transition temperature will be 1330 F and 1600 F upper transformation
8. Editorial and non-technical requirements are excluded (i.e. Revision #, Company Name, WPS
number, WPS Date, and Name of testing lab).
9. Supplemental Variables are excluded from Exam.
2
BodyofKnowledge
I. WPS/PQR/WPQ – BODY OF KNOWLEDGE

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3
Layout of the
ASME Section IX Code Book
Divided into 2 parts
QW – WELDING
QB - BRAZING (pages 204 – 243 is not on exam)
QW – Divided into 5 Articles

Article I – Welding general requirements (13 pages) QW100
Article II – Welding Procedure Qualifications (WPS/PQR) QW200
Article III – Welding Performance Qualifications (WPQ) QW300
Article IV – Welding Data QW400
Article V - Standard WPS Specifications (NOT ON TEST) QW500
4
Purpose of ASME Section IX
Section IX is focused on THREE things;
1. WPS - (Welding Procedure Specification)

Directions to welder to for making production welds
2. PQR - (Procedure Qualification Record)

Qualifies that the WPS can be used to make a quality
weld
3. WPQ - (Welder Performance Qualification)
Qualifies that the WELDER can make quality welds
with a Welding Process (i.e. SMAW, GTAW, SAW).
5
General requirements of ASME
Section IX $UWLFOH,
QW100.1 (page 1)
a. Provides directions to welder for making production welds in accordance
with CODE requirements.
b. WPS shall be qualified by Manufacturer/Contractor
c. WPS specifies conditions which welding must be performed
d. WPS must address essential and non-essential variables and supplemental
variables when applicable (supplemental variables are not on API 510
exam).
e. PQR establishes the properties of the weld, “not the skill of welder’.
f. PQR must address essential variables and and supplemental variables
when applicable (supplemental variables are not on API 510 exam).
QW100.2 (page 2)
a. WPQ determines welder’s ability to make sound welds.
6
Section IX (cont) $UWLFOH,
QW100.3
a. WPS qualified per Section IX, can be used to make welds in accordance
with Section VIII
b. WPS qualified in accordance with Section IX 1962 or later can be used.
c. WPS qualified in accordance with Section IX prior to 1962, can be used, if
all the 1962 requirements are met.
d. Prior to 2009, Section IX used “S” numbers. The 2010 Section IX
eliminated the “S” numbers. WPS’s created using “S” numbers must be
revised to show correct “P” number, but not RE-QUALIFIED.
e. New WPS’s and Welder Qualifications, must be per 2010 Edition of Section
IX
QW-101
a. Section IX applies to preparation of WPS, PQR, WPQ for all types of
manual & machine welding processes
7
QW102 (Definitions) (see QW492, page 193)

a. Groove Weld – weld made in a groove formed within a single or two members.
b. Heat-affected zone – base metal that was not melted, but whose mechanical
properties were altered during welding
c. Interpass temperature – highest temperature allowed in weld or weld joint prior
to welding.
o
d. Lower Transformation Temperature 1330 F – Ferrite begins to transform into
Austenite (P1, P3, P4, P5)
e. Macro-Examination - Observing a cross-section of a specimen by the unaided eye
or low magnification with or without etching.
f. Performance Qualification – welder’s ability to produce welds meeting prescribed
standards.
g. Preheating – heat applied prior to welding
o
h. Upper Transformation temperature 1600 F – Transformation from ferrite to
austenite is completed. (P1, P3, P4, P5)
i. Welder – one who performs manual or semi-automatic welding.
8
QW103.1 - Responsibility
a. Manufacturer is responsible for and shall conduct testing required to Qualify
WPS’s and Welders.
QW103.2 - Records
a. Manufacturer shall maintain a record of the results of WPS and Welder
Qualifications (i.e. PQR and WPQ).
QW110 – Weld Orientation

a. Weld orientations used for WPS and WPQ test are as indicated in figure QW
461.1 or QW 461.2 (page 151).
9
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4:
Answer- FindSA285GrCintableQW/QB422(page76).ItisP1Gr1.
15
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16
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tillyougettotheF-Nocolumn.F4isanswer
17
P-Number and F-Number
Practice Questions
31XPEHU 3UDFWLFH± ZKDW LVWKH3IRUIROORZLQJ"
Material PͲNumber
SA240Type 304
SA217TypeWC1
UNSS31000
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Filler MetalClassificationand/orSpecification FͲNumber
E7024
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SFA5.18
18
Test positions for Groove Welds
(plate)
QW120 – Test Positions

a. Test coupons may be oriented in any position indicate in figures QW 461.3 (plate) or QW
461.4 (pipe) …..see page 153
$UWLFOH,94:
4:
3DJHGRZQWLPHV
r 15deg
r 15deg
19
Test positions for Groove Welds
(Pipe)
$UWLFOH,94:
4:
3DJHGRZQWLPHV
r 15deg
r 15deg
20
“FIELD” Weld Orientations (QW110 page 151)
$UWLFOH,9
4: INCLINATION of AXIS
Tabulation of Positions of GROOVE WELDS
Diagram Inclination Rotation

4: Position Reference of Axis of Face
Flat A 0 to 15o 150 to 210o
Horizontal B 0 to 15o 80 to 150o

210 to 280o
Overhead C 0 to 80o 0 to 80o

210 to 360o
Vertical D 15 to 80o 80 to 280o

E 80 to 90o 0 to 360o
o
280
o
0
to
o
360
ROTATION of FACE 21
Groove Weld – POSITION of Field Welds
6WHS 6WHS 6WHS

Position Reference of Axis of Face

210 to 280o

210 to 360o

E 80 to 90o 0 to 360o
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Diagram Inclination Rotation Overhead C 0 to 80o 0 to 80o

Position Reference of Axis of Face 210 to 360o
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210 to 280o

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Practice Questions
for
Weld Orientations
3UDFWLFH4XHVWLRQ
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26
Practice Questions
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Weld Orientations
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Practice Questions
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Weld Orientations
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Practice Questions
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Weld Orientations
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7\SHVRI7HVW([DPV $UWLFOH,
QW141.1 – Tension Test

A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).
B. Types of Test - Reduced Section, Round (Turned), Full Section
2
C. Tensile Strength = Load/Area in lbs/in (psi)
QW141.2 – Guided Bend Test

A. Used to determine “degree of soundness and ductility” of groove weld joints.
B. Types - Root, Face and Side bend
QW141.3 – Fillet Weld Test

A. Used to determine “size, contour & degree of soundness ” of fillet welds.
QW141.4 – Charpy Impact

A. Used to determine “notch toughness” of the welds
QW142 – Special examination for welders

A. RT or UT may be substituted for mechanical test (bends) for welders.
QW144 – Visual examination

A. Used to determine welds meet “quality standards”
30
7(16,217(67
$UWLFOH,94:
4:SDJH
GRZQWLPHV
31
7(16,217(67
QW141.1 – Tension Test
A. Used to determine “ultimate strength” of groove weld joints (TENSILE STRENGTH).
B. Types of Test - Reduced Section, Round (Turned), Full Section
2
C. Tensile Strength = Load/Area in lbs/in (psi)
QW151 – Tension Test

QW 151.1 - Reduced section “may be” used for all thicknesses of plates
QW 151.1(a) - For thicknesses 1” “SHALL” be FULL thickness specimens
QW 151.1(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW 151.2 - Reduced section “may be” used for all thicknesses of pipe > 3” diameter.
QW 151.2(a) - For pipe thickness 1” “SHALL” be FULL thickness specimens
QW 151.2(b) - For thicknesses > 1” “may be” FULL thickness or multiple specimens
QW153 – Tension Test – Acceptance Criteria

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In order for a Tension test to pass, the specimen shall

have a tensile strength of not less than;
a) MSTS of the base metal (when it fails in weld)
b) MSTS of the weaker of the two metals joined together (when it fails in
the weld)
c) 95% of the MSTS of base metal (when it fails in the base metal).
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Load isȱtheȱamountȱofȱstressȱrequiredȱtoȱpullȱtheȱtensileȱspecimensȱapart
Area ofȱaȱtensileȱspecimenȱisȱtheȱwidthȱxȱthickness
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Bend Test - Specimens
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Bend Test
QW141.2 – Bend Test 4:SDJH
A. Used to determine “degree of soundness and ductility” of groove weld joints. $UWLFOH,
B. Types of Test - Face, Root, and Side bends (determined by which face is on “Convex” side)
Face and Root Bend Test 4:DSDJHIRU:36345DQG4:DSDJH:34
These two test are always done together. Therefore, what ever # of face $UWLFOH,9
bends are required, the same number of root bends are also required. 4:
4:
Side Bend Test
Side bends are only performed with other side bends (i.e. you will never see face, root
AND side bends required).
Side bends are only required for “THICKER” materials (i.e. ¾” or greater in thickness).
See Table QW 451.1(a) on page 147.
Acceptance Criteria 4:SDJH $UWLFOH,

1. Weld and Haz must be in the bent portion of bend.
2. No open discontinuity in weld or HAZ > 1/8” in any direction on convex surface
3. Open discontinuity at the corners are acceptable,unless result from LOF, slag or internal
discontinuities
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44
Visual Examinations
QW144 – Visual Examination
A. Used to determine if welds meet “q
quality standards”
B. Required for “PERFORMANCE” test, not PQR.
4:SDJH
QW-194 Acceptance Criteria
1. Welds must be inspected after welding is complete and before specimens
are removed (see QW-302.4)
$UWLFOH,,,
2. Must have complete Joint penetration
3. Must have complete fusion of weld metal and base metal
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4:SDJH
Radiography
QW142 – Radiography 4:SDJH
1. May be substituted for Groove weld Mechanical $UWLFOH,

Test for WELDERS.
QW-191 Acceptance Criteria 4:SDJH
1. No cracks, Lack of Fusion (LOF) or Incomplete Penetration (IP)

2. Elongated slag inclusions (i.e. indication is 3 times longer than width), max
size permitted;
1. Max length of 1/8” - for t up to 3/8”
2. Max length of 1/3 t - for t > 3/8” but < 2 ¼”
3. Max length ¾” - for t > 2 ¼”
4. Aligned inclusions with aggregate length > t in 12t length of weld
3. Rounded Indications
1. Smaller of 20% of t or 1/8”
2. For clustered, assorted or randomly dispersed configurations, see
Appendix I
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Welder Qualification Record
WelderPerformanceQualification(WPQ)
1. Coupon or production for each welding process (SMAW,
GTAW, SAW, etc) $UWLFOH,,,
4:SDJH
2. Qualified by;
a. Production weld must be examined by RT or UT
b. Coupon can be examined by VT and Mechanical or RT/UT See QW-300.1
NOTE:GMAWͲS“shortͲcircuitingmode”weldscannotbequalifiedbyRT
3. If examination is acceptable, welder is qualified within the limits of QW-304
4. WPQ is welded in accordance with a WPS. Preheat & PWHT required by WPS can be
omitted for WPQ
4:SDJH
51
Which of the following cannot be used to qualify a welder?
1. VT & Bend Test
2. RT of 1st Production weld
3. RT of test coupon
4. Tension Test $UWLFOH,,,
4:SDJH
52
WPQ Bend Specimen Requirements
Bends $UWLFOH,,,
AND $UWLFOH,9
1. Number of bends? 4:SDJH 4:
D3ODWHSHU)LJXUH
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53
Bend Specimen Requirements
for “Performance Qualification”
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Bends 4:
2. Dimensions? 4:
)LJXUHV4: D E SDJH VLGHEHQG 3DJHGRZQ

3DJH± )DFHDQGURRW SDJHV
54
WPQ Bend Specimens
Bends $UWLFOH,9
4:
Where to remove the specimens? 4:
4: FWRJ SDJHWKUX 3DJHGRZQ
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Alternative Inspection
(RT/UT) for WPQ
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Requirements WR4:
4:
NDE – Alternative Inspection (RT/UT in lieu of BENDS 4:SDJH
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1. Minimum Length of weld? ´ 1. Minimum Length of weld? ´XQOHVV*RU*
SRVLWLRQWKHQ
2. Pipe? )XOO&LUFXPIHUHQFH 2. Welder Operator? 0LQLPXPRIIW
RT cannot be used to test a welder for either of the following; 4:SDJH
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56
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4:
1. Fails Visual test; 4:SDJH
Qualify by: making 2 coupons, both must pass VT and 1 picked for
mechanical testing (bend)
2. Any of the bend test fail; 4:SDJH
Qualify by: making 2 coupons, both must pass mechanical test.
3. Fails RT exam; 4:SDJH

Qualify by; retest and RT twice the required length of weld
%4XDOLILFDWLRQ([SLUHV 4:SDJH
1. Welder has not used the Process for 6 months

2. Reason to question welder’s ability to make sound weld
Qualified by; Welding single coupon, plate or pipe, any
thickness/diameter/position, VT/Bend or RT.
57
Practice Questions for Welder
Qualification
$UWLFOH,,,
RT can be used to qualify a welder, except for the following?
1. Welding P21 material with GTAW process
4:
2. SAW process :HOGHU
3. SMAW Process
4. GMAW process in Short-circuiting mode
A welder is being qualified by welding using ½” thickA106B pipe coupon in 5G position. How many face bends
are required?
1.
2.
2
1
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3. 3 4:
4. 0
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A welder is being qualified for 2G and 5G on a single pipe 1” thick coupon (A240 type 304L coupon). How
many side bends are required?
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1. 6 4:
2. 2
3. 4
SDJHGRZQ
4. 0 SDJHV
58
Practice Questions for Welder
Qualification
Which of the following is the manufacturer/contractor prohibited from delegating to another organization?
1. Preparing test coupons
2. Performing mechanical or NDE inspection of specimens
3. Witnessing the welder making the weld coupon $UWLFOH,,,
4. Developing the WPQ record
3DU4:
A welder was making test coupons for a 2G and 5G pipe qualification test and the 2G coupon failed VT examination.
In order for the welder to be qualified, which of the following must occur?
$UWLFOH,,,
1. Make another 1G coupon and either RT or Mechanical Test the coupon 4:SDU
2. Make two 1G coupons and VT and RT examine both coupons
3. Make two 1G coupons and VT both coupons, but only RT one coupon
4:
4. Make two 2G coupons and VT both coupons, but only Mechanical test one coupon
A 6G qualification coupon failed the mechanical testing (one of the bends failed), In order for the welder to be
qualified, which of the following is required?
$UWLFOH,,, 1. Two more coupons have to be welded and all 4 bends for each of the coupons have to pass mechanical test
2. Two more coupons have to be welded and only one coupon has to pass the required mechanical test
4:SDU 3. Another coupon has to be welded and all 4 bends has to pass mechanical test
4: 4. Two more coupons have to be welded and both coupons must be either pass mechanical testing or RT examined .
59
WPQ
“P” Number Qualification Range
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“P”number
oftest “P”number
coupon Range
welded qualifiedto
weldin
FIELD
Answer:
31RWKUX)
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60
WPQ
“F” Number Qualification Range
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Answer:
“F”number
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61
WPQ
# of Bend Specimens
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Answer:
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# of Bend Specimens
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Answer:
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63
WPQ
Thickness Limits
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64
WPQ
Diameter Limits
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Answer:
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WPQ
Position Limits
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Answer:
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66
WPQ Record $UWLFOH,,,
4:
0XVWFRQWDLQIROORZLQJ 4:SDJH
1. Variables used (i.e. process, type(manual/automatic,
with/without backing, P-No, F-No, etc)
2. Essential Variables (i.e. joints, Base metal, Filler

Metal, Position, etc)
3. Type of Test (i.e. VT, Bends and/or RT/UT)
4. Test Results (i.e. Acceptable or Failed)
5. Ranges Qualified – (i.e. thickness range,

Positions, Diameters, fillet welds)
6. Certification (i.e. signature of

Manufacturer/Contractor)
67
WPQ – Essential Variables
Process
Essential
Paragraph Variable
SAW SMAW GTAW
Variables
QW402
.4 Ͳ Backing X X
Joints
.16 ØPipeDiameter X X X
QW403
BaseMetals
.18 ØPͲNumber X X X
$UWLFOH,,, .14 ± Filler X
4: .15 ØFͲNumber X X X
QW404Filler .22 ± Inserts X

Metals
ØSolidormetalͲcoredto
.23 X
fluxcore
.30 ØtWelddeposit X X X
.1 X X X
QW405
Positions .3 +Position X X
QW408
.8 ØјљVerƟcalwelding X
Gas
QW409
.4 ØCurrentorpolarity X
Electrical
68
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Step1 DetermineWhatweldingPROCESSandTYPEusedtomaketestcoupon SMAWandManual ThesearesetbyWPS
Step2 Findthe“Essential”variablesfortheweldingprocessusedinASMEIX. QW353forSMAW Page57
Step3 CompleteTestingVariablesandQualificationLimits(“RangeQualified” section) QW353forSMAW
WeldingVariables(QW350) ActualVariables RangeQualified $UWLFOH,9

4:
1. WeldingProcess(es) SMAW SMAW SDJHXS
WLPH
2. Type(i.e.manual,semi-automatic)used Manual . Manual
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3. Backing(withorwithout) (QW402.4) None F1toF3with,F3wo 4:
SDJHGRZQ
4. x TestCouponProductionWeld(dia ifpipe) (QW403.16Base) 6”NPS 27/8”OD WLPHV
5. BasemetalP-NumbertoP-Number (QW403.18P-Number) P1toP1 P1-P15F,P34,P41-49
6. FillerMetalorElectrodeSpec(SFA) 5.1 -------- $UWLFOH,9
4:
7. FillerMetalF-Number(QW404.15F-Number) F3 _F1,F2,andF3
8. ConsumableInsert(GTAWorPAW) N/A ------------ $UWLFOH,9
4:
9. FillerMetalType(solid/metalorfluxcored/powder) N/A ------------ SDJHXS
WLPH
69
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WeldingVariables(QW350) ActualVariables RangeQualified $UWLFOH,9
4:
10. DepositedThicknessforeachprocess(QW403.30) SDJHGRZQ
a. x
Process1: SMAW 3layersminimumYesNo . .280” . WLPHV
b. Process2: SMAW 3layersminimumYesNo . ------ ------------ .

11. Positionqualified(1G,2G,3G,4G,5G,6G,etc) . 2G F,H .
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12. Verticalprogression(uphillordownhill) . Uphill n/ahorz
13. InertGasBacking(GTAW,PAW,GMAW) . N/A ------------ 6HH4:
RQ
14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit) . N/A ------------ 3DJH
15. GTAWCurrenttype/polarity(AC,DCEP,DCEN) . N/A ------------

________________________________________________________________________________________________________________
Step4 Complete“Results:sectionandthenSignandDateForm
That’sIT,youjustcompletedaWPQRECORD
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PracticeQuestion#28 DetermineifEssential Variablesare“Correct” $UWLFOH,9
4:
WeldingVariables(QW350) ActualVariables RangeQualified SDJHXS
WLPH
1. WeldingProcess(es) . SMAW .. SMAW .
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2. Type(i.e.manual,semi-automatic)used . Manual . Manual 4:
3. Backing(withorwithout) With . F1,F2&F3with SDJHGRZQ
WLPHV
4. xTestCouponProductionWeld(dia ifpipe) . 3” .
27/8”MintoUnlimited
5. BasemetalP-NumbertoP-Number . P3 P1-P15F,P34,P41-49
. $UWLFOH,9
6. FillerMetalorElectrodeSpec(SFA) . 5.4 . ---------
4:
7. FillerMetalF-Number F3 . F1,F2,andF3 $UWLFOH,9

8. ConsumableInsert(GTAWorPAW) . N/A . -------- 4:
SDJHXS
9. FillerMetalType(solid/metalorfluxcored/powder) . N/A . -------- WLPH
10. DepositedThicknessforeachprocess $UWLFOH,9
4:
x
a. Process1: SMAW 3layersminimumYesNo .300” . Max of .600” SDJHGRZQ
b. Process1: SMAW 3layersminimumYesNo ------- . -------- WLPHV
11. Positionqualified(1G,2G,3G,4G,5G,6G,etc) 6G . ALL $UWLFOH,9

4:SDJH
12. Verticalprogression(uphillordownhill) Downhill . Downhill only GRZQWLPHV
13. InertGasBacking(GTAW,PAW,GMAW) N/A . --------
14. GMAWTransfermode(Spray,Globular,Pulse,orShortCircuit) N/A . --------
15. GTAWCurrenttype/polarity(AC,DCEP,DCEN) N/A . -------- 6HH4:
RQ
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71
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WPQ WeldingVariables
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73
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Welding Procedure - Requirements (WPS)
1. WPSrequirements (QW-200.1,page14)
a. WPSprovidesdirectionsformakingproductionwelds. $UWLFOH,,
b. Mustcontainessential,nonessentialandwhenrequired
supplementaryvariables.
1) MustreferencethesupportingPQR
c. Changescanbemadeto“nonessential”variableswithout
requalification.Changesto“essentialorsupplementary”variables
requirerequalification.
d. FormatofWPSmaybeanyformataslongaseveryessential,
nonessentialandsupplementaryvariableisincluded.
e. WPSmustbereadilyavailableatthefabricationsiteforreview by
welderandinspector.
79
Welding Procedure – Requirements (PQR)
345UHTXLUHPHQWV4:SDJH
$UWLFOH,,
a. IsaRecordoftheweldingdatausedtomakethetestcouponand
mechanicaltestresults.
a. Must;
1) Containessential andsupplementaryvariables(supplementalisnotAPI570Exam).
2) Recordrangeofvariablesusedtomakethecouponmustbeincluded
3) Becertifiedbythemanufacturer/contractor(i.e.signedanddated).
b. ChangestothePQRarenotallowed,exceptforeditorialtypechanges(i.e.P#entered
incorrectly,orCodechangestheF#forthematerialsused,etc.)AllchangestoaPQR,
requirerecertification(i.e.signedanddatedbymanufacturer/contractor).
c. Formatmaybeanyformataslongfollowingareincluded;
a. Essentialandsupplementaryvariables
b. Typeofmechanicaltest,numberoftestsandtestresults
d. PQRmustbeavailablefortheAI,butnotthewelder.
e. TherecouldbemultiplePQR’ssupportingoneWPSormultipleWPS’sforasinglePQR.
80
6WHSVWR48$/,)<D:HOGLQJ3URFHGXUH
1. WPS ispreparedforproductionweldsthataretobemade. (QW-100)

2. Welder(employeeorcontractedout),makesaTestCouponusingdirectionsfrom
theWPS. (QW-201)
3. Thecouponismechanicallytested- BendsandTensiontest (RTisnotallowed).
4. Ifmechanicaltestingisacceptable,WPSisQualifiedwithinrangessetby variables
usedtomakethetestcoupon. (QW-202.2)
5. PQRisarecordcreatedbasedonvariablesusedtomakethetestcouponand
subsequentmechanicaltestingresults.
NOTE:PQR“Must” besignedanddatedtobeCERTIFIED.
81
'LIIHUHQFHEHWZHHQ:36345DQG:34
1. WhatisthedifferencebetweentheProcedureQUALIFICATIONand
WelderQUALIFICATION?
A. ProcedurequalificationrequiresTWOdocuments(WPS/PQR).
B. Examinationsaredifferent;
1) WPS/PQR– requiresBends/TensiontestandCharpy testwhennotch
toughnessisrequired.Also,HardnesswhenPWHT’d.
2) WPQ– requiresVTandBendtestorRT/UTexamination.
C. WPQonlyrequires“Essential”variablestoberecorded,
whiletheWPSmustrecord“Essential,Non-EssentialandSupplementary
(whenrequired)variables”.
PQRmustrecord“EssentialandSupplementary”variables.
82
%DVLF6WHSVRI5HYLHZLQJ:36345
1. VerifyWPShasbeenproperlycompletedandaddressesrequirements
ofSectionIX (forAPIExam,meansEssentialVariablesandNon-Essentialvariablesare
addressed)API577par6.4page18
2. VerifyPQRhasbeenproperlycompletedandaddressesrequirements
ofSectionIX (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedand
dated)API577par6.4page18
3. VerifyPQRessentialvariablesproperlysupporttherangespecifiedin
WPS (forAPIExam,meansEssentialVariablesareaddressedandPQRissignedanddated)API577
par6.4page18
83
:363455HYLHZ,QVWUXFWLRQV
INSTRUCTIONSforCheckingWPSandPQR
STEP1 Locatetheappropriate“WeldingVariablesChart”fortheWeldingPROCESS(i.e.SMAW– QW253,SAW-QW254orGTAW-
QW256……thesearetheonlythreethatwillbeontheAPIExam).
STEP2 VerifyPQRissignedbyManufacture/Contractor– QW202(b).
STEP3 VerifyWPSreferencesthesupportingPQR– QW201(b).

STEP4 VerifyallNon-EssentialvariablesareaddressedontheWPS,andvalidatethatonthechecklist(e.g.enter“OK”or“ERROR”in
theVALIDATEcolumn)- QW201(b).
STEP5 Listvaluesforall“ESSENTIAL”variablesonChecklistfromthePQR– QW202(b).
STEP6 Listvaluesforall“ESSENTIAL”variablesonChecklistfromtheWPS– QW201(b).
STEP7 UseSectionIXtodetermineandlistthe“ACCEPTABLE”rangeforallessentialvariables(basedonthePQRresults)
STEP8 Comparethe“Acceptable”rangeagainsttheWPSvaluesanddocumentthefindingsinthe“VALIDATE”column.
STEP9 CheckTESTINGdataonPQRandverifycorrecttype/numberofBENDspecimens(i.e.2face&2Root,etc)weretestedand
resultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist.
STEP10 CheckTESTINGdataonPQRandverifycorrecttype/numberofTENSILEspecimens(i.e.2ormore,dependingonthickness)
weretestedandresultsareacceptableorrejectable.Recordanswerin“Validate”columnofchecklist.
STEP11 CheckforP-Noand/orF-Nomistakes.
84
Practice Question for Reviewing
WPS/PQR
3UDFWLFH4XHVWLRQ
5HYLHZ:36-&33DQG345-&334
1.)IsthePQRsigned&dated?
2.)NowchecktheEssential,Non-essentialvariablesandrangesqualified
85
WPS/PQR“Review”Results
$UWLFOH,9JCPP101
ReviewofWPS# Rev# 0 Dated: 9/11/2001
9/12/2001
4: JCPPQ101
SupportingPQR# Rev# 0 Dated:
STEP4 STEP5 STEP6 STEP7 Validate
Paragraph BriefofVariables Essential NonͲEssential PQR WPS QualifiedFor? OKorError

Par4:
.1 I GrooveDesign NE Ͳ ----- OK
.4 - Backing NE Ͳ ----- OK
QW402Joints
.10 I Rootspacing NE Ͳ ----- OK
OK
$UWLFOH,9 .11
.8
r Retainers
I Tqualified E
NE
½”
Ͳ
1/16”to1”
-----
3/16”to1” PQRshouldbe1/16”to1”
4:
QW403
BaseMetals
.9 tPass>½inch E ½”thk ½”thk ½”plateN/A OK
.11 I PͲNo.qualified E SA53GrB(P1_) P1 P1 OK
.4 I FͲNumber E F-4 F3 F3 ERROR– shouldbeF3
Par4: .5 I AͲNumber E 1 1 1 OK
QW404Filler OK
Metals
.6 I Diameter NE Ͳ -----
Par4: .30 It E ½” 1/16”to1” Maxof1” OK
.33 I AWSClassification NE Ͳ ----- OK
.1 +Position NE Ͳ ----- OK
QW405Positions
.3 I np Verticalwelding NE Ͳ OK
-----
4: 1. Decrease>100oF E 50oF 50oF 50oF OK
QW406Preheat
.2 I Preheatmaintenance NE Ͳ ----- OK
QW407PWHT
.1 I PWHT E None None None OK
.4 Tlimits E ----- ----- ----- OK
Par4: OK
QW409Electric
.4 I Currentorpolarity NE Ͳ -----
I I&Erange OK
.8 NE Ͳ -----
I String/Weave OK
Par4: .1 NE Ͳ -----
I Methodofcleaning OK
.5 NE Ͳ
-----
.6 I Methodbackgouge NE Ͳ ----- OK
Par4:
QW410 .9 I Multitosinglepass/side NE Ͳ ----- OK
Technique
.25 I Manualorautomatic NE Ͳ ----- OK
Par4:
.26 r Peening NE Ͳ -------- OK
.64 UseofThermalProcesses E None None None OK
86
WPS/PQR“Review”Results
BENDSPECIMENS
Numberofbends Results
Validate
Required OnPQR
AllowableDefects OnPQR (OkorError)
(#&Type) (#&Type)
2F&2ROR4S 4SIDES 1/8” OK OK $UWLFOH,9
NOTE: 1.OpendiscontinuityinweldorHAZ<1/8”(SeeQW-163,page6) 4:
2.Ignoreopendiscontinuityoncorners,unlessresultfromLOF,Slagorinternaldiscontinuity
TENSILESPECIMENS
NumberofTensileSpecimens CompareResults
Ultimate Validate
MSTSofBase Failure (OkorError)
#Required #onPQR Metal
Stress
57,038Base
2 2 60,000PSI 66,158Weld OK
NOTE:1.FailureStress(failedin“BaseMetal”)mustbe .95%ofMSTS(seeQW-153,page4)
2.FailureStress(failedin“WELD”)mustbe MSTS(QW-153)
3.Verifythatthe“UltimateFailureStress” iscalculatedproperly(S=Load/Area)– (seeQW-152,page4)
CheckforP-No,F-Noand/orSpecificationmistakesontheWPS/PQR.
Results- NoF-NoorP-Noerrors.
87
Practice Questions
for Reviewing WPS/PQR
Practice Question # 30 $UWLFOH,9
IstheP#qualifiedinaccordancewithASMESectionIX? 4:
6XSSOHPHQWDU\
Result– Yes,P8 (VVHQWLDO (VVHQWLDO 1RQHVVHQWLDO
$60(6HF $UWLFOH,9
,;4: 4:SDJH
SDJH :36-&33 345-&334
GRZQWLPH
Ifyoudon’tknowSA240Type304isP8,thenlookitupatP-NoTab 88
Practice Questions
8VH:36-&33DQG345-&334WRDQVZHUWKHIROORZLQJTXHVWLRQV
Practice Question # 31 $UWLFOH,9
4:
IsthebasemetalthicknessinaccordancewithASMESectionIX?
Result– No,PQRcouponwas½”whichqualifiesthk rangeof3/16”to1”,
WPSindicated1/16”to1”
89
Practice Questions
IstheshieldinggasinaccordancewithASMESectionIX?
Result– NO,WPSisforsinglegas(argon)andPQRisfor75/25mix
(VVHQWLDO
9DULDEOHV $UWLFOH,,
IRU*7$:
RQ3DJH
4:4:
Essential
SDJH
GRZQWLPHV
,QGLFDWHV12&+$1*(SHUPLWWHG³³
90
Practice Questions
IstheF#qualifiedinaccordancewithASMESectionIX?
Result– NO,ER304isF6&E7018isaF4 $UWLFOH,,
7DEOH4:

3DU4:
7DEOH4:
(LV)
(5LV)
91
Practice Questions
8VH:36-&33DQG345-&334WRDQVZHUWKLVTXHVWLRQ
ArethetensiletestinaccordancewithASMESectionIX?
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PWHT temps, see Table UCS-56
Partial HT requires 5 ft overlap for each successive heats (partial means part cannot fit
into furnace) per par UW-40(a)(2).
HT of welds includes a zone extend 1t or 2”, whichever is less, beyond each side of the
weld (par UW-40(a)
No control of temperature up to 800oF. Par UCS-56(c.)
Heating rate above 800oF shall not be more than 400oF per hr/max metal thickness. Par
UCS-56(d)(1)(2).
Variation in temperature cannot exceed 250oF in any 15 ft length of vessel. Par UCS-
56(d)(2)
Holding time is per Table UCS-56
During holding time, temperature cannot vary by more than 150oF. Par UCS-56(d)(3).
Cool down rate shall not be more than 500oF per hr/max metal thickness. No control
necessary below 800oF. Par UCS-56(d)(5).
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A 2” thick vessel fabricated from SA-516-70N was repaired and PWHT’d at 1000o F. How
long should the vessel be maintained at this PWHT temperature?
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8.1.6.4.1)
Ifapprovedbytheengineer.
Apreheatof300oForhigherismaintainedduringwelding
PWHTtemperaturemaintainedforadistancenotlessthan2xt,fromthetoeoftheweld.
Atleasttwothermocouplesmustbeused.
MetallurgistapprovesthePWHTprocedureifitisperformedforenvironmentalͲassisted
crackingresistance.
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maintainedduringtherepairforP1materials.And350oFforP3materials.ParUCS-
56(f)(4)(b). $60(9,,,
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Noweldingrecommendedattemperatureslowerthan0oF.Temperaturesbetween32oF
and0oF,surfaceswithin3”oftheweldshouldbeheatedtoaminimumof60oF.Par.
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1. Preheat temperature maintained at a minimum of 300oF.
2. Preheat temperature maintained at a distance of 4” or 4t, whichever is
greater, on each side of weld
3. Maximum interpass temperature of 600oF
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31
Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification

(WPQ)
Forms
Index
x WPS JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-PQ301
x Rod Burner WPQ Form – with qualified range
x Rod Burner WPQ Form – without qualified range
x Blank WPS Form
x Blank PQR Form
x Blank WPQ Form
ASME Section IX – WPS
QW-482 Suggested Format For Welding Procedure Specification (WPS)

(See Section IX QW-200.1)
Company Name JC Penny By Mr. Penny
Welding Procedure Specification No. JCP-P101 Date 9/11/2001 Supporting PQR No.(s)JCP-PQ101
Revision No. 0 Date 9/11/2001
Welding Process(es) SMAW Type(s) Manual

Test Description
Joints (QW 402)
Joint Design Single V Groove and Fillets
Root Spacing .0625” to 1.250”
Backing: Yes x No x
Backing Material (Type) Metal
(Refer to both backing and retainers)
Metal Nonfusing Metal

Nonmetallic Other
Sketches, Production drawings, weld symbols, or written description should show the general arrangement of the parts
to be welded. Where applicable, the details of weld groove may be specified.
(At the option of the manufacturer, sketches may be attached to illustrate joint design, weld layers, and bead sequence
(e.g. for notch toughness procedures, for multiple process procedures, etc)).
Base Metals (QW 403)
P-No. 1 Group No. to P-No. 1 Group No.
OR
Specification and type/grade to Specification and type/grade
OR
Chemical Analysis and Mech. Prop. to Chemical Analysis and Mech. Prop.
Thickness Range:
Base Metal: Groove 1/16” to 1” Fillet All
Maximum pass thickness ½” (yes) x (no)
Pipe Diameter (Groove) 2 7/8” (Fillet) All
Filler Metals (QW 404) 1st Filler Metal 2nd Filler Metal
Spec. No. (SFA) _ _ _ _ _ _ _ _ _ 5.1
AWS No. (Class) _ _ _ _ _ _ _ _ _ E-7018
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1
Size of Filler Metals_ _ _ _ _ _ _ _ 3/32”, 1/8”, 5/16”
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _ .0625” to 1.0”
Fillet_ _ _ _ _ _ _ _ _ _ _ _ .250” to 1.0”
Electrode-Flux (Class) _ _ _ _ _ _ _ N/A
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ N/A
Consumable Insert_ _ _ _ _ _ _ _ _ N/A
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Page of 2
WPS No. JCP-P101 Rev.# 0
Positions (QW 405) Postweld Heat Treatment (QW 407)
Position(s) of Groove ALL Temperature Range None
Welding Progression: UP X Down Time Range
Position(s) of fillet ALL Other
Preheat (QW 406) Gas (QW 408)

Preheat Temp, Min 50oF Percent Composition
Interpass Temp, Max 350oF Gases Mixtures Flow Rate
Preheat Maintenance None Shielding N/A
Trailing
(Continuous or special heating, where applicable, should be recorded. Backing
Other
Electrical Characteristics (QW 409)
Filler Metal Other (e.g

Current Wire Remarks, Com-
Energy or Travel
Weld Type Amps Feed Volts ments, Hot Wire
Process Classifi Power Speed
Pass(es) Diameter and (Range) Speed (Range) Addition,
-cation (Range) (Range)
Polarity (Range) Technique, Torch
Angle, etc)
All SMAW E-7018 1/8” DCEP 70 to N/A N/A 19 - 25 5 to 7

200
NOTE: Amps and volts, or power or energy range, should be recorded for each electrode size, position, and thickness, etc
Pulsing Current N/A Heat Input (max.) N/A

Tungsten Electrode Size and Type N/A
(Pure Tungsten, 2% Thoriated, etc)
Mode of Metal Transfer for GMAW or FCAW N/A
(Spray Arc, Short Circuiting Arc, Globular Arc, etc)
Technique (QW 410)

String or Weave Bead String or Weave
Orifice, Nozzle, or Gas Cup Size N/A
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping or Wire Brush
Method of Back Gouging Grinding

Oscillation N/A
Contact Tube to Work Distance N/A
Multiple or Single Pass (per side) Multiple or Single
Multiple of Single Electrodes Single
Peening N/A
Other
Page 2 of 2
ASME Section IX –PQR
QW-483 Suggested Format For Procedure Qualification Record (PQR)

Company Name JC Penny
PQR No. JCP-PQ101 WPS # JCP-P101 Date 9/12/2001
Joints (QW 402)
G
Groove D i off TTest C
Design Coupon
Base Metals (QW 403) Postweld Heat Treatment (QW 407)

Material Spec. SA-53 Gr B Temperature Range None
P-No. to P-No. Time Range
Thickness of Test Coupon ½” Other
Diameter of Test Coupon 6”
Other
Gas (QW 408)

Percent Composition
Gases Mixtures Flow Rate
Filler Metals (QW 404)
Shielding N/A
SFA Specification 5.1
Trailing
AWS Classification E-7018
Backing
Filler Metal F-No. 4
Weld Metal Analysis A-No. 1 Electrical Characteristics (QW 409)
Size of Filler Metal 5/32” Current DC
Other Polarity Straight
Amps: 150-300 Volts 20-28
Weld Metal Thickness Tungsten Electrode Size N/A
Other
Positions (QW 405)
Position of Groove ALL Technique (QW 410)
Weld Progression (Uphill, Downhill) Travel Speed 3”/min
Other String or Weave Bead Stringer
Oscillation
Preheat (QW 406) Multipass or Single Pass (per side) Multiple
Preheat Temp 50oF Single or Multiple Electrodes Single
Interpass Temp Other
Other
QW 483 (back)
PQR No. JCP-PQ101
Tensile Test (QW -150)
Specimen No. Width Thickness Area Ultimate Load Ultimate Stress Type of Failure
(inch) (inch) (sq. inches) (lbs) (psi) & Location
T1 .750 .455 .341 19,450 57,038 Pass - Base
T2 .756 .451 .341 22,560 66,158 Pass - Weld
Guided Bend Tests (QW -160)

Type and Figure No. Results
SIDE # 1 Pass
SIDE # 2 Pass
SIDE # 3 Pass
SIDE # 4 Pass
Notch Toughness Tests (QW -170)

Specimen Notch Notch Test Impact Lateral Exp Drop Weight
No. Location Type Temp Values % Shear Mils Break No Break
Fillet Weld Test (QW -180)

Result – Satisfactory: YES No Penetration into Parent Metal YES No
Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Jack Shift Jr Clock No. Stamp No. B2

Test conducted by: Laboratory Test No.
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of ASME Section IX.
Manufacturer JC Penny
Date 9/11/2001 By: Jack Shift Sr
Page 2 of 2

Welding Process(es) GTAW Type(s) Manual

Test Description
Joints (QW 402)
Joint Design Single V Groove
Root Spacing 1.250”
Backing: Yes x No x
Backing Material (Type) Solid Metal or weld metal
(Refers to both backing and retainers)

Nonmetallic Other
P-No. Group No. to P-No. Group No.
OR
Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304
OR
Thickness Range:

Spec. No. (SFA): 5.9
AWS No. (Class): ER304
F-No.: F-6
A-No.: A-8
Size of Filler Metals: 3/32”, 1/8”,5/16”
Weld MetalThickness Range: No single pass > ½”

Groove: .0625” to 1.0”
Fillet: No limit
Electrode-Flux (Class): N/A

Flux Type: N/A
Consumable Insert: None
Other: N/A
Page of 2

Preheat Maintenance None Shielding Argon
Trailing None
(Continuous or special heating, where applicable, should be recorded. Backing None
Other
Filler Metal Other

Current Wire (e.g Remarks,
Energy or Travel
Weld Type Amps Feed Volts Comments,
Pass(es) Diameter and (Range) Speed (Range) Hot Wire Addition,
Angle, etc)
All GTAW ER304 3/32” DCSP 60-100 N/A N/A N/A N/A
All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A

Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)
Technique (QW 410)

Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging Grinding or thermal process

Oscillation N/A
Multiple or Single Pass (per side) Multiple
Peening None
Other
Page 2 of 2

Joints (QW 402)
G
Design Coupon

Material Spec. SA-240 Type 304 Temperature Range None
P-No. 8 to P-No. 8 Time Range
Diameter of Test Coupon Plate
Other
Gas (QW 408)

Percent Composition
Shielding Argon/CO 75%/25% 15-25
Trailing None
Backing None
Size of Filler Metal N/A Current DC
Amps: 90-100 Volts 20-28
Weld Metal Thickness ½” Tungsten Electrode Size 1/8”
Other
Positions (QW 405)
Position of Groove 1G Technique (QW 410)
Weld Progression (Uphill, Downhill) N/A Travel Speed 5”/min
Other String or Weave Bead Weave
Oscillation
Interpass Temp 250oF Other
Other
QW 483 (back)
PQR No. JCP-PQ101
Specimen No. Width(W) Thickness(y) Area Ultimate Load Ultimate Stress Type of Failure
T1 .750 .440 .330 24,450 74,090 Pass - Weld
T2 .750 .449 .337 24,000 71,216 Pass - Base

Face # 1 Pass
Face # 2 Pass
Root # 3 Pass
Root # 4 Pass


Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….

Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001
Page 2 of 2


Test Description
Joints (QW 402)
Backing: Yes x No x

Nonmetallic Other
OR
OR
Thickness Range:
Spec. No. (SFA) _ _ _ _ _ _ _ _ _ 5.1
AWS No. (Class) _ _ _ _ _ _ _ _ _ E-7018
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _ .0625” to 1.0”
Fillet_ _ _ _ _ _ _ _ _ _ _ _ .250” to 1.0”
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ N/A
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Page 1 of 2

Trailing
Other

Energy or Travel
Angle, etc)

200

Technique (QW 410)


Oscillation N/A
Peening N/A
Other
Page 2 of 2

Joints (QW 402)
G
Design Coupon

Other
Gas (QW 408)

Percent Composition
Shielding N/A
Trailing
Backing
Amps: 150-300 Volts 20-28
Other
Positions (QW 405)
Oscillation
Other
QW 483 (back)
PQR No. JCP-PQ301
T1 .750 .455 .341 19,450 57,038 Pass - Base
T2 .756 .451 .341 22,560 66,158 Pass - Weld

SIDE # 1 Pass
SIDE # 2 Pass
Face # 1 Pass
Face # 2 Pass


Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….

Page 2 of 2
ASME Section IX – Welder Qualification
Homework – WPQ’s
QW-484A Suggested Format For Welder Performance Qualification (WPQ)

(See Section IX QW-301)
Welder(s) Name Mr. Rod Burner Identification Number A11

Test Description
Identification of WPS followed WPS 101 Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280
Testing Variables and Qualification Limits
Welding Variables (QW350) Actual Values Range Qualified
Welding Process(es) SMAW SMAW
Type (i.e. manual, semi-automatic) used Manual Manual
Backing (with or without) None F1 to F3 with,F3 wo
Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD
Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA) 5.1 -------
Filler Metal F-Number F3 F1,F2, & F3
Consumable Insert (GTAW or PAW) N/A -------
Filler Metal Type (solid/metal or flux cored/powder) N/A -------
Deposited Thickness for each process
Process 1: SMAW 3 layers minimum Yes No .280” .560
Process 2: 3 layers minimum Yes No ---- -------
Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H
Vertical progression (uphill or downhill) Uphill Uphill
Inert Gas Backing (GTAW, PAW, GMAW) N/A -------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------
GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------
RESULTS
Visual examination of completed weld (QW 302.4) Acceptable
Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Type Results Type Results
Face No defects – Acceptable
Root No defects - Acceptable
Alternative Volumetric Examination Results (QW 191) N/A RT or UT
Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A
Macro examination (QW 184) Fillet size (in.) x Concavity/convexity (in.)
Other tests
Film or specimens evaluated by Company
Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye
We certify that the statements in this record are correct and that the test coupons were prepared, welded, and tested in accordance with the
requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator
Date April 7, 2010 By John Doe
Welding Procedure (WPS),
Procedure Qualification Record (PQR)
and
Welder Performance Qualification

(WPQ)
Forms
Index
x WPS JCP-P101
x PQR JCP-PQ101
x WPS JCP-P201
x PQR JCP-PQ201
x WPS JCP-P301
x PQR JCP-PQ301
x Rod Burner WPQ Form – with qualified range
x Rod Burner WPQ Form – without qualified range
x Blank WPS Form
x Blank PQR Form
x Blank WPQ Form


Test Description
Joints (QW 402)
Backing: Yes x No x

Nonmetallic Other
OR
OR
Thickness Range:
Spec. No. (SFA) _ _ _ _ _ _ _ _ _ 5.1
AWS No. (Class) _ _ _ _ _ _ _ _ _ E-70
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _ .0625” to 1.0”
Fillet_ _ _ _ _ _ _ _ _ _ _ _ .250” to 1.0”
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ N/A
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Page of 2

Trailing
Other

Energy or Travel
Angle, etc)

200

Technique (QW 410)


Oscillation N/A
Peening N/A
Other
Page 2 of 2

Joints (QW 402)
Groove D
G Design
i off TTest C
Coupon

Other
Gas (QW 408)

Percent Composition
Shielding N/A
Trailing
Backing
Amps: 150-300 Volts 20-28
Other
Positions (QW 405)
Oscillation
Other
QW 483 (back)
PQR No. JCP-PQ101
T1 .750 .455 .341 19,450 57,038 Pass - Base
T2 .756 .451 .341 22,560 66,158 Pass - Weld

SIDE # 1 Pass
SIDE # 2 Pass
SIDE # 3 Pass
SIDE # 4 Pass


Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….

Page 2 of 2


Test Description
Joints (QW 402)
Joint Design Single V Groove
Root Spacing 1.250”
Backing: Yes x No x
Backing Material (Type) Solid Metal or weld metal
(Refers to both backing and retainers)

Nonmetallic Other
OR
Specification and type/grade SA 240 Type 304 to Specification and type/grade SA 240 Type 304
OR
Thickness Range:

Spec. No. (SFA): 5.9
AWS No. (Class): ER304
F-No.: F-6
A-No.: A-8
Size of Filler Metals: 3/32”, 1/8”,5/16”
Weld MetalThickness Range: No single pass > ½”

Groove: .0625” to 1.0”
Fillet: No limit
Electrode-Flux (Class): N/A

Flux Type: N/A
Consumable Insert: None
Other: N/A
Page of 2

Preheat Maintenance None Shielding Argon
Trailing None
(Continuous or special heating, where applicable, should be recorded. Backing None
Other
Filler Metal Other

Current Wire (e.g Remarks,
Energy or Travel
Weld Type Amps Feed Volts Comments,
Pass(es) Diameter and (Range) Speed (Range) Hot Wire Addition,
Angle, etc)
All GTAW ER304 5/16”” DCSP 90-160 N/A N/A N/A N/A

Tungsten Electrode Size and Type 2% Thoriated (EWTh-2) or Cesium Stablilized (EWCe-2)
Technique (QW 410)

Orifice, Nozzle, or Gas Cup Size 3/8” to ¾” diameter shielding gas cup size
Initial and Interpass cleaning (Brushing, Grinding, etc Grinding, Chipping, Wire Brush or Thermal process
Method of Back Gouging Grinding or thermal process

Oscillation N/A
Multiple or Single Pass (per side) Multiple
Peening None
Other
Page 2 of 2

Joints (QW 402)
G
Design Coupon

Material Spec. SA-240 Type 304 Temperature Range None
P-No. 8 to P-No. 8 Time Range
Diameter of Test Coupon Plate
Other
Gas (QW 408)

Percent Composition
Shielding Argon/CO 75%/25% 15-25
Trailing None
Backing None
Size of Filler Metal N/A Current DC
Amps: 90-100 Volts 20-28
Weld Metal Thickness ½” Tungsten Electrode Size 1/8”
Other
Positions (QW 405)
Position of Groove 1G Technique (QW 410)
Weld Progression (Uphill, Downhill) N/A Travel Speed 5”/min
Other String or Weave Bead Weave
Oscillation
Interpass Temp 250oF Other
Other
QW 483 (back)
PQR No. JCP-PQ01
Specimen No. Width(W) Thickness(y) Area Ultimate Load Ultimate Stress Type of Failure
T1 .750 .440 .330 24,450 74,090 Pass - Weld
T2 .750 .449 .337 24,000 71,216 Pass - Base

Face # 1 Pass
Face # 2 Pass
Root # 3 Pass
Root # 4 Pass


Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….

Test conducted by: Shear Metal Testing Lab Laboratory Test No. SM-1001
Page 2 of 2


Test Description
Joints (QW 402)
Backing: Yes x No x

Nonmetallic Other
OR
OR
Thickness Range:
Spec. No. (SFA) _ _ _ _ _ _ _ _ _ 5.1
AWS No. (Class) _ _ _ _ _ _ _ _ _ E-7018
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _ 1
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _ .0625” to 1.0”
Fillet_ _ _ _ _ _ _ _ _ _ _ _ .250” to 1.0”
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _ N/A
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Page 1 of 2

Trailing
Other

Energy or Travel
Angle, etc)

200

Technique (QW 410)


Oscillation N/A
Peening N/A
Other
Page 2 of 2

Joints (QW 402)
G
Design Coupon

Other
Gas (QW 408)

Percent Composition
Shielding N/A
Trailing
Backing
Amps: 150-300 Volts 20-28
Other
Positions (QW 405)
Oscillation
Other
QW 483 (back)
PQR No. JCP-PQ301
T1 .750 .455 .341 19,450 57,038 Pass - Base
T2 .756 .451 .341 22,560 66,158 Pass - Weld

SIDE # 1 Pass
SIDE # 2 Pass
Face # 1 Pass
Face # 2 Pass


Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….

Page 2 of 2

Welder(s) Name Mr. Rod Burner Identification Number A11

Test Description
Identification of WPS followed WPS 101 Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) A 106B to A106B Thickness .280
Welding Process(es) SMAW SMAW
Type (i.e. manual, semi-automatic) used Manual Manual
Backing (with or without) None F1 to F3 with,F3 wo
Test Coupon Production Weld (dia if pipe) 6” NPS __ 2 7/8” OD
Base metal P-Number to P-Number P-1 to P-1 P1-P15F, P34, P41-P49
Filler Metal or Electrode Spec (SFA) 5.1 -------
Filler Metal F-Number F3 F1,F2, & F3
Consumable Insert (GTAW or PAW) N/A -------
Filler Metal Type (solid/metal or flux cored/powder) N/A -------
Process 1: SMAW 3 layers minimum Yes No .280” .560
Process 2: 3 layers minimum Yes No ---- -------
Position qualified (1G,2G,3G,4G,5G,6G, etc) 2G F, H
Vertical progression (uphill or downhill) Uphill Uphill
Inert Gas Backing (GTAW, PAW, GMAW) N/A -------
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit) N/A -------
GTAW Current type/polarity (AC,DCEP,DCEN) N/A -------
RESULTS
Visual examination of completed weld (QW 302.4) Acceptable
Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Face No defects – Acceptable
Root No defects - Acceptable
Alternative Volumetric Examination Results (QW 191) N/A RT or UT
Fillet weld – fracture test (QW 181.2) N/A Length and percent of defects N/A
Other tests
Mechanical tests conducted by Ben Tension Laboratory test no. 123 Welding supervised by Red Eye
requirements of Section IX of the ASME Code. Organization Worlds Best Fabricator
Date April 7, 2010 By John Doe

Company Name By
Welding Procedure Specification No. Date Supporting PQR No.(s)
Revision No. Date
Welding Process(es) Type(s)

Test Description
Joints (QW 402)
Joint Design
Root Spacing
Backing: Yes No
Backing Material (Type)

Nonmetallic Other
OR
OR
Thickness Range:
Base Metal: Groove Fillet
Maximum pass thickness ≤ ½” (yes) (no)
Filler Metals (QW 404) 1st Filler Metal 2nnd Filler Metal
Spec. No. (SFA) _ _ _ _ _ _ _ _ _
AWS No. (Class) _ _ _ _ _ _ _ _ _
F-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
A-No. _ _ _ _ _ _ _ _ _ _ _ _ _ _
Size of Filler Metals_ _ _ _ _ _ _ _
Filler Metal Product Form_ _ _ _ _
Weld Metal:
Thickness Range:
Groove_ _ _ _ _ _ _ _ _ _ _
Fillet_ _ _ _ _ _ _ _ _ _ _ _
Electrode-Flux (Class) _ _ _ _ _ _ _
Flux Type_ _ _ _ _ _ _ _ _ _ _ _ _
Consumable Insert_ _ _ _ _ _ _ _ _
Other_ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Page 1 of 2
WPS No. Rev.#
Positions (QW 405)) Postweld Heat Treatment (QW 407))
Position(s) of Groove Temperature Range
Welding Progression: UP Down Time Range
Position(s) of fillet Other
Preheat (QW 406)) Gas (QW 408))

Preheat Temp, Min Percent Composition
Interpass Temp, Max Gases Mixtures Flow Rate
Preheat Maintenance Shielding
Trailing
Other

Energy or Travel
Angle, etc)
Pulsing Current Heat Input (max.)

Tungsten Electrode Size and Type
Mode of Metal Transfer for GMAW or FCAW
Technique (QW 410)

String or Weave Bead
Orifice, Nozzle, or Gas Cup Size
Initial and Interpass cleaning (Brushing, Grinding, etc
Method of Back Gouging

Oscillation
Contact Tube to Work Distance
Multiple or Single Pass (per side)
Multiple of Single Electrodes
Electrode Spacing
Peening
Other
Page 2 of 2
ASME Section IX – PQR

Company Name
PQR No. WPS # Date
Welding Process(es) Type(s)
Joints (QW 402)
.375"
Groove Design of Test Coupon

Material Spec. Temperature Range
Thickness of Test Coupon Other
Diameter of Test Coupon
Other
Gas (QW 408)

Percent Composition
Shielding N/A
SFA Specification
Trailing
AWS Classification
Backing
Filler Metal F-No.
Weld Metal Analysis A-No. Electrical Characteristics (QW 409)
Size of Filler Metal Current
Other Polarity
Amps: Volts
Weld Metal Thickness Tungsten Electrode Size
Other
Positions (QW 405)
Weld Progression (Uphill, Downhill) Travel Speed
Other String or Weave Bead
Oscillation
Preheat (QW 406) Multipass or Single Pass (per side)
Preheat Temp 50oF Single or Multiple Electrodes
Interpass Temp None Other
Other
QW 483 (back)
PQR No.



Macro Results
Other Tests
Type of Test
Deposit Analysis
Other
………………………………………………………………………………………………………………………………………………………………………………….
Welder’s Name Clock No. Stamp No.

Manufacturer
Date By:
Page 2 of 2

Welder(s) Name Identification Number

Test Description
Identification of WPS followed Test Coupon Production Weld
Specification and Type/Grade or UNS Number of base metal(s) Thickness
Welding Process(es)
Type (i.e. manual, semi-automatic) used
Backing (with or without)
Test Coupon Production Weld (dia if pipe)
Base metal P-Number to P-Number
Filler Metal or Electrode Spec (SFA)
Filler Metal F-Number
Consumable Insert (GTAW or PAW)
Filler Metal Type (solid/metal or flux cored/powder)
Process 1: 3 layers minimum Yes No
Process 2: 3 layers minimum Yes No
Position qualified (1G,2G,3G,4G,5G,6G, etc)
Vertical progression (uphill or downhill)
Inert Gas Backing (GTAW, PAW, GMAW)
GMAW Transfer mode (Spray, Globular, Pulse, or Short Circuit)
GTAW Current type/polarity (AC,DCEP,DCEN)
RESULTS
Visual examination of completed weld (QW 302.4)
□ Transverse face and root bends (QW 462.3(a) Longitudinal bends (QW 462.3(b) Side bends (QW 462.2)
Alternative Volumetric Examination Results (QW 191) RT or UT

Fillet weld – fracture test (QW 181.2) Length and percent of defects
Other tests
Mechanical tests conducted by Laboratory test no. Welding supervised by
requirements of Section IX of the ASME Code. Organization
Date By

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API 510 Course

NOTE: These calculations can be open and/or closed book exams.

II. Joint Efficiencies

Remaining Life InternalInspectionInterval

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 Determined by SHORT term or Long Term Calculations

 Newly installed or Change in Service (API 510, par 7.1.2)

 May have different corrosion-rates for large vessels with

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tlast Ͳ trequired :KDWLV.QRZQ"

= 8 yrs CorrosionͲrate = 0.003

tlast Ͳ trequired :KDWLV.QRZQ"

= 8 yrs CorrosionͲrate = 0.003

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Remaining March2000 March 1995

Vessel Thickness = 2.0”

Therefore, the minimum thickness allowed at the deepest pit is;

( ½ required thickness = 1.250”/2 = 0.625”)

 ,VWKHLQVWDOODWLRQRIDQR]]OHZLWKRXWDUHSDG DQ$/7(5$7,21"

A. Inspection plan must be established for all

G. Minimum Contents of Inspection Plan

 SHALL be conducted by the inspector (API 510 par 5.5.2.1)

 Inspector should consult with Corrosion Specialist to determine if it is necessary

 Vessels in non-continuous service, the interval is based on number of years of

 On-stream inspections performed by examiners shall be

 Performed by inspector or qualified others (qualified

 Conditions discovered by others, must be reported to

 Weld Joint Types

 Weld Joint Types

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 Joint Efficiency is based on;

RTͲ1 E=1 RTͲ3 E=0.85

RTͲ2 E=1 E=1 RTͲ4 E=0.70

Joint Efficiency For Seamless Parts SubͲSectionB,

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I :KHWKHUDKHDG HOOLSVRLGDORUKHPLVSKHULFDO PHHWV&RGHUHTXLUHPHQWVJLYHQERWKSUHVVXUHDQGPHWDOWKLFNQHVV

II. WELD SIZE FOR ATTACHMENT WELDS AT OPENING

III. Nozzle Reinforcement

tc = not less than smaller of ¼” or 0.707 x tmin tn

Step2: Calculate the throat size (tc) a

Step 3: Calculate weld size (Fillet weld Leg size);

Variables for nozzles without repads tn

2. One filler metal per process

4. Base metal limited to P1, P3, P4, P5 and P8

5. Dissimilar metals and/or thicknesses are excluded from exam

9. Supplemental Variables are excluded from Exam.

I. WPS/PQR/WPQ – BODY OF KNOWLEDGE

 QW – Divided into 5 Articles

Section IX is focused on THREE things;

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/RQJ7HUP tinitial Ͳ tlast

Determined by SHORT term or Long Term Calculations

Newly installed or Change in Service (API 510, par 7.1.2)

May have different corrosion-rates for large vessels with

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OHVVHURIò\HDUVRU\HDUV

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SHALL be conducted by the inspector (API 510 par 5.5.2.1)

Inspector should consult with Corrosion Specialist to determine if it is necessary

Vessels in non-continuous service, the interval is based on number of years of

On-stream inspections performed by examiners shall be

Performed by inspector or qualified others (qualified

Conditions discovered by others, must be reported to

Weld Joint Types

Weld Joint Types

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Joint Efficiency is based on;

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QW – Divided into 5 Articles

QW102 (Definitions) (see QW492, page 193)

QW110 – Weld Orientation

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Example - WhatistheP-NumberforSA285GrC? $UWLFOH,9

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QW141.1 – Tension Test

QW141.2 – Guided Bend Test

QW141.3 – Fillet Weld Test

QW141.4 – Charpy Impact

QW142 – Special examination for welders

QW144 – Visual examination

QW151 – Tension Test

QW153 – Tension Test – Acceptance Criteria

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In order for a Tension test to pass, the specimen shall

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Face and Root Bend Test 4:DSDJHIRU:36345DQG4:DSDJH:34

Acceptance Criteria 4:SDJH $UWLFOH,

QW-191 Acceptance Criteria 4:SDJH

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NDE – Alternative Inspection (RT/UT in lieu of BENDS 4:SDJH

RT cannot be used to test a welder for either of the following; 4:SDJH

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3. Fails RT exam; 4:SDJH

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