7. The PQR must be _________ to be “Code legal”.

a. certi
fi
ed
b. notarized
c. authorized
d. witnessed

8. Essenti
al vari
able # QW 403.9 has been:

a. correctlyaddressed on the W PS
b. i
ncorrectlyaddressed on the W PS
c. not addressed on the PQR
d. both B & C above

9. The posi
ti
on ofthe groove on the PQR i
s:

a. acceptable as shown
b. unacceptable -essential vari
able not addressed
c. unacceptable -positi
on shown does not correlate to plate
d. both B & C above

10. The PQR shows “stri

ng” beads. The W PS shows “both” stri
ng and weave beads. Thi
s condi
ti
on i
s:

a. unacceptable -doesn’ t meet Code

b. acceptable -meets Code
c. acceptable i
f“stri
ng” beads are i
n the root only
d. acceptable i
f“weave” beads are in the cap pass only

97
98
99
100
101
 ANSW ER SHEET
W ELDING PROCEDURE REVIEW QUESTIONS

102
ASME SECTION VIII

103
ASME SECTION VIII DIVISION 1
SUBSECTIONS - INFORMATION

INTRODUCTION PART UG - GENERAL PART UW - WELDING

x Scope x Materials x General

x General x Design x Materials
x Standards x Openings and x Design
Reinforcements x Fabrication
x Braced and Stayed x Inspection and
Surfaces Tests
x Ligaments x Marking and
x Fabrication Reports
x Inspection and x Pressure Relief
Tests Devices
x Marking and Reports
x Pressure Relief
Devices

PART UCS - CARBON STEEL PART UHA - HIGH ALLOY

x General x General
x Materials x Materials
x Design x Design
x Low Temperature Operation x Fabrication
x Fabrication x Inspection and Tests
x Inspection and Tests x Marking and Reports
x Marking and Reports x Pressure Relief Devices
x Pressure Relief Devices

SECTION VIII DIVISION 1 PRESSURE VESSELS

Pressure Vessels = containers forthe containm entofinternalorexternalpressure.

Pressure sources . external source

. heat (direct or indirect)
. combination

Structure of Division 1 Consists of: 3 subsections

Mandatory Appendices

Nonmandatory Appendices

104
Subsections of
Division 1

Subsection A General Requirements

Part UG General Requirements for all Methods of Construction and Materials

Subsection B Requirements Pertaining to Methods of Fabrication

Part UW Requirements for Pressure Vessels Fabricated by Welding

Part UF Requirements for Pressure Vessels Fabricated by Forging

Part UB Requirements for Pressure Vessels Fabricated by Brazing

Subsection C Requirements Pertaining to Classes of Materials

Part UCS Requirements for Pressure Vessels Constructed of Carbon and Low-Alloy
Steels

Part UNF Requirements for Pressure Vessels Constructed of Nonferrous Materials

Part UHA Requirements for Pressure Vessels Constructed of High-Alloy Steel

Part UCI Requirements for Pressure Vessels Constructed of Cast Iron

Part UCL Requirements for Pressure Vessels Constructed of Material with Corrosion
Resistant Integral Cladding,Weld Material Overlay Cladding,or with Applied
Linings

Part UCD Requirements for Pressure Vessels Constructed of Cast Ductile Iron

Part UHT Requirements for Pressure Vessels Constructed of Ferritic Steels with Tensile
Properties Enhanced by Heat Treatment

Part ULW Requirements for Pressure Vessels Fabricated by Layered Construction

Part ULT Alternative Rules for Pressure Vessels Constructed of Materials Having Higher
Allowable Stresses at Low Temperature

Part UHX New 2003 Addenda Rules For Shell & Tube Heat Exchangers

Mandatory Appendices ects NOT covered elsewhere in the Division

Address specific subj

Requirements are mandatory when the subj

ect is included in
CONSTRUCTION in this Division

Nonmandatory Provide Information

Appendices -- and --
Suggested good practices

Vessels NOT Within Those within the scope of other Sections

105
the Scope of Section VIII,
Division 1 Fired process tubular heaters

Pressure containers which are integral components of rotating or reciprocating

mechanical devices where the primary design considerations are drawn from
the functional requirements of the device.

Piping systems
Piping components (pipe, flanges, bolting, gaskets, valves, expansion joints,
and fittings) and the pressure containing parts of other components (i.e.,
strainers, mixers, separators, snubbers, distribution devices, metering and flow
controlling devices) which are generally recognized as piping components

Water containing vessels with capacity of 120 gallons or less, and those which
contain air (for cushioning)

Hot water storage tank which is:

- - indirectly heated
- - LESS THAN 200,000 Btu/hour
- - water temperature of 210 deg. F. or less
- - capacity of 120 gallons or less

Vessels with internal or external operating pressures of 15 psi or less

regardless of their size

Vessels with an inside diameter, width, height or cross section of 6

inches or less regardless of length

Design Pressures Rules based on vessels whose pressure does NOT exceed 3000 psi

For pressures above 3000 psi, there are usually specific additions to, and
deviations from, the rules of the Code. These special rules must be applied to
all such higher pressure vessels, before it may be stamped (new ASME VIII
Div. 3 to be developed).

Geometry of The scope of this division shall extend to:

Pressure Parts
x Where external piping is connected
- - the welding and connection for the first circumferential joint on welded
connections
- - the first threaded joint for screwed connections
- - the face of the first flange for bolted, flanged, connections
- - the first sealing surface for proprietary connections/fittings

x The weld attaching a nonpressure part directly to the internal or external

surface of a pressure vessel

x Pressure retaining covers for vessel openings (manhole/handhold)

x First sealing surface for proprietary fittings for which there are no rules in this
division such as gauges/instruments

106
Relief Devices and Scope includes those devices necessary to meet requirements of
Unfired Steam Boilers UG-125 through UG-136 and Appendix II

Unfired Steam Boilers (defined in Section I) constructed according to rules in

either Section 1 or this Division UG-125(b) and UW-2©

Pressure vessels in which steam is generated shall be constructed in

accordance with the rules of this Division.

Evaporators or heat exchangers

Where steam is generated by a processing system containing a number of

pressure vessels, such as in the chemical or petroleum industries

Fired Vessels and Pressure vessels or parts which are DIRECT FIRED, and which are
Fired Jacketed Steam not within the scope of Sections I, III, or IV, may be built in Kettles
accordance with the rules of this Division

Gas fired jacketed steam kettles with operating pressures below 50

psi, may also be constructed in accordance with the rules of this Division.

SECTION VIII -DIVISION 1

INTRODUCTION AND SUBSECTION A

U-1,Scope:
The scope of Section VIII - Division 1 should be reviewed closely. It defines what constitutes a pressure vessel
( “containers for the containment of pressure, either internal or external”), and details the overall sections and
subsections of the Code. In Paragraph (c), it states that the Code does not prohibit the use of the "U"Stamp on
any type of pressure vessel, providing all of the rules are satisfied in the final construction. Paragraph (C) goes
on to list 10 general classes of pressure vessels that are generally exempted from the Code. These should be
watched closely, as many jurisdictions with pressure vessel laws adopt these exemptions as shown, and
therefore, a particular vessel may not have to be inspected, stamped or registered if it falls under one of the
exemptions shown. The reader should be cautioned, however, that it is the law at the point of installation that
determines what pressure vessels must be constructed Code in order to be legally operated. Vessels requiring
in-service inspection vary widely from jurisdiction to jurisdiction.

U-1(d) is an important paragraph.. Contrary to what some believe, it does not limit the design of pressure vessel
to 3,000 psi. However, for pressure vessels constructed over 3,000 psi, deviations from and additions to the
rules may be necessary to satisfy the service conditions. If these deviations or additions (such as a complete
stress analysis of each component) still show the vessel meets the Code, then the item may be Code stamped.

U-1(e) is must be clearly understood to ensure a common understanding of where the “pressure vessel” ends
and where the “piping” begins.

107
 manway

Denot
esCodeScopeLi
mit
ati
ons
U-1 (e) describes the minimum boundaries to establish a completed pressure vessel, but does not prohibit the
Code application beyond the terminal points, provided all of the rules are satisfied in the extension and the
materials are properly listed on the Manufacturer’s Data Report. For example, a nozzle boundary can be
extended to any length, including all connecting piping many feet or meters away from the vessel. Conversely, a
nozzle can be extended and be in place when the pressure vessel is tested but still be excluded from the Code
construction by a proper entry on the Data Report. In this case, the nozzle does not have to meet Code
requirements.

U-1(f) states that Section VIII - Division 1 includes provisions for pressure relief devices in UG-125 through UG-
136.

U-1(g) allows alternative construction of unfired steam boilers to Section VIII - Division 1, instead of ASME I, as
some jurisdictions (such as Texas) classify these pressure vessels as boilers and require them to be
constructed under Section VIII.
U-1(h) covers direct fired pressure vessels NOT within the scope of ASME I, III, or IV, and U-1(I) covering gas
fired jacketed steam kettles under 50 psi. Both of these classes of vessels may be constructed to Section VIII -
Division 1, provided it is allowed at the point of installation.

108
U-1(j) provides for "UM" stamping of pressure vessels . Pressure vessels may be stamped "UM" provided full
radiography is not a requirement, no quick-opening closures are employed, and provided the following volume
and/or pressure limits are not exceeded:

(1) 5 cu. ft. - 250 psi

OR
(2) 3 cu. ft. - 350 psi
OR
(3) 1-1/2 cu. ft. - 600 psi

The primary difference between a pressure vessel stamped "UM" and a pressure vessel stamped "U" is that the
pressure vessel stamped "UM" will not have been inspected during construction by an Authorized Inspector.
Manufacturer’s Data Reports will not be furnished except upon specific request by the owner/user. See UG-120
for details.

U-2, GENERAL

U-2 (a) states that the user and/or his designated agent shall establish design requirements for pressure
vessels, taking into account startups, shutdowns, and upset conditions. Other design factors that the
owner/user must convey to the fabricator are:

*the need for corrosion allowance;

*lethal service, if required
*the need for PWHT if for service reasons (i.e., H2S service);
*for unfired steam boilers, the need for fittings complying to ASME I.

U-2(b) covers responsibilities, and clearly states that the manufacturer of the completed pressure vessel has the
total responsibility for Code compliance. The manufacturer of the pressure vessel may subcontract for parts
and/or service to complete the pressure vessel;however, the Manufacturer that will apply the final “U” Code
stamp to the item has the ultimate responsibility to ensure that the proper documentation is received and
available for all work not done by him. ASME stamped parts with Partial Data Reports are usually the document
used to allow manufacturers to accept welded parts from one another. The system of control of subcontracted
services must be defined in each Manufacturers quality control system.

U-2 (C) and (d) are self explanatory.

U-2 (e) requires the Authorized Inspector to make all inspections required by the rules, plus any other
inspections he deems necessary to permit him to certify that, to the best of his knowledge, the pressure vessel
meets the Code requirements. The Authorized Inspector is only required to verify that complete design
calculations exist and that are on file at the time the Data Report is signed. Any questions raised by the
Inspector must be resolved by the Manufacturer.

109
U-2(g) states that Section VIII - Division 1 does not contain rules for all types of construction and states that,
subject to the Inspector’s acceptance, other design rules may be used that will provide equivalent factors of
safety.

U-2(h) describes the methods and means to perform field erection and completion of vessels in the field.
Basically, this can occur in three ways:

(1) The manufacturer completes the pressure vessel in the field;

(2) The manufacturer receives Partial Data Reports for the individual parts, and then Code
stamps and certifies the vessel on a master Data Report, using the partials as supporting
evidence of Code compliance;

(3) The field portion is completed by a sub-contractor and a partial Data Report is
supplied. The Manufacturer, using the sub-contractor’s partial(s) prepares the master
Data Report, and applies the full “U” Code stamp to the vessel.

U-3 and Table U-3

The Table shows the exact year or edition accepted by ASME VIII for reference standards used and specified
throughout the book.

SUBSECTION A
GENERAL REQUIREMENTS

PART UG -GENERAL REQUIREMENTS FOR ALL METHODS OF CONSTRUCTION AND ALL MATERIALS

UG - 1 SCOPE

Part UG establishes general requirements applicable to all pressure vessels, and shall be used in conjunction
with the specific requirements in Subsections B and C that pertain to the methods of fabrication and material.

MATERIALS

UG-4 GENERAL
(a) -This paragraph requires that materials subject to stress due to pressure must be materials conforming to
Section II - Materials Specifications and further limits these materials to materials listed in the applicable Part of
Subsection C, except where allowed in Part UG.

(b) -Non-pressure part materials attached to pressure parts do not have to conform to Section II, but if welded
must be demonstrated to be of weldable quality.

(e ) -Materials outside the limits of size and/or thickness established in a material specification may be used if
the material is in compliance with the other requirements of the specification, and no size or thickness limitations
are shown in the stress tables in Section II Part D.

(f) - The selection of the right material for the intended service is very important, and is stressed here.

110
UG-5 through UG-9
These paragraphs provide some general details on the different product forms. Particular attention should be
given to UG-8, which discusses rules for integrally-finned tubes, and UG-9, which requires welding
consumables to meet the requirements of Section VIII, Section IX, and the welding procedure to be used.

UG-10 MATERIALS NOT FULLY IDENTIFIED TO AN ACCEPTABLE SPECIFICATION

This paragraph provides for the use of materials that are not fully marked or traceable to Code requirements. It
is only allowed to salvage materials that have lost their full identification, or for unacceptable materials that can
be “dual qualified” to a material specification that is acceptable under the rules of the Code.

UG-11 MISCELLANEOUS PRESSURE PARTS

This paragraph provides for the use of pre-fabricated or pre-formed pressure parts made of Code materials and
furnished under recognized standards that will normally not require Data Reports.
Nearly all standard pressure parts used in Section VIII - Division 1 pressure vessels will be supplied under an
ANSI or Manufacturer’s Standard. Manufacturer’s Standard pressure parts are acceptable only if the
manufacturer has detailed literature which describes the parts, materials, forming, etc. All miscellaneous parts
may be seamless or welded. Each part must have an applicable pressure rating, or it must be calculated under
the Code rules using allowable stress values obtained from the applicable stress table in ASME II Part D.

UG-12 - UG-14
Rules for bolts, studs, nuts, washers, and rods/bars are given, and are sometimes overlooked. These
paragraphs should be watched closely, as some simple requirements are given, and must be followed.

DESIGN

UG-16 GENERAL

(b) The minimum thickness of shells and heads, after forming and regardless of service shall be 1/16", exclusive
of corrosion allowance. This rule does not apply to :

* heat transfer plates

* 6" NPS or less inner pipe of double pipe Heat Exchangers
* Unfired steam boilers - 1/4" minimum
* Compressed air, steam, water 3/32"
minimum
* tubes in heat exchangers (air cooled or
cooling tower) provided
conditions a – d are met.

(c ) Plates are allowed an undertolerance of either .01" or 6% of ordered thickness, whichever is less.

(d) Pipe undertolerance shall be per UG-40, which is specified as 12.5% of nominal thickness. This is VERY
important when calculating shells or nozzles made from pipe, as this undertolerance must be considered and
the next heavier schedule must be used to ensure adequate wall thickness for the pressure.

UG-19 SPECIAL CONSTRUCTIONS

Combination units constructed of one or more independent chambers may be built under the rules. Each
chamber of such construction must be designed and constructed as an independent pressure vessel. Where
design rules are not given, a proof test in accordance with UG-101 may be done.

111
UG-20 DESIGN TEMPERATURE
These paragraphs are often overlooked and are very important to know. The maximum and minimum metal
temperatures MUST be established, and the minimum temperature may be based not only on operating
conditions, but also atmospheric conditions at the point of installation.

UG-20(f) This paragraph is very often overlooked when applying impact testing criteria from the other
subsections. This paragraph provides for “blanket” exemptions to the impact testing rules, provided all the
provisions listed (1-5) are complied with.

UG-22 LOADINGS
This paragraph requires that external loads from earthquakes and winds; reactions from piping supports and
lugs; pressure vessel weight; superimposed loads from operating equipment, supports, effects of thermal
reactions and abnormal pressures must be considered when designing a vessel. Specific rules for
“considering” these loadings are not given in the Code, however, many designers use the Pressure Vessel
Handbook or a computer program when confronted with these types of design details.

UG-23 STRESS VALUES

This paragraph guides the user to go to ASME Section II Part D for the allowable stress values for a given
material when calculating any particular vessel.

UG-24 CASTINGS
Steel casting require supplementary inspections in order to use a 90% or 100% quality factor in the design
calculations. The quality factor shall be 80% if only the basic material specification is satisfied. Castings of cast
iron and cast ductile iron are prohibited. See Mandatory Appendix 7 for more requirements on castings.

UG-25 CORROSION
The user or designated agent must tell the vessel manufacturer if corrosion allowance will be needed above and
beyond that required by the Code. This is a contractual matter, and one which the vessel manufacturer will,
undoubtedly, charge more for than for not providing such allowance. The only mandatory requirement for
corrosion allowance exists in Part UCS for pressure vessels used for air, steam, or water and this requirement
may be waived depending on the design used.

(e) Telltale holes are used in pressure vessels as an indicator that a vessel has corroded to a point of losing the
corrosion allowance. They can not be used in pressure vessels containing toxic or flammable substances. UG-
25(e) provides information on size, depth, location, and spacing of telltale holes.

UG-27 THICKNESS OF SHELLS UNDER INTERNAL PRESSURE

These are the basic design formulas and nomenclature for calculating the thickness or maximum allowable
working pressure of a cylindrical or spherical vessel shell. Note that these formulas only apply when the
circumferential joint efficiency is less than ½ the longitudinal joint efficiency and the radius/pressure and
pressure/stress ratios are in proportion to one another. Formulas are given in terms of inside radius. For outside
radius/diameter, the alternative formulas in Appendix 1 may be used.

UG-28 THICKNESS OF SHELLS AND TUBES UNDER EXTERNAL PRESSURE

Rules are given for computing the allowable external pressure on a shell. Note that the applicable External
Pressure Tables in ASME Section II Part D must be used to calculate these thicknesses.

UG-32 FORMED HEADS, PRESSURE ON THE CONCAVE SIDE

Rules for computing the thickness/MAWP of formed heads are provided. Four (4) types of head formulas are
given: Ellipsoidal, Hemispherical, Torispherical, and Conical. Formulas are based on STANDARD shapes with
INTERNAL dimensions (i.e. 2:1 Elliptical Heads). For heads with non-standard dimensions and/or for outside
diameters, the alternative rules in Appendix 1 must be used.

112
UG-33 AND UG-34, CONVEX PRESSURE HEADS AND FLAT HEADS
Rules and formulas are given for calculating required thickness or MAWP are given.

UG-35 OTHER TYPES OF CLOSURES

Spherically dished heads attached by bolts are specified in Appendix 1. Quick-actuating closures (other than
multibolted type) that provide quick access to a pressure vessel shall have the locking mechanism or locking
device designed so that the failure of a single element or component in the locking mechanism cannot result in
the failure of the elements and the release of the closure.

UG-36 THROUGH UG-42

These paragraphs all deal with basically the same issues - making an opening in a pressure vessel, and then
calculating the required reinforcement area to replace the area removed. UG-36 deals specifically with the
opening, and specific attention should be directed towards (b), which discusses maximum sizes of openings,
and (c ) (3) (a), which allows a blanket reinforcement exemption for certain openings in maximum thicknesses.
Note that corrosion allowance is never included in adding reinforcing strength.
UG-37 provides rules and a figure, UG-37.1, for calculating the required reinforcement of any given nozzle not
exempted by UG-36. UG-38 and UG-39 give rules for openings in formed and flat heads. UG-40 provides
narrative follow-up to the pictorial requirements of Figure UG-37.1, by establishing the maximum dimensions
that can be considered for reinforcement on both planes of the opening (parallel and perpendicular). UG-41
discusses the required strength of reinforcing material, and stipulates that the material must be as strong as the
vessel material, or the thickness of the reinforcement must be increased proportionally.

UG-42
The strength of the weld metal, particularly the attachment fillet welds must be calculated when the standard
weld details shown in UW-16 are not applied. Several Figures and formulas are given to allow this computation
to be performed. Reinforcement of multiple openings spaced closely together are covered in UG-42.

UG-43 METHODS OF ATTACHING NOZZLES TO VESSEL WALLS

Welded connections must meet the design details given in UW-15 and UW-16. Rules are given and a Table is
provided that details the requirements for threaded connections to a vessel wall. Note that this is not intended
for pipe-to-pipe connections.

UG-44 FLANGES AND PIPE FITTINGS

The acceptable ANSI standards for flanges and pipe fittings are specified.

UG-45 NOZZLE NECK THICKNESS

This paragraph is commonly misunderstood by many users. Basically, what the paragraph is trying to state is
that the thickness of a nozzle must be designed per UG-27, and additionally, cannot be less than the
SMALLEST of several given values:

* The thickness of the shell or head plus corrosion allowance;

* The minimum (not nominal) thickness of standard wall pipe, plus corrosion allowance.

UG-46 INSPECTION OPENINGS

All vessels subject to corrosion, erosion , or for compressed air shall have inspection openings as outlined or
exempted in this paragraph. Note that vessels with removable heads or covers (such as heat exchangers) do
not require inspection openings. Tell-tale holes complying with UG-25 may be used in lieu of inspection
openings. Also note that vessels over 36" i.d. shall be fitted with manways, or if impractical, at least two 4"x 6"
handholes or equivalent. Minimum manway dimensions are 12” x 16” or 16” circular.

113
UG-47 TO UG-50 BRACED AND STAYED SURFACES AND STAYBOLTS
Rules and design formulas are given for these types of vessels. This is a relatively unused section of the Code,
as not many pressure vessels are made, routinely, with stayed surfaces. The most likely usage would be for flat
heads or tubesheets that are high pressure and would require the extra bracing for strength purposes.

UG-53 LIGAMENTS
Ligaments are those spaces between multiple small openings (such as heat exchanger tubesheets) that must
be calculated to ensure that enough material is left to withstand the expected pressure. Again, this paragraph is
used basically for heat exchangers and unfired steam boilers that will be subject to multiple small openings.

FABRICATION

UG-76 CUTTING PLATES AND OTHER STOCK

Materials may be separated by mechanical means such as machining, shearing, grinding, or by oxygen or arc
cutting. If gas or arc cut, the slag and detrimental discoloration must be removed by mechanical means before
further fabrication. Exposed inside edges of cut materials (such as nozzles) must be chamfered or rounded.

UG-77 MATERIAL IDENTIFICATION (SEE ALSO UG-85)

This paragraph is another commonly overlooked or misunderstood passage. The manufacturer MUST maintain
traceability of ALL pressure retaining parts while the vessel is being fabricated (it is the “ALL” part that most
fabricators don’t understand or appreciate). How each manufacturer accomplishes this is up to him, but it must
be done. If material is to be separated or markings are to obliterated, the transfer of markings may occur either
before or after the operation, provided positive identity can be established to the satisfaction of the Authorized
Inspector.

Each manufacturer’s accepted quality control system must establish the details for control of materials and the
transfer of markings during fabrication. The use of coded markings must be described and available for review.
All new materials supplied must include the full marking as required by the applicable material specification.
Except for pressure parts furnished under an acceptable standard such as ANSI, non-welded material formed
by a subcontractor (such as heads must have the full identification as required by the applicable material
specification and must be supported by a Material Test Report.

UG-78 REPAIR OF DEFECTS IN MATERIALS

Repairs to material by the manufacturer are permitted provided acceptance of the Authorized Inspector is
obtained.

UG-80 PERMISSIBLE OUT-OF-ROUNDNESS

It is nearly impossible to make a perfectly round cylinder or sphere, especially when dealing with steel that has a
tendency to “stretch and relax”. The Code recognizes this fact, and allows some out-of-roundness when rolling
plate into these shapes:

x 1% of inside diameter maximum at no openings;

x 2% of inside diameter maximum when passing through an opening;
x 3% maximum (and recalculation for lower pressure) for enamel lined vessels;
x As calculated by (b) and Figure UG-80.1 for external pressure vessels

114
UG-84 CHARPY IMPACT TESTS
This is an extremely long and rather complicated paragraph that provides rules for HOW AND WHERE to
conduct Charpy Impact Tests when required by Subsection C for each class of material. Most importantly, it
also gives the ACCEPTANCE CRITERIA for each material based on the specific minimum yield strength.

UG-85 HEAT TREATMENT

Contrary to some beliefs, these provisions exist for heat treatment of materials to be carried out by other than
the material manufacturer (such as a subcontractor or the vessel manufacturer). If heat treatment is carried out
by anyone other than the material manufacturer, the pressure vessel manufacturer must maintain control over
this operation, and must ensure the markings described in this paragraph are included.

INSPECTIONS AND TESTS

UG-90 GENERAL
Examination (QC) requirements are established for the manufacturer and Inspection (QA) requirements are
established for the Authorized Inspector. The specific examinations required for each vessel are spelled out in
(b) (1) through (19), with appropriate references to other paragraphs which contain further information about the
subject. The vessel manufacturer must complete these examinations and provide some kind of objective
evidence (as detailed in the written QC Program) that these examinations have been successfully applied.

The Authorized Inspectors assigned duties are also spelled out in (c)(1) and (c)(2). The (c)(2) duties only apply
in a very special circumstance for multiple, duplicate pressure vessel manufacturers that may produce hundreds
of vessels per day at the same location (such as propane tank manufacturers).

The note under UG-92 explains that an Authorized Inspection Agency or AIA means an accredited inspection
agency in accordance with ASME QAI-1.

UG-93 INSPECTION OF MATERIALS

The manufacturer must obtain Material test reports for all plate and items made from plate (such as heads),
except for those items furnished under an ANSI or Manufacturer’s Standard per UG-11. For all other products,
the material can be accepted without MTR’S, provided it is properly marked in accordance with the applicable
markings required by ASME Section II.

(d) - All materials must be examined prior to examination. When a corner joint is made from flat plate, the joint
must be examined prior to welding (and sometimes after welding) by PT or MT to ensure freedom from
laminations.

UG-96 AND UG-97 DIMENSIONAL CHECK/INSPECTION DURING FABRICATION

The manufacturer has the responsibility of making dimensional checks to ensure that the shape and thickness is
acceptable as the vessel progresses through fabrication. The manufacturer shall furnish accurately formed
templates if required by the AI. An internal inspection by the AI must be done prior to closure, where possible.
An internal inspection is required in all lead-lined vessels.

UG-98 MAXIMUM ALLOWABLE WORKING PRESSURE

The terms maximum allowable working pressure (MAWP), design pressure, operating pressure, and working
pressure cause a lot of confusion. Basically, the terms “operating pressure” and “working pressure” are the
same and they relate to the pressure at which the item will actually run, not counting upsets or abnormal
conditions. These pressures are usually substantially less than the design pressure or maximum allowable
pressure. The design pressure is the target pressure of the pressure vessel designer, and can be the same
pressure that will be shown on the vessel stamping and in the Manufacturers Data Report as the maximum

115
allowable working pressure. The maximum allowable working pressure for a pressure vessel is the maximum
pressure permissible at the top of the pressure vessel in its normal operating position and at the operating
temperature specified for that pressure. This is the ABSOLUTE top end that the vessel can experience, and is
the pressure that the relieving devices should be based on.

UG-99 STANDARD HYDROSTATIC TEST

All completed pressure vessels, except for those pneumatically or proof tested in accordance with UG-100 or
UG-101 shall be hydrostatically tested to the requirements of this paragraph. Many believe that the test
pressure will always be 1.3 X MAWP. This is incorrect. This paragraph states that the ratio of the test
temperature to the design temperature must be considered, and therefore, the stress value of ALL materials
used in the vessel must be analyzed to ascertain if the test pressure must be increased to account for this
transition in temperature. It is important to note that pneumatic testing cannot be arbitrarily substituted for the
hydrostatic test.

The possibility of brittle fracture at the time of the hydrostatic test must be considered. Therefore, the Code
recommends the temperature of the test water be at least 30 degrees above the MDMT. The 120 degree
maximum is intended as a safety measure to ensure personnel do not get burned. The weight of the liquid must
also be considered by the designer, for the acceptability and strength of the supports.

UG-100 PNEUMATIC TEST

UG-100 provides for a pneumatic (air or gas) test when the physical size of the pressure vessel and/or the
design is such that it will not support the fluid or the service condition is such that moisture residue is
unacceptable. Safety is the primary consideration when conducting a pneumatic test, and therefore, the rules
differ from the hydrostatic test rules given in UG-99. This is the reason that pneumatic testing is
1.1 X maximum allowable working pressure and extreme care should be taken to not exceed that pressure.
Pressure increments are specified and must be closely followed to ensure the highest degree of safety. Also
see UW-50 for additional NDE that must be conducted when pneumatically testing a vessel.

UG-101 PROOF TESTS TO ESTABLISH MAWP

This paragraph contains provisions for proof testing when design formulas do not exist in the rules.
Proof testing can only be used to establish an allowable working pressure if the Code does not provide a design
formula to calculate the part. Proof testing is very expensive, and usually results in the test vessel being
discarded. The 4 types of proof tests are:
1. Brittle coating
2. Burst test
3. Strain measurement test
4. Displacement measurement test

A procedure must be developed for each test and that acceptance of the procedure must be obtained from the
Authorized Inspector before conducting the test. The proof test shall also be witnessed by and the test results
accepted by the Authorized Inspector.

UG-102 TEST GAUGES

Must have a test indicating gauge, visible to pump operator. Dial gauges must have a range not less than 1 ½
nor more than 4 times the test pressure. All gauges must be calibrated against a calibrated dead weight tester
or master gauge, anytime there is reason to suspect error.

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MARKING AND REPORTS

UG-116 REQUIRED MARKING

Section VIII - Division 1 requires all vessels to be marked (either by direct stamping or nameplate) to identify the
vessel and the basic design conditions relative to the vessel. This information is then traceable to the
Manufacturer’s Data Report, which can be used for further defining the criteria and materials used in
constructing the vessel.

(e) - Note the “RT-1" , “RT-2", “RT-3" and “RT-4" stamping requirements to indicate the extent of radiography
performed. This stamping is directly related to the design joint efficiencies used which also correlates to UW-3,
UW-11, and UW-12. These paragraphs will be discussed in more detail in that section.

(f) - Note also the heat treatment designations - “HT” when the entire vessel has been stress relieved; “PHT”
when only part of the vessel has been stress relieved.

UG-117 CERTIFICATES OF AUTHORIZATION AND CODE STAMPS

This paragraph details how to obtain a Code stamp, and the pre-requisites that must be met prior to applying for
the stamp. The manufacturer must have a contract in force at all times with an Authorized Inspection Agency,
and must have and implement a quality control program in compliance with Appendix 10 requirements. A Joint
Review will be conducted by an ASME Designee (usually a Jurisdictional Representative) and the Inspection
Agency Supervisor to ascertain the acceptability of the quality control program. If acceptable the Team will
submit a recommendation to ASME, and the stamp(s) and certificate(s) will be issued for a 3 year period. Every
3 years, the process is repeated.

UG-118 AND UG-119

These paragraphs are self-explanatory.

UG-120 DATA REPORTS

All ASME Code pressure vessels must be certified by use of a Manufacturer’s Data Report (“MDR”). There are
several kinds and types of data reports, and familiarity with each one is essential not only for new construction,
but also for field verifications, inspections, and repairs/alterations to existing vessels. Basically, there are 6 types
of MDR’s (see non-Mandatory Appendix W:

x U-1 Form - For multi-chamber vessels, such as exchangers

x U-1A Form - For single-chamber, completely shop-fabricated vessels
x U-2 Form - Partial Data Report for U-1 type vessels
x U-2A Form - Partial Data Report for U-1A type vessels
x U-3 Form - For miniature vessels (UM Vessels)
x U-4 Form - For supplement to all other forms, in case lack-of-space is a problem

PRESSURE RELIEF DEVICES

UG-125 THROUGH UG-136

These paragraphs all deal with pressure relief devices, and in particular, are aimed at manufacturers and
assemblers of relieving devices (UV Stamp holders). The key to remember is that these manufacturers and
assemblers all have the same basic kinds of requirements and restrictions imposed on them as for the pressure
vessel manufacturer (QC system requirements, design, test, material requirements, etc.), but are not subject to
the scrutiny of an Authorized Inspector, nor are they required to have MDR’s for each valve produced.

These paragraphs are all fairly straightforward, and will not be covered in detail in this course handout.

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SECTION VIII - DIVISION 1
SUBSECTION B

PART UW REQUIREMENTS FOR PRESSURE VESSELS FABRICATED BY WELDING

UW-1 SCOPE
These rules apply ONLY when producing welded pressure vessels, and should be used as supplemental
requirements to the applicable paragraphs in the Introduction and in Subsection A, Part UG.

UW-2 SERVICE RESTRICTIONS

There are several restrictions placed on welded vessels due to service requirements, such as lethal service,
unfired steam boilers, and direct fired vessels. Most of the restrictions have to do with joint design limitations
and additional radiography requirements.

UW-3 WELDED JOINT CATEGORY

Weld joint categories are basically LOCATIONS on the vessel that are subject to differing degrees or criticality
of stress when pressurized. They are also used by designers to assist the designer in selecting the proper type
of joint and the method of joint examination to satisfy Code requirements. Joint category designations should
not be confused with the TYPE of joint required or the AMOUNT of examination of the joint that must be done to
satisfy the rules of the Code. For example, a Category A weld may be of Type 1 or 2 or 3, and may have full
radiography or no radiography. This will be explained further as we go along.

There are 4 basic joint categories - A, B, C, and D. Category A joints are usually the most critical, as they
usually require the greatest degree of examination for the efficiency allowed. This follows the basic theory of
hoop stress which provides that on any given cylinder, the forces trying to open the vessel longitudinally will be
twice as strong as those trying to separate the vessel circumferentially. Therefore, the next category is B, and
those welds are usually the circumferential joints.

Category C welds connect flanges to nozzles, tubesheets, and flat heads, etc. Category D welds connect
nozzles or chambers to the main shell, and, if the Code is properly followed, will usually see the least amount of
examination (usually only visual).

See the following sketch for a further depiction of weld joint categories and where they are applied.

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UW-5 MATERIALS
States that materials are to comply with the UG section of the Code. Non pressure parts welded to a pressure
part do not have to be fully identified, provided a satisfactory welding procedure using that material has been
tested and qualified.

UW-9 DESIGN OF WELDED JOINTS

Discusses rules for providing a 3:1 tapered transition between surfaces of butt welds when the offset differs by
more than 1/4 of the thickness of the thinner section or 1/8", whichever is less. If formed by weld metal buildup
the taper must be checked by PT/MT per UW-42. Longitudinal joints must be staggered by at least 5 times the
thickness of the thinner plate, unless RT is applied 4" on each side of the circumferential joint.

UW-11 RADIOGRAPHIC AND ULTRASONIC EXAMINATION

Now that weld joint Categories and weld joint types are understood, the degree of examination will be
discussed.

(a) - “full” radiography is discussed in this paragraph. As previously shown, full radiography must be employed
if a joint efficiency penalty is to be avoided. This paragraph is saying that all of the following must be
Radiographically examined over their full length:

¾ All butt welds in shell and heads of vessel defined as lethal service. Plus nozzles over 10” NPS or 11/8
inch wall.

¾ All butt-welds over 11/2 inch thick or less as defined in UCS 57 etc. Note@ P5 materials it may be all
thicknesses.

¾ All butt welds in steam boilers exceeding 50 psi. Plus all nozzles over 10” NPS or 11/8” Wall.

¾ Additionally, other situations may require full radiography for service or excessive thickness that are
irrespective of the designers wishes, such as lethal service, unfired steam boilers or butt welds
exceeding 1.5".

Note that RT is not normally required for nozzle butt welds that neither exceed NPS 10 nor 1 1/8" wall
thickness.

(a) (5) (b) - this paragraph gives a lot of people fits. In a nutshell, it really only matters when calculating
seamless vessel sections and heads or when the vessel will be stamped “RT-2”.

¾ The paragraph says that all category A and D welds must be fully radiographed along their full
length.

¾ All Category A and B welds must be Type 1 or Type 2

¾ Category B and C welds must at least have spot radiography.

If you meet these requirements then what UW-12 (a) says later on is that you select the joint efficiency from
Column (a) of Table UW-12 even though you have not done full radiography on all welds.
You only use the efficiency in Column 9 (b) of Table UW012 when the requirements have not been met.

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(a) (7) - allows UT to be used for the final closure seam on vessels where entry cannot be made.
Absence of RT equipment is not justification for using UT.

CAUTION: There is an ASME Code Case in existence that overrides this rule when applied for thicknesses over
0.5” but does not permit manual ultrasonics.

(b) - discusses “spot” radiography, and references UW-52

(c) - discusses “no” radiography

(d), (e), and (f) - discuss RT rules for electroslag, electrogas, and inertia/friction drive welding processes.

Of course everyone spends so much time trying to understand UW-11 (a) they forget to look at UW-11 (b). For
many people working backwards helps clarify the point. UW-11 (b) discusses and defines ‘ spot’ radiography. It
is clear you may use ‘ spot’ (defined in UW-51 as a six inch area of weld) to check the weld quality and when you
do the penalty is that it drops you into column (b) of Table UW-12 for Joint Efficiency. In this case the vessel will
be stamped RT-3.

UW-11 © tells you when no radiography is required and if it is required and you do not do any then it drops you
in column 9c) of Table UW-12 for joint efficiency. In this case the vessel would be stamdped RT-4.

UW-12 JOINT EFFICIENCIES

UW-3 discussed the CATEGORY of joints that may be used in the vessel. Now we will discuss the TYPE of
joint that can be used for each category. Joint types are listed as 1, 2, 3, 4, 5, or 6 in Table UW-12 (shown on a
following page). As you can see from this Table, the joint types are listed in the far left hand side with a narrative
description of the joint in the next column to the right. The next column lists whatever limitations there are on
using that particular type of joint (if any), and the next column states which joint categories that the joint type can
be used with.

The final 3 columns are the ones that give everyone the most problems - degree of radiographic examination.
These are the columns that are used to find the applicable joint efficiency in the formulas in Part UG (remember
UG-27, and the formula for shells, which had a factor “E” that had to be found?). This is how to arrive at that
number, and will also dictate what stamping will be applied to the vessel (remember UG-116 and the RT-1, 2 , 3
& 4 stamping?). “Full” radiography means that the weld joint has been completely radiographed for it’s full length
per UW-51 rules. “Spot” radiography means that only a portion of the weld may be radiographed to assure
quality and acceptability of the welder’s production work. “No” radiography means just that - no radiography of
the joint has been performed.

The tricky part of using this table is that different types of joints and different degrees of radiography may exist
on the same vessel, and therefore, several calculations may have to be done using the correct efficiency for the
same part of one vessel. Also, most confusing is the fact that the Code Committees state that the design
philosophy used is “consider each joint separately”, but “spot” RT requirements are based on cumulative length
of welds on the entire vessel. This has always been a little inconsistent in some people’s minds. (Note: In 1986,
the Code changed from a “whole vessel” design approach to the current philosophy of “consider each welded
joint separately” - some like it, some don’t).

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The degree of radiographic examination of butt welds, the credit given for radiography, and the stress
reductions for not radiographing and/or using butt welds is an area greatly misunderstood by many designers. If
other than butt welds are used in the pressure vessel or if butt welds are not radiographed the penalty is an
increase in the required wall thickness by decreasing the allowable joint efficiency. However, depending upon
the service, the kind of material, or thickness of the material butt welds, radiography may become a
requirement regardless of the efficiency used in the design calculations.

The Table has been previously discussed, and requires very little further explanation, except to state that the
“limitations” and “joint category” columns are oftentimes overlooked, and must be consulted when finding the
appropriate joint efficiency to be used. Additionally, many people still cannot accept the fact that pressure
vessels can be joined with fillet welds, but as this Table states, the restrictions and efficiencies allow their use
within limitation.

As previously stated, UW-12 (d) is a “tie-in” to UW-11 (a)(5)(b), and pertains to seamless vessel sections and
heads that are not radiographed. This is an area NOT listed on the UW-12 Table, and therefore, gives many
people headaches. Just remember this - only two efficiencies apply for seamless vessels and heads joined by
Category B and C butt welds, either 1.0 for welds that meet the spot RT requirements or 0.85 for those welds
that are NOT Radiographed. Easy way to remember any Radiography E = 1.0 No Radiography E = 0.85

UW-12 (f) - requires an efficiency of .80 for the pressure welding processes, except ERW. Separate production
weld joint test plates must be made for these processes. (See UW-28).

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UW-13 ATTACHMENT DETAILS
Provides rules and sketches for attachment of heads to shells. Discusses tapered transitions in Para (b)(3), and
requires their use when joining abutting sections differing greatly in thickness. Requirements for “offset heads”
(pressed on heads used primarily in propane tanks) are given, with mandatory PT/MT of the offset prior to
attachment of the head (Sketch UW-13.1 (k)).

UW- 14 OPENINGS IN OR ADJACENT TO WELDS

Any opening meeting the reinforcement rules can be located in a weld joint; but non-reinforced openings require
special radiography rules and requirements, particularly when multiple non-reinforced openings are located in
line in a welded joint.

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UW-15 WELDED CONNECTIONS
This paragraph basically states that if you comply with one of the full penetration weld sketches shown in UW-
16, strength calculations are not required. For all other designs, the weld strength must be computed. Telltale
holes are required in reinforcing plates, per this paragraph.

UW-16 ATTACHMENT WELDS AT OPENINGS

Various Figures are shown and nomenclature is given describing the basic requirements for fillet welds and
other weld SIZES (not strength - this was given in UW-15). Many vessel designers have overlooked these
requirements and later had to re-weld the fillet welds because of insufficient size.

UW-21 FLANGE TO NOZZLE NECK WELDS

Minimum dimensions for socket welds (smaller of tn or .7 th ) and slip on flange welds (.7 tn ) are given.

FABRICATION

UW-26 GENERAL
UW-26 through UW-42 cover welding requirements. It is required to use an accepted welding process and to
qualify the welding procedure and welder and/or welding operator to the requirements of Section IX - Welding
Qualifications - prior to production welding.

However, welders not in the employ of the manufacturer can be used, but the manufacturer must add a list of
controls to his QC Manual and he must still qualify them per ASME IX, so it really doesn’t matter who pays
them.

UW-27 WELDING PROCESSES

The acceptable welding processes are given, with the arc/gas processes listed in (a) and the pressure
processes listed (b). Stud welds can only be used for non-load bearing attachments except for ultra-high
strength materials in UHT. Electroslag and electro gas processes can be used with full radiography.

UW-28 QUALIFICATION OF WELDING PROCEDURES

All pressure parts and non-pressure parts must be joined using a welding procedure qualified in accordance
with ASME IX. Non-load bearing attachments using automatic welding do not require procedure qualification.
Standard Welding Procedure (SWP’s) as allowed in ASME IX are specifically allowed here.

UW-29 TEST OF WELDERS AND WELDING OPERATORS

ASME Section IX performance qualification requirements for welders and welding operators are covered in this
paragraph for all pressure boundary welds and the attachment of load and non-load carrying attachments to
pressure boundary parts. Each manufacturer shall maintain a list of qualified welders showing the date and
result of tests, and the letter or number symbol assigned which the welder identifies his work.

UW-30 LOWEST TEMPERATURE

No welding below 0 degrees F is permitted. Between 0 and 32, the weld area should be heated warm to the
hand approximately 60 degrees F.

UW-31 CUTTING, FITTING, ALIGNMENT

Rules for fit-ups, clamps and tackwelds are given. Tackwelds must be properly prepared or must be removed. If
left in the weld, they must be made by a qualified welder. Tack welds made by a subcontractor do not require a
partial data report, but must provide certification for such welds. Joint mismatch tolerances are given in Table
UW-33, and cannot be exceeded

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UW-33 ALIGNMENT TOLERANCE
The alignment tolerances established in Table UW-33 must be followed. Any mismatch WITHIN the tolerance
must be faired at a 3:1 taper. If weld metal is used to taper, the PT/MT requirements of UW-42 must also be
met.

UW-34 SPIN HOLES –

Treat as buttwelds. Must be PT/MT tested after completion.

UW-35 FINISHED LONGITUDINAL AND CIRCUMFERENTIAL JOINTS

Butt welds shall have full fusion and penetration. Surfaces must be relatively free of coarse ripples and valleys
that may mask radiography. The term “undercut” is not used - “reduction in thickness due to the welding
process” is the term used, and 1/32" or 10% of nominal thickness is the allowable reduction. The footnote
clearly states that the intent is NOT to measure this, but if disagreements arise, then its acceptable to measure.
Maximum reinforcement of welds is given in a table in UW-35.

UW-37 MISCELLANEOUS WELDING REQUIREMENTS

Each welder must stamp an identifying number, letter, or symbol at intervals not more than 3 ft. along each
completed weld in ferrous materials 1/4" and over or in non-ferrous materials ½" and over, or a record must be
kept.

UW-39 PEENING
Peening is not prohibited, but can’t be used on the root or cap pass of welds unless subsequently PWHT’d.
Peening cannot be done in lieu of PWHT. Shot peening must be done after any required NDE and pressure
test.

UW- 40 PROCEDURES FOR POSTWELD HEAT TREATMENT

This paragraph gives basic procedures for conducting PWHT, when required by the various material
requirements in Subsection C. Basically, there are 8 ways to conduct PWHT:
1. Heating the whole vessel
2. Heating portions of the vessel in overlap stages
3. Heating Longitudinal joints and then circ. joints locally
4. Heating the vessel internally
5. Heating a band around the vessel containing nozzles
6. Heating the circ. joints in pipe or tube
7. Heating a local area around nozzles or welded attachments
8. Heating of other configurations than those about in (1) - (7)
This paragraph also contains the definition for “nominal thickness” as used in UCS-56.

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UW-42 SURFACE WELD METAL BUILDUP
Salvaging material by weld build-up to restore metal thickness and for using deposited weld metal to obtain the
transition between transition in thicknesses is described in this section. MT or PT is required in these areas.
Appendix 6 - Magnetic Particle, Appendix 8 - Liquid Penetrant, both of these appendices reference ASME
Section V for procedural details, and both contain acceptance criteria when conducting the examinations.

UW-50 NDE OF PNEUMATICALLY TESTED VESSELS

All welds around openings and attachment welds greater than 1/4" shall be MT/PT examined
prior to air/gas testing vessels.

UW-51 RADIOGRAPHIC EXAMINATION OF WELDED JOINTS

This section pertains to “full” RT. requirements, as discussed in earlier sections. Section V, Article 2, is required
for technique, and personnel must be qualified to a program that is in compliance to SNT-TC-1A. Alternatively,
personnel may be qualified and certified to the provisions contained in the ASNT Central Certification Program
or in CP-189. The final acceptance of a radiograph is based on meeting the density requirements and the ability
to show outline and the applicable hole or wire in the required IQI. A radiography written procedure is not
required, as specified in ASME V. The acceptance criteria is set forth in UW-51(b). UW-51(c) discusses rules for
Real Time Radioscopic Examination.

UW-52 SPOT RADIOGRAPHY

Spot RT is only a quality tool based on a random sample, and may allow defective welding to exist that will be in
accordance to code rules. This is very hard for people to understand, particularly when the vessel is
radiographed 10 years later in the field, and this “bad” welding is found. The rules state that :

x One spot for each 50 ft. of weld

x One spot for each welder or operator
x Locations to be chosen by the Inspector, except when he cannot make the choice due to absence
x Acceptance standards different than UW-51
UW-53 ULTRASONIC EXAMINATION
Ultrasonic examination can be used as a substitute for radiography to examine closure seams where
meaningful radiographs cannot be obtained. UT is also required as a supplement to radiography for some
electroslag and electrogas welds. Appendix 12 establishes the acceptance criteria for ultrasonic examinations
and references Section V, Article 5, for technique. Written procedures are required for ultrasonic examinations.

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SECTION VIII DIVISION 1

SUBSECTION C-REQUIREMENTS PERTAINING

TO CLASSES OF MATERIALS

PART UCS-REQUIREMENTS FOR PRESSURE VESSELS CONSTRUCTED OF CARBON

AND LOW-ALLOY STEELS
GENERAL

UCS-1 SCOPE
The rules in PART UCS are applicable to pressure vessels and pressure vessel parts constructed of carbon and
low-alloy steels. It is to be noted that the materials shall be limited to those listed in Table UCS-23 of ASME
Section II Part D. Part UCS should be used in combination with other materials covered in other sections of
Section VIII - Division 1. PART UCS is relatively straightforward (except for impact testing) and does not usually
create many problems for the reader.

MATERIALS

UCS-5 GENERAL
Carbon or low alloy steel having a carbon content greater than .35% shall not be welded or be oxygen cut.

UCS-6 STEEL PLATES

Structural steels can be used for pressure retaining materials, but are limited to SA-36, SA/CSA G40.21 38W
and SA-283 Grades A, B, C, and D with the following restrictions:

1. The vessel can not contain a lethal substance;

2. Not allowed in unfired steam boilers;
3. Shells, heads, and nozzles the plate thickness for high-strength welding is limited to 5/8”.

UCS-11 NUTS AND WASHERS

These are very simple, straightforward requirements, but are oftentimes overlooked by Code users. Note the
threading requirements in (c).

UCS-27 SHELLS MADE FROM PIPE

Seamless pipe may be used for shells and/or nozzles in a pressure vessel. ERW pipe is limited in diameter to
30 inches, if the material is produced by the open-hearth, basic oxygen, or electric-furnace methods.

UCS-56 REQUIREMENTS FOR POSTWELD HEAT TREATMENT

Welding procedures must be qualified with the correct PWHT time/temperature per ASME IX before applying
these requirements. The Tables shown provide EXEMPTIONS to mandatory PWHT - unless exempted, ALL
carbon/low alloy vessels shall be PWHT’d. If PWHT is a service requirement, the exemptions do not apply.
Table UCS-56.1 allows an increase in holding time for a reduction in temperature.

Provides clear rules for the initial temperature, the up/down heating rates, and the allowed cooling after PWHT.

Allows some limited base metal repairs after PWHT, but contractual arrangements usually preclude this from
happening.

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UCS-57 RADIOGRAPHIC EXAMINATION
Table UCS-57 is an overriding requirement that mandates full radiography of butt welds based on thickness and
material REGARDLESS of service or joint efficiency. Again, this paragraph takes precedence over the other
requirements, and must be consulted when constructing carbon/low alloy vessels.

TABLE UCS-57
THICKNESS ABOVE WHICH FULL RADIOGRAPHIC
EXAMINATION OF BUTT WELDED JOINTS IS MANDATORY

___________________________________________________________________________________

P-NO. & GR. NO. NOMINAL THICKNESS ABOVE

CLASSIFICATION WHICH BUTT WELDED JOINTS
OF MATERIAL SHALL BE FULLY RADIOGRAPHED, IN.
___________________________________________________________________________________

1 GR. 1, 2, 3 1 1/4
3 GR. 1, 2, 3 3/4
4 GR. 1, 2 5/8
5 GR. 1, 2 0
9A GR. 1 5/8
9B GR. 1 5/8
10A GR. 1 3/4
10B GR. 2 5/8
10C GR. 1 5/8
10F GR. 6 3/4
___________________________________________________________________________________

LOW TEMPERATURE OPERATION

UCS-66 MATERIALS
This paragraph deals and the accompanying Tables are probably the most misunderstood and hardest to apply.
Basically, the idea here is not about when you MUST impact test your materials, but how to GET OUT OF
impact testing your materials. This is reasonable, because if your base metal must be impact tested, then:

x the weld metal must be impact tested (or be bought with results listed)
x the welding procedures must be impact tested upon qualification
x the production welds must be impact tested

As one can imagine, this is quite a lengthy and involved process, and can be quite expensive if not performed
correctly. Therefore, it is in the fabricator’s best interest NOT to run impact tests if it can be avoided.

Fig UCS-66 lists exemptions for various grades and types of materials. The key to using this chart is to find the
Curve assigned to the specific material in question. If the material thickness and corresponding temperature are
ON or ABOVE the assigned curve, the material is exempted from impact testing. If the point of intersection falls
below the curve, the material must be impact tested.

127
If the material must be impact tested per Fig. UCS-66 then another “out” is provided in Fig. UCS-66.1. This
graph allows the designer to “over design” the vessel by making it more thick, and thereby increasing the safety
factor. This then allows for a reduction in the minimum design metal temperature without having to perform
impact testing. The flow chart provided in Fig. UCS-66.2 explains all this in a more clear-cut fashion.

UCS-67
As previously stated, if the base metal requires impact tests, then so too does the welding procedure.
Additionally, rules are given for welds made without the use of filler metal.

UCS-79 FORMING SHELL SECTIONS AND HEADS

When rolling or forming metal, the fibers will expand as the metal is formed, but residual stresses will be “locked
in” if PWHT is not performed. This is especially critical on items rolled from thick materials into a small radius.
Therefore, this paragraph gives rules for when PWHT will be required.

UCS-85 HEAT TREATMENT

Contrary to some beliefs, this paragraph only applies when the vessel manufacturer completes the material
specification heat treatments. It does not apply to regular PWHT requirements.

MANDATORY APPENDICES
The Mandatory Appendices are VERY important and should not be overlooked. In particular, the appendices
that will usually be consulted most often are:

x App. 1 - Supplemental Design Formulas

x App. 3 - Definitions
x App. 4 - Rounded Indication Charts (porosity) for RT acceptance
x App. 6 - Magnetic Particle methods
x App. 8 - Liquid Penetrant methods
x App. 12 - Ultrasonic examination of welds

Remember, all of these appendices are MANDATORY, and must be applied when referenced by the main body
of the Code. Many times users forget about these requirements stuck “way in the back”, but they must still be
followed, obscure as they are.

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 Open Book Practice Questions
ASME SECTION VIII, DIV. 1 PRACTICE QUESTIONS

1. An item, which can not be found on a mill test report for material, is:

A. SA Specification number
B. Heat number
C. Allowable stress value
D. Chemical composition

2. What is the minimum thickness of plate that can be used in the shell or head of a pressure vessel?

A. 1/4”
B. 3/16”
C. 1/16”
D. There is no minimum thickness

3. Surface defects in materials may be repaired when:

A. Approved by the Inspector

B. Accepted by the engineering department
C. Approved by the pressure vessel engineer
D. Less than 2” in depth

4. Design and fabrication of power boilers is in accordance with which of the following:

A. ASME Section I
B. ASME Section VIII
C. Engineering Guides and General Specifications
D. API – Pressure Vessels

5. Which of the following types of heads will normally require the greatest wall thickness?

A. 2:1 elliptical head

B. Dished torispherical
C. Hemispherical head
D. Flat head

6. Design and fabrication of pressure vessels shall be in accordance with which of the following:

A. ASME Section I
B. ASME Section VIII
C. Engineering Guides and General Specifications
D. API – Pressure Vessels Section IV

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7. A nozzle was originally PWHT when the vessel was constructed because of lethal service application.
The material was SA-516 Gr 70 with a thickness of 1/8 in. A full thickness repair is made. The
minimum holding time is _____ hours.

A. 1/2 hour
B. 1/4 hour
C. 1 hour
D. 4 hours

8. The maximum deviation from the true circular form of a vessel shall not exceed:

A. 2%
B. 1%
C. 10 % of the nominal inside diameter
D. 5%

9. DELETED

10. For non-ferrous and ductile cast iron, a casting quality factor of _________ maximum should be applied.

A. 80%
B. 90%
C. 100%
D. 70%

11. Which of the following liquid penetrant indications would be unacceptable?

A. Relevant linear indications

B. Relevant rounded indications greater than 3/16”
C. Four or more relevant rounded indications in a line separated by 1/16” or less
D. All of the above

12. According to the ASME Code, Section VIII, the metal temperature during pneumatic test shall be at
least _____ above the minimum design metal temperature to minimize the risk of brittle fracture.

A. 20qF
B. 30qF
C. 40qF
D. 50qF

13. The maximum postweld heat treatment cooling rate required for a 1 1/2inch, SA-516 Gr. 70 material,
flush patch installed as part of a repair to a pressure vessel is:

A. 333qF/hr
B. 500qF/hr
C. 267qF/hr
D. 400qF/hr

130
14. Ultrasonic examination may be substituted for radiography when:

A. Radiographic equipment is not available

B. Final closure seam of a vessel does not permit interpretable radiographs
C. Required by the designer
D. Final closure seam exceeds 2-in. thickness

15. If a vessel is so large that it must be PWHT in more than one heat, what is the minimum overlap in the
furnace?

A. 5’
B. 10’
C. 15’
D. 50’

16. What documentation is required for a plate of SA-516 Gr. 70 material to be used in a repair procedure?
A. A certified material test report
B. A certificate of conformity
C. A material test report
D. A certified certificate of compliance

17. A vessel nameplate is stamped RT 4 this indicates that:

A. Only part of the complete vessel has satisfied the radiographic requirements of UW-11(a)
B. The complete vessel satisfies the requirements of UW-11(a)(5) and the spot radiography
requirements of UW-11(a)(5)(b) have been applied
C. All butt welds have been 100% radiographed
D. All butt welds have been spot radiographed per UW-52

18. What is the maximum allowable working pressure of a vessel?

A. The vessel’s design pressure

B. The vessel’s design pressure plus the static head
C. The maximum gauge pressure permitted at the bottom of the vessel, which includes hydrostatic
head
D. The maximum gauge pressure permitted at the top of the vessel

19. The symbol “HT” on a pressure vessel nameplate indicates:

A. Vessel was hammer tested

B. Whole vessel was Post Weld Heat Treated
C. Vessel is good for high temperature
D. Vessel was hydrotested

20. If an additional ASME Code nameplate (in addition to the original nameplate) is installed on the skirt,
jacket or other permanent attachment to the vessel, how should the nameplate be marked?

A. SAMPLE
B. DUPLICATE
C. ADDITIONAL
D. EXTRA

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21. A welded carbon steel joint has an MDMT that is colder than 120qF, at what governing thickness must
impact tested materials always be used?

A. > 4 in.
B. < 2 in.
C. 6 in.
D. 3 in.

22 The Manufacturer’s Data report for a shop fabricated single chamber pressure vessel is:

A. U-1
B. U-3
C. U-1A
D. U-2

23. An isolated rounded indication is found in a 3/4 inch thick weld. The maximum acceptable size is:

A. 0.250 in.
B. 0.156 in.
C. 0.031 in.
D. 0.568 in.

24. What is the minimum size for a liquid pressure relief valve?
A. NPS 3/4
B. NPS 1/4
C. NPS 1/2
D. NPS 1 1/2

25. If a user signs a contract to build a pressure vessel on May 1, 1997, what edition and addenda of the
Code would be mandatory?

A. 1995 Edition, Addenda 1996

B. 1995 Edition, Addenda 1995
C. 1995 Edition, No Addenda
D. The date of the edition when the vessel is completed

26. Which of the following is not considered a piping component and therefore not exempt from the scope
of the Code?

A. Pipe
B. Fittings
C. Valves
D. Product storage vessel

27. Which of the following pressure vessel categories are exempt from inspection by an Authorized
Inspector during construction?

A. Those having a volume of 5 cu ft and design pressure of 250 PSI

B. Those having a volume of 3 cu ft and design pressure of 400 PSI
C. Those having a volume of 1.2 cu ft and design pressure of 900 PSI
D. Those having a volume of 1.5 cu ft and design pressure of 605 PSI

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28. Deleted

29. Who establishes the design requirements for a new pressure vessel?

A. Manufacturer
B. Design firm
C. The user or his designated agent
D. ASME

30. Which of the following are classified as service restrictions under Section VIII, Division 1?

A. Lethal
B. Vessels operating below certain temperatures
C. Unfired steam boilers exceeding 50 PSI
D. All of the above

31. Vessels containing lethal substances are required to be postweld heat treated in what thicknesses?

A. All
B. Above 5/8 in.
C. Above 1 1/4 in.
D. Above 1 in.

32. Butt welds in vessels that contain lethal substances are required to be _____ radiographed.

A. Spot
B. Fully
C. Partially
D. None of the above

33. Pressure vessels subject to direct firing do not permit what type weld joints for Category A and B joints?

A. 3
B. 4
C. 1
D. None of the above

34. Longitudinal welded joints within the main shell or nozzles are Category _____.

A. C
B. D
C. A
D. B

35. The temperature used when calculating the required thickness of a shell or head is known as the _____
design temperature.

A. Marginal
B. Minimum
C. Maximum
D. Optimal

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36. The acronym MDMT stands for _____.

A. Major Design Method Theory

B. Minimum Design Metal Temperature
C. Maximum Design Metal Temperature
D. Minimum Design Material Temperature

37. Which carbon low-alloy material listed below can be exempted from impact testing per UG-84?

A. P-No. 8, 1/2 in.

B. P-No. 1, Group 3, Curve E, 1 in.
C. P-No. 1, Group 1 or 2, Curve C, not exceeding 2 in.
D. P-No. 1, Group 1 or 2, Curve D, not exceeding 1 in.

38. P-No. 1, Group 1 or 2 material listed on Curve A is exempted from impact testing if it does not exceed
_____.

A. 1 in.
B. 2 in.
C. 1/2 in.
D. 9/16 in.

39. Loadings to be considered in designing a pressure vessel are:

A. Internal and external pressure

B. Wind
C. Snow
D. All of the above

40. If a steel casting has a weld seam with a joint efficiency of 0.70 and is examined in accordance with the
minimum requirements of the material specification, what would be the appropriate “E” value to use
when calculating the required thickness of the casting?
A. 0.70
B. 1.00
C. 0.80
D. 1.00

41. You are calculating the required thickness of a cylindrical shell under internal pressure. The inside
radius including corrosion allowance is 24 in. The corrosion allowance is 0.125 in. What inside radius
would you use?

A. 24 in.
B. 24.125 in.
C. 48.50 in.
D. 26 in.

42. A full size Charpy impact test specimen has a dimension of _____.

A. 10 mm x 11 mm
B. 0.394 in. x 0.394 in.
C. 0.394 in. x 0.393 in.
D. 0.262 in. x 0.394

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43. What is done when full size impact test specimens cannot be obtained?

A. Estimate the ft-lbf that could be obtained

B. Refer to standard tables
C. Subsize specimens are to be used
D. Use a drop weight test as an alternative

44. You are to impact test a material, which is 1 in. thick, and has a minimum specified yield strength of 55
ksi. What is the required average for the 3 specimens?

A. 20 ft-lbf
B. 15 ft-lbf
C. 30 ft-lbf
D. 50 ft-lbf

45. When full radiography is required of the Category A and D butt welds, the Category B and C butt welds
shall as a minimum meet the requirements for _____.

A. Full radiography in accordance with UW-51

B. Spot radiography in accordance with UW-52
C. Partial radiography in accordance with UW-53
D. Spot radiography in accordance with UW-51

46. Ultrasonic examination in accordance with UW-53 may be substituted for radiography for what
condition?

A. It is never permitted
B. When radiographic equipment is not available
C. For the final closure seam if the construction does not permit interpretable radiographs
D. For longitudinal welded seams when they are in excess of 1 1/4 in.

47. Joint efficiencies for welded joints shall be in accordance with _____.

A. Subsection C
B. UW-11(a)(5)(b)
C. Paragraph UW-12(d)
D. Table UW-12

48. When a value of E is taken from column (a) of Table UW-12 what are the values for Type 1 and Type 2
welded joints?
A. 1.00 & 0.90
B. 1.00 & 0.85
C. 0.85 & 0.70
D. 0.85 & 0.65

49. What would be the value of E for a butt-welded longitudinal joint welded from both sides on pipe?

A. 1.00
B. 0.85
C. 0.45
D. 0.60

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50. Material for pressure parts shall comply with the requirements for materials given in ___.

A. UG-4 thru UG-15

B. UG-93
C. UW-15
D. UG-15 thru UG-27

51. Material for non-pressure parts, which are welded to the vessel _____ prior to being used in the vessel.
A. Must be tested using PT or MT
B. Must be proven of weldable quality
C. Must be ultrasonic thickness tested
D. Must be pressure tested

52. For material which is not identifiable in accordance with UG-10, UG-11, UG-15, or UG-93, proof of
weldable quality can be demonstrated by:

A. Using weld material which meets the requirements of an SFA specification

B. Preparing a butt joint test coupon from each piece of non-identified material and making guided
bend tests
C. Satisfactory qualification of the welding procedure
D. Both 2 and 3 above

53. When adjacent abutting sections differ in thickness by more than the lesser of one-fourth the thickness
of the thinner section of 1/8 in. what must be done?

A. Provide a tapered transition of at least 3:1

B. Make six inch radiograph
C. Nothing
D. Provide a tapered transition of at least 4:1

54. Longitudinal welded joints of adjacent courses shall be separated by at least _____ to avoid additional
radiographic requirements.

A. Five times the minimum thickness of the plate

B. Five times the thickness of the thicker plate
C. Six inches
D. Four times the thickness of the thicker plate

55. Full radiography is required for which of the following butt welds:

A. In shells and heads of vessels containing lethal substances

B. In shells and heads of unfired steam boilers having design pressures less than 50 PSI
C. In all vessels where the least nominal thickness exceeds 1 in.
D. None of the above

56. Category B and C butt welds in nozzles and communicating chambers never require radiographic
examination provided they neither exceed:

A. NPS 10
B. 1 1/8 in.
C. NPS 6
D. NPS 10 nor 1 1/8 in.

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57. What formula would be used to determine the internal design pressure for a circular unstayed flat
cover?

A. UG-34, (1)
B. UG-34, (3)
C. UG-32 (e)
D. UG-34, (7)

58. The maximum inside diameter of a welded opening in a vessel head of 1/2 in. thickness, which does not
require a reinforcement calculation, is _____.

A. 3 1/2 in.
B. 6 in.
C. 3tr
D. 2 3/8 in.

59. No two isolated unreinforced openings shall have their centers closer to each other than:

A. Five times their radii

B. The sum of their diameters
C. 3d
D. 12 in.

60. When calculating the required thickness of a seamless nozzle for a reinforcement problem and the
nozzle is made from ERW pipe what efficiency would be used?
A. 0.65
B. 0.90
C. 1.00
D. 0.85

61. The allowable stresses of the nozzle and shell are 17500 and 13800 respectively, what would be the
maximum strength reduction factor?

A. 1.00
B. 1.268
C. 0.788
D. 0.60

62. What happens to the formula for A in Figure UG-37.1 when fr1 = 1.0?

A. Nothing
B. Everything after the plus (+) sign is equal to 0
C. (1 – fr1) = 1
D. F becomes 0.5

63. When calculating the limits of reinforcement normal to the surface and there is no reinforcing element
installed the value of _____ is used for te.

A. 1.0
B. 0.5
C. 0
D. 32

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64. The governing limit of reinforcement parallel to the vessel surface is the larger of:

A. R or Dn + t
B. D or Rn + tn + t
C. d or Rn + tn + t
D. 1 or 3 above

65. What is the set pressure tolerance for a pressure relief device set at 350 PSI?

A. +/- 2 PSI
B. +/- 30 PSI
C. +/- 10.5 PSI
D. +/- 15%

66. A pressure vessel, which is 50 in. inside diameter, has a flat spot. What is the maximum permitted out
of roundness at this location?

A. 2.00 in.
B. 1.00 in.
C. 0.750 in.
D. 0.500 in.

67. The formula that is to be used calculating thickness and pressure for cylindrical shells subject to
circumferential stress is found in Appendix _____.
A. 1-1, formula 2
B. 1-1, formula 1
C. 1-4, formula 3
D. 1-8, formula 1

68. When calculating the required thickness for external pressure of a shell factor B must be determined.
Considering the Do / t ratio what are the three parameters required to determine the factor?
A. Material, stress, temperature
B. Factor A, modulus of elasticity, material
C. Factor A, material, and the design temperature
D. Thickness, factor A, design temperature

69. A nozzle similar to Figure UW-16.1, sketch (e) has a shell thickness of 9/16 in. and a nozzle thickness
of 3/4 in., what is the value of tmin?

A. 9/16 in.
B. 1/2 in.
C. 1 1/2 in.
D. 1 in.

70 Two shells are to be butt welded together to form a circumferential joint. Each shell is 1” thick. What is
the maximum permitted offset?

A. 3/16 in.
B. 1/4 t
C. 1/8 in.
D. 3/4 in.

138
71. Pressure vessels with a volume of 1 1/2 cu ft and 600 PSI design pressure can be exempted from
Authorized Inspection provided they are not to be _____.

A. Provided with quick actuating closures

B. Used for water service only
C. Used for steam service less than 400oF
D. Used for noncorrosive service

72. If a head is formed with a flattened spot what is the C factor that must be used?

A. 0.33m
B. 0.25
C. 1.2
D. 0.17

73. When performing thickness calculations for shells and tubes under external pressure what value must
first be determined?

A. L / Do ratio
B. D / D ratio
C. Do / t ratio
D. t / Do ratio

74. Reinforcing plates and saddles of nozzles attached to the outside of a vessel shall be provided with at
least one telltale hole _____ in size.

A. Maximum NPS 1/4 tap

B. Maximum NPS 2
C. Maximum NPS 1/2 tap
D. 2 in.

75. A pressure vessel is to be hydrostatically tested in accordance with the ASME Code. The MAWP is 654
PSI. Sd = 8600 PSI and St = 17500 PSI. What is the minimum required test pressure?

A. 981
B. 818
C. 1730
D. 1308

76. The temperature of the furnace shall not exceed _____ oF at the time the vessel or part is placed in it.

A. 600
B. 500
C. 800
D. 300

77. Ultrasonic examination of welds shall be performed using methods described in _____ of ASME Code
Section V.

A. Article 1
B. Article 4
C. Article 5
D. Article 23

139
78. Ellipsoidal heads of what ratio are calculated using the formula in UG-32?

A. 3:1
B. 2:1.2
C. 4:1
D. 2:1

79. It is recommended that no welding be performed when the metal temperature is lower than _____oF.

A. 32
B. 60
C. 0
D. 5

SECTION VIII, SUBSECTION A QUESTIONS

80. If a user signs a contract to build a pressure vessel on January 1, 1997, what edition of the Code would
be applicable as a minimum?

A. 1995 Edition, Addenda 1996

B. 1995 Edition, Addenda 1995
C. 1995 Edition, no Addenda
D. The date of the edition when the vessel is completed

81. Which of the following is not considered a piping component and therefore not exempt from the scope
of the Code?

A. Pipe
B. Fittings
C. Valves
D. Product storage vessel

82. Which of the following pressure vessel categories are exempt from inspection by an Authorized
Inspector during construction?

A. Those having a volume of 5 cu ft and design pressure of 250 PSI

B. Those having a volume of 3 cu ft and design pressure of 400 PSI
C. Those having a volume of 1.2 cu ft and design pressure of 900 PSI
D. Those having a volume of 1.5 cu ft and design pressure of 605 PSI

83. Pressure vessels with a volume of 1 1/2 cu ft and 600 PSI design pressure can be exempted from
Authorized Inspection provided they are not required by the rules to be _______.

A. Provided with quick actuating closures

B. Used for water service only
C. Used for steam service less than 400oF
D. Used for noncorrosive service

84. Who establishes the design requirements for a new pressure vessel?

A. Manufacturer
B. Design firm
C. The user or his designated agent
D. ASME

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85. What is the date of the acceptable edition of SNT-TC-1A to be used for new construction?

A. 1992
B. 1984
C. 1996
D. 1975

86. Material subject to stress due to pressure shall conform to _____.

A. ASTM, latest edition

B. Section VIII, Division 1, Subsection B
C. Section VIII, Division 1, Subsection C
D. Section II

87. Which of the following parts are not considered to be subject to stress due to pressure?
A. Reinforcing pads
B. Legs of the vessel
C. Shells
D. Stiffening rings

88. The term plate is considered to also include:

A. Strip and sheet

B. Lugs
C. Skirts
D. Baffles

89. Welding materials only have to comply with the requirements for _____ to be used in the manufacture
of a pressure vessel.

A. Carbon content
B. Proper chemistry
C. Correct length
D. Marking or tagging

90. The Code paragraph that allows using of a material that is not fully identified with a specification
permitted by the Code is _____.

A. UG-77
B. UG-10
C. Appendix 3
D. UG-11

91. When no specific exceptions apply, the minimum thickness of the heat transfer plates of plate type heat
exchangers is _____.

A. 1/4 in.
B. No minimum
C. 1/16 in.
D. 3/8 in.

141
92. Plate material may be used at full design pressure when the mill undertolerance does not exceed
_____.

A. 12 1/2%
B. 18%
C. The value established by the owner
D. The smaller of 0.01 in. or 6% of the ordered thickness

93. Pipe is ordered by its nominal thickness, where would this manufacturing undertolerance limits be
found?

A. In the owners purchasing specification

B. In Section VIII, Division 1
C. In Section II, Part D
D. In the pipe and tube specifications listed in Subsection C

94. The dimensional symbols used in the design formulas throughout the Code represent dimensions in the
_____ condition.

A. Corroded
B. As built
C. As designed
D. Normally desirable

95. The temperature used when calculating the required thickness of a shell or head is known as the _____
design temperature.
A. Marginal
B. Minimum
C. Maximum
D. Optimal

96. The acronym MDMT stands for _____.

A. Major Design Method Theory

B. Minimum Design Metal Temperature
C. Maximum Design Metal Temperature
D. Minimum Design Material Temperature

97. Which carbon low-alloy material listed below can be exempted from impact testing per UG-84?

A. P-No. 8, 1/2 in.

B. P-No. 1, Group 3, Curve E, 1 in.
C. P-No. 1, Group 1 or 2, Curve C, not exceeding 2 in.
D. P-No. 1, Group 1 or 2, Curve D, not exceeding 1 in.

98. P-No. 1, Group 1 or 2 material listed on Curve A is exempted from impact testing if it does not exceed
_____.
A. 1 in.
B. 2 in.
C. 1/2 in.
D. 9/16 in.

142
99. Loadings to be considered in designing a pressure vessel are:

A. Internal and external pressure

B. Wind
C. Snow
D. All of the above

100. If a steel casting has a weld seam with a joint efficiency of 0.70 and is examined in accordance with the
minimum requirements of the material specification what would be the appropriate “E” value to use
when calculating the required thickness of the casting?

A. 0.70
B. 1.00
C. 0.80
D. 1.00

101. You are calculating the required thickness of a cylindrical shell under internal pressure. The inside
radius including corrosion allowance is 24 in. The corrosion allowance is 0.125 in. What inside radius
would you use?

A. 24 in.
B. 24.125 in.
C. 48.50 in.
D. 26 in.

102. What is the weld joint efficiency to be used on an NPS 12 nozzle of P-No. 1 material butt welded to a
3/4 in. shell, which has a backing strip, left in place and is spot radiographed?

A. 0.85
B. 0.60
C. 1.00
D. 0.80

103. When performing thickness calculations for shells and tubes under external pressure what value must
first be determined?

A. L / Do ratio
B. D / D ratio
C. Do / t ratio
D. t / Do ratio

104. You are calculating the required thickness for external pressure of a shell having a Do / t ratio of 66.
The actual L / Do ratio is 75. At what value would you enter Figure G on the L / Do ordinate?

A. 50
B. 75
C. 0.50
D. 0.20

143
105. When calculating the required thickness for external pressure of a shell factor B must be determined.
Considering the Do / t ratio what are the three parameters required to determine the factor?

A. Material, stress, temperature

B. Factor A, modulus of elasticity, material
C. Factor A, material, and the design temperature
D. Thickness, factor A, design temperature

106. The minimum required thickness of a formed head with pressure on the concave side is the thinnest
point after _____.

A. Cutting the plate

B. Forming
C. Heat treating
D. Welding

107. Ellipsoidal heads of what ratio are calculated using the formula in UG-32?

A. 3:1
B. 2:1.2
C. 4:1
D. 2:1

108. The semiellipsoidal form is defined as:

A. The minor axis equals one-half the inside head diameter

B. Half a sphere
C. Half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the outside
head diameter
D. Half the minor axis (inside depth of the head minus the skirt) equals one-fourth of the inside
head diameter

109. The UG-32 formula for determining minimum thickness of a torispherical head considers what specific
knuckle radius?

A. 10% of outside crown radius

B. 6% of the inside crown radius
C. 2.88 in.
D. 6% of the inside head diameter

110. If a head is formed with a flattened spot what is the C factor that must be used?

A. 0.33m
B. 0.25
C. 1.2
D. 0.17

111. An unstayed flat head similar to Figure UG-34(f) is made up of two pieces welded together using a Type
2 butt joint, which is only visually examined. What joint efficiency would be applicable?

A. 0.65
B. 0.80
C. 0.90
D. 1.00

144
112. A seamless unstayed flat head similar to Figure UG-34 (b)(1) is welded to a shell using a butt weld.
What efficiency would be used to calculate required thickness if there was no radiography performed on
the circumferential weld?

A. 1.00
B. 0.55
C. 0.85
D. 0.90

113. What formula would be used to determine the internal design pressure for a circular unstayed flat
cover?

A. UG-34, (1)
B. UG-34, (3)
C. UG-32,(e)
D. UG-34, (7)

114. The maximum inside diameter of a welded opening in a vessel head of 1/2 in. thickness, which does not
require a reinforcement calculation, is _____.

A. 3 1/2 in.
B. 6 in.
C. 3tr
D. 2 3/8 in.

115. No two isolated unreinforced openings shall have their centers closer to each other than:

A. Five times their radii

B. The sum of their diameters
C. 3d
D. 12 in.

116. When calculating the required thickness of a seamless nozzle for a reinforcement problem and the
nozzle is made from ERW pipe what efficiency would be used?

A. 0.65
B. 0.90
C. 1.00
D. 0.85

117. The allowable stresses of the nozzle and shell are 17500 and 13800 respectively, what would be the
maximum strength reduction factor?

A. 1.00
B. 1.268
C. 0.788
D. 0.60

145
118. What happens to the formula for A in Figure UG-37.1 when fr1 = 1.0?

A. Nothing
B. Everything after the plus (+) sign is equal to 0
C. (1 – fr1) = 1
D. F becomes 0.5
119. When calculating the limits of reinforcement normal to the surface and there is no reinforcing element
installed the value of _____ is used for te.

A. 1.0
B. 0.5
C. 0
D. 32

120. The governing limit of reinforcement parallel to the vessel surface is the larger of:

A. R or Dn + t
B. D or Rn + tn + t
C. d or Rn + tn + t
D. 1 or 3 above

121. With the exception of studding outlet flanges _____ within the limits of reinforcement shall not be
considered to have reinforcing value.

A. Bolted flange material

B. Split reinforcing elements
C. Bolting
D. Stiffener

122. Exposed inside edges shall be _____ or _____.

A. Machined, chamfered
B. Chamfered, rounded
C. Avoided, rounded
D. Tapered, rounded

123. Material traceability can be maintained by several methods. One of those is:

A. Transfer of the original identification markings

B. Tell the QC Inspector
C. A coded marking
D. Marking the ASTM material specification on the material

124. Where service conditions prohibit the use of die-stamping for material identification, which of the
following is a substitute?

A. Magic marker
B. vibro etching
C. color coding
D. All of the above

146
125. When plates are rolled to form a longitudinal joint for a cylindrical shell they are first _____ to avoid flat
spots along the finished joint.

A. Crimped
B. Beveled
C. Radiographed
D. Visually inspected

126. When a shell section is welded into a vessel operating under internal pressure the difference between
the maximum and minimum inside diameters at any cross section shall not exceed _____ of the
nominal diameter at the cross section being considered.

A. 2%
B. Square root of Rt
C. 5/8%
D. 1%

127. When pressure parts extend over pressure retaining welds the welds shall be _____ for the portion of
the weld to be covered.

A. Left as is
B. Ground flush
C. Notched
D. Radiographed

128. Non pressure parts extending over pressure retaining welds shall be _____ or _____ to clear those
welds
A. Ground flush, notched or coped
B. Machined, beveled
C. Radiographed, MT
D. MT, PT

129. Each set of impact test specimens shall consist of _____ specimens.

A. One
B. Two sets of three
C. Four
D. Three

130. A full size Charpy impact test specimen has a dimension of _____.

A. 10 mm x 11 mm
B. 0.394 in. x 0.394 in.
C. 0.394 in. x 0.393 in.
D. 0.262 in. x 0.394 in.

131. What is done when full size impact test specimens cannot be obtained?

A. Estimate the ft-lbf that could be obtained

B. Refer to standard tables
C. Subsize specimens are to be used
D. Use a drop weight test as an alternative

147
132. You are to impact test a material, which is 1 in. thick, and has a minimum specified yield strength of 55
ksi. What is the ft-lbf requirement?

A. 20 ft-lbf
B. 15 ft-lbf
C. 30 ft-lbf
D. 50 ft-lbf

133. The acceptance criteria for materials having a specified minimum tensile strength of 95,000 PSI or
greater is based on the _____.

A. The ratio of stresses to the ft-lbf value

B. Maximum lateral expansion opposite the notch
C. Minimum lateral expansion opposite the notch
D. Charpy V Notch values taken

134. A subsize impact test specimen must be used which is 0.118 in. thick. What temperature reduction
would be taken?

A. 30oF
B. 40oF
C. 80oF
D. 15oF

135. The material being impact tested has a minimum specified yield strength of 35 ksi. A _____
temperature difference is permitted.

A. 25oF
B. 15oF
C. 0oF
D. 10oF

136. When the plate material manufacturer does not performed the heat treatments required by the material
specification a letter _____ is marked next to the material specification designation on the plate.

A. T
B. G
C. NPT
D. N

137. Duties of the Inspector include which of the following:

A. Verifying that welding procedures and welders have been qualified

B. Verifying that heat treatments have been properly performed
C. Verifying that required nondestructive examinations have been performed
D. All of the above.

138. _____ materials are the only product form that must have a material test report provided.

A. Plate
B. Pipe
C. Casting
D. Forging

148
139. A 1 in. shell is to be welded to a tube sheet 3 in. thick using a corner joint per Figure UW-13.2. What
must be done to the weld preparation in the flat plate prior to welding?

A. Visually examine the entire surface

B. UT 10% of the circumference
C. Examined by either MT or PT
D. Examined by random radiography

140. Before welding a nozzle into a shell the Inspector must:

A. Make certain the nozzle fits the vessel curvature

B. Verify the identification markings
C. Examine the material for imperfections
D. All of the above

141. The maximum allowable working pressure for a complete vessel is:

A. Maximum internal or external pressure including static head

B. Maximum internal or external pressure excluding static head
C. Maximum pressure at the top of the vessel excluding any static head
D. Average maximum pressure between the top and bottom of the vessel

142. The maximum allowable working pressure for a vessel part is:

A. Maximum internal or external pressure including static head

B. Maximum internal or external pressure excluding static head
C. Maximum pressure at the bottom of the part
D. Average maximum pressure between the top and bottom of the vessel

143. The formula for hydrostatic testing is:

A. P = 1.5 x MAWP
B. P = 1.25 x MAWP x St /Sd
C. P = 1.3 x MAWP x St / Sd
D. P = 3 x Design Pressure

144. A special hydrostatic pressure test is permissible which utilizes the _____ thickness including corrosion
allowance and the allowable stress at _____ temperature multiplied by 1 1/2.

A. Nominal, test
B. Minimum, design
C. Postulated, 100oF
D. Assumed, test

145. When a hydrostatic test exceeds the test pressure either accidentally or intentionally what must be
done?

A. The vessel is rejected

B. Have an engineer perform a stress analysis
C. Stop the test and repeat
D. Must be inspected by the Inspector for visible distortion

149
146. When hydrostatic testing a pressure vessel which has more than one chamber, each chamber _____.

A. Shall be tested using the differential in any adjacent chamber

B. Shall be tested without pressure in any adjacent chamber
C. Shall be tested with the full test pressure in all other chambers
D. Shall be tested using a combined hydrostatic pneumatic test

147. Single wall pressure vessels designed for vacuum service only shall be hydrostatic pressure tested at
not less than _____.

A. 1.3 times the difference between normal atmospheric pressure and the minimum design internal
absolute pressure
B. 30” of water gage
C. Two times the difference between normal atmospheric pressure and the minimum design
internal absolute pressure
D. 15 PSI

148. The required visual inspection after application of the hydrostatic test pressure is conducted at not less
than _____.

A. Four-fifths the test pressure

B. The MAWP to be stamped on the vessel
C. The test pressure divided by 1.3
D. Ten percent above operating pressure

149. What type liquids may be used for hydrostatic testing?

A. Water
B. Any nonhazardous liquid if below its boiling point
o
C. Combustible liquids having a flash point less than 110 F
D. All of the above

150. The recommended test temperature above the MDMT for hydrostatic testing in accordance with the
ASME Code is _____.

A. 10oF
B. 30oF
C. 20oF
D. 50oF

151. The hydrostatic test pressure shall be applied to a filled pressure vessel when _____.
A. The vessel and its contents are at about the same temperature
B. The Inspector believes it should be applied
C. Required by the test procedure
D. All personnel are at a safe distance from the test site

152. What is the maximum metal temperature that need not be exceeded during a hydrostatic pressure test?

A. 70oF
B. 30oF above the MDMT
C. 120oF
D. 10oF above the Design temperature

150
153. A small liquid relief valve installed on the vessel set to _____ times the hydrostatic test pressure is a
recommended precaution to prevent overpressure and damage

A. 3
B. 2
C. 1 1/2
D. 1 1/3

154. Except for lethal service a vessel _____ be painted, coated or internally lined prior to the hydrostatic
pressure test.

A. May
B. May not
C. Should
D. Must

155. The formula for determining the pneumatic test pressure is:

A. P = 1.25 x Maximum Operating Pressure

B. P = 1.5 x MAWP x St / Sd
C. P = 1.1 x MAWP x St / Sd
D. P = 3 x Minimum Operating Pressure

156. The metal temperature during ASME pneumatic test shall be maintained at least _____ above the
MDMT.
A. 10oF
B. 20oF
C. 60oF
D. 30oF

157. The two steps in pressurizing a vessel for the pneumatic test are:

A. Increase to one-half test pressure then in steps of one-tenth test pressure until test pressure is
reached
B. Rapidly raise to one-third test pressure then raise slowly to test pressure
C. Increase to one-third test pressure then in steps of one-twentieth test pressure
D. Raise to one-half test pressure then to full test pressure in equal steps

158. The required visual inspection after application of the pneumatic test pressure is conducted at a
pressure equal to _____ of test pressure.

A. Two-thirds
B. Four-fifths
C. One-half
D. One-tenth

159. Except for lethal service a vessel _____ be painted, coated or internally lined prior to the pneumatic
pressure test.
A. May
B. May not
C. Should
D. Must

151
160. Indicating test gages shall be connected _____.

A. Directly to the vessel

B. Within 30 feet of the bottom of the vessel
C. In sets of three to the vessel
D. Always with a recording gage to the vessel

161. When the operator controlling a pressure test cannot see the pressure gage _____.

A. A telephone system shall be installed between the test gage observer and test controller
B. A second gage shall be installed that can be observed by the test pressure controller
C. They estimate when the test pressure is reached
D. Visual communication between pressure gage observer and pressure test controller must be
established

162. An indicating pressure gage, which has a range _____, should be used for pressure tests.

A. About double the test pressure

B. About 1 1/2 times the test pressure
C. About three times the test pressure
D. About 1 1/3 times the test pressure

163. In no case shall indicating pressure gages have a range of neither less than _____ nor more than
_____ times the test pressure.

A. 2, 4
B. 3, 4
C. 1 1/2, 4
D. 3, 5

164. A digital pressure gage having _____ may be used for pressure tests.

A. Any range
B. A range specified by the Inspector
C. A very narrow range
D. A range of only 0.5 to 6 times the test pressure

165. Pressure test gages shall be calibrated against _____.

A. A calibrated master gage

B. A standard deadweight tester
C. A deadweight test gage
D. Either 1 or 2 above

166. When magnetic particle examinations are prescribed they shall be done in accordance with Appendix
_____,

A. 12
B. 6
C. 8
D. 7

152
167. When liquid penetrant examinations are prescribed they shall be done in accordance with Appendix
_____,
A. 12
B. 6
C. 8
D. 7

168. The units of measurement that are mandatory for Manufacturer’s Data Reports and markings on
pressure vessels is:
A. U.S. Customary and metric
B. U.S. Customary
C. English
D. Metric

169. Which of the following can be found on the required marking for a pressure vessel?

A. The name of the manufacturer preceded by the words “made by”

B. The MAWP _____PSI at _____oF
C. The month and year built
D. The minimum design product temperature

170. A vessel is constructed by arc or gas welding, what symbol would appear under the Code symbol stamp
to denote this type of construction?

A. A
B. L
C. P
D. W

171. A vessel is constructed for special service as an unfired steam boiler, what symbol would appear under
the Code symbol stamp to denote this service condition?

A. UB
B. DF
C. W
D. HT

172. A vessel has been radiographed in accordance with UW-11 where the complete vessel satisfies the
requirements of UW-11(a)(5) and the spot radiography requirements of UW-11 (a)(5)(b) have been
applied, what marking would appear under the Code symbol stamp?

A. None
B. RT 2
C. RT 3
D. SR

173. A vessel has been radiographed in accordance with UW-11 where the complete vessel satisfies the
spot radiography requirements of UW-11(b), what marking would appear under the Code symbol
stamp?
A. None
B. SR 3
C. RT 3
D. RT 4

153
174. A vessel has been radiographed in accordance with UW-11 where only part of the vessel has satisfied
the radiographic requirements of UW-11(a) and none of the markings RT 1, RT 2 or RT 3 apply, what
marking would appear under the Code symbol stamp?
A. None
B. SR 3
C. RT 3
D. RT 4

175. A vessel has been radiographed in accordance with UW-11 where the complete vessel has had all butt
welds radiographically examined for their full length, what marking would appear under the Code
symbol stamp?

A. None
B. SR 2
C. RT 1
D. RT 2

176. A vessel has been designed with only visual examination required of the butt welded joints. What
marking would appear under the Code symbol stamp for this condition?

A. RT 4
B. None
C. RT 3
D. NR

177. The marking HT is used for vessels that have been _____.

A. Fully heat treated

B. Partially heat treated
C. Hydrostatically tested
D. Hydrogen tested

178. The marking PHT is used for vessels that have been _____.

A. Partially hydrogen tested

B. Partially head tested
C. Partially heat treated
D. Pneumatically tested

179. A pressure vessel is a single chamber and has been completely shop fabricated what Manufacturer'
s
Data Report form would be used?

A. U-1
B. P-4
C. P-1
D. U-1A

180. What Manufacturer’s Data Report form would be used for a pressure vessel part?

A. P-3
B. U-1
C. U-2
D. P-4A

154
181. All pressure vessels other than unfired steam boilers shall be protected by a pressure relieving device
that shall prevent the pressure from rising more than the greater of _____% or _____ PSI above the
MAWP.

A. 10, 3
B. 15, 5
C. 25, 10
D. 40, 3

182. What is the minimum size of liquid relief valve permitted by Section VIII, Division 1?

A. NPS 10
B. NPS 24
C. NPS 1
D. NPS 1/2

183. When a single pressure relief device is used on a pressure vessel it shall be set to operate at a
pressure not exceeding _____.

A. The MAWP
B. The operating pressure
C. The design pressure
D. The mean design pressure

SECTION VIII, SUBSECTION B QUESTIONS

184. Which of the following are classified as service restrictions under Section VIII, Division 1?

A. Lethal
B. Vessels operating below certain temperatures
C. Unfired steam boilers exceeding 50 PSI
D. All of the above

185. Vessels containing lethal substances are required to be postweld heat treated in what thickness?

A. All
B. Above 5/8 in.
C. Above 1 1/4 in.
D. Above 1 in.

186. Butt welds in vessels that contain lethal substances are required to be _____ radiographed.

A. Spot
B. Fully
C. Partially
D. None of the above

155
187. Pressure vessels subject to direct firing do not permit what type weld joints for Category A and B joints?

A. 3
B. 4
C. 1
D. None of the above

188. Longitudinal welded joints within the main shell or nozzles are Category _____.

A. C
B. D
C. A
D. B

189. Circumferential welded joints within the main shell or transitions in diameter are Category _____.

A. A
B. B
C. C
D. None of the above

190. Circumferential welded joints connecting hemispherical heads to main shells, to nozzles are Category
_____.

A. B
B. A
C. C
D. D

191. Welded joints connecting flanges, tubesheets or flat heads to main shell or formed heads are Category
_____.

A. B
B. A
C. C
D. D

192. Welded joints connecting communicating chambers or nozzles to main shells or heads are Category
_____.

A. A
B. B
C. C
D. D
o
193. When a Circumferential welded joint connecting a transition in diameter exceeds 30 it is not considered
a _____.

A. Butt weld
B. Groove weld
C. Fillet weld
D. Full penetration weld

156
194. Material for pressure parts shall comply with the requirements for materials given in _____.

A. UG-4 thru UG-15

B. UG-93
C. UW-15
D. UG-15 thru UG-27

195. Material for nonpressure parts which are welded to the vessel _____ prior to being used in the vessel.

A. Must be tested using PT or MT

B. Must be proven of weldable quality
C. Must be ultrasonic thickness tested
D. Must be pressure tested

196. For material which is not identifiable in accordance with UG-10, UG-11, UG-15, or UG-93 proof of
weldable quality can be demonstrated by:
A. Using weld material which meets the requirements of an SFA specification
B. Preparing a butt joint test coupon from each piece of nonidentified material and making guided
bend tests
C. Satisfactory qualification of the welding procedure
D. Both 2 and 3 above

197. When adjacent abutting sections differ in thickness by more than the lesser of one-fourth the thickness
of the thinner section or 1/8 in. what must be done?
A. Provide a tapered transition of at least 3:1
B. Make a six inch radiograph
C. Nothing
D. Provide a tapered transition of at least 4:1

198. Longitudinal welded joints of adjacent courses shall be separated by at least _____ to avoid the
radiographic requirement.

A. Five times the minimum thickness of the plate

B. Five times the thickness of the thicker plate
C. Six inches
D. Four times the thickness of the thicker plate

199. Full radiography is required for which of the following butt welds?

A. In shells and heads of vessels containing lethal substances

B. In shells and heads of unfired steam boilers having design pressure less than 50 PSI
C. In all vessels where the least nominal thickness exceeds 1 in.
D. None of the above

200. Category B and C butt welds in nozzles and communicating chambers never require radiographic
examination provided they neither exceed:

A. NPS 10
B. 1 1/8 in.
C. NPS 6
D. NPS 10 nor 1 1/8 in.

157
201. When full radiography is required of the Category A and D butt welds, the Category B and C butt welds
shall as a minimum meet the requirements for _____.

A. Full radiography in accordance with UW-51

B. Spot radiography in accordance with UW-52
C. Partial radiography in accordance with UW-53
D. Spot radiography in accordance with UW-51

202. Ultrasonic examination in accordance with UW-53 may be substituted for radiography for what
condition?

A. It is never permitted
B. When radiographic equipment is not available
C. For the final closure seam if the construction does not permit interpretable radiographs
D. For longitudinal welded seams when they are in excess of 1 1/4 in.
203. Joint efficiencies for welded joints shall be in accordance with _____.

A. Subsection C
B. UW-11(a)(5)(b)
C. Paragraph UW-12(d)
D. Table UW-12

204. When a value of E is taken from column (a) of Table UW-12 what are the values for Type 1 and Type 2
welded joints?

A. 1.00 & 0.90

B. 1.00 & 0.85
C. 0.85 & 0.70
D. 0.85 & 0.65

205. What would be the value of E for a butt welded longitudinal joint welded from one side?

A. 1.00
B. 0.85
C. 0.45
D. 0.60

206. A seamless vessel section is welded into a vessel with the requirements of UW-11(a)(5)(b) spot
radiography requirements met. What value of E would be used in the calculation for the shell?

A. 0.85
B. 0.65
C. 0.90
D. 1.00

207. A seamless head is welded to a vessel shell using a Type 4 joint. What value of E would be used in the
calculation for the head?

A. 0.55
B. 0.45
C. 0.85
D. 1.00

158
208. An ERW pipe is being used as the shell of a vessel, what E value would be used in the calculation of
the shell if the requirements of UW-11(a)(5)(b) were met?

A. 1.00
B. 0.85
C. 0.45
D. 0.60

209. A single unreinforced opening meeting the requirements of UG-36(c)(3) is located in a Category B weld
joint. What radiographic requirements must be met?

A. A radiograph must be taken that is two times the diameter of the hole in length
B. A six inch radiograph must be taken which is centered over where the hole will be placed
C. A twenty inch radiograph must be taken which is centered over the hole area
D. A radiograph must be taken that is three times the diameter of the hole in length
210. Strength calculations are required for which of the following nozzle configurations?

A. Figure UW-13.2, sketch h

B. Figure UW-16.1, sketch a-1
C. Figure UW-16.1, sketch b
D. Figure UW-13.1, sketch d

211. Reinforcing plates and saddles of nozzles attached to the outside of a vessel shall be provided with at
least one telltale hole _____ in size.

A. Maximum NPS 1/4 tap

B. Maximum NPS 2
C. Maximum NPS 1/2 tap
D. 2 in.

212. The largest throat size required for a tc fillet weld when only pressure loading is being considered is:
A. 3/4 in.
B. 1/3 the thickness of the nozzle
C. 3/16 in.
D. 1/4 in.

213. A nozzle similar to Figure UW-16.1, sketch (e) has a shell thickness of 9/16 in. and a nozzle thickness
of 3/4 in., what is the value of tmin?
A. 9/16 in.
B. 1/2 in.
C. 1 1/2 in.
D. 1 in.

214. When calculating the allowable load on fillet welds a joint efficiency of _____% is used.

A. 60
B. 55
C. 1.0
D. 85

159
215. Welding procedures used in welding pressure parts and in joining load-carrying nonpressure parts shall
be qualified in accordance with:

A. AWS B1
B. ASME Section IX
C. ASME Section VIII
D. Company engineering specifications

216. When welding nonpressure-bearing attachments, which have no load-carrying function, is made by any
automatic welding process procedure qualification testing is:

A. Required when thickness exceeds 1/2”

B. Required for pressure parts only
C. Not required
D. Not required unless requested by the inspector

217. Each welder and welding operator shall be assigned a/an _____ by the manufacturer/repair firm.

A. Clock number
B. Welding helmet
C. Blue uniform
D. Identifying number, letter or symbol
o
218. It is recommended that no welding be performed when the metal is lower than _____ F.

A. 32
B. 60
C. 0
D. 5

219. Tack welds used to secure alignment shall be:

A. Removed completely
B. Ground on the starting and stopping ends
C. Examined with the PT method
D. Either 1 or 2

220. Surfaces to be welded shall be cleaned within what distance from the weld joint?

A. 1”
B. Two times the plate thickness
C. There is no mandatory distance
D. As required by the inspector

221. Two shells are to be butt welded together to form a circumferential joint. Each shell is 1” thick. What is
the maximum permitted offset?

A. 3/16 in.
B. 1/4 t
C. 1/8 in.
D. 3/4 in.

160
222. What is the maximum permitted weld reinforcement for a butt in a pressure vessel shell that is 1 1/2 in.
thick?

A. 1/2 in.
B. 3/32 in.
C. 1/8 in.
D. 1/4 in.

223. When welds are identified by stamping, each welder or welding operator shall stamp their identification
at what intervals for steel fabrications?

A. 6 ft.
B. 2 ft.
C. 10 ft.
D. 3 ft.
224. Peening shall not be used on which of the following welds if the vessel is not subsequently post weld
heat treated?

A. Initial (root layer)

B. Intermediate layers
C. Final face layer
D. 1 and 3

225. What is the minimum overlap that must be provided when a vessel is heat treated in more than one
heat in a furnace?

A. 10 ft.
B. 5 ft.
C. No minimum specified
D. 15 ft.

226. Postweld heat treatment when required shall be done _____.

A. Either before or after the hydrostatic test

B. Prior to minor repairs
C. Before hydrostatic test
D. After hydrostatic test

227. An example of nominal thickness for the purpose of determining heat treatment time is:

A. The depth of a repair weld

B. The thickness of the attachment when a nonpressure part is welded to a pressure part
C. The thickness of the tubesheet in shell to tubesheet connections
D. The thicker of the two adjacent welded butt welded parts

228. Surface weld metal buildup is required to be examined over the full surface of the deposit by which of
the following?

A. Radiographic
B. Ultrasonic
C. Magnetic Particle
D. Acid etching

161
229. The Inspector shall assure that which of the following has been accomplished?

A. Welding procedures used have been qualified

B. Welders used have been qualified
C. Postweld heat treatments have been correctly performed
D. All of the above

230. When pneumatic testing is used instead of hydrostatic testing which of the following welds must be
examined with MT or PT?

A. All welds around openings

B. Welds around openings over 12 in. OD
C. Attachment welds with throat thickness exceeding 3/8 in.
D. None of the above

231. When full radiography is required the radiographic personnel shall be qualified to which standard?

A. SNT-TC-1A
B. ACCP
C. CP-189
D. Any of the above

232. A longitudinal butt weld is being fully examined. The weld is 3/4 in. thick which includes a 1/16 in.
reinforcement. What is the longest elongated inclusion permitted?

A. 3/16 in.
B. 1/4 in.
C. 3/4 in.
D. 1/2 t

233. For spot radiography, one spot shall be examined on each vessel for each _____ of length.

A. 50 ft.
B. 25 ft.
C. 60 ft.
D. 10%

234. The minimum length of a spot radiograph shall be _____.

A. 24 in.
B. No minimum specified
C. 12 in.
D. 6 in.

235. When a spot radiograph does not meet Code requirements _____.

A. The entire increment will be acceptable if the weld is repaired at the failed spot
B. Two additional spots shall be examined
C. One additional spot shall be examined
D. The entire increment must be rewelded and a new spot examined

162
236. Ultrasonic examination when required is performed in accordance with _____.

A. Section V, Article 5
B. Appendix 8
C. Appendix 12
D. Appendix 7

SECTION VIII, SUBSECTION C QUESTIONS

237. For welded construction the carbon content for carbon and low alloy steels shall not exceed _____%.

A. 0.035
B. 0.35
C. 3.5
D. 10
238. SA-36 SA-283 Grades A, B, C, and D and G 40.21 38W steel plates may be used as pressure parts for
which of the following applications?

A. Unfired steam boilers not exceeding 50 PSI

B. Vessels containing lethal substances
C. Vessels processing gasoline
D. None of the above

239. The term nominal thickness for determination of postweld heat treatment holding time is defined as:

A. Thickness of the weld including corrosion allowance

B. Thickness of the base metal
C. Thickness of the weld excluding corrosion allowance
D. Thickness of the base metal plus one-half the corrosion allowance

240. When pressure parts of two different P-Number groups are joined by welding the postweld heat
treatment shall be that specified in:

A. UCS-66 or UHT-56
B. UCS-56 or UHA-32
C. UHT-56 or UHA-32
D. UNF-56 or UCS-56
o
241. The temperature of the furnace shall not exceed _____ F at the time the vessel or part is placed in it.

A. 600
B. 500
C. 800
D. 300

242. Above 800oF the heating rate shall not be more than _____.

A. 500oF/hour divided by the maximum metal thickness

B. 400oF/hour divided by the maximum metal thickness
C. 900oF/hour divided by the maximum metal thickness
D. 200oF/hour divided by the maximum metal thickness

163
243. During the postweld heat treatment holding period there shall be no greater difference than _____oF
between the highest and lowest temperature throughout the portion of the vessel being heat treated.

A. 150
B. 200
C. 300
D. 250

244. During the heating and cooling periods, the furnace atmosphere shall be controlled as to avoid _____.

A. Excessive corrosion
B. Excessive bending
C. Excessive stress
D. Excessive oxidation
o
245. Above 800 F cooling shall be done in _____.
A. A furnace
B. A furnace or cooling chamber
C. A cooling chamber
D. Still air

246. Above 800oF the cooling rate shall not be more than _____.

A. 500oF/hour divided by the maximum metal thickness

B. 400oF/hour divided by the maximum metal thickness
C. 900oF/hour divided by the maximum metal thickness
D. 200oF/hour divided by the maximum metal thickness

247. What is the normal holding temperature for a P-No. 1 Group 3?

A. 1100oF
B. 1200oF
C. 900oF
D. 600oF

248. What is the minimum holding time for a P-No. 1 Group 2 welded joint 2 in. thick?

A. 4 hours
B. 2 hours 15 minutes
C. 2 hours
D. 3 hours

249. What is the minimum holding time for a P-No. 1 Group 3 welded joint 1/8 in. thick?

A. 1 hour
B. 12.5 minutes
C. 15 minutes
D. None of the above

164
250. What is the minimum holding time for a P-No. 3 Group 2 welded joint 6 in. thick?

A. 3 hours
B. 3 hours 30 minutes
C. 2 hours
D. 5 hours

251. A welded joint in a P-No. 1 Group 1 material is 1 3/16 in. thick. No special service requirements apply.
What would the minimum holding time be?

1. 1 hour 11.25 minutes

2. No PWHT required
3. 2 hours
4. None of the above

252. The special service conditions of UW-2 apply to a P-No. 1 Group 3 material. Which of the following can
o
be exempted from PWHT if a minimum 200 F preheat is applied?

A. Groove welds not over 1/2 in. that attach nozzles with an inside diameter of 2 in.
B. Fillet welds with a throat thickness of 3/4 in. that attach nonpressure parts to pressure parts
C. Any weld less than 1 1/2 in.
D. Any weld not over 1 1/4 in.

253. The maximum depth of a repair weld using the temper bead process that does not require a repostweld
heat treatment for a P-No. 1 Group 2 material is _____.

A. 2 in.
B. 1 1/4 in.
C. 1 1/2 in.
D. 5/8 in.

254. After completing all welding, the repair area shall be maintained at a temperature of _____ for a
minimum period of _____ hours.
o
A. 300-400 F 5 hours
B. 400-500oF 5 hours
C. 450-550oF 4 hours
D. 400-500oF 4 hours

255. The alternative postweld heat treatment temperate of 950oF is to be used for a P-No. 1 Group 2 weld
joint of 4 in. thick. What would the minimum holding time be?

A. 10 hours 45 minutes
B. 10 hours
C. 4 hours
D. 2 hours 30 minutes

165
256. For P-No. 1 Group 1 material full radiography is required when the thicknesses exceeds _____ in.

A. 0
B. 1 1/2
C. 1 1/4
D. 5/8

257. Unless otherwise exempted impact testing is required for a combination of thickness and _____.

A. Minimum design metal temperature

B. Maximum design temperature
C. Specification and grade of material
D. Allowable stress

258. Components, which are to be evaluated to establish impact test exemptions, are:

A. Shells
B. Heads
C. Attachments, which are essential to the structural integrity of the vessel when, welded to
pressure retaining components
D. All of the above
259. The governing thickness tg for a corner, fillet or lap welded joint is defined as:

A. The throat thickness of the attaching weld

B. The thinner of the two parts joined
C. The nominal thickness of the thickest welded joint
D. The thickness of the thicker member divided by 4

260. When the governing thickness for a welded joint exceeds _____ in. and is colder than _____oF impact
tested material shall be used.

A. 4, -50
B. 4, 120
C. 6, 120
D. 2, -50

261. The governing thickness of a flat nonwelded tubesheet of 16 in. thickness is:

A. 4 in.
B. 16 in.
C. Dependent on the attaching shell thickness
D. 6 in.

262. If the governing thickness of a nonwelded part exceeds 6 in., below what MDMT must the material be
impact tested?

A. 100oF
B. 60oF
C. 120oF
D. None of the above

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263. What is the basic minimum design metal temperature for a SA-216 Grade WCB casting which is
produced to a fine grain practice and water quenched and tempered with the largest nominal thickness
1 1/2 in.?

A. 88oF
B. 14oF
C. 43oF
D. 51oF

264. When the coincident ratio as defined in Figure UCS-66.1 is 0.70 what is the further reduction in the
MDMT of the material?

A. 20oF
B. 30oF
C. 40oF
D. 110oF

265. No impact testing is required for B16.5 steel flanges used at design metal temperatures no colder than
_____oF.

A. 120oF
B. -20oF
C. -50oF
D. 20oF
266. No impact testing is required for UCS materials less than _____ in. thick.

A. 1.000
B. 0.099
C. 0.100
D. 0.250

267. If postweld heat treating is performed on a weld joint joining P-No. 1 materials when not otherwise
required by Section VIII an additional _____oF in impact testing exemption temperature may be given to
the minimum permissible temperature from Figure UCS-66.

A. 30
B. 35
C. 50
D. 70

SECTION VIII, APPENDICES QUESTIONS

268. The formula that is to be used calculating thickness and pressure for cylindrical shells subject to
circumferential stress is found in Appendix _____.

A. 1-1, formula 2
B. 1-4, formula 3
C. 1-1, formula 1
D. 1-8, formula 1

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269. When evaluating rounded indications thickness “t” is the thickness of the weld _____.

A. Including the reinforcement on the pressure side only

B. Including any allowable reinforcement
C. Excluding a maximum of 1/32 in. allowable reinforcement on each side
D. Excluding any allowable reinforcement

270. A butt weld is 1/2 in. thick with the maximum weld reinforcement on each side. The maximum
acceptable size of a random rounded indication is _____ in.

A. 0.168
B. 0.125
C. 0.250
D. 0.063

271. For magnetic particle examinations, only indications that are greater than _____ in. shall be considered
relevant.

A. 1/8
B. 1/32
C. 1/16
D. 1

272. Which of the following are acceptance standards for liquid penetrant examination?
A. Relevant linear indications
B. Relevant rounded indications greater than 3/16 in.
C. Four or more relevant rounded indications in a line separated by 1/16 in., or less
D. All of the above

273. Liquid penetrant examiners are certified by the manufacturer with a _____.
A. NDE examiners certification
B. Certificate of Competency
C. SNT-TC-1A certification
D. None of the above

274. Ultrasonic examination of welds shall be performed using methods described in _____ of ASME Code
Section V.
A. Article 1
B. Article 4
C. Article 5
D. Article 23

275. Personnel performing examinations of welds shall be qualified in accordance with _____.
A. SNT-TC-1A
B. PCS-185
C. PAAC
D. Manufacturer’s standard

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276. For UT, other than cracks, lack of fusion and incomplete penetration, other imperfections are
unacceptable if the indications exceed the reference level and have lengths, which exceed:

A. 1/4 in. for t up to 3/4 in.

B. 1/3 t for t from 3/4 in. to 2 1/4 in.
C. 3/4 in. for t over 2 1/4 in.
D. All of the above

277. The manufacturer shall maintain a record of all UT reflections from uncorrected areas that exceed
_____% of the reference level.

A. 60
B. 50
C. 100
D. 20

278. The Manufacturer’s Data Report form used for a single chamber, completely shop fabricated vessel is:

A. U-3
B. U-1
C. U-1A
D. U-4

279. The Manufacturer’s Data Report form used for a part of a vessel is:

A. U-2
B. U-1A
C. U-3
D. U-4

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 ANSWER SHEET
ASME QUESTIONS

Section VIII General Questions

1. C

170