Instructor: Dipl.-Ing. Horst Michael

Instructor: Dipl.-Ing. Horst Michael
The new One The new One – the best one for you Welcome! Introduction Instructor: Dipl.-Ing. Horst Michael B31.PPT 09/03

www.ONETB.com The new One The new One – the best one for you
B31.PPT 09/03

Your Instructor: Dipl.-Ing. Horst Michael
Welcome! Guide to ASME Code Your Instructor: Dipl.-Ing. Horst Michael MOBILE PHONES QUIET PLEASE! FMTUEV.PPT 5/97

Welcome to OneTUVBV.ppt 12/02

How to fill in the Certificates of Attendance
KOLB\FMPRO.PPT 11-02

ASME Code Section VIII - Division 1
Introduction ASME Code Section VIII Div. 1 Manufacturer‘s Responsibility and Liability Scope and Boundaries Material Design MAWP and MDMT Joints, Welds, Types, Categories, Special Service Openings Impact Testing and Exemptions Fabrication and Welding Heat Treatment Nondestructive Examination Inspection Pressure Test and Reports Overpressure Protection KOLB\FMPRO.PPT 11-02

OneBeacon America Insurance Company
ONE/TÜV/BV's shareholders OneBeacon America Insurance Company Boston, USA Bureau Veritas Paris, France RWTÜV Systems GmbH Essen, Germany Shares: 1/3 1/3 1/3 Technische Inspektions GmbH Essen OneTUVBV.ppt 08/04

ASME Piping Code B31.3 Introduction 1 What is Piping? 3
B31.3 Process Piping Scope Fluid Service Design Components Material Systems Dimensions Fabrication, Assembly, Erection 43 Inspection and Testing KOLB\FMPRO.PPT 05-01

Customer's Benefit One/TÜV/BV assists
in getting access to international market to become certified by ASME to introduce Quality Systems to become familiar with American Codes & Standards to achieve the Registration with Canadian Jurisdictions in the Design Calculation or the Design Review to qualify welding procedures and welders to ASME Code to achieve State Special from Jurisdictions in the cost effective application of the ASME Code to minimize Product Liability risks in Codes and Standard Engineering FMTUEV.PPT 08/02

Hierarchy of Standards
Laws & Regulations at the location of installation (e.g. Minnesota, New York City, Quebec, Timbuktu,...) ASME - Boiler & Pressure Vessel Code National Board Inspection Code NBIC SEC0.PPT 05-03

Specimen law Minnesota
State Department Joel Amato, Chief Boiler Inspector Department of Labor and Industry Code Administration and Inspection Services 443 Lafayette Road North., Fourth Floor St. Paul, MN Tel: Fax: Web: Empowerment Commissioner of Labor and Industry empowered to make, alter, and amend rules and regulations. Date of Passage of Law Date of latest amendment to law: 1996. Date rules and regulations implemented: 1885. Date of latest rules and regulations: November 2001. State statute: Minnesota Statutes – 2002, Chapters to , Boilers. Rules for Construction and Stamping ASME Code (2001 Edition, 2002 Addendum) Sections I, II, III (Divisions 1,2), IV, V, VI, VII, VIII (Divisions 1,2,3), IX, X, XI and Code Cases. ASME CSD-1 (2002 Edition); ASME B31.1 (2001 Edition); ASME PVHO-1 (2001 Edition) Code addenda and case interpretations accepted automatically. Manufacturers must file a copy of Manufacturer's Data Report with the department on ASME forms, except tanks or cylinders used for storage or transfer of liquefied petroleum gases for which data reports are not required. Registration with the National Board of non-ASME Code items and use of these items is allowed to comply with GATT and NAFTA treaties. National Board Inspection Code (2001 Edition, 2002 Addendum); National Board registration required for boilers and pressure vessels CSA B51 (2001 Edition) with National Board registration number.. Special design or construction requires approval of the Chief Boiler Inspector. Minnesota Steam Fitters Contractors License required for all high-pressure steam piping and hot-water district heating over 30 psi. Foreign Codes: BS only with National Board registration numbers. Stamping: The use, where appropriate, of the following National Board Inspection Code stamps or ASME Code symbol stamps are required: National Board - NR, R, VR. ASME - ALL. PP, S or A stamp required up to second stop valve. High pressure piping license and permit required beyond boiler. Power piping stamps required by division for Section I piping. 2003 Edition SEC0.PPT 09/03

SOUTH CAROLINA Synopsis: Example 2002 Edition January 2002
State Department Department of Labor, Licensing and Regulation Rita M. McKinney, Director Division of Labor, Office of Occupational Safety and Health William M. Lybrand II, Administrator Landmark Building, 3600 Forest Drive P. O. Box 11329 Columbia, South Carolina Tel: (803) Fax: (803) WEB: The State of South Carolina does not have a boiler or pressure vessel law; however, the South Carolina General Assembly and State Building Code Council approved the adoption of the international Building Code (2000 Edition) for commercial buildings. SEC0.PPT 01/03

113 Countries Countries accepting ASME Code
Countries accepting ASME Code Construction and Requirement Boilers and Pressure Vessels Albania Algeria Argentina Australia Austria Bahamas Bahrain Bangladesh Barbados Belarus Belgium Bermuda Bolivia Bosnia and Herzegovina Brazil Burma (Myanmar) Canada Chile China Colombia Costa Rica Croatia Cuba Cyprus Denmark Djibouti Dominican Republic Ecuador * * * Egypt Estonia Ethiopia Finland Fiji France Gambia Georgia Germany Ghana Greece Hong Kong Hungary Iceland India Indonesia Iraq Ireland Israel Italy Ivory Coast Jamaica Japan Jordan Kazakhstan Kenya Korea Kuwait Latvia Lebanon Libya Lithuania Luxembourg Malawi Malaysia Malta Mauritius Mexico Moldowa Morocco Mozambique Netherlands New Zealand Nicaragua Nigeria Norway Oman Pakistan Paraguay Peru Philippines Poland Portugal Puerto Rico Quatar Romania Saint Lucia Saudi Arabia * * * Serbia Singapore South Africa Spain Sri Lanka Sudan Swaziland Sweden Switzerland Syria Taiwan Tanzania Thailand The Russian Federation Trinidad and Tobago Tunisia Turkey United Arab Emirates United Kingdom Uganda Uruguay USA Venezuela Yemen Yugoslavia Zambia Zimbabwe 113 Countries Source: Technical help to Exporters, British Standard Inst. (June 2004) * Subject to approval of local authority OneTUVBV.ppt 06/2004

S - sometimes - Society of M - maybe - Mechanical
What is ASME ? A - always - American S - sometimes - Society of M - maybe - Mechanical E - except - Engineers SEC0.PPT 05/98

Hierarchie der Standards
Verordnungen am Standort der Anlage (z.B. Minnesota, New York City, Quebec, Timbuktu,...) ASME - Boiler & Pressure Vessel Code Construction-Code Section I Section III Nuclear Power Section IV Section VIII Druckbehälter Section X Fiber Plastics Section XII Transport Tanks ASME B31.1 Rohrleitungen ASME B31.3 Dampfkessel Heizkessel Kraftw. Rohrleit. Reference Code ASME B31.1 Power Piping Section II Material Section V ZfP Section IX Schweißen "Inservice"-Code Section VI Heizkessel Section VII Dampfkessel Section XI Nuclear Power Normen, Empfehlungen ANSI ASTM AWS ASNT National Board Inspection Code NBIC SEC0.PPT

ASME Code Foreword This Code contains mandatory requirements,
specific prohibitions, and Nonmandatory Guidance for construction1 activities. The Code does not ad- dress all aspects of these activities and those aspects which are not specifically addressed should not be considered prohibited. The Code is not a handbook and cannot replace Education, Experience, and the use of engineering judgement. The phrase engineering judgement refers to technical judgements made by knowledgeable designers experienced in the application of the Code. 1 Construction, as used in this Foreword, is in all-inclusive term comprising materials, design, fabrication, examination, inspection, testing, certification, and pressure relief. SEC0.PPT 2/96

Guide to ASME Code ASME Code International Application and Acceptance
ASME, National Board, Authorized Inspector Manufacturer‘s Accreditation „Stamps“ ASME Material and ASTM Specifications ASME Section I, Power Boilers ASME Section IV, Heating Boilers ASME Section VIII, Pressure Vessels ASME Piping Codes B 31.1, 31.3 ASME Section IX, Welding ASME Section V, Nondestructive Examination NBIC National Board Inspection Code FMPRO.PPT 10/02

Everything not prohibited, is permitted
Using the ASME Code ASME Code = Checks and Balances to be applied to the formulated design It applies to construction only No fabrication tolerances provided, except misalignment reinforcement Everything not prohibited, is permitted SEC0.PPT 06/02

ASME Code Editions: Every 3 years new issuance (95, 98, 01...)
Addenda: Issuance every year. Replacement page format (coloured). Mandatory 6 months after issuance. Interpretations: Issued by ASME Code committees upon request. Not part of the Code. Code Cases: Formulated by the ASME Code Committee to clarify existing requirements or to provide rules not covered by the existing Code. Errata: Are mandatory immediately re-affirmed: referenced Codes & Standards ASME 16.5, E96 SEC0.PPT 05/02

ASME Code Key Words shall mandatory rules may not prohibition
may recommendations or can exemptions from prohibitions should recommendations SEC0.PPT 07/01

ASME Code Text Paranthetical Expressions nonmandatory
Footnotes caution, are easily overlooked Punctuation , = pause : = can be followed by ands or ors seperated by ; and finished by. Paragraph Structure: Tracks and switches UG-3 (a) (1) (b) etc. PG etc. SEC0.PPT E 95

Units ( Appendix ) Length: in = 25,4 mm Area: sq in = 6,4516 cm2
ft = 304,8 mm yd = 914,4 mm Area: sq in = 6,4516 cm2 sq ft = 0, m2 Volume: cu in = 16,387 cm3 cu ft = 28,317 l Force: lb f = 4,448 N Energy: ft lb = 1, Nm ( =J ) Pressure: psi = 0, bar Temperature: °F = 32+ 1,8 * Tc SEC0.PPT E 96

Abbreviations ASME American Society of Mechanical Engineers
ASNT American Society for Nondestructive Testing ASTM American Society for Testing and Materials ANSI American National Standards Institute AWS American Welding Society AIA Authorized Inspection Agency AI Authorized Inspector AIS Authorized Inspector Supervisor ANI Authorized Nuclear Inspector ANIS Authorized Nuclear Inspector Supervisor BP Boiler Proper BEP Boiler External Piping Nat´l Bd National Board of Boiler and Pressure Vessel Inspectors SEC0.PPT 02/96

Abbreviations QA Quality Assurance QC Quality Control
QSC Quality System Certificate (Material) RPE Registered Professional Engineer MAWP Maximum Allowable Working Pressure at uppermost point MDMT Minimum Temperature when pressure is applied ID Inside Diameter PWHT Postweld Heat Treatment NDE Non-Destructive Examination RT Radiographic Examination UT Ultrasonic Examination MT Magnetic Particle Examination PT Liquid Penetrant Examination VT Visual Examination WPS Welding Procedure Specification PQR Procedure Qualification Record WPQ Welders Performance Qualification SEC0.PPT 2/96

Literature ASME Boiler and Pressure Vessel Code ASME Order Department, Rao, K.R. (Editor) ASME Press, NY 2002 ($160) Companion Guide to the ASME Boiler & Pressure Vessel Code (Vol.1&2) Carroll, D.E. & Carroll D.E. Jr.: The ASME Code Simplified - Power Boilers, McGraw-Hill, New York, 1997 ($60) Chuse, R. & Carson, Bryce Sr.: The ASME Code Simplified - Pressure Vessels, McGraw-Hill, New York, 1997 ($60) Jawad, M.H. & Farr, J.R.: Structural Analysis and Design of Process Equipment, Wiley-Interscience Publications, 1984 Jawad, M.H. & Farr, J.R.: Guidebook for the design of ASME Section VIII pressure vessels ASME PRESS NY 1998 (65$) Brownell, L.E. & Young, E. H. Process Equipment Design, John Wiley & Sons, New York 1959 Steingress, F. M. & Frost, H. J. High Pressure Boiler American Technical Publishers, Homewood IL, 1994 ($35) Houle, Michael J. Practical Guide to ASME Section IX CASTI Publishing Inc. Edmonton, Alberta Canada ($90) Ernst, Richard: Wörterbuch der industriellen Technik, Oskar Brandstetter Verlag VDEh (Hrsg.): Stahleisen-Wörterbuch, Verlag Stahleisen mbH, 6. Auflage, 1994 SEC0.PPT 5-02

Useful Websites on the Internet
FMTÜVBV Homepage, Information and Services, Download Area, Code Finder, Links ASME Homepage >click „Codes and Standards“ Code Case Database, Certificate Holder Search, Data Report Forms, etc. National Archives and Records Administration Office of the Federal Register American Society of Nondestructing Testing American National Standards Institute Bureau Veritas Homepage OneBeacon Homepage Hartfort Steam Boiler Homepage Lloyd´s Register National Board Homepage with NB Bulletin and NBIC Interpretations Nuclear Regulatory Commission Royal & Sunalliance RWTÜV Systems GmbH FMTUEV.PPT 05/03

ASME American Society of Mechanical Engineers, New York
Professional technical society Members staff of 300 3000 volunteers Activities: Publishing and Maintenance of Codes and Standards for pressure bearing components Issuance of Certificates of Authorization to Manufacturers SEC0.PPT 10/95

Manufacturer What is Authorized Inspection? Jurisdiction USA & CANADA
National Board Members Licence ASME ASME Code Issuance Insurance Company Rebistration of Data Reports “R-Stamp“ Commissioning Authorized Inspectors Authorization “ASME Stamp“ Accreditation Licence Technische Inspektions GmbH Service Manufacturer FMTUEV.PPT 05/03

What is a Code - Manufacturer ?
Section VIII-I What is a Code - Manufacturer ? - QC-System according to the ASME Code - Audit by ASME, renewal every 3 years (U, U2) - valid Inspection-Service-Agreement between Manufacturer and an AIA - Authorized by ASME to use the Code Symbol Stamp(s). (Certificate of Authorization, max. validity 3 years (U, U2)) SEC81.PPT 11/02

Advantages of an ASME Certificate
Export into USA / Canada Countries Authorization to manufacture "stamped items" Publication in the list of ASME Certificate holders, and on the internet Certified know how in the use of the ASME Code Wide scope of responsibilities as an "ASME Manufacturer" Certified and world wide recognized Quality Control System "ASME„ Profit ! FMTUEV.PPT 07/02

Procedure of ASME Authorization
Obtain Application Forms from ASME Sign a Service Agreement with AIA Submit Application Forms to ASME and transfer Fees Purchase ASME Code Books Describe a QC-System according ASME Code Prepare a Demonstration Item Qualify Procedures and Personnel Pre-Joint Review by the Supervisor of AIA Joint Review (Audit) with ASME Designee, Inspektor und Supervisor Issuance of Certificate and Stamp by ASME FMTUEV.PPT 9/96

Efforts of an ASME Authorization
ASME Code Books QC Manual and Procedures Qualification of Procedures and Personnel 70% Representative Demo Item Drawing, Calculation, Part List, Purchase Orders, Material Test Reports Min. 4 Months of Preparation Demonstration of the QC- System in a Joint Review Issuance of Certificates and Stamps 1 month later FMTUEV.PPT 5-03

ASME Code Symbol Stamps
SEC0.PPT 05-02

ASME and National Board Stamps
Section VIII Div. 1 - Druckbehälter U Druckbehälter UM* Miniaturdruckbehälter UV * Sicherheitsventile UD * Berstscheiben Section VIII Div. 2 - Druckbehälter U2 Alternative Regeln für Druckbehälter Section VIII Div. 3 - Druckbehälter U3 Hochdruckbehälter UV3* Sicherheitsventile Section X - Faserverbundbehälter RP Druckbehälter aus faserverstärktem Kunstharz Section XII - Transportbehälter T Transportbehälter TV * Sicherheitsventile TD * Berstscheiben Section I - Dampfkessel S Dampfkessel A Dampfkesselmontage E elektrisch beheizte Kessel M Miniaturkessel PP Rohrleitungen (B31.1) V * Sicherheitsventile Section IV - Heizkessel H * gußeiserne Heizkessel H Stahlheizkessel HLW Trinkwassererhitzer HV * Sicherheitsventile * Komponenten nicht durch AI abnahmepflichtig, Auditierung duch ASME National Board Inspection Code R Reparaturen und Änderungen VR* Reparatur von Sicherheitsventilen SEC0.PPT 11-04

ASME "Nuclear Certificates"
ASME Code Section III (Nuclear Components) N Nuclear Components Vessels, Piping Systems, Valves, Pumps, etc. NA Nuclear Installer Assembly of Components NPT Nuclear Parts Welded Parts of Nuclear Components NV Nuclear Safety Valves NS Nuclear Supports Certificate of Accreditation QSC Quality System Certificate Material Manufacturers \SEC0.PPT 06/01

ASME Accreditations ASME Code Accreditations are not required for:
Material Manufacturers (except Section III) Manufacturers of Welding Consumables (except Section III) Valve Manufacturers (except Section III and Safety Valves) Suppliers of Services (Design, Heat Treatment, Machining) Piping Manufacturers (except Section III and Section I Boiler External Piping) KOLB\SEC0.PPT 5-01

ON THE USE OF ASME MARKING TO IDENTIFY MANUFACTURED ITEMS
ASME-Code STATEMENT OF POLICY ON THE USE OF ASME MARKING TO IDENTIFY MANUFACTURED ITEMS The ASME Boiler and Pressure Vessel Code provides rules for the construction of boilers, pressure vessels, and nuclear components. This includes requirements for materials, design, fabrication, examination, inspection, and stamping. Items constructed in accordance with all of the applicable rules of the Code are identified with the official Code Symbol Stamp described in the governing Section of the Code. Markings such as "ASME," "ASME Standard," or any other marking including "ASME" or the various Code Symbols shall not be used on any item which is not constructed in accordance with all of the applicable requirements of the Code. Items shall not be described on ASME Data Report Forms nor on similar forms referring to ASME which tend to imply that all Code requirements have been met when, in fact, they have not been. Data Report Forms covering items not fully complying with ASME requirements should not refer to ASME or they should clearly identify all exceptions to the ASME requirements. SEC0.PPT 3/98

Hierarchie of Standards in USA and Canada
Laws and Regulations in USA / Canada ASME - Boiler & Pressure Vessel Code Construction-Code Section I Steam Boilers Section IV Heating boilers ASME B31.1 Power Piping ASME B31.3 Section III Nuclear Power Section VIII Pressure Vessels Process Piping Section X Fiber Plastics Reference Code ASME B31.1 Power Piping Section II Material Section V NDE Section IX Welding "Inservice"-Code Section VI Heating Boilers Section VII Steam Boilers Section XI Nuclear Power Standards, Recommendations ANSI ASTM AWS ASNT National Board Inspection Code NBIC SEC0.PPT 05-03

Requirements for Code Material
Construction Code è Permissible Material Specifications + Service Limitations + Supplementary Requirements + Certification Requirements + other Requirements Section II Part A & B è Material Specification è other Reference Standards Section II Part D è permissible Stress Values è Material Properties SEC2.PPT 03/98

A - XXX (YYy) Gr Ty Cl ASTM Material Specification
Class of metallurgical structure Type of fabrication A-Ferrous B-Nonferrous Grade refers to tensile strength Year of Edition, Addenda Specification Number Examples: A (90) Gr 60 Pressure Vessel Plate, Carbon Steel, for Moderate- and Lower- Temperature Service A - 182M (93) F 316L Forgings, Fittings (...) A (92) TP 316L Seamless ferritic and austenitic alloy-steel(...) tubes SEC2.PPT 05-03

SA - 516 Gr 60 (Type, Class) ASME Material Specification
ASTM Material ASME Code Committee on Materials Acceptance for use in Code Constructions SA Gr 60 (Type, Class) no year Society for ASME ASME Material Published in Section II Part A/B Edition Addenda SEC2.PPT 05-03

Section II Materials Contents: Part A: Ferrous Material Specification
Part B: Nonferrous Material Specification Part C: Specifications for Welding Rods, Electrodes and Filler Metals Part D: Properties: (including Temperature and Stress Values) SEC2.PPT E95A95

(Identical with ASTM Specification A 182/A 182M-96 except for
Section II - SA-182/SA-182M SPECIFICATION FOR FORGED OR ROLLED ALLOYSTEEL PIPE FLANGES, FORGED FITTINGS, AND VALVES AND PARTS FOR HIGH-TEMPERATURE SERVICE SA-182/SA-182M (Identical with ASTM Specification A 182/A 182M-96 except for the clarified heat treatment requirements by the addition of Note 4 to table 1.) 1. Scope 1.1 This specification covers forged low alloy and stainless steel piping components for use in pressure systems. Included are flanges, fittings, valves, and similar parts to specified dimensions or to dimensional standards such as the ANSI specifications that are referenced in Section 2. 1.2 For bars and products machined directly from bar, refer to Specifications A 479/A 479M and A 739 for the similar grades available in those specifications. Products made to this specification are limited to a maximum weight of lb [4540 kg]. For larger products and products for other applications refer to Specification A 336 for the similar grades available in that specification. 1.3 Several grades of low alloy steels and ferritic, martensitic, austenitic, and ferritic/austenitic steels are included in this specification. Selection will depend upon design and service requirements. 1.4 Supplementary requirements are provided for use when additional testing or inspection is desired. These shall apply only when specified individually by the purchaser in the order. 1.5 This specification is expressed in both inchpound units and in SI units. However, unless the order specifies the applicable "M" specification designation (SI units), the material shall be furnished to inchpound units. 1.6 The value stated in, either inch-pound units or SI units are to be regarded separately as the standard. Within the text, the SI units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system must be used independently of the other. Combining values from the two systems may result in nonconformance with the specification. 2. Referenced Documents 2.1 ASTM Standards: A 234/A 234M Specification for Piping Fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures A 262 Practices for Detecting Susceptibility to Intergranular Attack in Austenitic Stainless Steels A 275/A 275M Test Method for Magnetic Particle Examination of Steel Forgings A 336/A 336M Specification for Steel Forgings, Alloy, for Pressure and High-Temperature Parts A 370 Test Methods and Definitions for Mechanical Testing of Steel Products A 403/A 403M Specification for Wrought Austenitic Stainless Steel Piping Fittings ... SEC2.PPT 08/00

Section II - SA-182/SA-182M 3. Ordering Information
3.1 It is the purchaser's responsibility to specify in the purchase order all ordering information necessary to purchase the needed material. Examples of such information include but are not limited to the following: 3.1.1 Quantity, 3.1.2 Size and pressure class or dimensions (Tolerances and surface finishes should be included), 3.1.3 Specification number, grade, and class if applicable (The year date should be included), 3.1.4 Supplementary requirements, 3.1.5 Additional requirements (See 5.1.2, Table 2 footnotes, 15.1, and 15.2), and 3.1.6 Requirement, if any, that manufacturer shall submit drawings for approval showing the shape of the rough forging before machining and the exact location of test specimen material (see 7.3.1). 4. Manufacture 4.1 The low-alloy ferritic steels may be made by the open-hearth, electric-furnace, or basic-oxygen process with separate degassing and refining optional. The basic-oxygen process shall be limited to steels containing not over 6% chromium. 4.2 The stainless steels shall be melted by one of the following processes: (a) electric-furnace (with separate degassing and refining optional); (b) vacuumfurnace; or (c) one of the former followed by vacuum or electrolag-consumable remelting. Grade F XM-27Cb may be produced by electron-beam melting. Because of difficulties that may be met in retaining nitrogen, vacuum melting or remelting processes should not be specified for Grades F XM-11, F 304LN, F 316LN, F 304N, F 316N, F XM-19, F 44, F 45, F 48, F 49, F 50, F 51, F 52, F 53, F 54, or F 55. 4.3 A sufficient discard shall be made to secure freedom from injurious piping and undue segregation. 4.4 The material shall be forged as close as practicable to the specified shape and size. Except for flanges of any type, forged or rolled bar may be used without additional hot working for small cylindrically shaped parts within the limits defined by Specification A 234/ A 234M for low alloy steels and martensitic stainless steels and Specification A 403/A 403M for austenitic and ferritic-austenitic stainless steels. Elbows, return bends, tees, and header tees shall not be machined directly from bar stock. 4.5 Except as provided for in 4.4, the finished product shall be a forging as defined in the Terminology section of Specification A 788. SEC2.PPT 02/01

Section II - SA-182/SA-182M 17. Certification
17.1 For forgings made to specified dimensions, when agreed upon by the purchaser, and for forgings made to dimensional standards, the application of identification marks as required in 18.1 shall be the certification that the forgings have been furnished in accordance with the requirements of this specification. 17.2 Test reports, when required, shall include certification that all requirements of this specification have been met. The specification designation included on test reports shall include year of issue and revision letter, if any. The manufacturer shall provide the following where applicable: Type heat treatment, Section 5. Product analysis results, Section 11 (Tables 2, 4, and 5). Tensile property results, Section 7 (Table 3), report the yield strength and ultimate strength, in ksi [MPa], elongation and reduction in area, in percent. Chemical analysis results, Section 6 (Table 2). IIardness results, Section 7 (Table 3). Grain size results, Section 8, and Any supplementary testing required by the purchase order. SEC2.PPT 02/01

Section II - SA-182/SA-182M 18. Product Marking
18.1 Identification marks consisting of the manufacturer's symbol or name (Note 3), the heat number or manufacturer's heat identification, designation of service rating, the specification number, the designation, Fl, F2, etc., showing the grade of material, and the size shall be legibly stamped on each forging or the forgings may be marked in accordance with Standard SP 25 of the Manufacturer's Standardization Society of the Valve and Fittings Industry, and in such position so as not to injure the usefulness of the forging. The specification number marked on the forgings need not include specification year of issue and revision letter. NOTE 3 - For purposes of identification marking, the manufacturer is considered the organization that certifies the piping component was manufactured, sampled, and tested in accordance with this specification and the results have been determined to meet the requirements of this specification. Quenched and tempered low alloy or martensitic stainless forgings shall be stamped with the letters QT following the specification designation. Forgings repaired by welding shall be marked with the letter "W" following the Specification designation. When repair-welded austenitic stainless steel forgings have not been postweld heat treated in accordance with Table 6, the letters "WNS" shall be marked following the specification designation. When test reports are required, the markings shall consist of the manufacturer's symbol or name the grade symbol, and such other markings as necessary to identify the part with the test report ( and shall apply). Parts meeting all requirements for more than one class or grade may be marked with more than one class or grade designation such as F 304/F 304H, F 304/F 304L, etc. 18.2 Bar Coding - In addition to the requirements in 18.1, bar coding is acceptable as a supplemental identification method. The purchaser may specify in the order a specific bar coding system to be used. The bar coding system, if applied at the discretion of the supplier, should be consistent with one of the published industry standards for bar coding. If used on small parts, the bar code may be applied to the box or a substantially applied tag. SEC2.PPT 02/01

Heat Treating Requirements
Section II - SA-182/SA-182M Table 1 Heat Treating Requirements SEC2.PPT 02/01

Table 2 Chemical Requirements
Section II - SA-182/SA-182M Table 2 Chemical Requirements SEC2.PPT 02/01

Tensile and Hardness Requirements
Section II - SA-182/SA-182M Table 3 Tensile and Hardness Requirements SEC2.PPT 02/01

Goodplate Mfgr. MTR No. 123 Material Test Report
Customer: Rusty Tank Comp. Essen Auftrag Nr. 0816 Material: ASME SA-516M Gr. 415 Edition 2001 no Addenda - ASTM A-516M-90 Gr.415 Thickness: 15 mm 1 Carbon Steel Plate Dimensions: 15,00x3700x3850mm Weight: 4026 kg Marking: GPM SA-516M Gr mm Plate No Heat No As rolled condition Melting process: Vacuum Furnace Chemical composition in % C Si Mn P S N Cu Ni Cr Mo AL 0,20 0,20 0,70 0,02 0,02 0,08 0,20 0,30 0,20 0,10 0,025 V: 0,00 Nb: 0,02 charpy impact Test acc. to SA at -52° C; 64J 86J 72J Tensile Test ASME SA-370, Rectangular Specimen (15 mm) Re, 0,2% Rm A, 2“ Fine Grain Practice ASME SA N/mm² 512 N/mm² 29% Goodplate Mfgr AG, Zuffenhausen, Germany März 2002 SEC2.PPT 05-02

ASME II - D Stress Values (1/4)
Table 1A SECTION I; SECTION II, CLASS 2 AND 3; * AND SECTION VIII, DIVISION 1 MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS (* See Maximum Temperature Limits for Restrictions on Class) SEC2.PPT 10/99

Appl. And Max. Temp. Limits (NP = Not Permitted) (SPT = Supports Only)
ASME II - D Stress Values (2/4) Appl. And Max. Temp. Limits (NP = Not Permitted) (SPT = Supports Only) G10 Upon prolonged exposure to temperatures above 800°F, the carbide phase of carbon steel may be converted to graphite. G18 For Section I applications, this material may not be used for parts of firetube boilers under external pressure. S1 For Section I applications, stress values at temperatures of 850°F and above are permissible but, except for tubular products 3 in. O.D. or less enclosed within the boiler setting, use of these materials at these temperatures is not current practice. T2 Allowanle stresses for temperatures of 750°F and above are values obtained from time-dependent properties. SEC2.PPT 10/99

Table 1A SECTION I; SECTION II, CLASS 2 AND 3; * AND SECTION VIII, DIVISION 1 MAXIMUM ALLOWABLE STRESS VALUES S FOR FERROUS MATERIALS (* See Maximum Temperature Limits for Restrictions on Class) Maximum Allowable Stress, ksi (Multiply by 1000 to Obtain psi, for Metal Temerature, °F, Not Exceeding SEC2.PPT 10/99

SEC2.PPT 10/99

Allowable Stress ASME Code / AD Merkblatt
AD-Merkblatt B0: S = K/1,5; K = yield strength at design temperature or average rupture stress after hr ASME Section VIII, Div. 1, E 98 A 98, Table 1A in Section II, Part D ASME VIII, Div. 1, E 98 A 99, (former Code Case 2290), allowable stresses based on tensile strength and Safety Factor 3.5 S [N/mm²] = Allowable Stress according to the respective design codes H II SA-516 Gr. 60 Addenda 99 SA-516 Gr. 60 Sec. II-D, Table 1A Add 98 T [°C] T [°C] Sec2.PPT 9/99

Section II - Part C Contents
SFA-5.1 Carbon Steel Electrodes for Shielded Metal Arc Welding SFA-5.2 Carbon and Low Alloy Steel Rods for Oxyfuel Gas Welding SFA-5.3 Aluminum and Aluminum Alloy Electrodes for Shielded Metal Arc Welding SFA-5.4 Stainless Steel Electrodes for.Shielded Metal Arc Welding SFA-5.5 Low-Alloy Steel Electrodes for Shielded Metal Arc Welding SFA-5.6 Covered Copper and Copper Alloy Arc Welding Electrodes SFA-5.7 Copper and Copper Alloy Bare Welding Rods and Electrodes SFA-5.8 Filler Metal for Brazing and Braze Welding SFA-5.9 Bare Stainless Steel Welding Electrodes and Rods SFA-5.10 Bare Aluminum and Aluminum Alloy Welding Electrodes and Rods SFA-5.11 Nickel and Nickel Alloy Welding Electrodes for Shielded Metal Arc Welding SFA-5.12 Tungsten and Tungsten Alloy Electrodes.for Arc Welding and.Cutting SFA-5.13 Solid Surfacing Welding Rods and Electrodes SFA-5.14 Nickel and Nickel Alloy Bare Welding Electrodes and Rods SFA-5.15 Welding Electrodes and Rods for Cast Iron SFA-5.16 Titanium and Titanium Alloy Welding Rods and Electrodes SFA-5.17 Carbon Steel Electrodes and Fluxes for Submerged Arc Welding SFA-5.18 Carbon Steel Filler Metals for Gas Shielded Arc Welding SFA-5.20 Carbon Steel Electrodes for Flux Cored Arc Welding SFA-5.21 Composite Surfacing Welding Rods and Electrodes SFA-5.22 Stainless Steel Electrodes for Flux Cored Arc Welding and Stainless Steel Flux Cored Rods for Gas Tungsten Arc Welding SFA-5.23 Low Alloy Steel Electrodes and Fluxes for Submerged Arc Welding SEC2.PPT 03/98

E7018, E7018M, E7016-1HZR E XXX X X XX Section II-C Filler Metals
SFA-5.1, 5.4 : SMAW Electrode Classification E7018, E7018M, E7016-1HZR E Electrode XXX Strength in KSI X Position 1 = all positions 2 = flat and horizontal fillets 4 = vertical down X 0 = DCEP d 1 = AC or DCEP d 2 = AC or DCEN m 3 = AC or DC l 4 = AC or DC l 5 = DCEP m 6 = AC or DCEP m 8 = AC or DCEP m "penetration" XX Chemical composition of weld deposit SEC2.PPT 01/00

ASME Code Scope Construction Codes Sections adress:
Manufacturer‘s Authorization Materials, Design, Fabrication, Examination, Inspection, Testing, Certification, (Assembly, Installation) Pressure Relief. Not adressed: Inservice Inspection, Repairs, Alterations SEC0.PPT 2/96

Section I – Service Limitations
Power Boilers (over 15 psi) generating steam for use external of itself Electric Boilers Miniature Boilers (< 16 in., < 20 sqft., < 5 cuft., < 100 psig.) High Temperature Water Boilers ( over 160 psi and/or 250 °F) Coil-Type Water Boilers see PG-2.3 Scope: Boiler Proper and Boiler External Piping SEC1.PPT 03/01

ASME Code Section I Boiler Proper ( BP ) terminates at:
first circumferential joint for welding end connections face of the first flange in bolted flange connections first threaded joint Boiler External Piping ( BEP ) begins where the BP terminates extends up to (incl.) the valves required by this Code Section SEC1.PPT A 95

ASME Accreditations for Power Boilers
ASME Code Section I : Engineering Contractor: S Manufacturing of Power Boilers (Shop and /or Field) S Welding of Boiler Parts S Welding of „Boiler External Piping“ S or PP Field Site Assembly of Power Boilers (no Design) S or A Boiler Safety Valves V SEC0.PPT 5-01

Section I Contents Foreword, Statement of Policy, Preamble
PG General requirements PW Welded Boilers PR Riveted Boilers PB Brazed Boilers PWT Watertube Boilers PFT Firetube Boilers PFH Feedwater heaters PMB Miniature Boilers PEB Electric Boilers PVG Organc Fluid Vaporizers Appendix SEC1.PPT 3/98

Section I Part PG Contents: General Materials Design
Openings and Compensation BEP and Connections Safety Valves Fabrication Inspection and Tests Certification by Stamping Referenced Standards and Editions: Appendix 360 SEC1.PPT A 95

Section I Boiler SEC1.PPT 06/99

Section I PG Boiler Proper BEP Non-BEP SEC1.PPT A 98

Section I Preamble (1/4) This Code covers rules for construction of power boilers(1), electric boilers,(2) miniature boilers,(3) and high-temperature water boilers (4) to be used in stationary service and includes those power boilers used in locomotive, portable, and traction service. (..) The Code does not contain rules to cover all details of design and construction. Where complete details are not given, it is intended that the manufacturer, subject to the acceptance of the Authorized Inspector, shall provide details of design and construction which will be as safe as otherwise provided by the rules in the Code. (1) Power boiler - a boiler in which steam or other vapor is generated at a pressure of more than 15 psi for use external to itself. (2) Electric boiler - a power boiler or a high-temperature water boiler in which the source of heat is electricity. (3) Miniature boiler - a power boiler or a high-temperature water boiler in which the limits specified in PMB-2 are not exceeded. (4) High-temperature water boiler - a water boiler intended for operation at pressures in excess of 160 psi and/or temperatures in excess of 250°F. SEC1.PPT A 98

Section I Preamble (2/4) The scope of jurisdiction of Section I applies to the boiler proper and to the boiler external piping. Superheaters, economizers, and other pressure parts connected directly to the boiler without intervening valves shall be considered as parts of the boiler proper, and their construction shall conform to Section I rules. Boiler external piping shall be considered as that piping which begins where the boiler proper or separately fired superheater terminates at: (a) the first circumferential joint for welding end connections; or (b) the face of the first flange in bolted fianged connections; or (c) the first threaded joint in that type of connection; and which extends up to and including the valve or valves required by this Code. ASME Code Certification (including Data Forms and Code Symbol Stamping), and/or inspection by the Authorized Inspector, when required by this Code, is required for the boiler proper and the boiler external piping. SEC1.PPT A 98

Section I Preamble (3/4) Construction rules for materials, design, fabrication, installation, and testing of the boiler external piping are contained in ASME B31.1, Power Piping. Piping beyond the valve or valves required by Section I is not within the scope of Section I, and it is not the intent that the Code Symbol Stamp be applied to such piping or any other piping. The material for forced-circulation boilers, boilers with no fixed steam and water line, and high-temperature water boilers shall conform to the requirements of the Code. All other requirements shall also be met except where they relate to special features of construction made necessary in boilers of these types, and to accessories that are manifestly not needed or used in connection with such boilers, such as water gages and water columns. Reheaters receiving steam which has passed through part of a turbine or other prime mover and separately fired steam superheaters which are not integral with the boiler are considered fired pressure vessels and their construction shall comply with Code requirements for superheaters, including safety devices. Piping between the reheater connections and the turbine or other prime mover is not within the scope of the Code. A pressure vessel in which steam is generated by the application of heat resulting from the combustion of fuel (solid, liquid, or gaseous) shall be classed as a fired steam boiler. SEC1.PPT A 98

Section I Preamble (4/4) Unfired pressure vessels in which steam is generated shall be classed as unfired steam boilers with the following exceptions: (a) vessels known as evaporators or heat exchangers; (b) vessels in which steam is generated by the use of heat resulting from operation of a processing system containing a number of pressure vessels such as used in the manufacture of chemical and petroleum products. Unfired steam boilers shall be constructed under the provisions of Section I or Section VIII. Expansion tanks required in connection with high-temperature water boilers shall be constructed to the requirements of Section I or Section VIII. A pressure vessel in which an organic fluid is vaporized by the application of heat resulting from the combustion of fuel (solid, liquid, or gaseous) shall be constructed under the provisions of Section I. Vessels in which vapor is generated incidental to the operation of a processing system, containing a number of pressure vessels such as used in chemical and petroleum manufacture, are not covered by the rules of Section I. SEC1.PPT A 98

Complex Case: Field Erected Watertube Boiler
Master P-4A Field P - 3 Part Shop P-4A Field P - 4 Part P-4A Economizer P - 6 P-4A Drums P - 7 Supple- mentary Piping Field Test Final Signature Safety Valves SEC1.PPT

Section I, PG-104 ... 111 Marking Rusty Tank Company
National Board ________ Certified by Rusty Tank Company Name of Manufacturer MAWP ______ psi HeatingSurface ______ SqFt Max. designed steaming capacity_____lb/hr Manufacturer's Serial No. 1234 Year Built 2001 SEC81.PPT 5-01

ASME Code Section IV Design, fabrication, Installation, inspection of
Steam heating boilers ( < 15 psig ) Hot water heating boilers ( < 160 psi ; 250° F ) Content: HG: general requirements HF: wrought material assemblies HC: cast iron assemblies HLW: potable water heaters SEC4.PPT E95

ASME Code Section VIII Section VIII Division 1
bis 3,000 psi (20 MPa), darüber besondere Anforderungen einfache Berechnungsmethoden keine Spannungsanalyse gefordert international weitverbreitete Anwendung für Druckbehälter Section VIII Division 2 bis 10,000 psi (70 MPa) Betreiber muß Betriebsbedingungen festlegen (User´s Design Specification) ein Registered Professional Engineer (RPE) muß die UDS zertifizieren höhere Festigkeitsausnutzung höhere Anforderungen an die Fertigung umfangreichere zerstörungsfreie Prüfung geringere Wandstärken sparen Kosten enthält Methoden für Spannungsanalyse, Ermüdung, Dauerfestigkeit Berücksichtigt auch Sekundärspannungen und Spannungsspitzen ein RPE muß den Design Report prüfen Section VIII Division 3 über 10,000 psi Spannungsanalyse ist gefordert vorgespannte Komponenten werden berücksichtigt umfangreiche zerstörungsfreie Prüfung verpflichtend sehr eingeschränkte Materialauswahl und Fertigung zwei Registered Professional Engineers sind gefordert SEC8.PPT 05-03

ASME Code Section VIII Div. 2
For which parameters does Div. 2 offer the more economical solution? 1. design pressure over 3,000 psi 2. diameter exceeding 60" and pressure above 1,000 psi 3. Diameter/wall thickness ratio greater 16 or plates thicker than 3" 4. Weight above 20 tons 5. Better quality / more expensive materials than P-No. 1 material 6. multi-layered vessels 7. cyclic loading 8. tough service conditions, hazardous media SEC82.PPT 12/98

ASME Code Section VIII - 1
U - I: Scope of Section VIII Div. 1 Examples: Heat Exchangers Vessels with Direct Firing Evaporators Reactors Pressure Vesels MAWP >15 psi (1,03 bar) Internal or External Pressure Up to 3000 psi (VIII Div. 2) Over 152 mm Inside Diameter No Piping or Piping Components No rotating or reciprocating Equipment... Also for gas fired double shell heat exchangers < 50 psi Not for Human Occupancy (PVHO) Not Water Vessel up to 300psi or 210°F Not within the scope of other Sections Not Steam Boilers with direct firing SEC81.PPT 05/03

Section VIII - 1 , U - I Scope of Section VIII Division I include:
the welding end of the first circumferential joint for 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 or fittings non pressure parts welded directly to a pressure retaining surface pressure retaining covers pressure relief devices SEC81.PPT 2/96

Section VIII - I U - 2 User's / Owner's Duties
- establish design requirements - state operating conditions incl.: - startup - shutdown - corrosion allowance - lethal service - PWHT beyond the Code - needs for piping and instrumentation of steam generators SEC81 .PPT A 95

How to order a Pressure Vessel
Date Place of Installation Number Description, Main Dimensions Construction Code Edition and Addenda Additional Requirements (jurisdictional) Additional Heat treatment, Material Restrictions Operating Conditions: Startup, Shutdown, Service, Testing, Pressure temperature, media, Cleaning Piping, instrumentation, overpressure protection. ASME Code Stamping National Board Registration SEC0.PPT 5-01

Section VIII - I U - 2 , UG - 90 Manufacturer's Responsibilities
- comply with all of the applicable requirements of the Code. - assure that all work done by others also complies. - have design calculation available. - assure that QC is performed. - assure that examinations are performed as required by the Code. - arrange Inspection and free access of the Inspector. SEC81 .PPT A 95

ASME Accreditations for Pressure Vessels
ASME Code Section VIII Engineering none Manufacturing of Pressure Vessels (Shop and /or Field) U Alternative Rules Section VIII, Division 2 (Shop and /or Field) U2 Manufacturing of High Pressure Vessels (Shop and /or Field) U3 Welding of Vessel Parts U, U2, U3 Field Assembly of Vessels U, U2, U3 Manufg of „Mini“ Pressure Vessels UM Pressure Vessel Safety Valves UV High Pressure Vessel Safety Valves UV3 Rupture Discs, Div. 1 UD KOLB\SEC0.PPT 5-01

Section VIII - 1 Contents
Foreword Introduction: U-1, U-2, U-3 Subsection A: UG - General Requirements Subsection B: Methods of Fabrication UW - Welding UF - Forging UB – Brazing Subsection C: Classes of Material - Special Constructions UCS - Carbon and Low Alloy Steel UNF - Non ferrous Materials UHA - High Alloy Steel UCI - Cast Iron UCL - Cladding and Lining UCD - Cast Ductile Iron UHT - Ferritic Steels with Heat Treatment ULW - Layered Constructions ULT - Low Temperature Service Add. 2003: UHX - Rules for Shell and Tube Heat Exchangers Mandatory and Nonmandatory Appendices Index SEC81.PPT 07/03

Manufacturer's Serial No. 1234
Section VIII-1, UG-118 Nameplate Certified by Rusty Tank Company Name of Manufacturer Vessel: MAWP 290 psi at 572 °F Jacket: MAWP 130 psi at 572 °F MDMT -20 °F at 290 psi / 130psi Manufacturer's Serial No. 1234 Year Built 2002 1 National Board No. Hersteller Auslegungsdruck Mindest Temp. unter MAWP Seriennummer (Herst.) Baujahr W RT 4 SEC81.PPT 01/2004

No Manufacturer's Authorization No Authorized Inspector involvement
ASME B31 Piping Codes B Power Piping B Process Piping B Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids – 2002 B Refrigeration Piping and Heat Transfer Components B Gas Transmission and Distribution Piping Systems No Manufacturer's Authorization No Authorized Inspector involvement Exemption: Boiler External Piping acc. to Section I B31.PPT 01/03

ASME B Scope Scope: Power and Auxiliary service Piping Systems for: electric generating stations industrial plants heating plants main aspect: heat transfer such as: Boiler External Piping Data Reports and Stamping required over NPS 1/2 within Jurisdictional Limits of Code Section I and: Nonboiler External Piping No Data Report and Stamping required ASME Code Committee for Pressure Piping is responsible this includes: > central and district heating systems > geothermal piping from wellheads > fuel gas and fuel oil piping downstream plantmeter set or inside the plant property line > steam jet cooling systems in the power plant cycle > gas and oil systems, air systems, hydraulic fluid systems B31_1.PPT

B 31.1 - 100.1, Scope (cont'd) but except:
piping covered by other Sections of the ASME BPV Code Boilers and pressure vessels itselves Stream heating piping £ 15 psig hot water heating piping £ 30 psig plumbing hydraulic / pneumatic tool piping downstream the stopvalve Federal control installations Nuclear installation piping ® Code Section III B 31.9 building services piping Fuel gas piping inside industrial buildings - ANSI Z 223.1 pulverized fuel piping ® NFPA 8503 B31_1.PPT

B 31.1 FIG 100.1.2(B) DRUM TYPE BOILERS
Boiler Proper BEP Non-BEP B31_1.PPT 06/99

ASME B 31.1 Contents Chapter I II III IV V VI Scope and definitions
Design Conditions and criteria Pressure design of piping components Selection and limitation of piping components Selection and limitation of piping joints Expansion, Flexibility, supporting Systems Materials Dimensional requirements Fabrication, assembly, erection Examination, inspection and testing Appendices B31_1.PPT

ANSI B 36.10 Dimensions of Steel Pipe (welded and smls)
B16.PPT 03/98

TABLE 2-1.1 RATINGS FOR GROUP 1.1 MATERIALS
ASME B 16.5 Pressure ratings in psig TABLE RATINGS FOR GROUP 1.1 MATERIALS Forgings Castings Plates A 105 (1) A 21 6 WCB(1) A 515 Gr. 70(1) A 350 Gr. LF2(1) A 516 Gr. 70(1, 2) A 537 CI. 1 (3) NOTES: (1) Permissible, but not recommended for prolonged usage above about 800°F. (2) Not to be used over 850°F. (3) Not to be used over 700°F. KOLB\B16.PPT 11/98

ASME B 31.3 300.1 Scope Scope: Piping for all fluids
Except: Definitions: Piping for all fluids within the property lines of facilities for chemicals and petroleum Main aspect: Product transportation non toxic fluids at psig and -20°F °F boiler external piping boiler proper, pressure vessels piping according to B 31.4, B 31.8, B 31.11 plumbing fire protection systems 300.2 B31_3.PPT

ASME B 31.3 Contents Chapter I II III IV V VI VII VIII IX
Scope and Definitions Design Conditions and criteria Pressure design of piping components Fluid Service Requirements Flexibility and Support Systems Materials Standards for Piping Components Fabrication, Assembly, Erection Examination, Inspection and Testing Nonmetallic Piping Piping for Category M Fluid Service High Pressure Piping Appendices B31_3.PPT

ASME B 31.3 chapter I Responsibilities (§ 300)
Owner: Overall responsibilities for Code compliance and establishment of (supplementary) requirements cover Jurisdictional requirements Designer: Responsible for compliance of engineering design with Code / additional requirements Manufacturer: Responsibility for material, components workmanship according to design and code Owner's Inspector: Ensure that inspection, examination, and testing requirements are met. KOLB\B31_3.PPT E 95

ASME B 31.3 Fluid Services Appendix M:
Category D fluid service: Nontoxic, nonflamable, not dangerous, designated by owner - design pressure £150psig. Normal fluid service Category M fluid service: Toxic fluids, even at single exposure of small quantities, non protected personal, designated by owner High pressure fluid service: over Class 2500, designated by owner alternative rules in chapter IX Servere Cyclic Service: Piping over 7000 Cycles and significant displacement stress B31_3.PPT 04-03

Section IX - Contents Part QW - Welding
Article I Welding General Requirements QW-100 ff Article II Welding Procedure Qualifications QW-200 ff Article III Welding Performance Qualifications QW-300 ff Article IV Welding Data QW-400 ff Article V Standard WPS (SWPS) QW-500 ff Add 2000 Part QB - Brazing APPENDICES (Welding and Brazing Forms, and list of SWPSs) SEC9.PPT 8-00

Welding Processes Section IX, QW-492
Fusion Welding Schmelzschweißen Arc Welding Lichtbogenschweißen OFW Oxyfuel Welding Autogenschweißen SMAW Shielded Metal Arc Welding E - Hand GTAW Gas Tungsten Arc Welding WIG SAW Submerged Arc Welding UP GMAW Gas Metal Arc Welding MIG / MAG FCAW Flux Cored Arc Welding Fülldraht PAW Plasma Arc Welding Plasmaschweißen LBW Laser Beam Welding Laserstrahlschweißen EBW Electron Beam Welding Elektronenstrahlschweißen FW Friction Welding Reibschweißen ESW Electroslag Welding Elektroschlackeschweißen RW Resistance Welding Widerstandsschweißen SEC9.PPT 4/00

ASME Code Definition of Definition of Welds Joints 0°-30° ~90° 30°-90°
SEC81.PPT 10/02

Section IX Base Material P-Numbers
1 Carbon Steel 3 Up to 1/2% Cr and up to 1/2% Mo 4 1 to 2% Cr and up to 1/2% Mo 5A 2 to 3% Cr, 1% Mo Alloy Steel 5B 5 to 10% Cr, 1% Mo Alloy Steel 5C All 5A and 5B Materials heat treated to 85ksi+ 6 Martensitic Stainless Steel 7 Ferritic Stainless Steel 8 Austenitic Stainless Steel 9 2 to 5% Ni Alloy Steel 10 Mn-V, Cr-V, 9%Ni, High Cr Alloy Steels 11 Low Alloy Steel, Quenched and Tempered to 95ksi+ 21 1.2% Mg or Mn alloy Aluminum 22 1.2% Mn, 2,5% Mg, 0.25% Cu Aluminium 23 1.3% Mg, 0.7% Si, 0.25% Cr Aluminium 25 1.5% Mg, 0.8% Mn, 0.15% Cr Aluminium 31 Copper 32 Admiralty, Naval, Aluminium Brass, Muntz Metal 33 Cu-Si Alloys 34 Cu-Ni Alloys 41 Nickel 51 Titanium 61 Zirconium SEC9.PPT 3/96

Grouping of Base Metals for Qualification
QW/QB-422 Ferrous P-Numbers and S-Numbers Grouping of Base Metals for Qualification SEC9.PPT 03/98

Qualification of a Welding Procedure
Drawing + Construction Code Materials Design Impact testing PWHT etc. RTC Draft WPS range of welding variables essentials and nonessentials RTC welding of a test coupon from the range RTC WPS essentials + nonessentials Date Signature Qualification testing PQR Record of actual values and results certification Date Signature Documentation RTC SEC9.PPT 10/01

ASME Code Section IX 1. Welding Procedure Specification (WPS)
All parameters or Variables (essential-, supplementary- and non-essential variables) shall be specified in this document (see QW-200). This shall provide guidance for the welding personnel in the work area. A WPS should specify ranges of variables in accordance with Section IX. A WPS shall be written and qualified - by the manufacturer using it for Code production. Qualification is obtained by welding test pieces using the specified variables and proving by mechanical testing that the welding process as specified can be used to produce sound welds. A2000: Alternatively AWS Standard WPSs listed in Appendix E may be used SEC9.PPT 8-00

ASME Code Section IX 2. Procedure Qualification Records (PQR)
A WPS may only be used after successful qualification. A test piece is welded using the specified variables and mechanically tested. Both welding data and testing results are documented in the PQR. A PQR shall list all essential variables at least. However, it is recommended to list additional information during qualification. A PQR as a record shall show actual values instead of qualified ranges, and may not be revised.A manufacturer's representative shall certify correctness of the records. SEC9.PPT 4/99

ASME Code Section IX Qualification of a welder:
Selection of welders Selection of welding variables, i.e. Distinguishing of positions Distinguishing of pipe diameters Distinguishing of used F-Numbers for fillermetals etc. RTC WPQ Certification Date Signature welding of test coupons testing (VT and 2 bend tests or RT) SEC9.PPT 10/01

ASME Code Section IX 3. Welder's Performance Qualification (WPQ)
A welder or welding operator is qualified by the manufacturer employing him under the requirements specified in QW-300. This shall prove the manual skills of the welder to deposit sound weld metal. Criteria such as welding positions, pipe diameter, thickness of deposited weld metal, etc. are relevant for the qualified range. The WPQ is used to specify the range of the welder's qualification, but also to document his qualification tests. The test pieces may be mechanically tested or examined by radiography. SEC9.PPT 4/99

Testing Procedures, Records, Personnel Qualification - SNT-TC-1A
Radiographic Examination - Example Construction Code Section VIII-1 Test Requirements UW-11: All Butt Welds in the shell and heads of vessels used in lethal service shall be Radiographically Examined... Referenced Code Section V Article 2 Testing Testing Procedures, Records, Personnel Qualification - SNT-TC-1A Testing Results Acceptance Criteria UW-51(b)(1): Unacceptable is any indication characterized as crack or zone of incomplete fusion or penetration... Construction Code Section VIII-1 SEC5.PPT E 95

General Requirements T-220 Procedure Compliance
Section V - Articles 2 & 22 General Requirements T-220 Procedure Compliance Density and penetrameter image Content of written procedure Surface Preparation Backscatter System for identification Permanent on radiograph, traceable to contract, component, weld, part-No. Equipment and Materials T-230 Films -SE-94 Screens -allowed unless restricted Film Processing -SE-94 -SE-999 IQI Design -SE142 and Table T-233 (A2000) number equals thickness (mm) 1T Hole equals thickness Calibration T-260 Source size Step wedge density traceability (A2000: traceable to a National Standard) SEC5.PPT 8/00

Section V - Articles 2 & 22 Examination T-270 Documentation T-290
Radiographic Technique Pipe and Tubes -Appx. A Selection of radiation energy Location Markers IQI Selection Table T-276 (A2000 Wire designation) Placement of IQIs -Appx. C Equivalent Wire IQI (A2000 Table T-276) Equivalent Hole Type Sensitivity (A2000 Table T-283) Documentation T-290 Information to accompany each group of radiographs Evaluation by Manufacturer -Records SEC5.PPT 8/00

B Radiographic Examination - Film Example 0 10 20 30 40 50 60 ASTM
ASTM B 1A 01 F RTC Order N W1 SEC5.PPT E 98

Section V SE-747 wire type IQI SEC5.PPT 03/98

Article 2: RT Procedure Contents of the written Procedure Material,
Thicknesses Isotope or X-Ray Energy Min. Distance Source to Object Max. Distance Source-side of Object to the Film at SOD Max. Focal Spot Size / Source Size Film Designation Intensifying screens and sufficient guidance for the examination personnel to assure Code compliance (Penetrameter selection, configuration, Film marking) Evaluation and acceptance criteria Shall be demonstrated to the AI SEC5.PPT 5-01

Written Practice Document to be established by employer of personnel
Employer (Manufacturer) is responsible to certify that personnel qualification and certification is according to the written practice. Contents (Guideline SNT-TC-1A-1996) Responsibility of Level III, II, I Training, Education Experience Examination Physical Requirements Certification Recertification SEC5.PPT 03/01

NDE Personnel Qualification
SNT-TC-1A (92) Level I: - calibration - examination to written procedure - evaluation to written procedure Level II: - all of the above - setup & calibrate equipment - interpret & evaluate NDE results acc. to Codes - training of personnel - report NDE results Level III: - all of the above - establish procedures - interpreting Codes & Standards - designate methods & procedures - responsible for NDE operations - training, examination and certification of other Level I, II, III SEC5.PPT 03/98

Level III Requirements
SNT-TC-1A-1996 Experience (e.g. engineering college grade and 1 year experience in NDE) Examinations (by manufacturer's representative) BASIC (45 questions) once Method (45 questions + 20 questions on Code) once per method Specific (20 questions related to products) once per method ASNT Level III Certificate may replace "Basic" and "Method" Examinations Certification by Manufacturer / Employer Eye-test (Jaeger 2 + colour contrast) valid for 5 years SEC5.PPT 03/01

National Board Inspection Code
Contents Part RA - Administrative Requirements Part RB - Inservice Inspection of pressure retaining items Part RC - Repairs and Alterations Part RD - Repair Methods Mandatory Appendices Nonmandatory Appendices NBIC.PPT 7/98

NBIC RB-1000 General Inservice Inspection
Location of Installation: Jurisdictional Requirements Construction Code Safety Valve Requirements Additional Requirements Inservice Inspection Code (NBIC) Frequency Scope Internal External Documentation Commissioning of State Inspectors NBIC.PPT 7/98

NBIC RC - Repairs and Alterations
RC-1000 General Construction, Accreditation, Material, Parts, Inspector, Welding, PWHT, NDE, Inspection, Stamping, Registration of Documentation RC-2000 Additional Requirements for Repairs Drawings, Authorization, Methods, Testing, Stamping, Documentation, ASME VIII-2 Vessels RC-3000 Additional Requirements for Alterations Design, Testing, Stamping, Documentation NBIC.PPT 7/98

NBIC RD - Repair Methods
RD-1000 Welding as Alternative to PWHT NDE of Welds, 3 Welding Methods RD-2000 Repair Methods Defect Repairs, Wasted Areas, Seal Welding, Re-Ending Pipes and Tubes Patches Stays NBIC.PPT 7/98

Instructor: Dipl.-Ing. Horst Michael

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