Additional Requirements for Heavy Wall IP 5-1-2

INTERNATIONAL Pressure Vessels, Thickness Over 2 Inches Page 1 of 5

PRACTICE
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

Changes shown by 

SCOPE
I 1.1 This practice covers additional requirements governing the design, fabrication, examination, and testing of
unfired pressure vessels having a thickness in excess of 2 in. (50 mm) and up to 6 in. (150 mm).
I 1.2 The examination and testing requirements of IP 5-1-1 are replaced in their entirety by those specified in
this practice. All other requirements are in addition to those in IP 5-1-1.
I 1.3 An asterisk () indicates that a decision by the Purchaser is required, or that additional information is
furnished by the Purchaser.
I  1.4 Additional requirements for pressure vessels having a thickness in excess of 6 in. (150 mm) will be
specified.

SUMMARY OF ADDITIONAL REQUIREMENTS

I 2.1 Table 1 lists the practices and standards which shall be used with this practice to supplement IP 5-1-1,
Table 1.

TABLE 1

PRACTICE
IP 5-1-1 Pressure Vessels
IP 18-10-1 Additional Requirements for Materials
STANDARDS
ASTM Standards
A 388 Ultrasonic Examination of Heavy Steel Forgings
A 578 / A 578M Straight-Beam Ultrasonic Examination of Plain and Clad Steel Plates for Special
Applications
E 94 Radiographic Testing

DESIGN
ANALYSIS
R  3.1 Thermal Stress. When thermal gradients exceed 150F (80C) in a distance equal to Rt, where R
and t are the mean radius and thickness of the vessel component in question, a thermal stress analysis
shall be performed in accordance with the applicable design code. If the design code used does not
contain procedures for thermal analysis, the procedures of the ASME Code Section VIII, Division 2 may
be used.
R  3.2 The Owner's Engineer shall specify if a fatigue analysis is required. An acceptable method for
determining the need for a fatigue analysis is contained in the ASME Code Section VIII, Division 2, Par.
AD-160. When a fatigue analysis is required, the procedures of the ASME Code Section VIII, Division 2
may be used for the analysis.

HEADS AND TRANSITION SECTIONS

R 3.3 Formed heads shall be 2:1 elliptical or hemispherical.
R 3.4 Knuckles for conical transition sections shall have an inside radius no less than 14% of the outside
diameter of the adjoining cylindrical section.

NOZZLES AND CONNECTIONS

R 3.5 Slip-on flanges shall not be used.

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 IP 5-1-2 Additional Requirements for Heavy Wall
Page 2 of 5 Pressure Vessels, Thickness Over 2 Inches INTERNATIONAL
PRACTICE
Rev. 1 March 1998 (This practice is appropriate for attachment to Inquiry or Purchase Document)

R 3.6 Nozzle configurations shall be as follows:

Figure Reference From Indicated Division of the ASME Code Section VIII
Nozzle NPS, in. (mm)(1)

Division 1 Division 2
 4 (100) Fig. UW 16.1 (a), (b), (c), (d) or (e) (2) Fig. AD 610.1 (a), (b), (c), (d), (e), (e-1) or (f)
> 4 (100) Fig. UW 16.1 (f1), (f2), (f3) or (f4) (3) (4) Fig. AD 613.1 (a), (b), (c), (c-1) or (d) (3) (5)
Notes:
(1) In all cases, nozzle configurations that are acceptable for diameters over NPS 4 (100 mm) may be used for
smaller diameters as well.
(2) Backing strips, if used, shall be removed after welding.

(3) Proposals to use alternative design details, which will permit either 100% radiographic or ultrasonic
examination of the nozzle to shell weld, shall be submitted to the Purchaser for approval by the Owner's
Engineer.
(4) Alternatively Figure UW 16.1 (g) may be used at design temperatures below 850F (450C).
(5) Alternatively Figure AD 610.1 (g) may be used at design temperatures below 850F (450C).
R 3.7 The minimum inside corner radius for all openings shall be the lesser of the following:
a. 1/4 of the thickness of the vessel component penetrated.
b. 1/4 of the finished inside diameter of the opening.
c. 3/4 in. (19 mm).
R 3.8 No exterior radius for attachments shall be less than 1/4 in. (6 mm).

VESSEL SUPPORT
R 
3.9 For skirt supported vessels with design temperatures above 500F (260C), excluding internally lined
vessels, the skirt to shell attachment shall be made by means of a forged head ring with stub, as shown
below, or weld build-up on the shell. If the weld build-up method is used, its design details shall be
approved by the Owner's Engineer.
R 3.10 For vessels with design temperatures above 500F (260C), excluding internally lined vessels, a support
skirt “hot box," as shown below, shall be provided at the vessel to skirt junction.

Vessel Shell
Skirt To Shell Attachment
Blend Grind (Weld Build-up Method Shown)
Toe Of Weld
Forged Head Ring Thermal 1 in. (25 mm) Radius
Insulation Minimum, Note (1)

Insulation Continuous Ring

Jacket (Welded Or Bolted
Construction)
18 in. (450 mm)
Minimum

1 in. (25 mm) Insulation

Minimum Radius Support
Ring Gunite per 14-3-1
Support Skirt

FORGED HEAD RING HOT BOX Support Skirt 050102F1

Note:

(1) If approved by the Owner's Engineer, the radius may be reduced based on a detailed stress analysis.

R 3.11 For lug supported vessels with design temperatures above 500F (260C), excluding internally lined
vessels, a thermal stress analysis shall be performed of the lug to vessel attachment.

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 Additional Requirements for Heavy Wall IP 5-1-2
INTERNATIONAL Pressure Vessels, Thickness Over 2 Inches Page 3 of 5
PRACTICE
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

FABRICATION

WELDING
R 4.1 Attachment welds on the vessel, including those for platform clips, shall be full penetration.
R 4.2 All major load bearing attachments including tray support rings, catalyst bed supports, etc., shall be
welded to the base material of the shell, and have the same nominal chemistry as the base material of the
shell, if the design temperature exceeds 300F (150C).

EXAMINATION AND TESTING

R 5.1 Additional examination and testing requirements for heavy wall pressure vessels covered by this
practice are summarized in Table 3.

EXAMINATION AND TESTING METHODS AND ACCEPTANCE CRITERIA

R 5.2 Ultrasonic examination of plates. Plates (and plate-like forgings such as forged shell rings) shall be
ultrasonically examined per ASTM A578/578M. Acceptance standard shall be Level II. In addition, all
areas within two plate thicknesses from the location of a major load bearing attachment weld or corner type
joint shall be longitudinal beam examined with a 100% scrub. Acceptance standard shall be Level I.
R 5.3 Ultrasonic examination of forgings. All forgings (except plate-like forgings and standard flanges per
ASME and API) shall be ultrasonically examined per ASTM A388, Par. 7.3. Transducers shall be 1 to 1-
1/8 in. (25 to 29 mm) diameter or 1 in. (25 mm) square for normal beam testing, and 1 x 1 in. or 1 x 1/2 in.
(25 x 25 mm or 25 x 13 mm), 45 degree, for angle beam testing.
I 5.4 For ultrasonic examination of welds and forgings, a report shall be submitted to the Inspector
indicating diagrams of surfaces scanned and indications obtained, repaired areas, nature of defects
repaired, and repair procedures used. The following information shall also be provided:
a. Pulse echo unit manufacturer, model, and damping control setting.
b. Search unit manufacturer, model, dimensions, and couplant.
c. Frequency used and test angle to component surface.
d. Wedge medium for angle beam examination.
R 5.5 Magnetic particle examination of edges prepared for welding and openings. Prior to welding, all
edges prepared for welding and plate openings shall be examined by the magnetic particle method (D-C
prod only). Indications found shall be cleared and back welded to provide a minimum depth of 1 in. (25
mm) of sound metal.
R 
5.6 Magnetic particle examination of welds. All accessible welds and, after grinding, all areas where
temporary lugs have been removed, shall be inspected by dry magnetic particle testing (MT) after
hydrotest (A-C yoke or coil method only). Wet fluorescent magnetic particle testing (WFMT) and wet
contrast (black powder) over a white contrast background testing (CWMT) are also acceptable inspection
techniques. Welds which will be overlayed shall be examined prior to overlay. The backside of the root
pass, if applicable, shall be examined after being prepared for welding, and both sides of the completed
weld.
Magnetic particle examination and acceptance criteria shall be per the ASME Code Section VIII
Division 1, Appendix 6. The D-C prod method shall be used prior to final postweld heat treatment, and the
A-C yoke or coil method after final postweld heat treatment.
R 5.7 Radiographic examination of welds. Except as noted below, all pressure retaining welds shall be 100%
examined by radiography per par. UW-51 of the ASME Code Section VIII, Division 1. Radiographic film
shall be equivalent to Type 1 or 2 per ASTM E94. Examination shall be conducted prior to weld overlay
and PWHT.
For nozzles which employ a design which is not readily radiographible, either of the following examination
methods may be substituted for radiography:
a. 100% ultrasonic examination of the completed weld.
b. Magnetic particle examination (D-C prod only) after every 1/4 in. (6 mm) of weld thickness deposited.
R 5.8 Ultrasonic examination of welds. Subsequent to postweld heat treatment, all pressure retaining welds
shall be ultrasonically examined per Appendix 12 of ASME Code Section VIII, Division 1, such that the
entire volume of deposited weld metal is examined from two directions.

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 IP 5-1-2 Additional Requirements for Heavy Wall
Page 4 of 5 Pressure Vessels, Thickness Over 2 Inches INTERNATIONAL
PRACTICE
Rev. 1 March 1998 (This practice is appropriate for attachment to Inquiry or Purchase Document)

PRODUCTION TEST PLATES

R 5.9 Test plates are required when the vessel thickness exceeds 4 in. (100 mm). The plates shall be prepared
after completing 200 ft (60 m) of each type of finished weld. The following requirements shall also apply:
a. One plate shall be prepared for each electroslag type weld seam, if any, and at least one plate shall
be prepared for each type of shell welding in each vessel.
b. The plates shall be subjected to the equivalent total thermal treatment as the finished vessel, and
shall be tested per Table 3.
c. The test plates shall be prepared from material actually used in construction of the vessel, having a
thickness within 10% of the finished vessel thickness.

MATERIALS TESTING
R 5.10 Chemical analysis per the applicable material specification shall be provided for base materials. Weld
metal analysis shall be performed on production test plates.
R 5.11 Tension tests. The number, orientation and location of specimens for both room temperature and hot
tension tests shall be per the applicable material specification, or weld procedure.
R 5.12 Transverse tension tests shall be per the ASME Code Section IX. Specimens from production test
plates need be tested at design temperature only.
R 5.13 Bend tests shall be per the ASME Code Section IX.

Revision Memo
9/68 Original Issue of Basic Practice
1/71 Revision 1
1/73 Revision 2
11/90 Revision 3
12/94 Revision 0 - Original Issue of International Practice
3/98 Revision 1
Complete editorial revision to rationalize this practice with the referenced standards and other IP’s. Significant changes
include: old Par. 1.4 deleted; old Par. 3.1 deleted, covered design to Div. 1 or Div. 2 of ASME Code which is covered
in IP 5-1-1; old Par. 4.1 deleted, require full penetration welding for pressure welds which is covered in IP 5-1-1; old
Par. 5.9 deleted, covered hardness testing per IP 5-1-1, now covered by IP 18-10-1. Table 3 modified hardness
testing and impact testing covered in IP 18-10-1.

 Exxon Research and Engineering Company, 1994, 1998

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 Additional Requirements for Heavy Wall IP 5-1-2
INTERNATIONAL Pressure Vessels, Thickness Over 2 Inches Page 5 of 5
PRACTICE
(This practice is appropriate for attachment to Inquiry or Purchase Document) Rev. 1 March 1998

 TABLE 3
INSPECTION AND TESTING REQUIREMENTS

Tension -
MATERIALS TO Chemical T.S., Y.S., Charpy Bend Transverse Magnetic Liquid Hardness
BE INSPECTED Analysis EL, R.A. (3) Impact Test Tension- Radiography Ultrasonics Particle Penetrant (Brinell)
T.S.
Base Material
1) Plates (2)
5.10 5.11 5.2
2) Forgings
5.10 5.11 (2) 5.3
3) Pipe
5.10 5.11 (2) —
4) Internals
5.10 5.11 —
—
Welding
Qualification
Plates
1) Weld metal 5.10 5.11 (2) — — — — —
2) Weld metal — — (2) 5.13 5.12 5.7 5.8 (4)
and heat
affected
zone
3) Weld (1) — (1) — — — —
overlay, if —
any
Production Test
Plates (per Par.
5.10)
1) Weld metal 5.10 5.11 (2) — — —
2) Weld metal — (2) 5.13 5.12 (4)
and heat
affected
zone
All Pressure
Retaining Welds
1) Edges to be — 5.5 —
welded
2) Before 5.7 — 5.6 —
overlay
3) After — 5.8 — (4)
PWHT(3)
4) After — — 5.6 —
hydrotest
Attachment and
5.6
Temporary
Welds
Weld Overlay
1) Before (1) (1) —
PWHT
2) After PWHT — — (1)
and
hydrotest

Notes:
(1) Inspection requirements shall be per IP 19-2-1.
 (2) Impact testing shall be per IP 18-10-1.
(3) Abbreviations used are: T.S. - Tensile Stress; Y.S. - Yield Stress; EL - Elongation; R.A. - Reduction of Area; PWHT -
Postweld Heat Treatment. All other numerals shown in Table 3 refer to corresponding paragraphs within this practice.
 (4) Hardness testing shall be per IP 18-10-1.

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