API 510 CODE

Lesson 19
Overview
Pressure Tests and Welding
 API 510

This Overview will be restricted primarily to a small part of

Sections 6 and 7of the API 510 the subject matter that is
the most difficult to understand and those items in API 510
that give rules different from those given in the ASME Code
Sections.
Other subject material such as, scope of the 510,
definitions and, responsibilities are covered by practice
exercises, practice exams and most importantly, the
students reading of the API 510 document.
 6.5 PRESSURE TEST

When the authorized pressure vessel inspector believes

that a pressure test is necessary or when, after certain
repairs or alterations, the inspector believes that one is
necessary (see 7.2.9), the test shall be conducted at a
pressure * in accordance with the construction code
used for determining the maximum allowable working
pressure.

* This means if a vessel was constructed to an edition

of the ASME Code or any other Code that requires a
different multiplier than 1.3 (hydro) or 1.1 (pneumatic)
then the original multiplier should be used.
 6.5 PRESSURE TEST

* To minimize the risk of brittle fracture during the test, the

metal temperature should be maintained at least 30°F
(17°C) above the minimum design metal temperature for
vessels that are more than 2 inches (5 centimeters) thick,
or 10°F (6°C) above for vessels that have a thickness of 2
inches (5 centimeters) or less. The test temperature need
not exceed 120°F (50°C) unless there is information on the
brittle characteristics of the vessel material indicating that a
lower test temperature is acceptable or a higher test
temperature is needed.

* This differs from the ASME which recommends 30°F in all

thicknesses. Use these rules for the exam.
 6.5 PRESSURE TEST

Pneumatic testing may be used when hydrostatic testing is

impracticable because of temperature, foundation,
refractory lining, or process reasons; however, the potential
personnel and property risks of pneumatic testing shall be
considered before such testing is carried out.
As a minimum, the inspection precautions contained in the
ASME Code shall be applied in any pneumatic testing
(NDE of UW-50 and brought up in steps of 1/10 beginning
at half way to test pressure).
Before applying a hydrostatic test to equipment,
consideration should be given to the supporting structure
and the foundation design.
 SECTION 7
Repairs, Alterations, and Rerating of
Pressure Vessels

7.2.3
Preheat or Controlled Deposition Welding Methods as
Alternatives to Postweld Heat Treatment
 Definition Controlled Deposition

• 3.19 controlled-deposition welding:

• Any welding technique used to obtain controlled

grain refinement and tempering of the underlying
heat affected zone (HAZ) in the base metal.
 Definition Controlled Deposition

• Various controlled deposition techniques, such as

temper-bead (tempering of the layer below the current
bead being deposited) and half-bead (requiring removal
of one-half of the first layer), are included.
 Definition Controlled Deposition

• Controlled-deposition welding requires control of the

entire welding procedure including the joint detail,
preheating and post heating, welding technique, and
welding parameters. Refer to supporting technical
information found in Welding Research Council
Bulletin 412.
 Preheat/Controlled Deposition
• Benefits
• May allow welded repairs to a vessel that was
constructed to the ASME Section VIII Div.1 which
required PWHT to be repaired without further PWHT of
the vessel’s material.
• Preheat and controlled deposition welding, as described
in 7.2.3.1 and 7.2.3.2, may be used in lieu of post-weld
heat treatment where PWHT is inadvisable or
mechanically unnecessary.
• Prior to using any alternative method, a metallurgical
review conducted by a pressure vessel engineer shall
be performed.
 Preheat/Controlled Deposition

• The review should consider factors such as the reason

for the original PWHT of the equipment, susceptibility of
the service to promote stress corrosion cracking,
stresses in the location of the weld, susceptibility to high
temperature hydrogen attack, susceptibility to creep, etc.

• Selection of the welding method used shall be based on

the rules of the construction code applicable to the work
planned along with technical consideration of the
adequacy of the weld in the as-welded condition at
operating and pressure test conditions.
 Preheat/Controlled Deposition

• When reference is made in this section to materials by

the ASME designation, P-Number and Group Number,
the requirements of this section apply to the applicable
materials of the original code of construction, either
ASME or other, which conform by chemical composition
and mechanical properties to the ASME P-Number and
Group Number designations.
• Vessels constructed of steels other than those listed in
7.2.3.1 and 7.2.3.2 that initially required PWHT shall be
post-weld heat treated if alterations or repairs involving
pressure boundary welding are performed. When one of
the following methods is used as an alternative to PWHT,
the PWHT joint efficiency may be continued if it has been
used in the currently rated design.
 Preheat/Controlled Deposition

7.2.3.1
Preheating Method (Notch Toughness
Testing Not Required)
Preheating Method Notch Toughness Not Required

a. Notch toughness testing is not required when this

welding method is used.
b. The materials shall be limited to P-No. 1, Group 1, 2, and
3, and to P-No. 3, Group 1 and 2 (excluding Mn-Mo
steels in Group 2).
c. The welding shall be limited to the shielded-metal-arc
welding (SMAW), gas-metal-arc welding (GMAW), and
gas tungsten-arc welding (GTAW) processes.
 Preheating Method Notch Toughness Not
Required
d. The weld area shall be preheated and maintained at a
minimum temperature of 300°F during welding.
• The 300°F temperature should be checked to assure
that 4 in. of the material or four times the material
thickness (whichever is greater) on each side of the
groove is maintained at the minimum temperature during
welding. The maximum interpass temperature shall not
exceed 600°F.
• When the weld does not penetrate through the full
thickness of the material, the minimum preheat and
maximum interpass temperatures need only be
maintained at a distance of 4 in. or four times the depth
of the repair weld, whichever is greater on each side of
the weld joint.
 Controlled Deposition Notch Toughness Required

a. Notch toughness testing, such as that established by

ASME Code Section VIII Division 1, parts UG-84 and
UCS-66, is necessary when impact tests are required by
the original code of construction or the construction code
applicable to the work planned.
b. The materials shall be limited to P-No. 1, P-No. 3, and P-
No. 4 steels.
c. The welding shall be limited to the shielded-metal arc
welding (SMAW), gas-metal-arc welding (GMAW), and
gas tungsten-arc welding (GTAW) processes.
 Controlled Deposition Notch Toughness Required

d. A weld procedure specification shall be developed and

qualified for each application. The welding procedure
shall define the preheat temperature and interpass
temperature and include the post heating temperature
requirement in f (1) below. The qualification t for the test
plates and repair grooves shall be in accordance with
Table 7-1.
 Table 7-1
Welding Methods as Alternatives to Postweld Heat Treatment

• Qualification Thicknesses For Test Plates and Repair Grooves

_______________________________________________________________________
Depth t of Test Repair Groove Thick. T of Test Thick. Base Metal
Groove Welded Depth Qualified Coupon Welded Qualified
___________________________________________________________________________________________________________________

t <t <2 in. <T

t <t > 2 in. 2 in. to unlimited

Note: The depth of the groove used for procedure qualification must be
deep enough to allow removal of the required test specimens.
Controlled Deposition Notch Toughness Required
Example Coupon
 Controlled Deposition Notch Toughness Required

d. (cont’d) The test material for the welding procedure

qualification shall be of the same material specification
(including specification type, grade, class and condition
of heat treatment) as the original material specification
for the repair.
• If the original material specification is obsolete, the
test material used should conform as much as possible
to the material used for construction, but in no case shall
the material be lower in strength or have a carbon
content of more than 0.35%.
 Controlled Deposition Notch Toughness Required

e. When impact tests are required by the construction code

applicable to the work planned, the PQR shall include
sufficient tests to determine if the toughness of the weld
metal and the heat affected zone of the base metal in the
as-welded condition is adequate at the minimum design
metal temperature (such as the criteria of ASME Section
VIII Div. 1, parts UG-84 and UCS 66).
• If special hardness limits are necessary (for example, as
set forth in NACE RP 0472, and MR 0175) for corrosion
resistance, the PQR shall include hardness tests as well.
 Controlled Deposition Notch Toughness Required

• f. The WPS shall include the following additional

requirements:
1. The supplementary essential variables of ASME Code,
Section IX paragraph QW-250, shall apply;
2. The maximum weld heat input for each layer shall not
exceed that used in the procedure qualification test;
3. The minimum preheat temperature for welding shall not
be less than that used in the procedure qualification test;
 Controlled Deposition Notch Toughness Required

4. The maximum interpass temperature for welding shall

not be greater than that used in the procedure
qualification test;
5. The preheat temperature shall be checked to assure that
4 in. of the material or four times the material thickness
(whichever is greater) on each side of the weld joint will
be maintained at the minimum temperature during
welding.
• When the weld does not penetrate through the full
thickness of the material, the minimum preheat
temperature need only be maintained at a distance of 4
in. or four times the depth of the repair weld, whichever
is greater on each side of the joint;
 Controlled Deposition Notch Toughness Required
6. For the welding processes in 7.2.3.2 (c), use only
electrodes and filler metals that are classified by the filler
metal specification with an optional supplemental
diffusible-hydrogen designator of H8 or lower. When
shielding gases are used with a process, the gas shall
exhibit a dew point that is no higher than -60°F.
• Surfaces on which welding will be done shall be
maintained in a dry condition during welding and free of
rust, mill scale and hydrogen producing contaminants
such as oil, grease and other organic materials;
7. The welding technique shall be a controlled-deposition,
temper-bead or half-bead technique. The specific
technique shall be used in the procedure qualification
test;
 Controlled Deposition Notch Toughness Required

8. For welds made by SMAW, after completion of welding

and without allowing the weldment to cool below the
minimum preheat temperature, the temperature of the
weldment shall be raised to a temperature of 500°F plus
or minus 50°F for a minimum period of two hours to
assist out-gassing diffusion of any weld metal hydrogen
picked up during Welding.

• This hydrogen bake-out treatment may be omitted

provided the electrode used is classified by the filler
metal specification with an optional supplemental
diffusible-hydrogen designator of H4 (such as E7018-
H4); and;
 Controlled Deposition Notch Toughness Required

9. After the finished repair weld has cooled to ambient

temperature, the final temper bead reinforcement layer
shall be removed substantially flush with the surface of
the base material.