API 510
Mathematical Calculations
Pressure Vessel Inspection Code:-
Maintenance Inspection, Rating,
Repair, and Alteration
Section 5.4
Maximum Allowable Working Pressure
Determination
§ Establish using latest ASME Code edition or original Code edition to which
vessel constructed
§ Certain essential details must be known prior to performing computations
§ In corrosive service the wall thickness used shall be actual thickness
determined by inspection minus twice the estimated corrosion loss before
next inspection
§ The “t” in the pressure formula is replaced by the following:
t = tactual – 2(Corrosion rate x years to next inspection)
P = SEt/R + 0.6t
Math Problem #1
Maximum Allowable Working Pressure Determination
A pressure vessel has an MAWP of 500 psi at 400F and is made of SA
516 Gr.70 material with a stress value of 20,000 psi and has a measured
thickness of 0.875 inches. The efficiency is 1.0, inside radius is 24 inches
and there is no corrosion allowance. The observed corrosion rate is 0.01
inches/year and the next planned inspection is 5 years. What will be the
MAWP at the end of 5 years?
1) 633 psi
2) 500 psi
3) 450 psi
4) 900 psi
Math Problem #1
Maximum Allowable Working Pressure Determination
________________________________________________________________________
Step 1: List down all “Given” info
MAWP = 500 psi tactual=0.875” R=24” Next inspection = 5 yrs
S=20,000 psi E=1.0 CR= 0.01 inch/year
MAWP at the end of next 5 years?
________________________________________________________________________
Step 2: Formula P = SEt/R+0.6t
t = tactual – 2(CR x next inspection)
________________________________________________________________________
Step 3: Calculate t = 0.875” – 2(0.01 x 5) = 0.775”
________________________________________________________________________
Step 4: Plug in value into P = SEt/R+0.6t
=(20,000)(1)(0.775)/24+(0.6)(0.775)=633 psi
________________________________________________________________________
Math Problem #2
Maximum Allowable Working Pressure Determination
A pressure vessel has an MAWP of 350 psi at 300F and is made of SA 515 Grade 60
material with a stress value of 16,000 psi. The efficiency of the longitudinal joint is
0.70 and the inside radius is 36 inches with 1.25 inch corrosion allowance. The
measured thickness is 0.750 inches and the corrosion rate is 0.02 ipy. The next planned
inspection is in 6 years. What will be the MAWP at the end of six years?
1) 440 psi
2) 350 psi
3) 602 psi
4) 157 psi
Math Problem #2
Maximum Allowable Working Pressure Determination
__________________________________________________________________________
Step 1: List down all “Given” info
MAWP = 350 psi tactual=0.875” R=36” Next inspection = 6 yrs
S=16,000 psi E=7.0 CR= 0.02 inch/year
MAWP at the end of 6 years?
__________________________________________________________________________
Step 2: Formula P = SEt/R+0.6t
t = tactual – 2(CR x next inspection)
__________________________________________________________________________
Step 3: Calculate t = 0.75” – 2(0.02 x 6) = 0.51”
__________________________________________________________________________
Step 4: Plug in value into P = SEt/R+0.6t
=(16,000)(0.7)(0.51)/36+(0.6)(0.51)
=5,712/36.306
= 157.3 psi
Section 5.7
Corrosion and Minimum Thickness Evaluation
• Corrosion may cause uniform loss or may cause a pitted appearance
• Minimum actual thickness and maximum corrosion rate determined by:
– NDE thickness testing and drilled test holes
– Measurement through openings
– Gauging from uncorroded surfaces
• When the minimum actual thickness or maximum corrosion rate is to be
adjusted, one of the following evaluation techniques should be
considered
1) Averaging for large areas
2) Evaluation of widely scattered pit
3) Evaluation of corrosion on weld surface with joint factor other than 1
4) Measuring corroded thickness of ellipsoidal & torispherical head
Section 5.7
Averaging for Large Areas
Math Problem #3
Averaging for Large Areas
An eight foot diameter vessel has a large area of general corrosion (32
inches in length and width) and has thickness readings taken in the
circumferential (lettered row) and longitudinal (numbered row) directions
as shown below. What would be the least thickness along the most critical
element considering circumferential stress applies.
1a-0.298” 2a-0.243” 3a-0.192” 4a-0.185” 5a-0.267”
1b-0.264” 2b-0.230” 3b-0.185” 4b-0.193” 5b-0.220”
1c-0.223” 2c-0.180” 3c-0.204” 4c-0.210” 5c-0.246”
1. 0.206”
2. 0.193”
3. 0.179”
4. 0.195”
Math Problem #3
Averaging for Large Areas
An eight foot diameter vessel has a large area of general corrosion (32
inches in length and width) and has thickness readings taken in the
circumferential (lettered row) and longitudinal (numbered row) directions
as shown below. What would be the least thickness along the most critical
element considering circumferential stress applies.
1a-0.298” 2a-0.243” 3a-0.192” 4a-0.185” 5a-0.267”
1b-0.264” 2b-0.230” 3b-0.185” 4b-0.193” 5b-0.220”
1c-0.223” 2c-0.180” 3c-0.204” 4c-0.210” 5c-0.246”
___________________________________________________________________________
0.2616” 0.2176” 0.1936” 0.196” 0.569”
1. 0.206” a b c
2. 0.193”
1
3. 0.179”
4. 0.195” 2
3
4
5
Math Problem #4
Averaging for Large Areas
An six foot diameter vessel has a large area of general corrosion (24
inches in length and width) and has thickness readings taken in the
circumferential (lettered row) and longitudinal (numbered row) directions
as shown below. What would be the least thickness along the most critical
element considering circumferential direction.
1a-0.456” 2a-0.443” 3a-0.388” 4a-0.443” 5a-0.550”
1b-0.458” 2b-0.423” 3b-0.334” 4b-0.457” 5b-0.589”
1c-0.398” 2c-0.399” 3c-0.368” 4c-0.447” 5c-0.498”
1. 0.447”
2. 0.363”
3. 0.191”
4. 0.422”
Math Problem #4
Averaging for Large Areas
An six foot diameter vessel has a large area of general corrosion (24
inches in length and width) and has thickness readings taken in the
circumferential (lettered row) and longitudinal (numbered row) directions
as shown below. What would be the least thickness along the most critical
element considering circumferential direction.
0.456”
1a-0.456” 2a-0.443” 3a-0.388” 4a-0.443” 5a-0.550”
1b-0.458” 2b-0.423” 3b-0.334” 4b-0.457” 5b-0.589” 0.452”
1c-0.398” 2c-0.399” 3c-0.368” 4c-0.447” 5c-0.498” 0.422”
1. 0.447”
2. 0.363” a b c
3. 0.191”
1
4. 0.422”
2
3
4
5
Section 5.7
Widely Scattered Pit
Math Problem #4
Widely Scattered Pit
A pressure vessel is 48 inches in diameter. There is some widely scattered
pitting present. The wall thickness including 0.125 inch corrosion allowance
is 0.750 inch. One group is encircled by an eight inch diameter circle that
contains the following;
One 1” dia x 0.20” deep pit, three ¾” dis x 0.20” pit and one 1-1/2” dia x
0.15 deep pit. A straight line is drawn through the most pits within the circle
and includes the ¾”, 1” and 1-1/2” pits.
a) What is the total area of the its within the 8 inches circle?
1)2.5 inch2 2)3.876 inch2 3)1.325 inch2 4)7.25 inch2
b) What would have to be done to the pits in the straight line to make them
acceptable?
1) Nothing, they are acceptable as is
2) Weld repair the 1.5” dia pt
3) Fill all pits with epoxy materials
4) None of the above apply
Math Problem #4
Widely Scattered Pit
A pressure vessel is 48 inches in diameter. There is D=48”
some widely scattered pitting present. The wall Tnom = 0.75
thickness including 0.125 inch corrosion allowance CA=0.125
is 0.750 inch. One group is encircled by an eight inch
diameter circle that contains the following;
Pit #1: 1” dia x 0.2” depth
Pit #2: 0.75” dia x 0.2” depth x (3nos)
One 1” dia x 0.20” deep pit, three ¾” dis x 0.20” pit Pit#3: 1.5” dia x 0.15” depth
and one 1-1/2” dia x 0.15 deep pit. A straight line is
drawn through the most pits within the circle
a) Total area of the pits
and includes the ¾”, 1” and 1-1/2” pits. Formula for area: ∏r2
Area of Pit#1 + Area of Pit#2 x 3 + Area of Pit#3
a) What is the total area of the its within the 8 = ∏(0.5)2 + ∏(0.375)2 x 3 + ∏(0.75)2
inches circle? = 0.785 + 1.325 + 1.767
1)2.5 inch2 = 3.878 inches2
2)3.876 inch2
3)1.325 inch2
4)7.25 inch2 b) Sum of dimension of pits within the 8
inches circle
b) What would have to be done to the pits in the Dia Pit#1 + Dia Pit#2 + Dia Pit#3
straight line to make them acceptable? = 1 + 0.75 + 1.5
1) Nothing, they are acceptable as is = 3.25” which is exceed the limit of 2”.
2) Weld repair the 1.5” dia pt Thus by repair 1.5” pit then the sum of
3) Fill all pits with epoxy materials dimension will be 1.75” which <2”
4) None of the above apply
Another Problem
Widely Scattered Pit
Four scattered pits are found on the shell of a vessel. All the pits are contained within
an 8 inch diameter circle. Pit no 1 is 0.75 inch diameter and 0.25 inch deep. Pit no 2 is
0.49 inch diameter and 0.61 inch deep. Pit no 3 is 0.6 inch diameter and 0.51 inch
deep. Pit no 4 is 1.5 inch diameter and 0.16 inch deep. The required thickness is 0.781
inch and the actual thickness is 1 inch.
a) What is the total area of the pits in the 8 inch circle?
1) 2.678 inch2 2)3.335 inch2 3)1.002 inch2 4) 6 inch2
b) What pit(s) are unacceptable due to remaining thickness?
1) No 1 & 3 2) No 2 3) No 4 4) No 1 & 2
c) What pit(s) are unacceptable because of straight line out tolerance?
1) No 1&2 2) No 2&3 3) No 3&4 4) N0 2&4
Another Problem Pit #1 : 0.75” dia x 0.25” depth
Pit #2 : 0.49” dia x 0.61” depth
Pit # 3 : 0.6” dia x 0.51” depth
Widely Scattered Pit Pit # 4 : 1.5” dia x 0.16” depth
tmin = 0.781”
tactual = 1”
Four scattered pits are found on the shell of a vessel. a) What is the total area of the pits in the 8 inch
All the pits are contained within an 8 inch diameter circle?
circle. Pit no 1 is 0.75 inch diameter and 0.25 inch Formula for area: ∏r2
deep. Pit no 2 is 0.49 inch diameter and 0.61 inch = Area Pit#1 + Area Pit#2 + Area Pit#3 + Area Pit#4
deep. Pit no 3 is 0.6 inch diameter and 0.51 inch = ∏(0.375)2+ ∏(0.245)2+ ∏(0.3)2+ ∏(0.75)2
deep. Pit no 4 is 1.5 inch diameter and 0.16 inch = 0.4418 + 0.1886 + 0.2827 + 1.7671
deep. The required thickness is 0.781 inch and the = 2.68 inch2
actual thickness is 1 inch.
b) What pit(s) are unacceptable due to remaining
a) What is the total area of the pits in the 8 inch thickness?
circle? Remaining t below the pit >½(tmin)
1) 2.678 inch2 ½ x tmin = ½ x 0.781 = 0.3905”
2)3.335 inch2 Pit#1: 1” – 0.25” = 0.75”
3)1.002 inch2 Pit#2: 1” – 0.61” = 0.39”
4) 6 inch2 Pit#3: 1” – 0.51” = 0.49”
Pit#4: 1” – 0.16” = 0.84”
b) What pit(s) are unacceptable due to remaining
thickness? c) What pit(s) are unacceptable because of straight
1) No 1 & 3 2) No 2 3) No 4 4) No 1 & 2 line out tolerance?
Pit#1 + Pit#2 = 0.75 + 0.49 = 1.24”
c) What pit(s) are unacceptable because of straight Pit#2 + Pit#3 = 0.49 + 0.6 = 1.09”
line out tolerance? Pit#3 + Pit#4 = 0.6 + 1.5 = 2.1” – not acceptable
1) No 1&2 2) No 2&3 3) No 3&4 4) N0 2&4 Pit#2 + Pit#4 = 0.49 + 1.5 = 1.99”
Section 5.7
Evaluation of Corroded Weld Surface
Math Problem #6
Evaluation of Corroded Weld Surface
A pressure vessel is found to have a corroded area that
includes the longitudinal welded seam. An evaluation must be
made to determine whether the thickness at the weld or
remote from the weld governs. The inside radius is 36 inch
which includes 0.125 inch corrosion allowance. The MAWP is
500 psig, S=17500 psi. The nameplate has no extent of
radiography shown under the code stamp. The longitudinal seam is Type 1.
What would be the width of the evaluation if the width from toe to toe was 1
inch?
1) 7 inch
2) 2 inch
3) 3.022 inch
4) 7.044 inch
Math Problem #6
Evaluation of Corroded Weld Surface
A pressure vessel is found to have a corroded
area that includes the longitudinal welded seam. MAWP = 500 psi, S= 17,500, R=36”, CA=0.125”
An evaluation must be made to determine E = 0.7 [Type 1 with no RT].
whether the thickness at the weld or remote from Width of area for evaluation of the weld and area
the weld governs. The inside radius is 36 inch remote from weld?
which includes 0.125 inch corrosion allowance.
The MAWP is 500 psig, S=17500 psi. The nameplate Section 5.7: The greater of 1” on either side of
has no extent of radiography shown under the weld or 2 x tmin on either side of weld
code stamp. The longitudinal seam is Type 1.
What would be the width of the evaluation if the tmin = PR/SE-0.6P
width from toe to toe was 1 inch? = (500)(36)/(17,500)(0.7) – 0.6(500)
= 18,000/11,900
1) 7 inch = 1.51”
2) 2 inch 2 x t min = 3.01” which is > 1”
3) 3.022 inch
4) 7.044 inch Thus, total area of evaluation
= both side of the weld + weld area
= (3.01) x 2 + 1
= 7.03”
Section 5.7
Measuring Corroded Thickness of Ellipsoidal &
Torispherical Head
Math Problem#7
Measuring Corroded Ellipsoidal Head
#7. There has been a corrosion in the center of ellipsoidal head. The
head is a 2:1 elliptical with a D of 60 inches and h of 15 inches. What is
the required thickness in the center portion of this head if the MAWP is
300 psi, E=1.0 and the S= 15,600 psi?
a) 0.520 in
b) 0.750 in
c) 1.050 in
d) 0.889 in
Math Problem#7
Measuring Corroded Ellipsoidal Head
MAWP = 300 psi, E=1.0, S=15,600 psi,
D=60, h=15.
What is treq or tmin?
As per Section if 5.7 thickness at central
portion calculation for elipsoidal or
torispherical to use spherical head formula:
t = PR/2SE-0.2P
Calculate R
R=kD, find value K from table.
For D/2h = 60/2(15) = 2 value k=0.9
R = 0.9 (60) =54”
t = (300)(54)/2(15,600)(1)-0.2(300)
= 16,200/31,140
= 0.52”
Math Problem#13
Measuring Corroded Torispherical Head
#13. A torispherical head is to be repaired by replacement of the center
portion of the head. What is the required thickness for a dishead repair
plate that is 50% of the head diameter. The material is SA 516 Grade 70
and S=18,000, P=300 psi, the crown radius = 96 inch. E=0.65 and a Type
2 joint will be used.
1) 2.0 in
2) 1.233 in
3) 0.556 in
4) 0.234 in
Math Problem#13
Measuring Corroded Torispherical Head
MAWP = 300 psi, S=18,000, R=96”
E=0.65, Type 2 joint
What is the t min?
As per Section if 5.7 thickness at central
portion calculation for elipsoidal or
torispherical to use spherical head
formula:
t = PR/2SE-0.2P
The radius of torispherical to be used as
radius of spherical segment.
t = (300)(96)/2(18,000)(0.65) – 0.2(300)
= 28,800/23,340
= 1.234”
Section 5
Calculating P when the vessel is corroding
API 510 - During an internal inspection a corroded area on a vessel is discovered with a
current thickness of 0.446 inches. You determine that the corrosion rate is 0.004 ipy.
Operations would like to have a 6 year run before performing the next internal inspection on
this vessel. What pressure is the wasted area “good for” for the end of 6 year. The shell has a
5 inch internal diameter and has joint efficiency of 1.0. The allowable stress of the material at
design conditions is 15,000 psi.
ASME VIII-During the inspection of horizontal pressure vessel a corroded area was found on
the inside surface, the thickness at the point was measured to be 0.906 inches thick.
Checking the ASME data report for the vessel it was found that the shell plate was 1-1/4 inch
purchased thickness,48 inch inside diameter of SA-516 Gr. 70 Material, the shell was rolled
and welded using type 1 longitudinal seam with full radiography examination. The MAWP is
600 psig at 300 F. All openings in the vessel are fully reinforced, welded connections. S is
20,000 psi. What would be the maximum pressure permitted for this thinned area
API 5.4
