12/9/2018 ASME Methods Blog – Pressure Vessel Engineering

Lethal Service – Quick Guide

Requirements for lethal service are scattered through VIII-1, the code cases,
interpretations and PTB-4. Here they are all in one place.

LINK

Lethal Service – Quick Guide

File: PVE-3856, Last updated June 6 2017 LRB / CT

Introduction
Requirements for lethal service are scattered through VIII-1, the code cases and the
interpretations. ASME VIII-1 section UW-2 has most of the requirements for lethal service.
Two definitions of lethal service are provided in UW-2. The second definition is also
duplicated in the end notes:

[A] vessel is to contain uids of such a nature that a very small amount mixed
or unmixed with air is dangerous to life when inhaled[.]
By “lethal substances” are meant poisonous gases or liquids of such a nature
that a very small amount of the gas or of the vapour of the liquid mixed or
unmixed with air is dangerous to-life when inhaled. For purposes of this
Division, this class includes substances of this nature which are stored under
pressure or may generate a pressure if stored in a closed vessel.

It is up to the user to determine if a service is lethal. We at Pressure Vessel Engineering do not

determine if the vessel service is lethal (but we might have opinions based on previous jobs).

ASME VIII-1 Lethal Service Code References

UW-2 Service Restrictions is a very important section for lethal service vessels and must be
read in its entirety. A few brief points from UW-2:
UW-2(a) and UW-11(a)(1) – All butt welds shall be 100% radiographed
UW-2(a) – ERW pipe (like some grades of SA-53) is not permitted but interpretation VIII-1-01-118
says it is acceptable if the long seam is fully radiographed
UW-2(a) – Post weld heat treatment is required for CS and Low Alloy
UW-2(a)(1)(a) – Category A welds shall be type 1 only (butt welded with no permanent backing
strip)
UW-2(a)(1)(b&c) &Interpretation VIII-1 92-211 – Category B & C welds shall be type 1 or 2 only
(butt welded). No slip on flanges! No Figure UW-13.2 Flange or Head to Shell attachments
Interpretation VIII-I-98-23 – Category D welds (typically nozzles) shall be full penetration.
UW-2(a)(1)(c) – Category C joints for stub ends have a long list of requirements
UW-2(a)(2 and 3) – Heat exchangers have a long list of requirements
Read all of UW-2 for more restrictions…

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When it has been determined that a vessel is in Lethal Service, some of the following code
sections will apply. Other code sections might also be required. (List last updated June 16
2015 based on the ASME 2013 VIII-1 code edition.)
U-2(a)(2) – The user determines if the service is lethal.
UG-16(5)(a) – Air cooled and cooling tower heat exchanger tube walls to be 1/16″ min.
UG-24(6) – Casting RT requirements.
UG-25(e) – No telltale holes.
UG-99(g),(k) – Hydro test visual leak inspection cannot be waived. Do not paint or line prior to
the hydro test.
UG-100(d)(4) – Pneumatic tests cannot be used for lethal service vessels, but also see code
cases 2046-2, 2055-2, 2407 regarding pneumatic instead of hydrostatic testing.
UG-100(e)(3) – Do not paint or line prior to the pneumatic test.
UG-116(c) – “L” stamping must be added to the nameplate.
UG-120(d)(1) – “lethal service” is added to the data report
UW-2 – Service Restrictions – main source of info on Lethal Service (see lots more from UW-2
below)
UW-11(a)(1) – All shell and head butt welds to be 100% RT
Fig UW-13.5 – One possible lap joint stub end configuration – see also interpretation BC-79-680
/ VIII-80-111
UB-3 – Brazed vessels shall not be used
UCS-6 – Do not use SA-36, 38W or SA-283
UCS-79 – PWHT and extreme fiber elongation – read for rules when heat treatment is required
UCI-2, UCD-2 Cast iron and ductile cast iron vessels are not allowed.
UIG-2(c) – Metal parts for graphite vessels are to be designed to UIG requirements
UIG-23(b) – Factor of safety for lethal service
UIG-60 – Lethal service
UIG-99 – Lethal service pressure tests
ULW-1 & ULW-26(b)(4) – Layered vessels lethal restrictions apply to the inner shell and heads
only
UHX-19.1(b) – Heat exchanger markings
Appendix 2-5(d) & 2-6 – Maximum Flange Bolt Spacing
Appendix 2-14(a) – Mandatory flange flexibility
Appendix 7-1, 7-5 – Steel casting examination for 100% quality factor
Appendix 9-8 – if the jacket does not carry lethal substances, lethal service restrictions do not
apply to it
Appendix 17-2(a) – Dimple jackets will not contain lethal substances
Appendix 35-3(c) & 35-7(d) – Mass production rules
Appendix W Table W-3 – Filing out the U forms
Appendix KK (note 12) – Filling out User Design Requirements forms
Appendix NN Table NN-6-5 – User or designated again determines if the contents are lethal
End notes 65 – Definition of lethal service

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Weld restrictions by category

Special lap joint stub end for lethal service – see also Fig All partial penetra
UW-13.3 and Fig 2-4(5) and (6)

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All figure UW-13.2 corner welds are prohibited No s

Code Cases
The following Code Cases refer to lethal service for VIII-1 vessels (2013 edition):
1750-20(g) – A126 not to be used for PRVs, or rupture disks.
2249 – Furnace Brazing
2318 – slip on flanges in lethal service
2321-1 PWHT of P4 and P5A materials
2324 – Ultrasonic inspection
2334 – single fillet lap joint tubesheet to shell connection
2346-1 & 2537 – Alternative rules for SE and F&D head to shell attachment
2369 – Testing of covers separate from vessels
2377 – RT of SA-612 steel
2421 – Single fillet joints in Heat exchanger tubes
2437 – Diffusion bonded heat exchangers
2527 – Pneumatic testing of UM vessels
2537 – alternative F&D and SE head to shell attachment is not for lethal service
2621 – Diffusion bonding
2751 – alternative spherical head to shell attachment is not for lethal service

Interpretations
With interpretations now available on line at
cstools.asme.org/Interpretation/SearchInterpretation.cfm it is now easier to find relevant and up to
date interpretations. A search for “BPV Section VIII Div 1” keyword: “lethal” returns
many records. The comments on the most interesting lethal service interpretations are listed
below. Refer to the actual interpretations for the full text.
VIII-1-01-118 and VIII-1-83-77R – ERW pipe may only be used if the long seam is radiographed
VIII-82-65 – volumetric examination of category D joints is not always required
VIII-1-01-42 and VIII-1-04-48 – cone >30° and and corner joints not permitted

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VIII-1-86-84 and VIII-1-95-138 – prohibited flange attachments – Fig UW-13.2(m) and Fig 2-4
sketches (7), (8), (8a), (8b), and (9)
VIII-1-92-112 – full radiography of category C and D butt welds is required except for UW-11(a)(4)
VIII-1-92-194 – full penetration angle joints are not permitted
VIII-1-92-211 – Fig UW-13.2 attachments are not permissible
VIII-1-98-113 – permissible repad and flange pad arrangements
VIII-1-98-23 – Fig UW-16.1 (a) and (c) are permissible nozzle attachments, others are not
discussed
VIII-77-62 – “It is the intent of Section VIII, Division 1 that Category B and C butt welds in nozzles
and communicating chambers that neither exceed 10 in. nominal pipe size or 1-1/8 wall thickness
are excluded from the provisions of radiography, even though the vessel is in lethal service. This
overrides the provisions of UW-2(a).”
VIII-80-02 – do not use corner joints from Fig UW-13.2 – redesign to create butt joints that can be
radiographed
VIII-80-111 – acceptable lap joint flanges include Fig. 2-4(1) and Fig. UW-13.3 and Fig. 2-4(5)
and (6)
rec 15-634 – PWHT and cladding, see also 14-1910
rec 15-1154 – Full RT does not include the reinforcing rings per UG-29
rec 15-1264 – welding of non-round vessels
rec 15-1288 – lethal and non-lethal sections of heat exchangers per UW-2(a)(3)
rec 16-32 – UG-25(e) telltale holes in the shell are not the same as UG-37(g) telltale holes in
repads
rec 16-39 – Fig 1-6(d) is category C
rec 16-72 – clarification on RT-4 and UG-116(e)(4)
rec 17-11 – UG-82(b) and attachments after hydrotest per UG-99(g)

PTB-4
“ASME Section VIII – Division 1 Example Problem Manual” PTB-4-2013 provides illustrative
example for the use of VIII-1 rules.
E7.1 – RT-1 radiography on a vessel to meet the requirements of lethal service. Required
radiography to meet RT-1 and the appropriate weld efficiencies are illustrated and commented
on. The sample illustrates items like sumps and nozzles that can be exempt from radiography
based on size and still maintain the RT-1 rating for the vessel.
E4.16.1 and E4.16.2 – maximum allowed flange bolt spacing for lethal service per App 2-5(d)

Disclaimer: This material is provided for educational uses only. Only ASME can make code
interpretations.

Pressure Vessel Engineering Ltd.

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Waterloo, Ontario, Canada
N2V 1C6
519-880-9808

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