Online Pressure Vessel Training.pdf

Pressure Vessels - Online Training May 2020
CoDesign Engineering 1
CoDesign Engineering Slide 1
PRESSURE VESSEL 101
RAMESH TIWARI, P.E.
SAFETY MOMENT
 Social distancing
 Wash hands
frequently
 Online meetings
 Monitor health
RETURNING BACK TO OFFICE

TRAINING OBJECTIVE
 Introduction to ASME
Code
 Design a simple
pressure vessel
 Instill a desire to learn
more about the
ecosystem surrounding
pressure vessels
PRESSURE VESSELS 101
WHAT IS A PRESSURE VESSEL?
Pressure vessels are containers for the
containment of pressure, either internal or
external.
ASME Section VIII, Division 1
Para. U-1(a)(2)

PRESSURE VESSEL TYPES
Storage Vessels
Heat Exchangers
Process Vessels
PRESSURE VESSEL - EXAMPLES
Butane Storage Tanks
Storage
Vessels

Heat Exchangers
Heat
Exchangers
Distillation Columns
Process
Vessels

TYPICAL ETHYLENE PLANT
Total number of equipment 439
Drums 83
Towers 9
Reactor 1
Dryers 3
Shell-and-tube heat exchangers 76
Total pressure vessels 172
(40%)
ASME BOILER & PRESSURE VESSEL CODE
I: Power Boilers
II: Materials
III: Nuclear Components
IV: Heating Boilers
V: NDE
VI: Heating Boilers – Care
and Operation
VII: Power Boilers – Care
VIII: Pressure Vessels
IX: Welding
X: FRP
XI: Nuclear Components –
In-service Inspection
XII: Transport Tanks

I: Power Boilers
IV: Heating Boilers
and Operation
X: FRP
II: Materials
V: NDE
IX: Welding
I: Power Boilers
IV: Heating Boilers
and Operation
X: FRP
II: Materials
V: NDE
IX: Welding

ASME SECTION VIII, DIVISION 1
 Worldwide acceptance
 “U” certification
 Review of the Code
 Use code formulas to design
a simple pressure vessel
 Review those aspects that
are not addressed by code
ASME CODE STRUCTURE
 Introduction
 Subsection A – General
requirements
 Subsection B – Methods of
fabrication
 Subsection C – Classes of
materials
 Mandatory Appendices
 Nonmandatory Appendices

INTRODUCTION
Paragraphs U-1 through U-5
 U-1 Scope: This Division contains mandatory
requirements, specific prohibitions, and
nonmandatory guidance for design and
construction of pressure vessel
 Provides requirements for pressure vessel
materials, design, fabrication, examination,
inspection, testing, certification, and pressure
relief.
INTRODUCTION
Paragraphs U-1 through U-5
 ASME Code generally applicable for design
pressure 15 psi [100 kPa] and above
 There is no upper limit for design pressure

INTRODUCTION
Design Pressure – Industry Practice
Pressure Range Applicable Code
0 to 2.5 psi API 650
2.5 to 15 psi API 620
15 to 3000 psi ASME Section VIII, Division 1
3000 to 10,000 psi ASME Section VIII, Division 2
Above 10,000 psi ASME Section VIII, Division 3
INTRODUCTION
Code scope with respect to the geometry
Piping Code
Piping Code
ASME Code

INTRODUCTION
Responsibilities
 User or designated agent, Manufacturer and
Inspector
 User is responsible for design requirements
 U-2: Responsibilities for Manufacturer and
Inspectors
 As of November 2018, 22 Authorized Inspection
Agencies worldwide
ASME CODE STRUCTURE
 Introduction
requirements
fabrication
materials

SUBSECTION A – GENERAL REQUIREMENTS
Scope UG-1
Materials UG-4 thru 15 Product forms, welding materials
Design UG-16 thru 35
Design temperature and pressure, loadings,
maximum allowable stress values, shells,
formed heads, flat heads
Openings and
Reinforcements
UG-36 thru 46
Openings, reinforcements, multiple
openings, methods of attachment, nozzle
necks, inspection openings
Braced and
Stayed
Surfaces
UG-47 thru 50 Braced and stayed surfaces, staybolts
Ligaments UG-53 thru 55 Ligaments and supports
SUBSECTION A – GENERAL REQUIREMENTS
Fabrication UG-75 thru 85
Material identification, repairs, out-of-
roundness, tolerances, charpy impact tests,
heat treatment
Inspection
and Tests
UG-90 thru
103
Responsibility of inspector, MAWP, hydrostatic
test, pneumatic test, proof test
Markings and
Reports
UG-115 thru
120
Markings on nameplates, data reports
Overpressure
Protection
UG-125 thru
140
Pressure relief valves, markings, certification,
installation, protection by system design

ASME CODE STRUCTURE
 Introduction
requirements
fabrication
materials
Three methods of fabrication:
 UW – Welding
 UF – Forging
 UB – Brazing
SUBSECTION B – METHODS OF FABRICATION

Three methods of fabrication:
 UW – Welding
 UF – Forging
 UB – Brazing
SUBSECTION B – METHODS OF FABRICATION
Welded joint category:
SUBSECTION B – UW: FABRICATION BY WELDING

Welded joint types:

SERVICE RESTRICTIONS
 Lethal service
o Full radiography of all butt welds
o When fabricated of carbon and low alloy steels, the vessel
shall be postweld heat treated.
 Vessels operating below certain temperatures
o Restriction on types of welds
 Unfired steam boilers
o Full radiography of butt welds
o Postweld heat treatment of vessels
WHEN IS FULL RADIOGRAPHY REQUIRED?
1. Lethal service
2. Nominal thickness at welded joints greater than 1-1/2 in (38 mm)
3. Unfired steam boilers when design pressure greater than 50 psi
(350 kPa)
4. Nozzles where nominal thickness at welded joints greater than
1-1/2 in (38 mm)
5. Nozzles attached to shells and heads that require full
radiography. Nozzles that do not exceed NPS 10 (DN 250) or
1-1/8 (29 mm) wall thickness are excluded.

WHAT IS SPOT RADIOGRAPHY?
 Spot radiography will not ensure a predetermined quality level
throughout.
 One spot must be examined for every 50 ft (15 m) increment of
weld.
 For each increment of weld, a sufficient number of spots must be
taken to examine welding of each welder.
 Location of spots to be chosen by AI after completion of the
increment of weld to be examined.
 Minimum length of spot radiograph to be 6 in. (150 mm).
EVALUATION OF SPOT RADIOGRAPHY
 If the spot radiograph is acceptable, the entire weld
increment is acceptable.
 If the spot radiograph is not acceptable, two additional spots
away from original spot must be selected by AI and
examined.
 If the two additional spot radiographs are acceptable, the
entire weld increment is acceptable.
 If either of the two additional spots is not acceptable, the
entire weld increment is rejected.

 Article 1: General Requirements
 Article 2: Radiographic Examinations
 Article 4 & 5: Ultrasonic Exam.
 Article 6: Liquid Penetrant Exam.
 Article 7: Mag. Particle Examination
 Article 8: Eddy Current Examination
 Article 9: Visual Examination
 Article 10: Leak Testing
 Article 12 & 13: Acoustic Emission
Examination
ASME SECTION V – NDE EXAMINATIONS
 Attachment welds
 Openings in and adjacent to welds
 Welded connection (nozzles)
 Plug welds and fillet welds
 Welded stayed constructions
 Tube-to-tubesheet welds
 Welding processes, qualification of
welding procedure, tests of welders
and operators
 Welding fabrications
ASME SECTION IX – WELDING

ASME CODE STRUCTURE
 Introduction
requirements
fabrication
materials
SUBSECTION C – CLASSES OF MATERIALS
Part UCS Carbon and Low Alloy Steels
Part UNF Nonferrous Materials
Part UHA High Alloy Steel
Part UCI Cast Iron
Part UCL Material with Corrosion Resistant Cladding, Weld Metal Overlay
Cladding, or with Applied Lining
Part UCD Cast Ductile Iron
Part UHT Ferritic Steels with Tensile Properties Enhanced by Heat
Treatment
Part ULW Layered Construction
Part ULT Materials Having Higher Allowable Stress at Lower Temp.
Part UHX Shell & Tube Heat Exchangers
Part UIG Impregnated Graphite

Part UCS Carbon and Low Alloy Steels
Part UNF Nonferrous Materials
Part UHA High Alloy Steel
Part UCI Cast Iron
Part UCL Material with Corrosion Resistant Cladding, Weld Metal Overlay
Cladding, or with Applied Lining
Part UCD Cast Ductile Iron
Part UHT Ferritic Steels with Tensile Properties Enhanced by Heat
Treatment
Part ULW Layered Construction
Part ULT Materials Having Higher Allowable Stress at Lower Temp.
Part UHX Shell & Tube Heat Exchangers
Part UIG Impregnated Graphite

Subpart 1: Stress Tables
Subpart 2: Physical properties
Table
Subpart 3: External Pressure
Charts and Tables
Mandatory Appendices
Nonmandatory Appendices
ASME SECTION II – MATERIALS

STRESS TABLES
Tables applicable to materials permitted by ASME Section VIII,
Division 1 are:
Table 1A Allowable Stresses for Ferrous Materials
Table 1B Allowable Stresses for Nonferrous Materials
Table 3 Allowable Stresses for Bolting Materials
STRESS TABLES – Table 1A (SA 516 Gr. 70)
Line
No.
Nominal
Composition
Product
Form
Spec.
No.
Type/
Grade
Alloy Desig./
UNS No.
Class/
Condition/
Temper
Size/
Thickness
(in.)
P.No. Group
No.
33 Carbon Steel Plate SA-516 70 K02700 --- 1 2
Page 20
Line
No.
Min.
Tensile
Strength
(ksi)
Min.
Yield
Strength
(ksi)
Applicability and Max. Temperature
Limits
External
Pressure
Chart
Notes
I III VIII-1 XII
33 70 38 850 700 1000 650 CS-2 G10, S1, T2
Page 21

STRESS TABLES – Table 1A (SA 516 Gr. 70)
Line
No.
Maximum Allowable Stress, ksi
100 150 200 250 300 400 500 600 650 700 750 800 850 900
33 20.0 20.0 20.0 --- 20.0 20.0 20.0 19.4 18.8 18.1 14.8 12.0 9.3 6.7
Page 22
Line
No.
Maximum Allowable Stress, ksi
950 1000 1050 1100 1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650
33 4.0 2.5
Page 23
Back to
Part UCS…

Paragraphs UCS-65 through UCS-68
EXAMPLE VESSEL
Design Conditions:
Design pressure, P = 150 psi
Design Temperature, T = 400°F
Material of construction:
Carbon steel (SA 516 70)
Calculate:
Shell thickness
Heads thickness
Nozzle thickness
Nozzle reinforcement

EXAMPLE VESSEL - SHELL
Internal Pressure (UG-27)
Circumferential Stress (Longitudinal Joints)
Conditions: t < 0.5R and P < 0.385 SE
(In terms of inside radius)
t =
( . )
t =
, . .
t = 0.226“ [Use 0.25”]
Definitions (UG-32)
L is the inside spherical or crown radius. The value of L for
ellipsoidal heads shall be determined from the following table:
Example
For a 2:1 ellipsoidal head with
inside diameter of 60”:
D/2h = 2.0
K1 = 0.90
Spherical radius, L
= 60 x 0.9
= 54”
EXAMPLE VESSEL – ELLIPSOIDAL HEAD

For t/L ≥ 0.002:
These formulas are valid for 2:1 ellipsoidal heads where half
the minor axis (inside depth of head minus the skirt) equals
one-fourth of the inside diameter of the head skirt. An
acceptable approximation of a 2:1 ellipsoidal head is one with
a knuckle radius of 0.17D and spherical radius of 0.9D.
t =
.
t =
, .
t = 0.225” [Use 0.25”]
EXAMPLE VESSEL – ELLIPSOIDAL HEAD
When thickness ≤ 0.356L or P ≤ 0.665SE :
(UG-32)
t =
.
t =
, .
t = 0.113“ [Use 0.1875”]
EXAMPLE VESSEL – HEMISPHERICAL HEAD

Para UG-34 provides rules for minimum required thickness of
unstayed flat heads, cover plates and blind flanges. Some
acceptable types of flat heads are shown in Fig. UG-34.
EXAMPLE VESSEL – FLAT HEAD
The minimum required thickness of a flat head is given by:
(UG-34)
t = d CP SE
⁄
t = 60 0.33 x 150 20,000 x 1
⁄
t = 2.985“ [Use 3”]
EXAMPLE VESSEL – FLAT HEAD

EXAMPLE VESSEL - NOZZLE
Internal Pressure (UG-27)
Circumferential Stress (Longitudinal Joints)
Conditions: t < 0.5R and P < 0.385 SE
(In terms of inside radius)
t =
( . )
t =
.
, . .
t = 0.115“ [Use Std Sch pipe (0.375”)]
EXAMPLE VESSEL - NOZZLE
Check Flange
Rating

Reinforcement of openings in shells and heads: UG-37
Total cross-sectional area of reinforcement A required in any
given plane through the opening for a shell or formed head
under internal pressure shall not be less than:
A = dt F + 2t t F 1 − f
EXAMPLE VESSEL – NOZZLE REINFORCEMENT
15.25”
0.25”
A = dt F + 2t t F 1 − f
15.25”
0.25”
= 15.25 x 0.25
= 3.82 in2

A = dt F + 2t t F 1 − f
15.25”
0.25”
= 15.25 x 0.25
= 3.82 in2
15.25” 15.25”

EXAMPLE VESSEL
Vacuum (External Pressure) UG-28 to 30
Wind Loading ASCE 7
Seismic Loading ASCE 7
Nozzle Loading WRC Bulleting 537
Saddle Supports Paper by L.P. Zick
Hydrotest UG-99
Pneumatic Test UG-100
INSPECTION OPENINGS
Vessels that are permitted by UG-46 from inspection opening requirement:
Manufacturer Data Report must include one of the notations listed under
the “Remarks” section.
All vessels 12 in (300 mm) to 18 in (450 mm) diameter: at least two
handholes, or two plugged threaded inspection openings of not less
than NPS 1½ (DN 40)
All vessels 18 in (450 mm) to 36 in (900 mm) diameter: A manhole, or two
handholes, or two plugged threaded inspection openings of not less
than NPS 2 (DN 50)
All vessels over 36 in (900 mm) diameter: one manhole, or where a
manhole is impractical, two handholes 4 x 6 in (100 mm x 150 mm)
or two equal openings of equivalent area

MARKINGS AND REPORTS
Required Marking
 The requirements for markings and reports on pressure vessels
are provided in paragraphs UG-115 through UG-120
 The U code symbol to be affixed
on the pressure vessel are shown
at left
 In addition to the above symbol, the name of the manufacturer
preceded by words “certified by” shall be marked on the vessel
Required Marking (Contd.)
The type of construction used for the vessel shall be
indicated directly under the code symbol:
Type of Construction Letter(s)
Arc of gas welded W
Pressure welded (except resistance) P
Brazed B
Resistance welded RES

When a vessel is intended for special service, the appropriate
lettering shall be applied as follows:
Lethal service L
Unfired Steam Boiler UB
Direct firing DF
When radiographic or ultrasonic examination has been performed,
marking shall be applied under the code symbol as follows:
1. RT 1 when all pressure retaining butt welds are fully radiographed
2. RT 2 when the vessel satisfies the requirements of paragraph UW-
11(a)(5) and when spot radiography requirements of UW-11(a)(5)(b)
have been applied
3. RT 3 when the complete vessel satisfies the spot radiography
requirements
4. RT 4 when none of the markings “RT 1”, “RT 2”, or “RT 3” are
applicable

Other markings required by Code are:
 Maximum allowable working pressure _________ at
temperature ____________
 Maximum allowable external working pressure __________ at
temperature ____________
 Minimum design metal temperature __________ at maximum
allowable working pressure _____________
 Manufacturer’s serial number
 Year built
Various Data Reports used for pressure vessels are:
 Form U-1 Manufacturer’s Data Report for Pressure Vessel
 Form U-1A Alternative form for single chamber, completely
shop of field fabricated vessels only
 Form U-2 Manufacturer’s Partial Data Report
 Form U-2 Manufacturer’s Partial Data Report (Alternate Form)
 Form U-3 Manufacturer’s Certificate of Compliance covering
pressure vessels to be stamped with UM symbol
 Form U-4 Manufacturer’s Data Report Supplementary Sheet

FURTHER STEPS
Resources to expand expertise:
 Books
 Internet articles
 YouTube videos
 Online training
o June 13/14 and June 20/21 (Indian subcontinent)
 Certificate
PRESSURE VESSELS 101
Ramesh Tiwari
ramesh.tiwari@codesignengg.com
www.linkedin.com/in/rameshtiwari

Online Pressure Vessel Training.pdf

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