Pressure Vessel Code Guide Instructors

Overview of Pressure Vessel Design
Instructors Guide
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Overview of Pressure Vessel Design By: Vincent A. Carucci Carmagen Engineering, Inc.
Copyright 1999 by
All Rights Reserved
TABLE OF CONTENTS
Abstract 5 Introduction..6 Organizing Unit Responsibilities..7 Instructor Guidelines and Responsibilities.9 Overview of Pressure Vessel Design Outline/ Teaching Plan11 Instructor Notes.13 Appendix A: Reproducible Overheads Appendix B: Course and Instructor Evaluation Form Appendix C: Continuing Education Unit (CEU) Submittal Form Course Improvement Form Instructors Biography Form
ABSTRACT
Pressure vessels are typically designed, fabricated, installed, inspected, and tested in accordance with the ASME Code Section VIII. Section VIII is divided into three separate divisions. This course outlines the main differences a mong the divisions. It then concentrates on and presents an overview of Division I. This course also discusses several relevant items that are not included in Division I.
INTRODUCTION
This Overview of Pressure Vessel Design course is part of the ASME International Career Development Series an educational tool to help engineers and managers succeed in todays business/engineering world. Each course in this series is a 4hour (or half-day) self-contained professional development seminar. The course material consists of a participant manual and an instructors guide. The participant manual is a self-contained text for students/participants, while the guide (this booklet) provides the instructional material designed to be presented by a local knowledgeable instructor with a minimum of preparation time. The balance of this instructors guide focuses on: 1. 2. 3. Organizing Unit Responsibilities Instructor Guidelines and Responsibilities Comprehensive teaching materials which may be used as is or adapted to incorporate experiences and perspective of the instructor.
Welcome to the ASME International Career Development Series! We wish you all the best in your presentation, operation and delivery of this course.
10
Suggested Outline/Teaching Plan

Time, min. Major Interval 10 Class Segment Introduction Sub-Segment Interval 5 5 Sub-Segment Introduction/Logistics Outline Module Module based primarily on the ASME Code Section VIII, Division 1. Divisions 2 and 3 will be briefly described Main Pressure Vessel Components Scope of ASME Code Section VIII Division 1 Division 2 Division 3 Structure of Section VIII, Division 1 Material Selection Factors Strength Corrosion Resistance Resistance to Hydrogen Attack Fracture Toughness Fabricability Maximum Allowable Stress Material Selection Based On Fracture Toughness Design Conditions and Loadings Pressure Temperature Other Loadings Design for Internal Pressure Weld Joints Cylindrical Shells Heads Conical Sections Sample Problem Design for External Pressure and Compressive Stresses Cylindrical Shells Other Components Sample Problem Overheads/ Participant Pages OV 1 Part. 65 OV 2 Part. 65
25
General
10 10
OV 3-9 Part. 67 OV 10-13 Part. 75
5 20 Materials of Construction 15
OV 14 Part. 78 OV 15-31 Part. 79
5 10 10 55 Exercise Break Design 10 10 10
OV 32-34 Part. 87 OV 35-38 Part. 91 OV 39-43 Part. 92
25
OV 44-55 Part. - 98
20
OV 56-65 Part. 109
11
Suggested Outline/Teaching Plan, continued

Time, min. Major Interval 10 - 50 15 Class Segment Major Break Exercise 15 Sub-Segment Interval Sub-Segment Lunch or Major Break Required Thickness for Internal Pressure Reinforcement of Openings (Include Sample Problem) Flange Rating (Including Sample Problem) Flange Design Maximum Allowable Working Pressure (MAWP) Local Loads Vessel Internals Acceptable Welding Details Postweld Heat Treatment (PWHT)Requirements Inspection Pressure Testing Summary Questionnaire (fill in and collect) CEU Form (hand out individual responsibility to return) OV 66-68 Part. - 118 OV 69-84 Part. 119 OV 85-90 Part. 127 OV 91-97 Part. 131 OV 98 Part. 138 OV 99 Part. 139 OV 100-102 Part. 141 OV 103-106 Part. 143 OV 107 Part. 146 OV 108-113 Part. 148 OV 114-115 Part. 152 OV 116 Part. - 155 Overheads/ Participant Pages
50
Design (Contd.)
20 10 15 5
10 20
Break Other Design Considerations
10 10
20
Fabrication
10 10
15
Inspection and Testing
10 5
10
Closure
10
12

Instructors Personal Notes
OVERVIEW OF PRESSURE VESSEL DESIGN

By: Vincent A. Carucci Carmagen Engineering, Inc .
Instructors Outline
1. Course discusses pressure vessel design and is introductory in nature. 2. Based on ASME Code Section VIII. 3. Preliminary emphasis is on Division 1 but Divisions 2 and 3 are highlighted. 4. Introduces several items that are not covered in the ASME Code.
Major Learning Points

Course Introduction
13

Course Overview
General Materials of Construction Design Other Design Considerations Fabrication Inspection and Testing
2
Instructors Outline
1. The objective: Provide a general knowledge of design requirements for pressure vessels. 2. This is not a comprehensive course. It provides sufficient information for management personnel to have an overall understanding of this subject. Individuals having more detailed responsibility will receive a solid starting point to proceed further. 3. Review outline. 4. Establish schedule. 5. Participation is key: Questions Discussion/interaction

Establish course objectives. Outline course content, a road map.
14

Pressure Vessels
Containers for fluids under pressure Used in variety of industries Petroleum refining Chemical Power Pulp and paper Food
3
Instructors Outline
1. Describe what a pressure vessel is. 2. Note that pressure vessels are used in a wide variety of industries. They can be designed for a wide variety of conditions and in a broad range of sizes.

Define pressure vessels. Identify wide variety of industrial applications.
15

Horizontal Drum on Saddle Supports
Nozzle A Shell Head Head
Saddle Support (Sliding) A
Saddle Support (Fixed)
SectionA-A
Figure 2.1
4
Instructors Outline
1. Use this and following overheads to describe main pressure vessel components and shapes. 2. Shell is primary component that contains pressure. Curved shape. 3. Vessel always closed by heads. 4. Components typically welded together. 5. Vessel shell may be cylindrical, spherical, or conical. 6. Multiple diameters, thicknesses or materials are possible. 7. Saddle supports used for horizontal drums. Spreads load over shell. One support fixed, other slides.

Main pressure vessel components and configurations.
16

Vertical Drum on Leg Supports
Head Shell Nozzle
Head
Support Leg
Figure 2.2
Instructors Outline
1. Most heads are curved shape for strength, thinness, economy. 2. Semi-elliptical shape is most common head shape. 3. Small vertical drums typically supported by legs. Typically maximum 2:1 ratio of leg length to diameter. Number, size, and attachment details depend on loads.

Main pressure vessel components and shapes.
17

Tall Vertical Tower
Nozzle Head Trays Shell Nozzle
Cone
Nozzle Shell
Nozzle
Head Skirt Support
Figure 2.3
Instructors Outline
1. Nozzles used for: Piping systems Instrument connections Manways Attaching other equipment

2. Ends typically flanged, may be welded. 3. Sometimes extend into vessel.
18

Vertical Reactor
Inlet Nozzle Head Upper Catalyst Bed
Shell
Catalyst Bed Support Grid
Lower Catalyst Bed Outlet Collector Head Outlet Nozzle Support Skirt
Figure 2.4
Instructors Outline
1. Skirt supports typically used for tall vertical vessels: Cylindrical shell Typically supported from grade

2. General support design (not just for skirts) Design for weight, wind, earthquake. Pressure not a factor. Temperature also a consideration for material selection and thermal expansion.
19

Spherical Pressurized Storage Vessel

Shell
Support Leg
Cross Bracing
Figure 2.5
8
Instructors Outline
1. Spherical storage vessels typically supported on legs. 2. Cross-bracing typically used to absorb wind and earthquake loads.

20

Vertical Vessel on Lug Supports
Figure 2.6
Instructors Outline
1. Vessel size limits for lug supports: 1 10 ft diameter 2:1 to 5:1 height/diameter ratio

Main pressure vessel components and configurations.
2. Vessel located above grade. 3. Lugs bolted to horizontal structure.
21

Scope of ASME Code Section VIII
Section VIII used worldwide Objective: Minimum requirements for safe construction and operation Division 1, 2, and 3
10
Instructors Outline
1. Section VIII is most widely used Code. 2. Assures safe design. 3. Three divisions have different emphasis.

Define scope of ASME Code Section VIII.
22

Section VIII Division 1
15 psig < P 3000 psig Applies through first connection to pipe Other exclusions
Internals (except for attachment weld to vessel) Fired process heaters Pressure containers integral with machinery Piping systems
11
Instructors Outline
1. Review scope of Division 1. 2. Division 1 not applicable below 15 psig. 3. Additional rules required above 3000 psig. 4. Items that are connected to pressure vessels not covered by Division 1, except for: Their effect on pressure part. Welded attachment to pressure part.

Scope of Division 1 Exclusions from scope
23

Section VIII, Division 2, Alternative Rules

Scope identical to Division 1 but requirements differ
Allowable stress Stress calculations Design Quality control Fabrication and inspection
12
Choice between Divisions 1 and 2 based on economics
Instructors Outline
1. Review differences between Divisions 1 and 2. 2. Division 2 allowable membrane stress is higher. 3. Division 2 requires more complex calculations. 4. Division 2 does not permit some design details that are permitted in Division 1. 5. Division 2 requires more stringent material quality control, fabrication, and testing requirements.

Differences between Division 1 and 2.
24

Division 3, Alternative Rules High Pressure Vessels
Applications over 10,000 psi Pressure from external source, process reaction, application of heat, combination of these Does not establish maximum pressure limits of Division 1 or 2 or minimum limits for Division 3.
13
Instructors Outline
1. Review application of Division 3. 2. Newest Division of Section VIII and has least applicability. 3. After this point, this course only addresses Division 1 requirements when code-specific items are discussed.

Scope of Division 3
25

Subsection A Subsection B
Requirements based on fabrication method Parts UW, UF, UB
Structure of Section VIII, Division 1
Part UG applies to all vessels
Subsection C
Requirements based on material class Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT, ULW, ULT
14
Mandatory and Nonmandatory Appendices
Instructors Outline
1. Review Division 1 organization 2. Fabrication methods: Welded Forged Brazed

Basic organizational structure of Division 1.
3. Material classes Carbon and low-alloy steel Non-ferrous metals High alloy steel Cast iron Clad and lined material Ductile iron Heat treated steels Layered construction Low-temperature material
4. Highlight several mandatory and nonmandatory appendices.
26

Material Selection Factors

Strength Corrosion Resistance Resistance to Hydrogen Attack Fracture Toughness Fabricability
15
Instructors Outline
1. ASME Code does not specify particular materials to use in each application. Owner must do this. 2. ASME Code specifies permitted materials and the requirements that these must meet.

Primary factors that influence pressure vessel material selection.
27

Strength
Determines required component thickness Overall strength determined by:
Yield Strength Ultimate Tensile Strength Creep Strength Rupture Strength
16
Instructors Outline
1. Strength: Materials ability to withstand imposed loading. 2. Higher strength material thinner component. 3. Describe properties that are used to define strength.

Material strength and pressure vessel design.
28

Corrosion Resistance
Deterioration of metal by chemical action Most important factor to consider Corrosion allowance supplies additional thickness Alloying elements provide additional resistance to corrosion
17
Instructors Outline
1. Corrosion is thinning of metal. 2. Adding extra component thickness (i.e., corrosion allowance) is most common method to address corrosion. 3. Alloy materials are used in services where corrosion allowance would be unreasonably high if carbon steel were used.

Importance of corrosion resistance in materials selection.
29

Resistance to Hydrogen Attack

At 300 - 400F, monatomic hydrogen forms molecular hydrogen in voids Pressure buildup can cause steel to crack Above 600F, hydrogen attack causes irreparable damage through component thickness
18
Instructors Outline
1. Low-temperature H 2 attack can cause cracking. 2. Higher temperature H 2 attack causes through-thickness strength loss and is irreversible. 3. H2 attack is a function of H 2 partial pressure and design temperature. Increased alloy content (i.e., Cr) increases H 2 attack resistance. Reference API-941 for Nelson Curves.

Hydrogen attack can damage carbon and low-alloy steel.
30

Brittle Fracture and Fracture Toughness
Fracture toughness: Ability of material to withstand conditions that could cause brittle fracture Brittle fracture
Typically at low temperature Can occur below design pressure No yielding before complete failure
19
Instructors Outline
1. Describe brittle fracture as equivalent to dropping a piece of glass. 2. Material selection must ensure that brittle fracture will not occur.

Brittle fracture and its consequences.
31

Brittle Fracture and Fracture Toughness, contd
Conditions required for brittle fracture
High enough stress for crack initiation and growth Low enough material fracture toughness at temperature Critical size defect to act as stress concentration
20
Instructors Outline
1. A brittle fracture will occur the first time the appropriate conditions occur. 2. Brittle fracture occurs without warning and is catastrophic.

Three conditions that are required for a brittle fracture to occur.
32

Factors That Influence Fracture Toughness
Fracture toughness varies with:
- Temperature - Type and chemistry of steel - Manufacturing and fabrication processes
Other factors that influence fracture toughness:

- Arc strikes, especially if over repaired area - Stress raisers or scratches in cold formed thick plate
21
Instructors Outline
1. Describe influence of material and temperature factors on fracture toughness. 2. Other factors increase brittle fracture risk.

Primary factors that influence material fracture toughness.
33

Charpy V-Notch Test Setup
Scale Starting Position Hammer
Pointer
End of swing Specimen h' Anvil
h'
22
Instructors Outline
1. Charpy V-Notch test is most widely used measure of material fracture toughness. 2. Describe test set-up.

Charpy V-Notch testing.
34

ASME Code and Brittle Fracture Evaluation
Components to consider
Shells Manways Heads Reinforcing pads Backing strips that remain in place
23
Nozzles Tubesheets Flanges Flat cover plates Attachments essential to structural integrity that are welded to pressure parts
Instructors Outline
1. ASME Code contains brittle fracture evaluation procedure. 2. Review components to be included only items that relate to structural integrity of pressure-containing shell.

Components to consider is ASME Code brittle fracture evaluation.
35

Temperatures to Consider
Minimum Design Metal Temperature (MDMT)
Lowest temperature at which component has adequate fracture toughness
Critical Exposure Temperature (CET)

Minimum temperature at which significant membrane stress will occur
24
Instructors Outline
1. Describe the distinction between MDMT and CET. MDMT is a material property. CET is an environmental factor.

Two temperatures to be considered in brittle fracture evaluation.
2. Important to understand this distinction.
36

Simplified ASME Evaluation Approach
Material specifications classified into Material Groups A through D Impact test exemption curves
For each Material Group Acceptable MDMT vs. thickness where impact testing not required
If combination of Material Group and thickness not exempt, then must impact test at CET
25
Instructors Outline
1. Outline ASME procedure. 2. Details described in following overheads.

Simplified ASME brittle fracture evaluation procedure.
37

MATERIAL GROUP
Curve A
Material Groups
APPLICABLE MATERIALS
All carbon and low alloy steel plates, structural shapes, and bars not listed in Curves B, C & D SA-216 Gr. WCB & WCC, SA-217 Gr. WC6, if normalized and tempered or water-quenched and tempered
Curve B
SA-216 Gr. WCA, if normalized and tempered or water-quenched and tempered SA-216 Gr. WCB & WCC for maximum thickness of 2 in., if produced to fine grain practice and water-quenched and tempered SA-285 Gr. A & B SA-414 Gr. A SA-515 Gr. 60 SA-516 Gr. 65 & 70, if not normalized Except for cast steels, all materials of Curve A if produced to fine grain practice and normalized which are not included in Curves C & D
All pipe, fittings, forging, and tubing which are not included in Curves C & D
Table 3.1 (Excerpt)

26
Instructors Outline
1. Materials are grouped based on common fracture toughness properties. 2. Groups A through D move from worst to best fracture toughness. 3. Point out several common materials. SA-516 Gr. 65 and 70 are Curve B if not normalized. Most pipe, fittings and forgings are Curve B.

Material group classifications for brittle fracture evaluations.
38

Material Groups, contd
MATERIAL GROUP
Curve C

APPLICABLE MATERIALS
SA-182 Gr. 21 & 22, if normalized and tempered SA-302 Gr. C & D SA-336 Gr. F21 & F22, if normalized and tempered SA-387 Gr. 21 & 22, if normalized and tempered SA-516 Gr. 55 & 60, if not normalized SA-533 Gr. B & C SA-662 Gr. A All material of Curve B if produced to fine grain practice and normalized which are not included in Curve D SA-203 SA-508 Cl. 1 SA-516, if normalized SA-524 Cl. 1 & 2 SA-537 Cl. 1, 2 & 3 SA-612, if normalized SA-662, if normalized SA-738 Gr. A
Curve D
Bolting and Nuts

27
See Figure UCS-66 of the ASME Code Section VIII, Div. 1, for impact test exemption temperatures for specified material specifications
Table 3.1 (Excerpt)
Instructors Outline
1. Identify other common materials. SA-516 Gr. 55 and 60 are Curve C if not normalized. SA-516 (all grades) is Curve D if normalized.

Material group classifications for brittle fracture evaluations.
2. Highlight points. Lower strength grades of same specification have better fracture toughness. Normalization improves fracture toughness.
39

Impact Test Exemption Curves for Carbon and Low-Alloy Steel

140 120 100 Minimum Design Metal Temperature, F 80 60 C 40 20 0 -20 -40 -55 -60 -80 0.394 1 2 3 4 5 Nominal Thickness, in. (Limited to 4 in. for Welded Construction) Impact testing required D A B
Figure 3.1
28
Instructors Outline
1. Describe relationship between Material Group, component thickness, and MDMT. 2. Impact testing not required if point is at or below curve (i.e., OK if MDMT CET). 3. Example: 1.5 in. thick Group B material does not require impact testing if CET 50 F. 4. If not exempt, must impact test material at CET. 5. Exemption means there is enough experience that material has adequate fracture toughness without need for further testing.

Impact test exemption curves.
40

Additional ASME Code Impact Test Requirements
Required for welded construction over 4 in. thick, or nonwelded construction over 6 in. thick, if MDMT < 120 F Not required for flanges if temperature -20F Required if SMYS > 65 ksi unless specifically exempt
29
Instructors Outline
1. Review additional requirements. 2. Note that most flanges will not require impact testing.

Additional impact test requirements.
41

Additional ASME Code Impact Test Requirements, contd

Not required for impact tested low temperature steel specifications
May use at impact test temperature
30F MDMT reduction if PWHT P-1 steel and not required by code MDMT reduction if calculated stress < allowable stress
30
Instructors Outline
1. Review additional requirements. 2. PWHT reduces MDMT by 30 F provided PWHT not required by Code and resulting MDMT -55 F. 3. Can take MDMT credit if component thickness greater than needed (i.e., calculated stress < allowable stress).

Additional impact test requirements.
42

Fabricability
Ease of construction Any required special fabrication practices Material must be weldable
31
Instructors Outline
Describe fabricability.

Definition of fabricability.
43

Maximum Allowable Stress

Stress: Force per unit area that resists loads induced by external forces Pressure vessel components designed to keep stress within safe operational limits Maximum allowable stress:
Includes safety margin Varies with temperature and material
ASME maximum allowable stress tables for permitted material specifications

32
Instructors Outline
1. Discuss the use of allowable stress in determining vessel component design. 2. Section II, Part D, Appendix I contains allowable stress criteria for materials other than bolting. 3. Section II, Part D contains allowable stress tables.

Description of allowable stress. ASME Code allowable stress tables
44

Maximum Allowable Stress, contd

ALLOWABLE STRESS IN TENSION FOR CARBON AND LOW-ALLOY STEEL Nominal P-No. Group No. Min. Yield Min. Tensile Composition (ksi) (ksi) Carbon Steel Plates and Sheets SA-515 55 C-Si 1 1 30 55 60 C-Si 1 1 32 60 65 C-Si 1 1 35 65 70 C-Si 1 2 38 70 Spec No. Grade SA-516 55 60 65 70 C-Si C-Mn-Si C-Mn-Si C-Mn-Si 1 1 1 1 3 3 4 4 4 4 5 5 1 1 1 2 1 2 1 1 1 1 1 1 30 32 35 38 33 45 33 40 35 45 30 45 55 60 65 70 55 70 55 65 60 75 60 75
Plate - Low Alloy Steels SA-387 2 Cl.1 1/2Cr-1/2Mo 2 Cl.2 1/2Cr-1/2Mo 12 Cl.1 1Cr-1/2Mo 12 Cl.2 1Cr-1/2Mo 11 Cl.1 1 1/4Cr-1/2Mo-Si 11 Cl.2 1 1/4Cr-1/2Mo-Si 22 Cl.1 2 1/4Cr-1Mo 22 Cl.2 2 1/4Cr-1Mo
ASME Maximum Allowable Stress (Table 1A Excerpt) Figure 3.2

33
Instructors Outline
1. Describe information contained in first section of table. 2. Information is grouped by material chemistry and material form.

ASME Code allowable stress tables.
45

Maximum Allowable Stress, contd

ALLOWABLE STRESS IN TENSION FOR CARBON AND LOW ALLOY STEEL Max Allowable Stress, ksi (Multiply by 1,000 to Obtain psi) for Metal Temperature, F, Not Exceeding 650 13.8 15.0 16.3 17.5 13.8 15.0 16.3 17.5 13.8 17.5 13.8 16.3 15.0 18.8 15.0 17.7 700 13.3 14.4 15.5 16.6 13.3 14.4 15.5 16.6 13.8 17.5 13.8 16.3 15.0 18.8 15.0 17.2 750 12.1 13.0 13.9 14.8 12.1 13.0 13.9 14.8 13.8 17.5 13.8 16.3 15.0 18.8 15.0 17.2 800 10.2 10.8 11.4 12.0 10.2 10.8 11.4 12.0 13.8 17.5 13.8 16.3 15.0 18.8 15.0 16.9 850 8.4 8.7 9.0 9.3 8.4 8.7 9.0 9.3 13.8 17.5 13.4 15.8 14.6 18.3 14.4 16.4 900 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 13.3 16.9 12.9 15.2 13.7 13.7 13.6 15.8 950 4.5 4.5 4.5 4.5 4.5 4.5 4.5 4.5 9.2 9.2 11.3 11.3 9.3 9.3 10.8 11.4 1000 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 5.9 5.9 7.2 7.2 6.3 6.3 8.0 7.8 Spec No. 1050 1100 1150 1200 Carbon Steel Plates and Sheets ----SA-515 ----SA-515 ----SA-515 ----SA-515 ----------------SA-516 SA-516 SA-516 SA-516
Plate-Low Alloy Steels (Cont'd) ----SA-387 ----SA-387 4.5 2.8 1.8 1.1 SA-387 4.5 2.8 1.8 1.1 SA-387 4.2 2.8 1.9 1.2 SA-387 4.2 2.8 1.9 1.2 SA-387 5.7 3.8 2.4 1.4 SA-387 5.1 3.2 2.0 1.2 SA-387
ASME Maximum Allowable Stress (Excerpt), cont'd Figure 3.2, cont'd

34
Instructors Outline
1. Review allowable stress vs. design temperature. 2. Most ferritic materials have a constant allowable stress at temperatures through 650F.

ASME Code allowable stress tables.
46

Material Selection Based on Fracture Toughness
Exercise 1
35
New horizontal vessel CET = - 2F Shell and heads: SA-516 Gr. 70 Heads hemispherical: in. thick Cylindrical shell: 1.0 in. thick No impact testing specified Is this correct? If not correct, what should be done?
Instructors Outline
1. This independent Exercise gives the Participants practice in material selection based on fracture toughness. 2. Review the given information together. 3. Allow approximately 10 minutes for the Participants to solve the problem. Then review the solution with them.

Participant Exercise 1 covering fracture toughness.
47

Exercise 1 - Solution
Must assume SA-516 Gr. 70 not normalized. Therefore, Curve B material (Ref. Table 3.1). Refer to Curve B in Figure 3.1.
in. thick plate for heads: MDMT = -7 F in. thick plate exempt from impact testing since MDMT < CET
1 in. shell plate: MDMT = +31F

Not exempt from impact testing
36
Instructors Outline
1. Review difference between normalized and non-normalized material with respect to fracture toughness. 2. Review MDMT determination in each case. 3. Note difference between MDMT and CET in each case.

Solution to Participant Exercise.
48

Exercise 1 - Solution, contd
One approach to correct: Impact test 1 in. plate at -2F. If passes, material acceptable. Another approach: Order 1 in. plate normalized
Table 3.1: normalized SA-516 is Curve D material Figure 3.1: 1 in. thick Curve D, MDMT = -30F Normalized 1 in. thick plate exempt from impact testing
37
Instructors Outline
1. Review possible solutions for the 1 in. plate.

Solution to Participant Exercise.
49


Choice of option based on cost, material availability, whether likely that 1 in. thick nonnormalized plate would pass impact testing
38
Instructors Outline
1. Review rationale for which option to select.

Solution to Participant Exercise 1.
50

Design Conditions and Loadings

Determine vessel mechanical design Design pressure and temperature, other loadings Possibly multiple operating scenarios to consider Consider startup, normal operation, anticipated deviations, shutdown
39
Instructors Outline
1. Review conditions to be considered. 2. Worst case operating scenario determines mechanical design.

Design conditions and loadings to be considered in pressure vessel mechanical design.
51

Design Pressure
P T = Design Pressure at Top of Vessel
= Weight Density of Liquid in Vessel
H = Height of Liquid
PBH = Design Pressure of Bottom Head
Figure 4.1
40
Instructors Outline
1. May have internal of external pressure, or both at different times. 2. Must have margin between maximum operating pressure at top of vessel and design pressure. 3. Hydrostatic pressure of operating liquid (if present) must be considered at corresponding vessel elevation.

Design pressure as a mechanical design condition.
52

Temperature Zones in Tall Vessels
Section 4 (T-Z) Section 3 (T-Y)
Section 2 (T-X)
Section 1 (T) F Support Skirt Grade
Figure 4.2
41
Instructors Outline
1. Margin required between operating temperature and design temperature. 2. Maximum design temperature needed to determine allowable stress and thermal expansion considerations. 3. CET needed for material selection considering brittle fracture. 4. There may be a wide temperature variation between the bottom and top of a tall tower.

Design temperature as a mechanical design condition.
53

Additional Loadings
Weight of vessel and normal contents under operating or test conditions Superimposed static reactions from weight of attached items (e.g., motors, machinery, other vessels, piping, linings, insulation) Loads at attached internal components or vessel supports Wind, snow, seismic reactions
42
Instructors Outline
1. Highlight other loads that must be considered in the mechanical design. 2. These other loads may govern the mechanical design in local areas.

Loadings other than pressure and temperature must also be considered.
54

Additional Loadings, contd

Cyclic and dynamic reactions caused by pressure or thermal variations, equipment mounted on vessel, and mechanical loadings Test pressure combined with hydrostatic weight Impact reactions (e.g., from fluid shock) Temperature gradients within vessel component and differential thermal expansion between vessel components
43
Instructors Outline
1. Review these additional other loads.

Additional other loadings to consider.
55

Weld Joint Categories

C A A D B D B A C A B C C A
D B A
Figure 4.3
44
Instructors Outline
1. Review the ASME Code Weld Joint Categories. 2. Only specific weld types may be used in each category.

ASME Code defines welded joints by category.
56

Weld Types
1 Buttjointsasattainedbydouble-weldingorbyother means which will obtain the same quality of deposited weld metal on the inside and outside weld surface. Backing strip, if used, shall be removed after completionofweld. Single-welded butt joint with backing strip which remainsinplaceafterwelding. 2
For circumferential joint only
Single-welded butt joint without backing strip.
Double-fullfilletlapjoint.
5 6
Single-full fillet lap joint with plug welds.
Single-full fillet lap joint without plug welds.
Figure 4.4
45
Instructors Outline
1. Review the different weld types. 2. Limited applications for Types 3 through 6.

ASME Code defines specific weld types that may be used.
57

Weld Joint Efficiencies
Joint Type 1 2 3 4 5 6 Acceptable Joint Categories Degree of Radiographic Examination Full A, B, C, D A, B, C, D (See ASME Code for limitations) A, B, C A, B, C (See ASME Code for limitations) B, C (See ASME Code for limitations) A, B, (See ASME Code for limitations) 1.00 0.90 NA NA NA NA Spot 0.85 0.80 NA NA NA NA None 0.70 0.65 0.60 0.55 0.50 0.45
Figure 4.5
46
Instructors Outline
1. Weld joint efficiency, E, is a measure of weld quality and accounts for stress concentrations. 2. E is needed in component thickness calculations. 3. Review information in table. 4. Note that corrosion allowance was previously discussed.

Weld joint efficiency vs. Joint Type, Category, Radiographic Examination.
58

Summary Of ASME Code Equations

Part Cylindrical shell Thickness, tp , in. Pressure, P, psi Stress, S, psi
Pr SE1 0.6P Pr 2SE1 0.2P
SE 1t r + 0.6t
2SEt r + 0.2t 2SEt D + 0.2t SEt 0.885L + 0.1t 2SEt cos D + 1.2t cos
P(r + 0.6t) tE1
Spherical shell 2:1 Semi - Elliptical head Torispherical head with 6% knuckle Conical Section ( = 30)
P(r + 0.2t ) 2tE P(D + 0.2t ) 2tE P (0.885L + 0.1t ) tE P(D + 1.2t cos ) 2tE cos
PD 2SE 0.2P 0.885PL SE 0.1P
PD 2 cos (SE 0.6P)
Figure 4.6
47
Instructors Outline
1. Circumferential stress governs minimum required component thickness in most cases. 2. Longitudinal stress may govern local thickness in some cases (e.g., under wind or earthquake loads). 3. Review ASME Code equations for internal pressure design. May calculate required thickness, permitted pressure, component stress. Must account for corrosion allowance.

ASME Code equations for various components under internal pressure.
59

Typical Formed Closure Heads
t t R sf sf ID Flanged t t h sf Elliptical h Flanged and Dished (torispherical) sf ID Hemispherical
sf ID Conical r ID Toriconical
48
Figure 4.7
Instructors Outline
1. Review the different head types. 2. The 2:l semi-elliptical head is the most common.

Different types of closure heads may be used.
60

Hemispherical Head to Shell Transition

th th Thinner Part Thinner Part
l 3y
Tangent Line y
l 3y
Length of required taper, l, may include the width of the weld ts
ts
Figure 4.8
49
Instructors Outline
1. Required thickness of a hemispherical head is about half that of the connected cylindrical shell. 2. Must have a tapered thickness transition in the head to end up matching the shell thickness.

Thickness transition at a hemispherical head.
61

Sample Problem 1
Hemispherical DESIGN INFORMATION Design Pressure = 250 psig Design Temperature = 700 F Shell and Head Material is SA-515 Gr. 60 Corrosion Allowance = 0.125" Both Heads are Seamless Shell and Cone Welds are Double Welded and will be Spot Radiographed The Vessel is in All Vapor Service Cylinder Dimensions Shown are Inside Diameters 4' - 0" 60' - 0"
10' - 0"
6' - 0" 30' - 0"
2:1 Semi-Elliptical
Figure 4.9
50
Instructors Outline
1. Sample Problem 1 illustrates calculation of required shell and head thicknesses for internal pressure. 2. Review the given information. 3. Review the problem solution with the Participants.

Sample Problem to illustrate calculation of required thickness for internal pressure.
62

Sample Problem 1 - Solution
Required thickness for internal pressure of cylindrical shell (Figure 4.6):
tp =
Pr SE1 0. 6P
Welds spot radiographed, E = 0.85 (Figure 4.5) S = 14,400 psi for SA- 515/Gr. 60 at 700F (Figure 3.2) P = 250 psig
51
Instructors Outline
1. Review the relevant equation for a cylindrical shell. 2. Note the sources used for the various parameters.

Sample Problem 1 solution.
63

Sample Problem 1 Solution, contd

For 6 ft. - 0 in. shell r = 0.5D + C = 0.5 72 + 0.125 = 36.125 in. Pr 250 36.125 tp = = S E1 0.6P 14,400 0.85 0.6 250 = 0.747 in. t = tp + c = 0.747 + 0.125 t = 0.872 in., including corrosion allowance
52
Instructors Outline
1. The corrosion allowance must be added to obtain the inside radius. 2. The corrosion allowance must be added to the calculated thickness.

64

For 4 ft. - 0 in. shell r = 0.5 48 + 0.125 = 24.125 in.
tp = 250 24.125 14,400 0. 85 0. 6 250
= 0.499 in.
t = 0.499 + 0.125 t = 0.624 in., including corrosion allowance

53
Instructors Outline
1. The calculation is repeated for the other cylindrical shell section.

65


Both heads are seamless, E = 1.0. Top Head - Hemispherical (Figure 4.6) r = 24 + 0.125 = 24.125 in.
tp =
Pr 250 24.125 = 0.21 in. = 2SE1 0.2P 2 14,400 1 0.2 250

t = tp + c = 0.21 + 0.125 t = 0.335 in., including corrosion allowance
54
Instructors Outline
1. Review the relevant equation for a hemispherical head. 2. Note the sources for the relevant parameters and how corrosion allowance is accounted for.

66


Bottom Head - 2:1 Semi-Elliptical (Figure 4.6) D = 72 + 2 0.125 = 72.25 in.
tp =
PD 250 72 .25 = = 0.628 in. 2SE 0.2P 2 14,400 1 0.2 250

t = 0.628 + 0.125 t = 0.753 in., including corrosion allowance
55
Instructors Outline
1. Review the relevant equation for a semi-elliptical head. 2. Note the sources for the relevant parameters and how corrosion allowance is accounted for.

67

Design For External Pressure and Compressive Stresses

Compressive forces caused by dead weight, wind, earthquake, internal vacuum Can cause elastic instability (buckling) Vessel must have adequate stiffness
Extra thickness Circumferential stiffening rings
56
Instructors Outline
1. Buckling of a shell under external pressure or compressive forces is analogous to column buckling under a compressive force. 2. Addition of stiffener rings reduces effective buckling length.

Different procedures are used to design for external pressure or compressive loads.
68

Design For External Pressure and Compressive Stresses, contd

ASME procedures for cylindrical shells, heads, conical sections. Function of:
Material Diameter Unstiffened length Temperature Thickness
57
Instructors Outline
1. Highlight the main parameters that affect buckling strength. 2. ASME Code has design procedure for each type of shell or head.

Parameters that affect compressive strength.
69

Stiffener Rings
Moment Axis of Ring h/3
h/3 h = Depth of Head
Figure 4.10
58
Instructors Outline
1. Stiffener rings reduce the buckling length of a shell and may be either inside or outside. 2. Stiffener rings are not used for heads.

Use and location of stiffener rings.
70

Sample Problem 2
DESIGN INFORMATION Design Pressure = Full Vacuum Design Temperature = 500 F Shell and Head Material is SA-285 Gr. B, Yield Stress = 27 ksi Corrosion Allowance = 0.0625" Cylinder Dimension Shown is Inside Diameter
4' - 0"
150' - 0"
2:1 Semi-Elliptical (Typical)
Figure 4.11
59
Instructors Outline
1. Sample Problem 2 illustrates procedure for calculation of required cylindrical shell thickness for external pressure. 2. The problem does not cover all aspects of the general procedure since it is geometry-specific. 3. Review the given information. 4. Review the problem solution with the participants.

Sample Problem to illustrate calculation of required cylindrical shell thickness for external pressure.
71


Calculate L and Do of cylindrical shell. L = Tangent Length + 2 1/3 (Head Depth) L = 150 12 + 2/3 (48/4) = 1,808 in. Do = 48 + 2 7/16 = 48.875 in. Determine L/Do and Do/t Account for corrosion allowance: t = 7/16 1/16 = 6/16 = 0.375 in. Do/t = 48.875 / 0.375 = 130 L/Do = 1808 / 48.875 = 37
60
Instructors Outline
1. Corroded shell diameter and thickness are used in the calculations. 2. The unstiffened length of the shell must include part of the head depth.

72


Determine A. Use Figure 4.12, Do /t, and L/Do. Note: If L/Do > 50, use L/Do = 50. For L/Do < 0.05, use L/Do = 0.05
61
Instructors Outline
1. Factor A is determined based only on geometry. 2. Note the source of Factor A.

73


A = 0.000065
.0001 .00001 Do/t = 100 D o/t = 125 4 5 6 789
0 00 ,00 00 00 800 = 4 t=5 t = 6 =1 /t / / /t = /t Do Do Do Do Do
Do /t = 130
D o/t = 150 D /t = 200

o
D o/t = 300 50.0 40.0 35.0 30.0 25.0 20.0 18.0 14.0 16.0
10.0 9.0
8.0
7.0
6.0
2.0 1.8
1.6 1.4
12.0
5.0
4.0
3.5 3.0
Length + Outside Diameter = L/Do
L/Do = 37
Factor A Figure 4.12

62
Instructors Outline
1. Note how Factor A is determined from these curves. 2. After determine Factor A, go to applicable material chart.

2.5
1.2
D o/t = 250
74


GENERAL NOTE: See Table CS-1 for tabular values up to 300F 500F 700F 800F 900F 20,000 18,000 16,000 14,000 12,000 9,000 8,000 7,000 6,000 5,000 4,000 3,500 3,000 2,500 2,000 2 .00001 3 4 5 6 789 .0001 2 3 4 5 6 789 .001 FACTOR A 2 3 4 5 6789 .01 2 3 4 5 6 789 .1 FACTOR B 10,000
E=29.0 x 106 E=27.0 x 106 E=24.5 x 106 E=22.8 x 106 E=20.8 x 106
A=0.000065
63
Factor B Figure 4.13
Instructors Outline
1. Different material charts are used for different material types. This is chart used for most carbon and lowalloy steels. 2. If A is under curves: Move up to intersect with temperature line. Move right to get B. B is then used to calculate allowable external pressure.

3. Since A is to left of curves in our case, must use alternate procedure.
75


Calculate maximum allowable external pressure
Pa =
Where:
2AE 3(Do / t )
E = Young's modulus of elasticity E = 27 106 psi (Figure 4.13) at T = 500F P a = 9 psi

64
Instructors Outline
1. Pa is calculated using indicated equation because A is not under curves. 2. Must use E from curves at design temperature.

76

Since Pa < 15 psi, 7/16 in. thickness not sufficient Assume new thickness = 9/16 in., corroded thickness L = 1/2 in.
A = 0.000114
Do 48. 875 = = 97.75 t 0. 5
L = 3 7 (as before) Do
Pa =
65
2 0.000114 27 10 6 = 15. 7 psi 3 130. 33
Instructors Outline
1. Since P a < 15 psi, must either increase shell thickness or add stiffeners to decrease L. 2. Problem illustrates results if increase thickness. 3. Choice of whether to increase thickness or add stiffeners depends on cost.

77

Exercise 2 - Required Thickness for Internal Pressure

66
Inside Diameter - 10 - 6 Design Pressure - 650 psig Design Temperature - 750F Shell & Head Material - SA-516 Gr. 70 Corrosion Allowance - 0.125 in. 2:1 Semi-Elliptical heads, seamless 100% radiography Vessel in vapor service
Instructors Outline
1. This independent Exercise gives the Participants practice in determining required vessel thicknesses for internal pressure. 2. Review the given information together. 3. Allow approximately 15 minutes for the Participants to solve the problem. Then review the solution with them. 4. Note that this Exercise may be skipped and assigned as homework if available class time is an issue.

Participant Exercise 2 covering required thickness for internal pressure.
78

Exercise 2 - Solution
For shell
tp = Pr SE 1 0 .6P
P = 650 psig r = 0.5 D + CA = (0.5 126) + 0.125 = 63.125 in. S = 16,600 psi, Figure 3.3 for SA-516 Gr. 70 E = 1.0, Figure 4.8 for 100% radiography
650 63. 125 = 2. 53 in. (16,600 1 .0 ) (0 .6 650)
tp =
67
Instructors Outline
1. Note the relevant equation for the cylindrical shell and the appropriate parameters. 2. Note how corrosion allowance is accounted for.

Exercise 2 solution.
79


Add corrosion allowance tp = 2.53 + 0.125 = 2.655 in. For the heads
tp = PD 2 SE 0. 2P 650 (126 0 . 9) + 0 . 250 = 2 . 23 in. (2 16, 600) (0 . 2 650 )
tp =
Add corrosion allowance

68
tp = 2.23 + 0.125 = 2.355 in.
Instructors Outline
1. Note the relevant equation for the heads and the appropriate parameters. 2. Note how corrosion allowance is accounted for.

Exercise 2 solution.
80

Reinforcement of Openings
Simplified ASME rules - Area replacement Metal used to replace that removed:
-
Must be equivalent in metal area Must be adjacent to opening
69
Instructors Outline
1. Simplified ASME rules do not require stress calculations. Use area replacement approach. 2. Metal removed must be replaced by equivalent metal.

Openings must be reinforced to account for metal removed.
81

Cross Sectional View of Nozzle Opening
Dp tn t rn Rn 2.5t or 2.5t n + te Use smaller value te tr
2.5t or 2.5t n Use smaller value
d or R n + tn + t Use larger value
d or R n + tn + t Use larger value
For nozzle wall inserted through the vessel wall
For nozzle wall abutting the vessel wall
Figure 4.14
70
Instructors Outline
1. Review cross-sectional view of region and associated nomenclature. 2. Note the different areas involved in the calculations and the reinforcement zone in the nozzle and shell.

Region near opening and nomenclature.
82

Nozzle Design Configurations

(a) Full Penetration Weld With Integral Reinforcement (a-1) (a-2) Separate Reinforcement Plates Added (a-3)
(b)
(c)
(d)
(e)
Full Penetration Welds to Which Separate Reinforcement Plates May be Added
(f-1)
(f-3)
(f-2) (f-4) (g)
Self - Reinforced Nozzles
71
Figure 4.15
Instructors Outline
1. Note the different nozzle design details that may be used. 2. The actual detail used in each case depends on the design conditions and the needed reinforcement.

Typical nozzle configurations.
83

Additional Reinforcement
Necessary if insufficient excess thickness Must be located within reinforcement zone Allowable stress of reinforcement pad should be that of shell or head Additional reinforcement sources
Pad Additional thickness in shell or lower part of nozzle
72
Instructors Outline
1. The method used to provide additional reinforcement depends on the particular situation. 2. The ASME Code specifies circumstances where nozzle reinforcement evaluation is not needed. The opening is considered to be inherently reinforced in these cases.

Requirements for additional reinforcement.
84

Sample Problem 3
DESIGN INFORMATION Design Pressure = 300 psig Design Temperature = 200 F Shell Material is SA-516 Gr. 60 Nozzle Material is SA-53 Gr. B, Seamless Corrosion Allowance = 0.0625" Vessel is 100% Radiographed Nozzle does not pass through Vessel Weld Seam
NPS 8 Nozzle (8.625" OD) 0.5" Thick
0.5625" Thick Shell, 48" Inside Diameter
Figure 4.16
73
Instructors Outline
1. Sample Problem 3 illustrates evaluation of an opening for adequate reinforcement. 2. Review the given information. 3. Review the problem solution with the Participants.

Sample Problem to illustrate evaluation of nozzle reinforcement.
85

Calculate required reinforcement area, A A = dtrF Where: d = Finished diameter of circular opening, or finished dimension of nonradial opening in plane under consideration, in. tr = Minimum required thickness of shell using E = 1.0, in. F = Correction factor, normally 1.0
74
Instructors Outline
1. Required replacement area is based on the cross-sectional area removed. 2. Calculated using the required shell thickness, not the actual.
Major Learning Points Sample Problem 3 solution.
86


Calculate diameter, d. d = Diameter of Opening 2 (Thickness + Corrosion Allowance) d = 8.625 1.0 + .125 = 7.750 in. Calculate required shell thickness, t r (Figure 4.6) tr = 0.487 in. Assume F = 1.0
75
Instructors Outline
1. Corrosion allowance is accounted for. 2. tr is calculated using the appropriate shell equation.

87


Calculate A A = dtr F A = (8.625 - 1.0 + 0.125) 0.487 1 = 3.775 in.2 Calculate available reinforcement area in vessel shell, A 1, as larger of A 11 or A1 2 A1 1 = (E lt - Ftr)d
76
A1 2 = 2 (Elt-Ftr)(t + tn)
Instructors Outline
1. Required area is calculated using the previously calculated parameters. 2. Two equations must be checked to determine the reinforcement area available in the shell.

88


Where: E l = 1.0 when opening is in base plate away from welds, or when opening passes through circumferential joint in shell (excluding head to shell joints). E l = ASME Code joint efficiency when any part of opening passes through any other welded joint. F = 1 for all cases except integrally reinforced nozzles inserted into a shell or cone at angle to vessel longitudinal axis. See Fig. UG-37 for this special case. tn = Nominal thickness of nozzle in corroded condition, in.
77
Instructors Outline
Review the relevant parameters.

89


A 11 = (Elt - Ftr)d = (0.5625 - 0.0625 - 0.487) 7.75 = 0.1 in.2 A 12 = 2 (Elt - Ftr ) (t + t n) = 2(0.5625-0.0625-0.487) (0.5625-0.0625+0.5 -0.0625) = 0.0243 in. 2 Therefore, A1 = 0.1 in.2 available reinforcement in shell
78
Instructors Outline
Available shell reinforcement area is determined.

90

Calculate reinforcement area available in nozzle wall, A2, as smaller of A21 or A22. A21 = (tn-tr n) 5t A22 = 2 (t n-tr n) (2.5 tn + t e)
79
Instructors Outline
Available reinforcement area in the nozzle is determined by checking two equations.

91


Where: trn = r = te = te = te =
80
Required thickness of nozzle wall, in. Radius of nozzle, in. 0 if no reinforcing pad. Reinforcing pad thickness if one installed, in. Defined in Figure UG-40 for self-reinforced nozzles, in.
Instructors Outline
Review the relevant parameters.

92


Calculate required nozzle thickness, trn (Figure 4.6)
t rn =
Pr SE1 0. 6P
t rn =
300 (3. 8125 + 0. 0625) = 0. 0784 in. 15,000 1 0. 6 300
81
Instructors Outline
Calculate required thickness using the equation for a cylinder.

93

Calculate A2. A21 = (tn - trn)5t = (0.5 - 0.0625 - 0.0784) 5 (0.5625 - 0.0625) = 0.898 in.2 A22 = 2 (tn - t rn) (2.5 tn + te) = 2 (0.5 - 0.0625 - 0.0784) [2.5 (0.5 - 0625) + 0] = 0.786 in.2 Therefore, A2 = 0.786 in.2 available reinforcement in nozzle.
82
Instructors Outline
1. The available reinforcement in the nozzle is determined. 2. Note that in this case, the nozzle has much more excess metal available than the shell.

94


Determine total available reinforcement area, A T; compare to required area. AT = A1 + A2 = 0.1 + 0.786 = 0.886 in.2 AT < A, nozzle not adequately reinforced, reinforcement pad required. Determine reinforcement pad diameter, Dp. A5 = A - AT A5 = (3.775 - 0.886) = 2.889 in.2
83
Instructors Outline
1. The nozzle is not adequately reinforced because it does not have enough reinforcement available. 2. The problem now proceeds to determine the required dimensions of a reinforcement pad. Note, however, that the additional reinforcement could also be added by using a thicker nozzle or by using a thicker shell section near the nozzle.

95


Calculate Dp te = 0.5625 in. (reinforcement pad thickness) A 5 = [Dp - (d + 2 t n)] te 2.889 = [Dp - (7.75 + 2(0.5 - 0.0625)] 0.5625 Dp = 13.761 in. Confirm Dp within shell reinforcement zone, 2d 2d = 2 7.75 = 15.5 in.
84
Therefore, Dp = 13.761 in. acceptable
Instructors Outline
1. The reinforcement pad thickness was assumed to be equal to the shell thickness. This is common practice. 2. A final check is made to ensure that the reinforcement pad is within the reinforcement zone.

96

Flange Rating
Based on ASME B16.5 Identifies acceptable pressure/temperature combinations Seven classes (150, 300, 400, 600, 900, 1,500, 2,500) Flange strength increases with class number Material and design temperature combinations without pressure indicated not acceptable
85
Instructors Outline
1. ASME B16.5 provides standard flange dimensional details. 2. Flange strength is based on dimensions and material used.

The flange rating establishes acceptable temperature/pressure combinations and is based on ASME B16.5
97

Material Specification List

Material Groups
Material Group Number Nominal Designation Steel
Product Forms Forgings

Spec. No. Grade
Castings
Spec. No. Grade
Plates
Spec. No. Grade
1.1
Carbon C-Mn-Si Carbon 2 Ni 3 Ni
1.2
A105 A350 ----A350
-LF2 ----LF3
A216 --A216 A352 A352 A352
WCB --WCC LCC LC2 LC3
A515 A516 A537 --A203 A203
70 70 Cl.1 --B E
ASME B16.5, Table 1a, Material Specification List (Excerpt)
Figure 4.17
86
Instructors Outline
1. Acceptable flange materials are grouped based on similarities in strength. 2. The Material Group is determined based on the specified material.

Flange Material Group Number is based on material specification and product form.
98

Pressure - Temperature Ratings
Material Group No. Classes Temp., F -20 to 100 200 300 400 500 600 650 700 750 800 850 900 950 1000 1.1 150 285 260 230 200 170 140 125 110 95 80 65 50 35 20 300 740 675 655 635 600 550 535 535 505 410 270 170 105 50 400 990 900 875 845 800 730 715 710 670 550 355 230 140 70 150 290 260 230 200 170 140 125 110 95 80 65 50 35 20 1.2 300 750 750 730 705 665 605 590 570 505 410 270 170 105 50 400 1000 1000 970 940 885 805 785 755 670 550 355 230 140 70 150 265 250 230 200 170 140 125 110 95 80 65 50 35 20 1.3 300 695 655 640 620 585 534 525 520 475 390 270 170 105 50 400 925 875 850 825 775 710 695 690 630 520 355 230 140 70
Figure 4.18
87
Instructors Outline
1. This table combines information for three Material Groups for illustrative purposes. 2. Review the information in this table and how it is used to determine the appropriate flange rating.

Pressure/temperature rating is a function of Material Group and design temperature.
99

Sample Problem 4
Determine Required Flange Rating Pressure Vessel Data: Shell and Heads: Flanges: SA-516 Gr.70 SA-105
Design Temperature: 700F Design Pressure: 275 psig
88
Instructors Outline
1. Sample Problem 4 illustrates how to determine flange rating. 2. Review the given information. 3. Review the problem solution with the Participants.

Sample Problem to illustrate determining flange rating.
100

Identify flange material specification SA-105 From Figure 4.17, determine Material Group No. Group 1.1 From Figure 4.18 with design temperature and Material Group No. determined in Step 3
Intersection of design temperature with Material Group No. is maximum allowable design pressure for the flange Class
89
Instructors Outline
Review the problem solution.

101


Table 2 of ASME B16.5, design information for all flange Classes Select lowest Class whose maximum allowable design pressure required design pressure.
At 700F, Material Group 1.1: Lowest Class that will accommodate 275 psig is Class 300. At 700F, Class 300 flange of Material Group 1.1: Maximum design pressure = 535 psig.
90
Instructors Outline
1. Use the lowest flange class that is suitable for the design conditions. Flange cost increases as the class increases. 2. A given flange class is good for a range of temperature/pressure combinations for a particular Material Group.

102

Flange Design
Bolting requirements During normal operation (based on design conditions) During initial flange boltup (based on stress necessary to seat gasket and form tight seal
Am =
91
W S
Instructors Outline
1. Division 1 Appendix 2 procedure for custom-designed flanges. 2. Used if flange size not covered by ASME B16.5 or ASME B16.47. 3. Typical application is girth flange for shell-and-tube heat exchanger.

ASME procedure must be used for custom-designed flanges.
103

Flange Loads and Moment Arms

Gasket t A hT HT G g1 HG HD B Flange Hub g0 hG W hD C h Flange Ring
Figure 4.19
92
Instructors Outline
1. Applied loads act at different flange locations. 2. Flange moments are calculated for the operating and gasket seating cases.

Various flange loads are applied on corresponding moment arms.
104

Stresses in Flange Ring and Hub

Calculated using: Stress factors (from ASME code) Applied moments Flange geometry Calculated for: Operating case Gasket seating case
93
Instructors Outline
1. Various stresses are calculated for each case and must be kept within allowable limits. 2. Flange dimensions are adjusted as needed to meet allowable stresses (e.g., increase thickness, change hub dimensions, etc.). 3. Equipment suppliers use computer programs to optimize flange design to be least weight (i.e., lowest cost).

Flange stresses are calculated and compared to allowable values. Both operating and gasket seating cases must be checked.
105

Flange Design and In-Service Performance

Factors affecting design and performance ASME Code m and y parameters. Specified gasket widths. Flange facing and nubbin width, w Bolt size, number, spacing
94
Instructors Outline
1. Flange is designed for specific gasket type, dimensions, and facing details. Changing any of these after flange is fabricated (e.g., gasket type) can adversely affect in-service performance. 2. TEMA specifies minimum gasket width and bolt spacing criteria.

Various parameters affect flange design and performance.
106

ASME Code m and y Factors

Gasket Type and Material Gasket Factor, m Min. Design Seating Stress y, psi 5,500 6,500 7,600 8,000 9,000 9,000 Facing Sketch and Column in ASME Table 2-5.2 (Figure 4.21)
Flat metal, jacketed asbestos filled: Soft aluminum Soft copper or brass Iron or soft steel Monel 4-6% chrome Stainless steels and nickel-base alloys Solid flat metal: Soft aluminum Soft copper or brass Iron or soft steel Monel or 4-6% chrome Stainless steels and nickel-base alloys
3.25 3.50 3.75 3.50 3.75 3.75
(1a), (1b), (1c), (1d); (2); Column II
4.00 4.75 5.50 6.00 6.50
8,800 13,000 18,000 21,800 26,000
(1a), (1b), (1c), (1d); (2), (3), (4), (5); Column I
Figure 4.20
95
Instructors Outline
1. This is an excerpt from Table 2-5.1. 2. Review the variation in m and y with gasket type.

Gasket m and y factors are based on gasket type. Gasket type also affects gasket width used in calculations.
107

ASME Code Gasket Widths

Facing Sketch (Exaggerated) Basic Gasket Seating Width bo Column I Column II (1a)
N
N
N 2
N 2
(1b)
w T N
(1c)
w
w N
T
w + T ; w + N max 2 4
w+ T w+ N ; max 2 4
(1d)
w N
HG G O.D. Contact Face b hG G HG hG Gasket C L Face
For b o > in.
For b o< in.
ASME Code Gasket Widths (Table 2-5.2 excerpt)
Figure 4.21
96
Instructors Outline
1. This is an excerpt from Table 2-5.2. 2. Review the flange facings shown.

The gasket width used in the calculations depends on the type of flange facing.
108

Gasket Materials and Contact Facings

Gasket Materials and Contact Facings Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y Gasket Material Gasket Factor m Min. Design Seating Stress y, psi 5500 6500 7600 8000 9000 9000 Sketches Facing Sketch and Column in Table 2-5.2 (1a), (1b), (1c),2, (1d) 2, (2)2, Column II
Flat metal, jacketed asbestos filled: Soft aluminum Soft copper or brass Iron or soft steel Monel 4% - 6% chrome Stainless steels and nickel-base alloys
3.25 3.50 3.75 3.50 3.75 3.75
Figure 4.22
97
Instructors Outline
Review the additional gasket information shown.

Information on additional gasket types.
109

Maximum Allowable Working Pressure (MAWP)

Maximum permitted gauge pressure at top of vessel in operating position for designated temperature MAWP Design Pressure Designated Temperature = Design Temperature Vessel MAWP based on weakest component
Originally based on new thickness less corrosion allowance Later based on actual thickness less future corrosion allowance needed
98
Instructors Outline
1. Emphasize that MAWP is based on the as-supplied component thicknesses. 2. Thicknesses used exclude corrosion allowance and thickness added to absorb other loads. 3. MAWP is useful to know for potential future rerate.

MAWP is defined.
110

Local Loads
Piping system Platforms, internals, attached equipment Support attachment
99
Instructors Outline
1. Review the typical external loads that may be applied. 2. External loads cause local stresses that must be evaluated. 3. Other industry standards must be used to evaluate local stresses (e.g., WRC 107 and 297).

Externally applied loads must also be considered in vessel design.
111

Types of Vessel Internals

Trays Inlet Distributor Anti-vortex baffle Catalyst bed grid and support beams Outlet collector Flow distribution grid Cyclone and plenum chamber system
100
Instructors Outline
1. Different types of internals are used to perform various process functions. 2. Review list of internals. 3. ASME Code does not cover design of internals. End-user, vessel vendor, and/or contractor must develop requirements.

Several types of vessel internals may be installed.
112

ASME Code and Vessel Internals

Loads applied from internals on vessel to be considered in design Welding to pressure parts must meet ASME Code
101
Instructors Outline
Discuss ASME requirements for loads applied to vessel and welding to pressure parts.

ASME Code requires that internals be considered only to extent of their effect on pressure shell.
113

Corrosion Allowance For Vessel Internals

Removable internals: CA = CA of shell
Costs less Easily replaced
Non-removable internals: CA = 2 (CA of shell)

Corrosion occurs on both sides
102
Instructors Outline
1. Potential corrosion of internals should not be ignored. 2. Corrosion allowance should be considered in a practical and costeffective manner.

Corrosion allowance should be considered in the design of internals.
114

Head-to-Shell Transitions
th Thinner part th Thinner part y t
s
l y
Tangent Line
ts
th
th
y l
Thinner part
Tangent Line
y l Thinner part t
s
Fillet Weld
Butt Weld Intermediate Head Attachment
Figure 6.1
103
Instructors Outline
1. Review typical acceptable welding and fabrication details. 2. Details for openings were previously reviewed. 3. Highlight thickness taper. 4. Intermediate heads should retain fillet weld in refinery applications.

ASME Code specifies acceptable welding and fabrication details.
115

Typical Shell Transitions

C L y In all cases, l shall not be less than 3y. C L
l l
C L
Figure 6.2
104
Instructors Outline
Review thickness taper requirements.

ASME Code fabrication details.
116

Nozzle Neck Thickness Tapers
Figure 6.3
105
Instructors Outline
Thickness taper may be required in nozzle neck.

117

Stiffener Rings
In-Line Intermittent Weld Staggered Intermittent Weld
Continuous Fillet Weld On One Side, Intermittent Weld On Other Side
Figure 6.4
106
Instructors Outline
1. Vacuum stiffening ring attachment details. 2, ASME Code specifies weld spacing, size, and length.

118

Post Weld Heat Treatment
Restores material properties Relieves residual stresses ASME Code PWHT requirements
Minimum temperature and hold time Adequate stress relief Heatup and cooldown rates
107
Instructors Outline
1. ASME Code specifies PWHT requirements only for relief of residual stresses. 2. Need for PWHT due to other reasons must be specified by end-user or contractor. Service considerations (e.g., wet H 2S, caustic) Weld hardness reduction

ASME Code PWHT requirements.
119

Inspection and Testing
Inspection includes examination of:
Base material specification and quality Welds Dimensional requirements Equipment documentation
108
Instructors Outline
Highlight main areas included in inspection.

ASME Code inspection requirements.
120

Common Weld Defects
Between Weld Bead and Base Metal Between Adjacent Passes
Lack of Fusion
Incomplete Filling at Root on One Side Only
Incomplete Filling at Root
Incomplete Penetration
ExternalUndercut
Internal Undercut
Undercut
Figure 7.1
109
Instructors Outline
Review common types of weld defects.

Particular types of weld defects may occur.
121

Weld Defects
Presence of defects: Reduces weld strength below that required Reduces overall strength of fabrication Increases risk of failure
110
Instructors Outline
Review why weld defects can reduce vessel integrity.

Presence of unacceptable weld defects reduces vessel integrity.
122

Types of NDE
NDE TYPE Radiographic DEFECTS DETECTED Gas pockets, slag inclusions, incomplete penetration, cracks Porosity holes, slag inclusions, weld undercuts, overlapping Weld surface-type defects: cracks, seams, porosity, folds, pits, inclusions, shrinkage Cracks, porosity, lack of fusion Subsurface flaws: laminations, slag inclusions ADVANTAGES Produces permanent record. Detects small flaws. Most effective for butt-welded joints. Helps pinpoint areas for additional NDE. LIMITATIONS Expensive. Not practical for complex shapes. Can only detect what is clearly visible. Visual
Liquid Penetrant
Used for ferrous Can only detect and nonferrous surface materials. Simple imperfections. and less expensive than RT, MT, or UT. Flaws up to in. beneath surface can be detected. Can be used for thick plates, welds, castings, forgings. May be used for welds where RT not practical. Cannot be used on nonferrous materials. Equipment must be constantly calibrated.
Magnetic Particle Ultrasonic
Figure 7.2
111
Instructors Outline
1. Review NDE methods and types of defects detected. 2. Review advantages and limitations of each NDE method.

Different NDE methods are best suited to detect particular defect types. Each NDE method has advantages and disadvantages.
123

Typical RT Setup
X-Ray Tube
X-Ray
Film
Test Specimen
Figure 7.3
112
Instructors Outline
Review typical setup for RT inspection.

Typical RT setup.
124

Pulse Echo UT System

Cathode Ray Tube (CRT) A B C Read Out BaseLine
Input-Output Generator Transducer A Couplant Test Specimen
Cable
B C
Flaw
Figure 7.4
113
Instructors Outline
Review how pulse echo UT system can detect defects.

Typical pulse echo UT system.
125

Pressure Testing
Typically use water as test medium Demonstrates structural and mechanical integrity after fabrication and inspection Higher test pressure provides safety margin PT = 1.5 P (Ratio)
114
Instructors Outline
1. Water is a safer test medium than air. Pneumatic testing should only be used on an exception basis. 2. Ratio is the lowest value of:

Pressure test is used as final demonstration of vessel integrity.
S( test temperatur e) S ( design temperatur e)
126

Pressure Testing, contd

Hydrotest pressures must be calculated: For shop test. Vessel in horizontal position. For field test. Vessel in final position with uncorroded component thicknesses. For field test. Vessel in final position and with corroded component thicknesses. PT Flange test pressure Stress 0.9 (MSYS) Field test with wind
115
Instructors Outline
Review additional pressure test design considerations.

Pressure test considerations.
127

Summary
Overview of pressure vessel mechanical design ASME Section VIII, Division 1 Covered
Materials Fabrication Testing Design Inspection
116
Instructors Outline
1. Highlight the subjects covered in the course. 2. Note that much more time is required for an in-depth discussion of pressure vessel design. This course provides a good starting point to proceed further for those who need to. 3. Provide the evaluation form for the class to complete. Collect these and return them to the sponsoring unit. 4. Distribute the CEU form to the participants and point out that they will have to mail it in themselves, with the required standard fee. All the information is on the form.

Summarize course.
128
Appendix A
Reproducible Overheads
Appendix B
Course & Instructor Evaluation Form
ASME Career Development Series Course Evaluation

Course Title: ________________________________________________ Location: ___________________________________________________ Instructor: __________________________________________________ Please assist us in the evaluation of this program. Answer the following questions by circling only one answer unless otherwise stated. We will be using your feedback to plan future programs. Your assistance is most appreciated. Please return to instructor as requested. A. Course Evaluation Please record your overall reaction to the program by placing a circle around the appropriate number on the scale. 10 9 Excellent 876 Good 543 Poor 210
Fair
Please evaluate the course by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location. 1. Course content Relevance of New matches brochure course notes/ Applicability Knowledge Overall description workbook to your job Gained
Rating
1.1 E G F P 2.
1.2 E G F P
1.3 E G F P
1.4 E G F P 1.5 E G F P
What do you think was the best feature of the course?
3.
What changes, if any, would you make in the program content and/or format?
4.
Can you share with us any comments about this program that we coul use as a quote on our course literature?
Optional Information: Name: _______________________________ Company: ____________________________
Title: _______________________________ City, State: __________________________
131
B.
Instructors Evaluation Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location Effective knowledge of subject matter Effectiveness Effective of teaching use of Class method class time Openness to Overall Participation Rating
5.
1.1 E G F P C. 6. 7. 8. 9.
1.2 E G F P
1.3 E G F P
1.4 E G F P 1.5 E G F P
Facilities How would you rate the meeting site? How would you rate the overnight accommodations (if applicable)? In what other cities would you like to see this course held? Additional Comments:
D. 10.
Future Courses and Educational Products (Video, Self Study, Software) What other courses would you like to see sponsored?
11.
What educational products would you like to see sponsored by ASME and in what medium?
E. 12.
On-Site Company Training Would your organization be interested in holding this course or other ASME courses at your facility? If so, please indicate the area of interest and the contact person. Thank you. Course Name/Topic: _________________________________________________________ Contact Name: ________________________________ Phone No.: ___________________
13. 14.
132
Appendix C
Continuing Education Unit (CEU) Submittal Form Course Improvement Form
133
ASME Career Development Series Continuing Education Unit (CEU) Request Form
Each 4-hour ASME Career Development Series Course earns 0.4 CEUs PLEASE PRINT ALL YOUR INFORMATION CLEARLY YOUR CERTIFICATE WILL BE PREPARED FROM THIS FORM Title of Program: _____________________________________________________ Date Held: __________________________________________________________ Instructor: __________________________________________________________ Location: ___________________________________________________________ Number of CEUs Earned: (0.4 per 4-hour module) ____________ Last Name: __________________________________________ First Name, Middle Initial: ______________________________ Title/Position: ________________________________________ Company: ___________________________________________ Address: ____________________________________________ City: _______________________ State: __ Zip: ____________ Telephone: __________________ Fax: ____________________ Email: _________________________ Please send this form, along with a check made out to ASME for the standard fee of $15.00 to: ASME Continuing Education Institute Three Park Avenue New York, NY 10016-5990 Your Certificate will be prepared and sent to the address you indicated above.
134
ASME Career Development Series Course Improvement Form
Important Note: Submission of this form is optional. However, we would like to solicit the comments of the Instructor so that we may continuing improve on the Career Development Series. Any instructors who would like to write a course should indicate so on this form and an authors package will be forwarded to you. Thank you for helping us with the Career Development Series Name: _________________________________________________________ Address: _______________________________________________________ City/State/Zip: __________________________________________________ Telephone: ______________________________ Fax: ____________________________________ Email: __________________________________ Comments:
Please send this form to: ASME Continuing Education Institute Three Park Avenue New York, NY 10016-5990
135
ASME Career Development Series Instructors Biography Form
Important Note: Submission of this form is required every time a Career Development Series Course is taught. ASME cannot process attendees CEU requests without this form. Attachments to this form must include: 1. A biographical sketch of the instructor. 2. Course evaluations filled out by the participants at the completion of the course.
Course: ____________________________________________________ Date Presented: ______________________________________________ Location: ___________________________________________________ Instructor: __________________________________________________ Number of participants: ________________________________________ Sponsoring Unit: _____________________________________________
136
Your Path to Lifelong Learning

ASME offers you exciting, rewarding ways to sharpen your technical skills, enhance personal development and prepare for advancement. Short Courses More than 200 short courses offered each you keep you up to speed in the technology fast laneor, help you fill in any gaps in your technical background. Customized Training at your organizations site Do you have ten or more people at your site who could benefit from an ASME course? Most of our courses can be offered in -house and tailored to your latest engineering project. Bring course to your company too. Self-study materials meet the needs of individuals who demand substantive, practical information, yet require flexibility, quality and convenience. Return to each program again and again, as a refresher or as an invaluable addition to your reference library. FE Exam Review A panel of seasoned educators outline a wide range of required topics to provide a thorough review to help practicing engineers as well as engineering students prepare for this challenging examination. Videotape Review PE Exam Review A comprehensive review of all the major exam topics that demonstrates the necessary math, logic and theory. Videotape, Online, or Online Live Revie w available. FOR MORE INFORMATION CALL 1-800-THE-ASME __________________________________________________________________________ INFORMATION REQUEST FORM Please mail to ASME at 22 Law Drive, P. O. Box 2900, Fairfield, NJ 07007-2900, or fax to 973-882-1717, call 1-800-THE-ASME, or email infocentral@asme.org . Send me information on the following: ____ Short Courses ____ In-House Training ____ Self-Study Programs ____ FE Exam Review ____ PE Exam Review (videotape) ____ PE Exam Review (Online) ____ PE Exam Review (Online Live) Name: ______________________________________________ Title: _______________________________________________ Organization: _________________________________________ Business Address: _____________________________________ City: _________________ State: __ Zip Code: _____________ Business Phone: _________________ Fax: ________________ Email: ______________________________________________
137

Pressure Vessel Code Guide Instructors

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Overview of Pressure Vessel Design

International Regional Office 1-800-THE-ASME

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Suggested Outline/Teaching Plan

OV 3-9 Part. 67 OV 10-13 Part. 75

OV 14 Part. 78 OV 15-31 Part. 79

5 10 10 55 Exercise Break Design 10 10 10

OV 32-34 Part. 87 OV 35-38 Part. 91 OV 39-43 Part. 92

OV 56-65 Part. 109

Suggested Outline/Teaching Plan, continued

Break Other Design Considerations

Inspection and Testing

Overview of Pressure Vessel Design

OVERVIEW OF PRESSURE VESSEL DESIGN

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Saddle Support (Sliding) A

Saddle Support (Fixed)

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Head Skirt Support

Major Learning Points

2. Ends typically flanged, may be welded. 3. Sometimes extend into vessel.

Overview of Pressure Vessel Design

Catalyst Bed Support Grid

Major Learning Points

Overview of Pressure Vessel Design

Spherical Pressurized Storage Vessel

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

2. Vessel located above grade. 3. Lugs bolted to horizontal structure.

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Section VIII, Division 2, Alternative Rules

Choice between Divisions 1 and 2 based on economics

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Structure of Section VIII, Division 1

Part UG applies to all vessels

Mandatory and Nonmandatory Appendices

Major Learning Points

4. Highlight several mandatory and nonmandatory appendices.

Overview of Pressure Vessel Design

Material Selection Factors

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Major Learning Points

Overview of Pressure Vessel Design

Resistance to Hydrogen Attack