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TABLE OF CONTENTS
Part 1 Part 2 Part 3 Part 4 Part 5 Part 6 Part 7 Part 8 Part 9 Part 10 Part 11 INTRODUCTION TO ASME CODE GENERAL REQUIREMENTS MATERIAL REQUIREMENTS DESIGN REQUIREMENTS DESIGN OF OPENINGS EXTERNAL LOADINGS ON NOZZLES DESIGN OF FLAT HEADS FABRICATION REQUIREMENTS SUMMARY OF OTHER REQUIREMENTS STRESS ANALYSIS FATIGUE ANALYSIS
PART 1
Part 1 - 1
Part 1 - 2
Part 1 - 3
NEW DIV. 2
A re-write of Div. 2 scheduled to be published July 2007. Will be mandatory 6 months after date of publication Contains major revisions and expanded rules Will allow higher stress allowable. Design margin on tensile strength will be reduced from 3.0 to 2.4 (joint efficiency introduced). The same margin applied to room temperature and elevated temperature values The design factor on yield strength will remain at 1.5. Stainless steel and strain hardening materials will not benefit
Part 1 - 4
NEW DIV. 2
Formatted and paragraph numbered in accordance with ISO Use of appendices has been minimized and they are called Normative (mandatory) and Informative (nonmandatory) Units not specified in formulas, to allow use of different units Formulas provided for all curves, to facilitate computerization Material properties will be in the book (not II-D). An efficient index method (categories of materials) has been introduced Scope almost identical with old Div. 2. But, vessels falling under Section I or IV may not be U2 stamped No provision for lethal service
PART 2
GENERAL REQUIREMENTS
Part 2 - 1
ORGANIZATION OF DIVISION 2
This Division is divided into 8 Parts, each addressing a specific area. Much more organized than Division 1 Part AG on General requirements provide the scope, the jurisdiction, and the responsibilities Part AM on Material Requirements covers the allowed materials and all material requirements Part AD on Design Requirements contains requirements for design of vessels and parts Part AF on Fabrication requirements contains all fabrication rules Part AR on Pressure Relief Devices contains rules for pressure relieving devices Part AI on Inspection and radiography contains contains requirements regarding third party inspection and radiography Part AT on Testing contains testing requirements and procedures Part AS on Marking, Stamping, Reports, and Records contains requirements for Data Reports and stamping of vessels and parts
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 2 - 2
ORGANIZATION OF DIVISION 2
Mandatory Appendices include rules that are additional to those in the body of the Code, for specific applications Non-Mandatory Appendices provide information and suggested good practices Each Part is broken into a number of Articles Each Article consists of several Paragraphs and subparagraphs
Part 2 - 3
NEW DIV. 2
The following is how the new Div.2 will be set up: Part01_General Part02_Responsibilities and Duties Part03_Materials Part04_Design_By_Rules Part05_Design_By_Analysis Part06_Fabrication Part07_Examination Part08_Testing Part09_Pressure_Relief
Part 2 - 4
Part 2 - 5
NEW DIV. 2
Responsibilities and duties almost the same Provisions provided for others than a P.E. to certify UDS and MDR. More than one individual can certify. Registered P.E. in U.S. and Canada Responsible individuals in charge elsewhere More details on what needs to be in UDS and MDR MDR will have to include much more detail regarding computer programs and FEA Record maintenance rules spelled out. Much more extensive than old rules
PART 3
MATERIAL REQUIREMENTS
Part 3 - 1
Part 3 - 2
Part 3 - 3
NEW DIV. 2
Stress allowable will be in a Annex Materials categorized into strength parameters. Physical properties specified in terms of these parameters List of materials more extensive Material requirements more detailed New material purchase requirements introduced New material NDE added Above creep temperatures allowed only for design by rule Analytical expressions are provided for determining the specified minimum yield and specified minimum tensile, as a function of temperature Formula for establishing stress-strain curves Expressions for determining Tangent Modulus
Part 3 - 4
NEW Div. 2
Basic concept for toughness rules the same (exemption curves). But, values are different Much more refined. Differentiate between as-weled and PWHTed weldments Credit for low stress different Differentiate based on yield governing thickness the same The -20F impact exemption for ASME B16.5 flanges allowed, only if heat treated For material with governing thickness (based on weld joint) over 1 in., and not PWHTed, impact test is mandatory Allows establishing the MDMT by fracture mechanics methods of Part 5
PART 4
DESIGN REQUIREMENTS
Part 4 - 1
Part 4 - 2
Part 4 - 3
All of the following primary stress allowables must be met, for design by analysis (secondary and peak stress limits will be covered with Appendix 4 analysis) All the following limits may be increased by 1.2, for load combinations including wind or seismic
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 4 - 4
Part 4 - 5
Thickness required for axial stress ( this will control only if F is positive and has a value greater than 0,5PR
t = 0 . 5 PR + F S 0 .5 P
Thickness required to prevent axial buckling. If F is negative, thickness must be adequate for axial bucking rules
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 4 - 6
Thickness required to prevent buckling. If F is negative, shell buckling must be considered For CONICAL HEADS, the minimum required shell thickness shall be determined the same way as for cylindrical shells, except the conical radius must be used For HEMISPHERICAL HEADS, the minimum thickness is calculated the same way as that for spheres For TORISPHERICAL HEADS, the minimum required thickness after forming must be established by Figure AD-204.1 (see next page). These rules not applicable for t/L less than 0.002 (buckling is a concern) or t/L greater than 0.045 (thin shell theory not accurate). Interpolation allowed, but not extrapolation. Crown radius limited to shell diameter. Knuckle radius limited to 6% of shell diameter and 3t
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 4 - 7
PART 5
DESIGN OF OPENINGS
Part 5 - 1
REINFORCEMENT OF OPENINGS
Nozzle reinforcement rules for pressure are provided in Article D-5 Rules are not provided for external loadings Area replacement rules may be overridden by analysis, but not normally done Rules apply to circular and elliptical openings with major to minor diameter ratio not exceeding 1.5 The d/D ratio shall not be greater than 0.5 There is a limit on how close the center lines of two adjacent nozzles can get together. See AD-501(a)(3). For more closely spaced nozzles need to do analysis The area must be replaced along all planes thru nozzle centerline. Usually check along the two major axes Nozzles may be located in a butt weld. Should be avoided, if possible Openings with diameters less than 0.2 times square root of Rt of shell are exempt from reinforcement (notice the difference with Division 1). The center of two such nozzles can not be closer than 1.5 times the sum their diameters. Unreinforced openings can not be too close to discontinuities (within 2.5 SQRT)
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 5 - 2
Part 5 - 3
NEW DIV. 2
Provides design formulas similar to existing Div. 2. But, allows design by analysis to over ride the formulas, including the basic thickness formulas for external and internal pressure. A basic difference Basic thickness allowed is 1/16 in., with some exceptions Uses the term MAWP Uses Von Mises failure criteria. Existing Code uses Tresca (Maximum shear) theory, which is simpler and more conservative. Equation in new Code are much more complicated The term stress intensity is now equivalent stress Specifies design load combinations (in line with ASCE). No 1.2 increase in allowable for short term loadings
Part 5 - 4
NEW DIV. 2
All weld joint types allowed by existing Code are allowed without analysis Any other detail (including Div. 1 details) are allowed, with analysis Old joint categories maintained Category E introduced for attaching non-pressure parts and stiffeners Weld joint types similar to existing Codes. Types 9 and 10 introduced for partial penetration and fillet welds A lot of detailed sketches added
Part 5 - 5
NEW DIV. 2
Formulas for internal pressure design look different (more exact and based on Lame equations), but give very close results Design rules for ellipsoidal/torispherical rules are those of Code Cases 2260/2261, without fatigue consideration (they have been put in different format). See WRC Bulletin 501 for background and comparisons. Temperature limitations of the CC were removed The concern for fatigue in the knuckle (due to large deformations) has been addressed by imposing a lower number of cycles, for allowing exemption from fatigue analysis Local thin area evaluation procedure is the same as that of API-579, but the criteria is more limiting
Part 5 - 6
NEW DIV. 2
Formulas provided for combined loading (pressure plus overturning) Cone-cylinder junction design rules are totally new and rather complicated (based on limit analysis External pressure and buckling rules are the same as those of CC-2268. (see WRC Bulletins 406 and 444 for background) More sophisticated buckling analysis allowed, in accordance with Part 5 Fatigue exemption rules the same Design by proof test not allowed (use FEA)
Part 5 - 7
NEW DIV. 2
Design rules for openings based on Bildy theory (beams on elastic foundations) Rules provided for external loadings Better correlation with test data than area replacement rules Can override by analysis Specific minimum nozzle neck thickness requirements have been added. A lot more complicated than old rules. Let a computer program do it
PART 6
Part 6 - 1
Part 6 - 2
WRC Bulletin is more up to date and more accurate Is based on shallow shell theory and accounts for nozzle neck Gives stresses on the nozzle neck, as well as on shell Limitations shown on a following page. Nomenclature also shown A typical curve included here WRC Bulletin 368 is based on the same shallow shell theory. This Bulletin gives the stresses due to pressure Limitations and formulas of Bulletin 368 shown here
PART 7
Part 7 - 1
The Rules for design of flat heads and covers are included in Article D-7 The minimum required thickness of a flat head, attached by welding, is calculated by the following formula:
T =d CP S
Where,
d is the diameter of the head subject to pressure (I.D. of vessel) C is from the appropriate detail of Fig. AD-701 S is the stress allowable
The factor of 1.5 for the allowable bending stress is built into the above formula For flat covers attached by bolts, an additional term is added to the design formula, to account for bending due to bolt loads (see AD-702) The C values of Div. 2 are not the same as those of Div.1. These values are rather arbitrary and are to account for the boundary effects associated with the attachment detail See attached Fig. AD-701.3, for some details
Date: 30th October ~ 3rd November 2006 Organized By: EDS ASIA SDN. BHD. ~ED Knowledge Team~
Part 7 - 2
PART 8
FABRICATION REQUIREMENTS
Part 8 - 1
Part 8 - 2
Part 8 - 3
Part 8 - 4
NEW DIV.2
Fabrication rules have been expanded Welding and PWHT requirements are similar Forming requirements have been made more stringent Material traceability requirements expanded Some new tolerances added
PART 9
Part 9 - 1
Part 9 - 2
NEW DIV. 2
Examination requirements expanded and new ones added Allows UT or RT Joint efficiency concept basically the same Some concern about added costs Detailed cost comparisons being made, by several fabricators Need to compete with European codes
Part 9 - 3
NEW DIV.2
Concept of examination groups introduced Rules provided for reduction in examination, based on successful experience Additional NDE requirements introduced, for vessels in cyclic service All documentation of examinations must be provided to the Purchaser Minimum hydrotest pressure has been increased to greater of: 1.43MAWP 1.25 MAWP(S/S)
Part 9 - 4
PART 10
STRESS ANALYSIS
Part 10 - 1
Part 10 - 2
Part 10 - 3
Part 10 - 4
NEW DIV. 2
The equivalent elastic stress analysis method has been kept (due to using Von Mises, the formulas much more complicated and will require a computer program) The term stress intensity has been replaced by equivalent stress Procedure and acceptance criteria provided for limit analysis and elastic-plastic analysis All different modes of failure are addressed Fatigue exemption criteria is the same (except for heads with a knuckle), but in different format Ratcheting rules expanded
PART 11
FATIGUE ANALYSIS
Part 11 - 1
FATIGUE ANALYSIS
If the design does not meet the fatigue exemption rules of AD-160, a fatigue analysis, in accordance with Appendix 5 must be performed. Fatigue curves are based on strain cycling data. Plotted values are equivalent elastic stresses The curves are based on margins of 2 on stress amplitude and 20 on the number of cycles. But these factors, in addition to providing safety margins, are to account for a number of other factors such as size effects, surface roughness, environmental effects, etc. (Some believe these factors do not provide adequate safety margins) Fatigue rules use Miners linear damage theory. The order of various cycles are not taken into consideration The curves have been adjusted to conservatively account fro mean stresses. Therefore, mean (non-cyclic)stresses do no have to included in fatigue analysis. For meeting the limits on primary plus secondary stress and primary plus secondary plus peak stress. The range of stress intensity must be calculated When the principal stress direction does not change (no shear stresses), the stress intensity range is calculated as follows: Pick a number of points in time (various load conditions), at which the stresses may have an extreme value (based on judgment
Part 11 - 2
Part 11 - 3
Part 11 - 4
NEW DIV. 2
The equivalent elastic fatigue analysis has been brought forward Rules have been provided for elastic-plastic fatigue analyses The Master Curve concept for fatigue analysis has been proposed by Pingsho Dong. But, very controversial and will probably not get into original issue The Master Curve is generated from test data and requires calculation of structural stresses only (not local peak stresses). One curve may be used for all joint details and for all materials Guidelines provided for finite element analyses Equations provided for fatigue curves, allowing easy programming Fracture mechanics evaluation also allowed, using the procedures of API-579 Stress indices of the old Code (Fatigue Strength Reduction Factors based on FEA at nozzle intersections) are reproduced in an Annex