Asme Section Viii Div.1 4h362t
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PRESSURE VESSEL CODE ASME SECTION VIII DIVISION 1
Introduction to ASME Codes (Section I to Section XII)
2004 ASME BOILER & PRESSURE VESSEL CODE SECTIONS I. II.
Rules for construction of Power Boilers Materials
III.
Part A - Ferrous Material Specifications Part B - Nonferrous Material Specifications Part C - Specifications for Welding Rods, Electrodes, and Filler Metals Part D – Properties (Customary), Properties (Metric) Subsection NCA – General Requirement for Division 1 and Division 2
Division 1 Subsection Subsection Subsection Subsection Subsection Subsection Subsection
NB – Class 1 Components NC – Class 2 Components ND – Class 3 Components NE – Class MC Components NF – s NG – Core Structures NH – Class 1 Components in Elevated Temperature Service Appendices Division 2 – Code for Concrete Containments Division 3 – Containments for Transport and Storage of Spent Nuclear Fuel and High Level Radioactive Material and Waste
2004 ASME BOILER & PRESSURE VESSEL CODE (Continued) IV V VI VII VIII
IX X XI XII
Rules for Construction of Heating Boilers Nondestructive Examination Recommended Rules for Care & Operation of Heating Boilers Recommended Guidelines for the Care of Power Boilers Rules for Construction of PRESSURE VESSELS DIVISION-1 DIVISION-2 – Alternative Rules DIVISION-3 – Alternative Rules for Construction of High Pressure Vessels Welding & Brazing Qualifications. Fiber-Reinforced Plastic Pressure Vessels Rules for Inservice Inspection of Nuclear Power Plant Components Rules for Construction and Continued Service of Transport Tanks.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Pressure Vessel Rules Published Pressure Limits
Organisation
Design Factor
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
<1940
1968
1997
Normally up to 3000 psig
No limits either way, usually 600+ psig
No limits, Normally from 10,000 psig
General, Construction Type & Material U, UG, UW, UF, UB, UCS, UNF, UCI, UCD, UHT, ULT
General, Material, Design, Fabrication and others AG, AM, AD, AF, AR, AI, AT, AS
Design Factor 3.5 on tensile (4 used previously) and other yield and temperature considerations
Design Factor 3 on tensile (lower factor under reviewed) and other yield and temperature considerations
Similar to Division 2 KG, KM, KD, KF, KR, KE, KT, KS
Yield based with reduction factor for yield to tensile ratio less than 0.7
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1
Section VIII Div.2
Section VIII Div.3
“Unfired” Pressure Vessel Rules
Alternative Rules
Alternative Rules for High Pressure
Design Rules
Membrane-Maximum stress Generally Elastic analysis Very detailed design rules with Quality (t efficiency) Factors. Little stress analysis required, pure membrane without consideration of discontinuities controlling stress concentration to a safety factor of 3.5 or higher
Shell of Revolution – Max. Shear stress Generally Elastic Analysis Membrane + Bending. Fairly detailed design rules. In addition to the design rules, discontinuities, fatigue and other stress analysis considerations may be required unless exempted and guidance provided for in Appendix 4, 5 and 6
Maximum shear stress Elastic/plastic Analysis and more. Some design rules provided; Fatigue analysis required, Fracture mechanics evaluation required unless proven leakbefore-burst, Residual stresses become significant and may be positive factors
Experimental stress Analysis
Normally not required
Introduced and may be required
Experimental design verification but may be exempted
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Material and Impact Testing
Few restriction on materials; Impact required unless exempted, extensive exemptions under UG20, UCS 66/67
More restriction of materials; impact required in general with similar rules as Division 1
Even more restrictive than Division 2 with different requirements. Fracture toughness testing requirement for fracture mechanics evaluation crack tip opening displacement (CTOD) testing and establishment of Klc and/or Jlc values
NDE Requirements
NDE requirements may be exempted through increased design factor
More stringent NDE requirements, extensive use of RT, as well as UT, MT and PT.
Even more restrictive than Division 2, UT used for all butt welds, RT otherwise, extensive use of PT and MT
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Welding and Fabrication
Different types with butt welds and others
Extensive use/requirement of butt welds and full penetration welds including non pressure attachment welds
Butt welds and extensive use of other construction methods such as threaded, layered, wire-wound, interlocking stripwound and others
or designated agent to provide specifications (see U-2(a))
’s Design Specification with detailed design requirements (see AG-301.1) include AD 160 for fatigue evaluation
’s Design specification with more specific details (see KG-310) including contained fluid data, etc. with useful operation life expected and others. Designer defined.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Manufacturer
Manufacturer to declare compliance in data report
Manufacturer’s Design Report certifying design specification and code compliance in addition to data report
Same as Division 2
Professional Engineer Certification
Normally not required
Professional Engineers’ Certification of ’s Design Specification as well as Manufacturer’s Design report Professional Engineer shall be experienced in pressure vessel design
Same as Division 2 but the Professional Engineer shall be in high-pressure vessel design and shall not sign for both and Manufacturer.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Safety Relief Valve
Pressure
UV Stamp
Section VIII Div.2 Alternative Rules
UV Stamp
Section VIII Div.3 Alternative Rules for High Pressure
UV3 Stamp
Code Stamp and Marking
U Stamp with Addition marking including W, P, RES, L, UB, DF, RT, HT
U2 Stamp with Additional marking including HT
U3 Stamp with additional marking denoting construction type, HT, PS, WL, M, F, W, UQT, WW, SW
Hydrostatic Test
1.3 (was 1.5 before the use of the 3.5 Design factor in the 1999 Addenda)
1.25
1.25
Structure of ASME Section VIII Div-1 ASME SEC –VIII DIV- 1 Consists of: Introduction -U Subsection A -General Requirements (Part UG) Subsection B -Specific Requirements - Methods (Parts UW, UF, UB) Subsection C -Specific Requirements - Materials (Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT, ULW, ULT, UHX) Mandatory Appendices -Appendix 1 to 33 Non Mandatory Appendices -Appendix A, C, … FF, GG (20 nos.)
Subsection A -General Requirements Part UG : General Requirements for all Methods of Construction and all Materials Materials UG-4 to UG-15 Design UG-16 to UG-35 Openings and Reinforcement UG-36 to UG-46 Braced and stayed surfaces UG-47 to UG-50 Ligaments UG-53 to UG-55 Fabrication UG-75 to UG-85 Inspection and Tests UG-90 to UG-103 Markings and Reports UG-115 to UG-120 Pressure Relief Devices UG-125 to UG-137
Subsection B -Requirements pertaining to methods of Fabrication of Pressure Vessels Part UW : Requirements for Pressure vessels fabricated by Welding General Materials Design Fabrication Inspection and Tests Markings and Reports Pressure Relief Devices
UW-1 to UW-3 UW-5 UW-8 to UW-21 UW-26 to UW-42 UW-46 to UW-53 UW-60 UW-65
Part UF : Requirements for Pressure vessel fabricated by Forging Part UB : Requirements for Pressure vessel fabricated by Brazing
Subsection C -Requirements pertaining to Classes of Materials Part UCS – Requirements for Pressure Vessels Constructed of Carbon and Low Alloy Steels Part UNF – Requirements for Pressure Vessels Constructed of Non Ferrous Materials Part UHA – Requirements for Pressure Vessels Constructed of High Alloy Steel Part UCI – Requirements for Pressure Vessels Constructed of Cast Iron Part UCL – Requirements for Welded Pressure Vessels Constructed of Material non corrosion resistant, Integral Cladding, Weld Metal Overlay, Cladding or with Applied Linings Part UCD – Requirements for Pressure Vessels Constructed of Cast Ductile Iron
pertaining to Classes of Materials(Continued) Part UHT – Requirements for Pressure Vessels Constructed of Ferritic Steels with Tensile Properties enhanced by Heat Treatment Part ULW – Requirements for Pressure Vessels Constructed of Layered Construction Part ULT – Alternative Rules for Pressure Vessels Constructed of Material having higher allowable stresses at lower temperatures Part UHX – Rules for Shell and Tube Heat Exchangers
Mandatory Appendices Appendix 1 Appendix 2 Appendix 3 Appendix 4
Supplementary Design Formulas Rules for Bolted Flange Connections With Ring Type Gaskets Definitions Rounded Indications Charts Acceptance Standard for Radiographically Determined Rounded
Indication Appendix ts Appendix Appendix Appendix Appendix Appendix Appendix Appendix
5
in Welds Flanged and Flued or Flanged Only Expansion
6 7 8 9 10 11 12
Methods for Magnetic Particle Examination(MT) Examination of Steel Castings Methods for Liquid Penetrate Examination (PT) Jacketed Vessels Quality Control System Capacity Conversion for Safety Valves Ultrasonic Examination of Welds (UT)
Mandatory Appendices Appendix 13 Appendix 14 Appendix 16 Appendix 17 Appendix 18 Appendix 19 Appendix 20 Appendix 21 Appendix 22 Appendix 23
Vessels of Noncircular Cross Section Integral Flat Heads With a Large, Single, Circular, Centrally Located Openings Submittal of Technical Inquiries to the Boiler and Pressure Vessel Committee Dimpled or Embossed Assemblies Adhesive Attachments of Name Plates Electrically Heated or Gas Fired Jacketed Steam Kettles Hubs Machined From Plates Jacketed Vessels Constructed of Work-Hardened Nickel Integrally Forged Vessels External Pressure Design of Copper, Copper Alloy, Titanium Alloy condenser and Heat Exchanger Tubes With Integral Fins
(continued)
Mandatory Appendices Appendix 24 Appendix 25
Appendix 26 Appendix 27 Appendix 28 Appendix 30 Appendix 31 Appendix 32 Appendix 33
(continued)
Design Rules for Clamp Connections Acceptance of Testing Laboratories and Authorized Observer for Capacity Certification of Pressure Relief Valves Pressure Vessels and Heat Exchangers Expansion ts Alternative Requirements for Glass-Lined Vessels Alternative Corner Weld t Detail for Box Headers for Air Cooled Heat Exchangers Rules for Drilled Holes Not Penetrating to Vessel Wall Rules for Cr-Mo steels With Additional Requirements for Welding and Heat Treatment Local Thin Areas in Cylindrical Shell and in Spherical Segments of Shells Standard Units for Use in Equations
Non mandatory Appendices Appendix A Appendix C Appendix D Structures Appendix E Appendix F Appendix G Appendix H Appendix K Appendix L Formulas Appendix M
Basis for Establishing Allowable Loads for Tube-toTubesheet ts Suggested Methods for Obtaining the Operating Temperature of Vessel Walls in Service Suggested Good Practice Regarding Internal Suggested Good Practice Regarding Corrosion Allowance Suggested Good Practice Regarding Linings Suggested Good Practice Regarding Piping Reactions and Design of s and Attachments Guidance to Accommodate Loading Produced by Deflagration Sectioning of Welded ts Examples Illustrating the Application of Code and Rules Installation and Operation
Non mandatory Appendices Appendix P Appendix R Appendix S Connections Appendix T Appendix W Appendix Y Appendix DD Appendix EE Appendix FF Appendix GG Units
(Continued)
Basic for Establishing Allowable Stress Values Preheating Design Considerations for Bolted Flange Temperature Protection Guide for Preparing Manufacturer’s Data Reports Flat Faced Flanges With Metal-to-Metal Outside the Bolt Circle Guide to Information Appearing on Certificate of Authorization (See Fig. DD-1) Half-Pipe Jackets Guide For the Design and Operation of QuickActuating (Quick-Opening) Closures Guidance for the Use of U.S.Customary and SI in the ASME Boiler and Pressure Code
INTERNAL PRESSURE DESIGN
Thickness of shells under Internal Pressure(UG-27) All dimensions in code are in corroded condition Provision for any loading Symbols : t = min. required thickness P = internal design pressure R = inside radius of shell S = max. allowable stress value (Sec II D) E = t efficiency (UW-12)
Cylindrical Shells (UG-27) 1.
Circumferential Stress (Longitudinal ts). t ≤ 0.5R,
PR t SE 0.6 P
P ≤ 0.385SE or
SEt P R 0.6t
2. Longitudinal Stress (Circumferential ts). t ≤ 0.5R,
PR t 2 SE 0.4 P
P ≤ 1.25SE or
2SEt P R 0.4t
Relevant when additional loadings are applicable
Thickness Calculation based on Outside diameter(Appendix 1-1) 1.
Circumferential Stress (Longitudinal ts). PR0 t SE 0.4 P
or
SEt P R0 0.4t
Where R0= outside radius of shell
2. Longitudinal Stress (Circumferential ts). PR0 t 2 SE 1.4 P
or
2 SEt P R0 1.4t
Spherical Shells (UG-27) Stresses in biaxial direction are same. t ≤ 0.356R,
PR t 2SE 0.2 P
P ≤0.665SE
or
2SEt P R 0.2t
Based on Outside Diameter (Appendix 1-1)
PR0 t 2SE 0.8P
or
2SEt P R0 0.8t
Where R0= outside radius of shell
Conical Shells Sections (UG-32) α = one half of the included (apex) angle of the cone (α<30º) D = inside diameter at point under consideration. Do = outside diameter at point under consideration(Appendix 1-4)
1. Circumferential Stress (Longitudinal ts) PD 2 SEt cos t P 2 cos ( SE 0.6 P) D 1.2t cos or 2 SEt cos PD0 P t D0 0.8t cos 2 cos ( SE 0.4 P ) or
Conical Shells Sections (UG-32) (Continued…)
2. Longitudinal Stress (Circumferential ts). PD t 4 cos ( SE 0.4 P ) PD0 t 4 cos ( SE 1.4 P )
or
4 SEt cos P D 0.8t cos
or
4 SEt cos P D0 2.8t cos
Formed Heads UG-32 –Formed Heads -Ellipsoidal -Torispherical -Hemispherical -Conical -Toriconical
Formed Heads
(Continued…)
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
t = minimum required thickness of head after forming P = internal design pressure D = inside diameter of the head skirt, or inside length of the major axis pf an ellipsoidal head S = max. allowable stress value in tension (Sec II D) E = lowest efficiency of any t in the head D0 = outside diameter of the head skirt, or outside length of the major axis of an ellipsoidal head h = the inside depth of the ellipsoidal head measured from the tangent line K = a factor in formulas for ellipsoidal heads depending on the head proportion D/2h
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
Table 1-4.1 Values of factor K (Use nearest Values of D/2h; Interpolation Unnecessary)
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
(Continued…)
t/L ≥ 0.002 Inside Depth = ¼ Inside diameter
PD t 2SE 0.2 P
or
2 SEt P D 0.2t
2:1 ellipsoidal HeadApproximation: Knuckle Radius = 0.17D Spherical Radius = 0.90D
Ellipsoidal Heads (UG-32) (Appendix 1-4) (Continued…) t/L ≥ 0.002
PDK t 2SE 0.2 P PD0 K t 2 SE 2 P( K 0.1)
OR
2 SEt P KD 0.2t
OR
2SEt P KD0 2t ( K 0.1)
1 D K 2 6 2h 2
Where
Torispherical Heads (UG-32)
(Appendix 1-4)
t = min. required thickness of head after forming P = internal design pressure D = inside diameter of the head skirt, S = max. allowable stress value in tension (Sec II D) E = lowest efficiency of any t in the head r = Inside Knuckle Radius L = inside spherical or crown radius Do = outside diameter of the head skirt, L0 = outside spherical or Crown radius M = a factor in formulas for Torispherical heads depending on the head proportion L/r
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
Table 1-4.2 Values of factor M (Use nearest Values of L/r; Interpolation Unnecessary)
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
t/L ≥ 0.002 Knuckle radius = 6% of inside crown radius Inside crown radius = outside diameter of skirt
0.885PL t SE 0.1P
or
SEt P 0.885L 0.1t
Where minimum tensile strength > 70,000 psi
Allowable Stress Value at Temprature S 20000 Allowable Stress Value at Room Temprature
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
PLM t 2 SE 0.2 P
PL0 M t 2 SE P( M 0.2)
Where
or
or
1 L M 3 4 r
2 SEt P LM 0.2t 2 SEt P ML0 t ( M 0.2)
Hemispherical Heads (UG-32) t ≤ 0.356L,
(Appendix 1-4)
P≤ 0.665SE
PL t 2 SE 0.2 P
or
L = inside spherical radius
2 SEt P L 0.2t
Sample Problem Design of Vertical Cylindrical Pressure Vessel for Internal Pressure Design Data Design pressure Design temperature Radiography Corrosion Allowance Material Inside Diameter Tan to Tan length Liquid head/ density
:12 Kg/cm²g : 250º C : Spot : 3 mm : SA 515 Gr. 70 : 2500 mm : 10000 mm : 4000mm from bottom tan line/ 1200 Kg/cu.m
Calculate the Following : Shell Thickness Thickness of 2:1 ellipsoidal dished head Thickness of Torispherical head with crown radius 2500 mm and Knuckle radius 300 mm Thickness of Hemispherical head
Sample Problem
(Continued…)
Shell Thickness as per UG-27[c] (Solution) Design pressure P=12 Kg/cm²g = 0.12 kg/mm² Corroded Inside radius R=1250mm Corrosion Allowance C= 3 mm t Efficiency E=0.85 Allowable stress S= S for SA 515 Gr.70 at 482ºF (250ºC) is 20000 psi (As per Section II D) Now, 1 pound = 0.45359237 Kg
20 103 0.4536 2 S 14 . 062 Kg / mm 2 ( 25 . 4 ) Total Pressure at Bottom Tan line P = Internal Pressure + Liquid Pressure Liquid Pressure = ρ*g*h = 1200 x 9.81 x 4 = 47088 N/m² kg m =47088/9.81x1000000 Kg/mm² 47088 2 m sec 2 = 0.0048 kg/mm² so, Total Design Pressure P= 0.12+0.0048 = 0.1248 kg/mm²
Sample Problem
(Continued…)
Required Thickness for Circumferential Stress P= 0.1248 ≤ 0.385SE=4.6 kg/mm² (So condition Satisfied) PR 0.1248 1253
t
SE 0.6 P
C
(14.062 0.85 0.6 0.1248)
3
13.13 3 16.13mm Required Thickness for Longitudinal Stress P= 0.1248 ≤ 1.25SE=14.94 kg/mm² (So condition PR 0.1248 1253 Satisfied) t C 3
2 SE 0.4 P
(2 14.062 0.85 0.4 0.1248) 6.512 3 9.512mm
Sample Problem 2:1 Ellipsoidal head as Design pressure Corroded Inside radius Corrosion Allowance t Efficiency Allowable stress (Sec-IID)
Inside Depth
h
(Continued…)
per UG-32 (Solution) P=0.12 Kg/mm² R=1253mm C= 3 mm E=0.85 S= 14.062 kg/mm² at 482°F
D 2500 3 3 628mm 4 4
1 D 1 2506 K 2 2 6 2h 6 2 628 1mm 2
Factor K
2
Sample Problem
(Continued…)
Required Thickness at top
PDK t C 2 SE 0.2 P 0.12 2506 1 3 2 14.062 0.85 0.2 0.12 15.59mm
Sample Problem
(Continued…)
Torispherical head as per UG-32 (Solution) Design pressure P=0.12 Kg/mm² Corroded Inside Diameter D=2506mm Corrosion Allowance C= 3 mm t Efficiency E=0.85 Allowable stress S= 14.062 kg/mm² at 482°F (Sec-IID)
Corroded Crown Radius Corroded Knuckle Radius
L≈ D (2500 mm) r>6% of Inside Diameter (consider r=300 mm)
1 L 1 2500 3 M 3 4 r 4 300 Factor M
1.47 mm
Sample Problem
(Continued…)
Torispherical head as per UG-32
(Solution) continued… Required thickness at top
PLM 0.12 2500 1.47 t C 3 2 SE 0.2 P 2 14.062 0.85 0.2 0.12 21.47 mm
Sample Problem
(Continued…)
Hemispherical head as per UG-32 (Solution) Design pressure at bottom P=12+[5.25*1.2/10]=0.1263 Kg/mm² Corroded Inside Diameter D=2506mm Corrosion Allowance t Efficiency Allowable stress (Sec-IID) Corroded Crown Radius
C= 3 mm E=0.85 S= 14.062 kg/mm² at 482°F L=1253 (D/2)
Required thickness
t
PL 0.1263 1253 C 3 2 SE 0.2 P 2 14.062 0.85 0.2 0.1263 9.63mm
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
ASME procedures for cylindrical shells, heads, conical sections. Function of: – Material – Diameter – Unstiffened length – Temperature – Thickness
Subsection B Requirements pertaining to methods of Fabrication of Pressure Vessels Part UW : Requirements for Pressure vessels fabricated by Welding General Materials Design Fabrication Inspection and Tests Markings and Reports Pressure Relief Devices
UW-1 to UW-3 UW-5 UW-8 to UW-21 UW-26 to UW-42 UW-46 to UW-53 UW-60 UW-65
Part UF : Requirements for Pressure vessel fabricated by Forging Part UB : Requirements for Pressure vessel fabricated by Brazing
Part UW UW-2 - Service Restrictions (a) Lethal Service (b) Low Temperature Service (c) Steam Service (d) Direct fired Service (a) Lethal Service
-
Vessels with lethal substances, all butt welds shall be full radiographed.
CS/LAS vessels shall be post weld heat treated. - It shall be responsibility of to specify – if vessel is for lethal service. - All “category A” ts shall be “type (1)” - All “category B & C” ts shall be “type (1) or (2)” - All “category D” shall be full penetration welds.
(b) Low Temperature Service -
All “category A” ts shall be “type (1)” All “category B” ts shall be “type (1) or (2)” All “category C” ts shall be full penetration welds. All “category D” shall be full penetration welds.
Part UW (Continued..) UW-2 - Service Restrictions (c) Unfired Steam Boilers - All “category A” shall be “type (1)” and “B” shall be “type (1) or (2)” - All butt welds shall be radiographed - CS/LAS vessels shall have PWHT
(d) Direct Fired Vessels - All “category A” shall be “type (1)” and “B” above 16mm thickness “type (1) or (2)” - CS above 16mm and LAS vessels shall have PWHT. - Parts with other than type (1) & (2) welds subjected to radiation. Design temperature shall be maximum surface metal temp.
Part UW (Continued..) UW-3 - Weld t Category - Categories – A, B, C and D - Category defines the location of a t in a vessel. - Used for specifying - type of t - degree of inspection - Based on service, material and thickness, special requirements are specified in code
Part UW (Continued..) UW-11 - Radiographic Examination (a) Full Radiography (1) All butt welds in shell & heads of vessels with lethal service. (2) All butt welds, where t>38 mm or exceeds lesser thickness specified elsewhere in code. - Categories B and C butt welds in nozzles that neither exceed 10” size nor 29 mm thickness, do not require radiography. (5) All category A and D butt welds with t efficiency [of full radiography] (a) Cat. A and B butt welds of vessel sections or heads shall be of type (1) or (2). (b) Cat. B or C butt welds (not including those in nozzles except as required above) which intersect Cat.A butt welds or connect seamless vessel sections or heads shall meet spot radiography requirement. (7) UT may be substituted for closing seam if RT is not possible.
Part UW (Continued..) UW-11 - Radiographic Examination (b) Spot Radiography - Butt weld ts of type (1) or (2) which are not required to be fully radiographed. -If spot radiography is specified for entire vessel, radiography is not required of Cat B and C butt welds in nozzles that exceed neither 10” size not 29 mm thickness (c) No Radiography - No radiography is required when vessel is designed for external pressure only or where t efficiency is as per table UW-12 (C)
Part UW (Continued..) UW-12 - t Efficiency - Values of E given in column (a) for fully radiographed butt ts. - When UW-11(a)(5) is not met, value of E will be as given in (b) - Value if E given in column (b) for spot radiographed butt ts. - Value if E given in column (c) for no radiography ts. - Seamless vessel sections/heads E = 1.0 when spot radiography requirements of UW11(a)(5)(b) are met. E = 0.85 when above is not met, or when Cat A or B welds are type 3, 4, 5 or 6.
Part UW (Continued..)
Part UW (Continued..)
Part UW (Continued..)
UW-13 Attachment Detail Heads Attached to Shells
Part UW (Continued..) UW-13 Attachment Detail
Heads Attached to Shells (continued..)
Part UW (Continued..) UW-13 Attachment Detail
Heads Attached to Shells (continued..)
Part UW (Continued..) UW-13 Attachment Detail
Attachments of Pressure Parts to flat plates
Part UW (Continued..) UW-13 Attachment Detail Attachments of Pressure Parts to flat plates (Continued..)
Part UW (Continued..) UW-13 Attachment Detail Pressure Parts with butt welded hubs
Part UW (Continued..) UW-16
Nozzle welded to shells
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Subsection C -Requirements pertaining to Classes of Materials
Part UCS Requirement for Pressure Vessels Constructed of Carbon Steel and Low Alloy Steels
Part UCS UCS-23 – Maximum Allowable Stress values: When design metal temp. is below -29°C, allowable stress value shall not exceed those given for 40 °C -
Part UCS (Continued…)
POST WELD HEAT TREATMENT UCS-56 – POST WELD HEAT TREATMENT (PWHT): OBJETCIVE: - TO REDUCE THE RESIDUAL STRESSES AT WELD & HAZ
- TO MODIFY THE MICRO-STRUCTURE (HAZ)
EFFECT: - SUSCETIBLITIES TO BRITTLE FAILURE DECREASES. - RESISTANCE TO STRESS CORROSION CRACKING INCREASES. - DIMENSIONAL STABILITIES INCREASES. PWHT PARAMETER - HEATING RATE
- SOAKING TEMPERATURE - COOLING RATE
Part UCS (Continued…) UCS-56 – PWHT
Part UCS (Continued…) UCS-56 – PWHT - Procedure - Temp. of furnace shall not exceed 800°F(425°) at the time of vessel placed in it. - Above 425°C, rate of heating shall not be more than 400°F (222°C)/hr, divided by max. metal thickness of shell or head in inches, but in no case more than 222°C/hr - Variation in temp. shall not be more than 250°F (139°C) within any 4.6m interval, during heating. - Variation in temp. shall not be more than 150°F(83°C) between highest and lowest temp. throughout the vessel during holding time. - No direct impingement of flame on the vessel (to control excessive oxidation). - Above 425°C, rate of cooling shall not be more than 500°F(278°C)/hr divided by max. metal thickness of shell or head in inches, in furnace, but in no case more than 278°C/hr. - From 800°F(425°C) vessel may be cooled in still air.
Part UCS (Continued…) UCS-56 – PWHT -General - Rate of heating and cooling need not be less than 100°F(38°C)/hr - Holding temp./holding time in excess of min. value may be used. - Intermediate PWHT need not confirm to table UCS-56 - Holding time need not be continuous. It may be addition of time of multiple PWHT cycles. - When P numbers are different, higher PWHT temperature shall be used. - When non pressure part is welded to pressure part, PWHT of pressure part shall control. -Exemptions given are not permitted when PWHT is a service requirement.
Part UCS (Continued…) Table UCS-56
Part UCS (Continued…) PWHT Requirements TABLE UCS-56
Part UCS (Continued…) PWHT Requirements TABLE UCS-56
Part UCS (Continued…) Table UCS-56.1
Part UCS (Continued…) UCS-57 -Radiographic Examination -when thickness exceeds given in table, radiography is required. -Thickness of thinner plate is considered.
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -Unless otherwise exempted - Impact testing is required for a combination of MDMT and thickness, which is below the curve in fig. UCS-66. - Above the curve the Impact Testing is not required.
Impact Test Exemption Curve
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -General Notes on Assignment of Materials to Curves: (a) Curve A applies to (1) All carbon and all low alloy steel plates, structural shapes, and bars not listed in Curve B, C and D below, (b) Curve B applies to : (1) SA-285 Grades A and B SA-515 Grade 60 SA-516 Grades 65 and 70 if no normalized (2) Except for cast steels, all materials of Curve A if produced to fine grain practice and normalized which are not listed in Curve C and D below, (3) all pipe, fittings, forgings and tubing not listed for Curve C and D below, (4) parts permitted under UG-11 shall be included in Curve B even when fabricated from plate that otherwise would be assigned to a different curve.
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -General Notes on Assignment of Materials to Curves (continued…) (c) Curve C applies to (1) SA-182 Grades 21 and 22 if normalized and tempered. SA-302 Grades C and D SA-336 F 21 and F 22 if normalized and tempered. SA-387 Grades 21 and 22 if normalized and tempered. SA-516 Grades 55 and 60 if not normalized. SA-533 Grades B and C (2) All material of Curve B if produced to fine grain practice and normalized and not listed for Curve D below. (d) Curve D applies to : SA-203 SA-508 Grade 1 SA-516 if normalized SA-537 Classes 1, 2 and 3
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -Coincident Ratio (UCS 66-1) where MDMT>-49°C) -When coincident ratio is less than 1, MDMT can be lower than desired above, in the procedure given in UCS-66.2 -When components are not stressed to allowable limit, MDMT can be lower. -Lower MDMT -When MDMT is between -48°C and -105°C and coincident ratio is less than 0.35, impact testing is not required. - If PWHT is performed when not required by code, for P1 material, MDMT can be lower by 17°C, even lower than -48°C - In all other cases when MDMT is lower than -48°C, impact testing is required.
Part UCS (Continued…) Reduction in MDMT Without Impact Testing
THANK YOU
Introduction to ASME Codes (Section I to Section XII)
2004 ASME BOILER & PRESSURE VESSEL CODE SECTIONS I. II.
Rules for construction of Power Boilers Materials
III.
Part A - Ferrous Material Specifications Part B - Nonferrous Material Specifications Part C - Specifications for Welding Rods, Electrodes, and Filler Metals Part D – Properties (Customary), Properties (Metric) Subsection NCA – General Requirement for Division 1 and Division 2
Division 1 Subsection Subsection Subsection Subsection Subsection Subsection Subsection
NB – Class 1 Components NC – Class 2 Components ND – Class 3 Components NE – Class MC Components NF – s NG – Core Structures NH – Class 1 Components in Elevated Temperature Service Appendices Division 2 – Code for Concrete Containments Division 3 – Containments for Transport and Storage of Spent Nuclear Fuel and High Level Radioactive Material and Waste
2004 ASME BOILER & PRESSURE VESSEL CODE (Continued) IV V VI VII VIII
IX X XI XII
Rules for Construction of Heating Boilers Nondestructive Examination Recommended Rules for Care & Operation of Heating Boilers Recommended Guidelines for the Care of Power Boilers Rules for Construction of PRESSURE VESSELS DIVISION-1 DIVISION-2 – Alternative Rules DIVISION-3 – Alternative Rules for Construction of High Pressure Vessels Welding & Brazing Qualifications. Fiber-Reinforced Plastic Pressure Vessels Rules for Inservice Inspection of Nuclear Power Plant Components Rules for Construction and Continued Service of Transport Tanks.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Pressure Vessel Rules Published Pressure Limits
Organisation
Design Factor
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
<1940
1968
1997
Normally up to 3000 psig
No limits either way, usually 600+ psig
No limits, Normally from 10,000 psig
General, Construction Type & Material U, UG, UW, UF, UB, UCS, UNF, UCI, UCD, UHT, ULT
General, Material, Design, Fabrication and others AG, AM, AD, AF, AR, AI, AT, AS
Design Factor 3.5 on tensile (4 used previously) and other yield and temperature considerations
Design Factor 3 on tensile (lower factor under reviewed) and other yield and temperature considerations
Similar to Division 2 KG, KM, KD, KF, KR, KE, KT, KS
Yield based with reduction factor for yield to tensile ratio less than 0.7
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1
Section VIII Div.2
Section VIII Div.3
“Unfired” Pressure Vessel Rules
Alternative Rules
Alternative Rules for High Pressure
Design Rules
Membrane-Maximum stress Generally Elastic analysis Very detailed design rules with Quality (t efficiency) Factors. Little stress analysis required, pure membrane without consideration of discontinuities controlling stress concentration to a safety factor of 3.5 or higher
Shell of Revolution – Max. Shear stress Generally Elastic Analysis Membrane + Bending. Fairly detailed design rules. In addition to the design rules, discontinuities, fatigue and other stress analysis considerations may be required unless exempted and guidance provided for in Appendix 4, 5 and 6
Maximum shear stress Elastic/plastic Analysis and more. Some design rules provided; Fatigue analysis required, Fracture mechanics evaluation required unless proven leakbefore-burst, Residual stresses become significant and may be positive factors
Experimental stress Analysis
Normally not required
Introduced and may be required
Experimental design verification but may be exempted
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Material and Impact Testing
Few restriction on materials; Impact required unless exempted, extensive exemptions under UG20, UCS 66/67
More restriction of materials; impact required in general with similar rules as Division 1
Even more restrictive than Division 2 with different requirements. Fracture toughness testing requirement for fracture mechanics evaluation crack tip opening displacement (CTOD) testing and establishment of Klc and/or Jlc values
NDE Requirements
NDE requirements may be exempted through increased design factor
More stringent NDE requirements, extensive use of RT, as well as UT, MT and PT.
Even more restrictive than Division 2, UT used for all butt welds, RT otherwise, extensive use of PT and MT
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Welding and Fabrication
Different types with butt welds and others
Extensive use/requirement of butt welds and full penetration welds including non pressure attachment welds
Butt welds and extensive use of other construction methods such as threaded, layered, wire-wound, interlocking stripwound and others
or designated agent to provide specifications (see U-2(a))
’s Design Specification with detailed design requirements (see AG-301.1) include AD 160 for fatigue evaluation
’s Design specification with more specific details (see KG-310) including contained fluid data, etc. with useful operation life expected and others. Designer defined.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Pressure
Section VIII Div.2
Section VIII Div.3
Alternative Rules
Alternative Rules for High Pressure
Manufacturer
Manufacturer to declare compliance in data report
Manufacturer’s Design Report certifying design specification and code compliance in addition to data report
Same as Division 2
Professional Engineer Certification
Normally not required
Professional Engineers’ Certification of ’s Design Specification as well as Manufacturer’s Design report Professional Engineer shall be experienced in pressure vessel design
Same as Division 2 but the Professional Engineer shall be in high-pressure vessel design and shall not sign for both and Manufacturer.
A Brief Discussion on ASME Section VIII Divisions 1 and 2 and The New Division 3 Section VIII Div.1 “Unfired” Vessel Rules
Safety Relief Valve
Pressure
UV Stamp
Section VIII Div.2 Alternative Rules
UV Stamp
Section VIII Div.3 Alternative Rules for High Pressure
UV3 Stamp
Code Stamp and Marking
U Stamp with Addition marking including W, P, RES, L, UB, DF, RT, HT
U2 Stamp with Additional marking including HT
U3 Stamp with additional marking denoting construction type, HT, PS, WL, M, F, W, UQT, WW, SW
Hydrostatic Test
1.3 (was 1.5 before the use of the 3.5 Design factor in the 1999 Addenda)
1.25
1.25
Structure of ASME Section VIII Div-1 ASME SEC –VIII DIV- 1 Consists of: Introduction -U Subsection A -General Requirements (Part UG) Subsection B -Specific Requirements - Methods (Parts UW, UF, UB) Subsection C -Specific Requirements - Materials (Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT, ULW, ULT, UHX) Mandatory Appendices -Appendix 1 to 33 Non Mandatory Appendices -Appendix A, C, … FF, GG (20 nos.)
Subsection A -General Requirements Part UG : General Requirements for all Methods of Construction and all Materials Materials UG-4 to UG-15 Design UG-16 to UG-35 Openings and Reinforcement UG-36 to UG-46 Braced and stayed surfaces UG-47 to UG-50 Ligaments UG-53 to UG-55 Fabrication UG-75 to UG-85 Inspection and Tests UG-90 to UG-103 Markings and Reports UG-115 to UG-120 Pressure Relief Devices UG-125 to UG-137
Subsection B -Requirements pertaining to methods of Fabrication of Pressure Vessels Part UW : Requirements for Pressure vessels fabricated by Welding General Materials Design Fabrication Inspection and Tests Markings and Reports Pressure Relief Devices
UW-1 to UW-3 UW-5 UW-8 to UW-21 UW-26 to UW-42 UW-46 to UW-53 UW-60 UW-65
Part UF : Requirements for Pressure vessel fabricated by Forging Part UB : Requirements for Pressure vessel fabricated by Brazing
Subsection C -Requirements pertaining to Classes of Materials Part UCS – Requirements for Pressure Vessels Constructed of Carbon and Low Alloy Steels Part UNF – Requirements for Pressure Vessels Constructed of Non Ferrous Materials Part UHA – Requirements for Pressure Vessels Constructed of High Alloy Steel Part UCI – Requirements for Pressure Vessels Constructed of Cast Iron Part UCL – Requirements for Welded Pressure Vessels Constructed of Material non corrosion resistant, Integral Cladding, Weld Metal Overlay, Cladding or with Applied Linings Part UCD – Requirements for Pressure Vessels Constructed of Cast Ductile Iron
pertaining to Classes of Materials(Continued) Part UHT – Requirements for Pressure Vessels Constructed of Ferritic Steels with Tensile Properties enhanced by Heat Treatment Part ULW – Requirements for Pressure Vessels Constructed of Layered Construction Part ULT – Alternative Rules for Pressure Vessels Constructed of Material having higher allowable stresses at lower temperatures Part UHX – Rules for Shell and Tube Heat Exchangers
Mandatory Appendices Appendix 1 Appendix 2 Appendix 3 Appendix 4
Supplementary Design Formulas Rules for Bolted Flange Connections With Ring Type Gaskets Definitions Rounded Indications Charts Acceptance Standard for Radiographically Determined Rounded
Indication Appendix ts Appendix Appendix Appendix Appendix Appendix Appendix Appendix
5
in Welds Flanged and Flued or Flanged Only Expansion
6 7 8 9 10 11 12
Methods for Magnetic Particle Examination(MT) Examination of Steel Castings Methods for Liquid Penetrate Examination (PT) Jacketed Vessels Quality Control System Capacity Conversion for Safety Valves Ultrasonic Examination of Welds (UT)
Mandatory Appendices Appendix 13 Appendix 14 Appendix 16 Appendix 17 Appendix 18 Appendix 19 Appendix 20 Appendix 21 Appendix 22 Appendix 23
Vessels of Noncircular Cross Section Integral Flat Heads With a Large, Single, Circular, Centrally Located Openings Submittal of Technical Inquiries to the Boiler and Pressure Vessel Committee Dimpled or Embossed Assemblies Adhesive Attachments of Name Plates Electrically Heated or Gas Fired Jacketed Steam Kettles Hubs Machined From Plates Jacketed Vessels Constructed of Work-Hardened Nickel Integrally Forged Vessels External Pressure Design of Copper, Copper Alloy, Titanium Alloy condenser and Heat Exchanger Tubes With Integral Fins
(continued)
Mandatory Appendices Appendix 24 Appendix 25
Appendix 26 Appendix 27 Appendix 28 Appendix 30 Appendix 31 Appendix 32 Appendix 33
(continued)
Design Rules for Clamp Connections Acceptance of Testing Laboratories and Authorized Observer for Capacity Certification of Pressure Relief Valves Pressure Vessels and Heat Exchangers Expansion ts Alternative Requirements for Glass-Lined Vessels Alternative Corner Weld t Detail for Box Headers for Air Cooled Heat Exchangers Rules for Drilled Holes Not Penetrating to Vessel Wall Rules for Cr-Mo steels With Additional Requirements for Welding and Heat Treatment Local Thin Areas in Cylindrical Shell and in Spherical Segments of Shells Standard Units for Use in Equations
Non mandatory Appendices Appendix A Appendix C Appendix D Structures Appendix E Appendix F Appendix G Appendix H Appendix K Appendix L Formulas Appendix M
Basis for Establishing Allowable Loads for Tube-toTubesheet ts Suggested Methods for Obtaining the Operating Temperature of Vessel Walls in Service Suggested Good Practice Regarding Internal Suggested Good Practice Regarding Corrosion Allowance Suggested Good Practice Regarding Linings Suggested Good Practice Regarding Piping Reactions and Design of s and Attachments Guidance to Accommodate Loading Produced by Deflagration Sectioning of Welded ts Examples Illustrating the Application of Code and Rules Installation and Operation
Non mandatory Appendices Appendix P Appendix R Appendix S Connections Appendix T Appendix W Appendix Y Appendix DD Appendix EE Appendix FF Appendix GG Units
(Continued)
Basic for Establishing Allowable Stress Values Preheating Design Considerations for Bolted Flange Temperature Protection Guide for Preparing Manufacturer’s Data Reports Flat Faced Flanges With Metal-to-Metal Outside the Bolt Circle Guide to Information Appearing on Certificate of Authorization (See Fig. DD-1) Half-Pipe Jackets Guide For the Design and Operation of QuickActuating (Quick-Opening) Closures Guidance for the Use of U.S.Customary and SI in the ASME Boiler and Pressure Code
INTERNAL PRESSURE DESIGN
Thickness of shells under Internal Pressure(UG-27) All dimensions in code are in corroded condition Provision for any loading Symbols : t = min. required thickness P = internal design pressure R = inside radius of shell S = max. allowable stress value (Sec II D) E = t efficiency (UW-12)
Cylindrical Shells (UG-27) 1.
Circumferential Stress (Longitudinal ts). t ≤ 0.5R,
PR t SE 0.6 P
P ≤ 0.385SE or
SEt P R 0.6t
2. Longitudinal Stress (Circumferential ts). t ≤ 0.5R,
PR t 2 SE 0.4 P
P ≤ 1.25SE or
2SEt P R 0.4t
Relevant when additional loadings are applicable
Thickness Calculation based on Outside diameter(Appendix 1-1) 1.
Circumferential Stress (Longitudinal ts). PR0 t SE 0.4 P
or
SEt P R0 0.4t
Where R0= outside radius of shell
2. Longitudinal Stress (Circumferential ts). PR0 t 2 SE 1.4 P
or
2 SEt P R0 1.4t
Spherical Shells (UG-27) Stresses in biaxial direction are same. t ≤ 0.356R,
PR t 2SE 0.2 P
P ≤0.665SE
or
2SEt P R 0.2t
Based on Outside Diameter (Appendix 1-1)
PR0 t 2SE 0.8P
or
2SEt P R0 0.8t
Where R0= outside radius of shell
Conical Shells Sections (UG-32) α = one half of the included (apex) angle of the cone (α<30º) D = inside diameter at point under consideration. Do = outside diameter at point under consideration(Appendix 1-4)
1. Circumferential Stress (Longitudinal ts) PD 2 SEt cos t P 2 cos ( SE 0.6 P) D 1.2t cos or 2 SEt cos PD0 P t D0 0.8t cos 2 cos ( SE 0.4 P ) or
Conical Shells Sections (UG-32) (Continued…)
2. Longitudinal Stress (Circumferential ts). PD t 4 cos ( SE 0.4 P ) PD0 t 4 cos ( SE 1.4 P )
or
4 SEt cos P D 0.8t cos
or
4 SEt cos P D0 2.8t cos
Formed Heads UG-32 –Formed Heads -Ellipsoidal -Torispherical -Hemispherical -Conical -Toriconical
Formed Heads
(Continued…)
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
t = minimum required thickness of head after forming P = internal design pressure D = inside diameter of the head skirt, or inside length of the major axis pf an ellipsoidal head S = max. allowable stress value in tension (Sec II D) E = lowest efficiency of any t in the head D0 = outside diameter of the head skirt, or outside length of the major axis of an ellipsoidal head h = the inside depth of the ellipsoidal head measured from the tangent line K = a factor in formulas for ellipsoidal heads depending on the head proportion D/2h
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
Table 1-4.1 Values of factor K (Use nearest Values of D/2h; Interpolation Unnecessary)
Ellipsoidal Heads (UG-32)
(Appendix 1-4)
(Continued…)
t/L ≥ 0.002 Inside Depth = ¼ Inside diameter
PD t 2SE 0.2 P
or
2 SEt P D 0.2t
2:1 ellipsoidal HeadApproximation: Knuckle Radius = 0.17D Spherical Radius = 0.90D
Ellipsoidal Heads (UG-32) (Appendix 1-4) (Continued…) t/L ≥ 0.002
PDK t 2SE 0.2 P PD0 K t 2 SE 2 P( K 0.1)
OR
2 SEt P KD 0.2t
OR
2SEt P KD0 2t ( K 0.1)
1 D K 2 6 2h 2
Where
Torispherical Heads (UG-32)
(Appendix 1-4)
t = min. required thickness of head after forming P = internal design pressure D = inside diameter of the head skirt, S = max. allowable stress value in tension (Sec II D) E = lowest efficiency of any t in the head r = Inside Knuckle Radius L = inside spherical or crown radius Do = outside diameter of the head skirt, L0 = outside spherical or Crown radius M = a factor in formulas for Torispherical heads depending on the head proportion L/r
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
Table 1-4.2 Values of factor M (Use nearest Values of L/r; Interpolation Unnecessary)
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
t/L ≥ 0.002 Knuckle radius = 6% of inside crown radius Inside crown radius = outside diameter of skirt
0.885PL t SE 0.1P
or
SEt P 0.885L 0.1t
Where minimum tensile strength > 70,000 psi
Allowable Stress Value at Temprature S 20000 Allowable Stress Value at Room Temprature
Torispherical Heads (UG-32)
(Appendix 1-4)
(Continued…)
PLM t 2 SE 0.2 P
PL0 M t 2 SE P( M 0.2)
Where
or
or
1 L M 3 4 r
2 SEt P LM 0.2t 2 SEt P ML0 t ( M 0.2)
Hemispherical Heads (UG-32) t ≤ 0.356L,
(Appendix 1-4)
P≤ 0.665SE
PL t 2 SE 0.2 P
or
L = inside spherical radius
2 SEt P L 0.2t
Sample Problem Design of Vertical Cylindrical Pressure Vessel for Internal Pressure Design Data Design pressure Design temperature Radiography Corrosion Allowance Material Inside Diameter Tan to Tan length Liquid head/ density
:12 Kg/cm²g : 250º C : Spot : 3 mm : SA 515 Gr. 70 : 2500 mm : 10000 mm : 4000mm from bottom tan line/ 1200 Kg/cu.m
Calculate the Following : Shell Thickness Thickness of 2:1 ellipsoidal dished head Thickness of Torispherical head with crown radius 2500 mm and Knuckle radius 300 mm Thickness of Hemispherical head
Sample Problem
(Continued…)
Shell Thickness as per UG-27[c] (Solution) Design pressure P=12 Kg/cm²g = 0.12 kg/mm² Corroded Inside radius R=1250mm Corrosion Allowance C= 3 mm t Efficiency E=0.85 Allowable stress S= S for SA 515 Gr.70 at 482ºF (250ºC) is 20000 psi (As per Section II D) Now, 1 pound = 0.45359237 Kg
20 103 0.4536 2 S 14 . 062 Kg / mm 2 ( 25 . 4 ) Total Pressure at Bottom Tan line P = Internal Pressure + Liquid Pressure Liquid Pressure = ρ*g*h = 1200 x 9.81 x 4 = 47088 N/m² kg m =47088/9.81x1000000 Kg/mm² 47088 2 m sec 2 = 0.0048 kg/mm² so, Total Design Pressure P= 0.12+0.0048 = 0.1248 kg/mm²
Sample Problem
(Continued…)
Required Thickness for Circumferential Stress P= 0.1248 ≤ 0.385SE=4.6 kg/mm² (So condition Satisfied) PR 0.1248 1253
t
SE 0.6 P
C
(14.062 0.85 0.6 0.1248)
3
13.13 3 16.13mm Required Thickness for Longitudinal Stress P= 0.1248 ≤ 1.25SE=14.94 kg/mm² (So condition PR 0.1248 1253 Satisfied) t C 3
2 SE 0.4 P
(2 14.062 0.85 0.4 0.1248) 6.512 3 9.512mm
Sample Problem 2:1 Ellipsoidal head as Design pressure Corroded Inside radius Corrosion Allowance t Efficiency Allowable stress (Sec-IID)
Inside Depth
h
(Continued…)
per UG-32 (Solution) P=0.12 Kg/mm² R=1253mm C= 3 mm E=0.85 S= 14.062 kg/mm² at 482°F
D 2500 3 3 628mm 4 4
1 D 1 2506 K 2 2 6 2h 6 2 628 1mm 2
Factor K
2
Sample Problem
(Continued…)
Required Thickness at top
PDK t C 2 SE 0.2 P 0.12 2506 1 3 2 14.062 0.85 0.2 0.12 15.59mm
Sample Problem
(Continued…)
Torispherical head as per UG-32 (Solution) Design pressure P=0.12 Kg/mm² Corroded Inside Diameter D=2506mm Corrosion Allowance C= 3 mm t Efficiency E=0.85 Allowable stress S= 14.062 kg/mm² at 482°F (Sec-IID)
Corroded Crown Radius Corroded Knuckle Radius
L≈ D (2500 mm) r>6% of Inside Diameter (consider r=300 mm)
1 L 1 2500 3 M 3 4 r 4 300 Factor M
1.47 mm
Sample Problem
(Continued…)
Torispherical head as per UG-32
(Solution) continued… Required thickness at top
PLM 0.12 2500 1.47 t C 3 2 SE 0.2 P 2 14.062 0.85 0.2 0.12 21.47 mm
Sample Problem
(Continued…)
Hemispherical head as per UG-32 (Solution) Design pressure at bottom P=12+[5.25*1.2/10]=0.1263 Kg/mm² Corroded Inside Diameter D=2506mm Corrosion Allowance t Efficiency Allowable stress (Sec-IID) Corroded Crown Radius
C= 3 mm E=0.85 S= 14.062 kg/mm² at 482°F L=1253 (D/2)
Required thickness
t
PL 0.1263 1253 C 3 2 SE 0.2 P 2 14.062 0.85 0.2 0.1263 9.63mm
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
ASME procedures for cylindrical shells, heads, conical sections. Function of: – Material – Diameter – Unstiffened length – Temperature – Thickness
Subsection B Requirements pertaining to methods of Fabrication of Pressure Vessels Part UW : Requirements for Pressure vessels fabricated by Welding General Materials Design Fabrication Inspection and Tests Markings and Reports Pressure Relief Devices
UW-1 to UW-3 UW-5 UW-8 to UW-21 UW-26 to UW-42 UW-46 to UW-53 UW-60 UW-65
Part UF : Requirements for Pressure vessel fabricated by Forging Part UB : Requirements for Pressure vessel fabricated by Brazing
Part UW UW-2 - Service Restrictions (a) Lethal Service (b) Low Temperature Service (c) Steam Service (d) Direct fired Service (a) Lethal Service
-
Vessels with lethal substances, all butt welds shall be full radiographed.
CS/LAS vessels shall be post weld heat treated. - It shall be responsibility of to specify – if vessel is for lethal service. - All “category A” ts shall be “type (1)” - All “category B & C” ts shall be “type (1) or (2)” - All “category D” shall be full penetration welds.
(b) Low Temperature Service -
All “category A” ts shall be “type (1)” All “category B” ts shall be “type (1) or (2)” All “category C” ts shall be full penetration welds. All “category D” shall be full penetration welds.
Part UW (Continued..) UW-2 - Service Restrictions (c) Unfired Steam Boilers - All “category A” shall be “type (1)” and “B” shall be “type (1) or (2)” - All butt welds shall be radiographed - CS/LAS vessels shall have PWHT
(d) Direct Fired Vessels - All “category A” shall be “type (1)” and “B” above 16mm thickness “type (1) or (2)” - CS above 16mm and LAS vessels shall have PWHT. - Parts with other than type (1) & (2) welds subjected to radiation. Design temperature shall be maximum surface metal temp.
Part UW (Continued..) UW-3 - Weld t Category - Categories – A, B, C and D - Category defines the location of a t in a vessel. - Used for specifying - type of t - degree of inspection - Based on service, material and thickness, special requirements are specified in code
Part UW (Continued..) UW-11 - Radiographic Examination (a) Full Radiography (1) All butt welds in shell & heads of vessels with lethal service. (2) All butt welds, where t>38 mm or exceeds lesser thickness specified elsewhere in code. - Categories B and C butt welds in nozzles that neither exceed 10” size nor 29 mm thickness, do not require radiography. (5) All category A and D butt welds with t efficiency [of full radiography] (a) Cat. A and B butt welds of vessel sections or heads shall be of type (1) or (2). (b) Cat. B or C butt welds (not including those in nozzles except as required above) which intersect Cat.A butt welds or connect seamless vessel sections or heads shall meet spot radiography requirement. (7) UT may be substituted for closing seam if RT is not possible.
Part UW (Continued..) UW-11 - Radiographic Examination (b) Spot Radiography - Butt weld ts of type (1) or (2) which are not required to be fully radiographed. -If spot radiography is specified for entire vessel, radiography is not required of Cat B and C butt welds in nozzles that exceed neither 10” size not 29 mm thickness (c) No Radiography - No radiography is required when vessel is designed for external pressure only or where t efficiency is as per table UW-12 (C)
Part UW (Continued..) UW-12 - t Efficiency - Values of E given in column (a) for fully radiographed butt ts. - When UW-11(a)(5) is not met, value of E will be as given in (b) - Value if E given in column (b) for spot radiographed butt ts. - Value if E given in column (c) for no radiography ts. - Seamless vessel sections/heads E = 1.0 when spot radiography requirements of UW11(a)(5)(b) are met. E = 0.85 when above is not met, or when Cat A or B welds are type 3, 4, 5 or 6.
Part UW (Continued..)
Part UW (Continued..)
Part UW (Continued..)
UW-13 Attachment Detail Heads Attached to Shells
Part UW (Continued..) UW-13 Attachment Detail
Heads Attached to Shells (continued..)
Part UW (Continued..) UW-13 Attachment Detail
Heads Attached to Shells (continued..)
Part UW (Continued..) UW-13 Attachment Detail
Attachments of Pressure Parts to flat plates
Part UW (Continued..) UW-13 Attachment Detail Attachments of Pressure Parts to flat plates (Continued..)
Part UW (Continued..) UW-13 Attachment Detail Pressure Parts with butt welded hubs
Part UW (Continued..) UW-16
Nozzle welded to shells
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Part UW (Continued..) UW-16
Nozzle welded to shells (continued)
Subsection C -Requirements pertaining to Classes of Materials
Part UCS Requirement for Pressure Vessels Constructed of Carbon Steel and Low Alloy Steels
Part UCS UCS-23 – Maximum Allowable Stress values: When design metal temp. is below -29°C, allowable stress value shall not exceed those given for 40 °C -
Part UCS (Continued…)
POST WELD HEAT TREATMENT UCS-56 – POST WELD HEAT TREATMENT (PWHT): OBJETCIVE: - TO REDUCE THE RESIDUAL STRESSES AT WELD & HAZ
- TO MODIFY THE MICRO-STRUCTURE (HAZ)
EFFECT: - SUSCETIBLITIES TO BRITTLE FAILURE DECREASES. - RESISTANCE TO STRESS CORROSION CRACKING INCREASES. - DIMENSIONAL STABILITIES INCREASES. PWHT PARAMETER - HEATING RATE
- SOAKING TEMPERATURE - COOLING RATE
Part UCS (Continued…) UCS-56 – PWHT
Part UCS (Continued…) UCS-56 – PWHT - Procedure - Temp. of furnace shall not exceed 800°F(425°) at the time of vessel placed in it. - Above 425°C, rate of heating shall not be more than 400°F (222°C)/hr, divided by max. metal thickness of shell or head in inches, but in no case more than 222°C/hr - Variation in temp. shall not be more than 250°F (139°C) within any 4.6m interval, during heating. - Variation in temp. shall not be more than 150°F(83°C) between highest and lowest temp. throughout the vessel during holding time. - No direct impingement of flame on the vessel (to control excessive oxidation). - Above 425°C, rate of cooling shall not be more than 500°F(278°C)/hr divided by max. metal thickness of shell or head in inches, in furnace, but in no case more than 278°C/hr. - From 800°F(425°C) vessel may be cooled in still air.
Part UCS (Continued…) UCS-56 – PWHT -General - Rate of heating and cooling need not be less than 100°F(38°C)/hr - Holding temp./holding time in excess of min. value may be used. - Intermediate PWHT need not confirm to table UCS-56 - Holding time need not be continuous. It may be addition of time of multiple PWHT cycles. - When P numbers are different, higher PWHT temperature shall be used. - When non pressure part is welded to pressure part, PWHT of pressure part shall control. -Exemptions given are not permitted when PWHT is a service requirement.
Part UCS (Continued…) Table UCS-56
Part UCS (Continued…) PWHT Requirements TABLE UCS-56
Part UCS (Continued…) PWHT Requirements TABLE UCS-56
Part UCS (Continued…) Table UCS-56.1
Part UCS (Continued…) UCS-57 -Radiographic Examination -when thickness exceeds given in table, radiography is required. -Thickness of thinner plate is considered.
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -Unless otherwise exempted - Impact testing is required for a combination of MDMT and thickness, which is below the curve in fig. UCS-66. - Above the curve the Impact Testing is not required.
Impact Test Exemption Curve
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -General Notes on Assignment of Materials to Curves: (a) Curve A applies to (1) All carbon and all low alloy steel plates, structural shapes, and bars not listed in Curve B, C and D below, (b) Curve B applies to : (1) SA-285 Grades A and B SA-515 Grade 60 SA-516 Grades 65 and 70 if no normalized (2) Except for cast steels, all materials of Curve A if produced to fine grain practice and normalized which are not listed in Curve C and D below, (3) all pipe, fittings, forgings and tubing not listed for Curve C and D below, (4) parts permitted under UG-11 shall be included in Curve B even when fabricated from plate that otherwise would be assigned to a different curve.
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -General Notes on Assignment of Materials to Curves (continued…) (c) Curve C applies to (1) SA-182 Grades 21 and 22 if normalized and tempered. SA-302 Grades C and D SA-336 F 21 and F 22 if normalized and tempered. SA-387 Grades 21 and 22 if normalized and tempered. SA-516 Grades 55 and 60 if not normalized. SA-533 Grades B and C (2) All material of Curve B if produced to fine grain practice and normalized and not listed for Curve D below. (d) Curve D applies to : SA-203 SA-508 Grade 1 SA-516 if normalized SA-537 Classes 1, 2 and 3
Part UCS (Continued…) Low Temperature Operations UCS-66 -Materials -Coincident Ratio (UCS 66-1) where MDMT>-49°C) -When coincident ratio is less than 1, MDMT can be lower than desired above, in the procedure given in UCS-66.2 -When components are not stressed to allowable limit, MDMT can be lower. -Lower MDMT -When MDMT is between -48°C and -105°C and coincident ratio is less than 0.35, impact testing is not required. - If PWHT is performed when not required by code, for P1 material, MDMT can be lower by 17°C, even lower than -48°C - In all other cases when MDMT is lower than -48°C, impact testing is required.
Part UCS (Continued…) Reduction in MDMT Without Impact Testing
THANK YOU
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