GUIDEBOOK FOR THE DESIGN OF ASME SECTION VIII PRESSURE VESSELS Second Edition

by

James R. Farr Wadsworth, Ohio

Maan H. Jawad Nooter Corporation St. Louis, Missouri

ASME Press New York 2001

Copyright © 200 I The American Society of Mechanical Engineers

Three Park Ave., New York, NY 10016

Library of Congress Cataloging-in~Publication Data

Farr, James R. Guidebook for the design of ASME Section vrn pressure vesselslby James

R. Farr, Maan H. Jawad.-2nd ed. p. em.

Includes bibliographical references and. index, ISBN 0-7918-0172-1 I. Pressure vessels-Design and construction. 2. Structural engineering. 1. Jawad, Maan H. II. Title. TA660. T34 F36 2001 681 '.76041-dc21

2001046096

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To our children,

Katherine, David, Susan, Nancy, and Thomas

Jennifer and Mark

Cover Photo Courtesy of Nooter Corp.

PREFACE TO

SECOND EDITION

The ASME Boiler and Pressure Vessel Code, Section VIII, is a live and progressive document. It strives to contain the latest, safe and economical rules for the design and construction of pressure vessels, pressure vessel components, and heat exchangers. A major improvement was made within the last year by changing the design margin on tensile strength from 4.0 to 3.5. This reduction in the margin permits an increase in the allowable stress for many materials with a resulting decrease in minimum required thickness. This was the first reduction in this design margin in 50 years and was based upon the many improvement') in material properties, design methods, and inspection procedures during that time.

Chapters and parts of chapters have been updated to incorporate the new allowable stresses and improve­ments which have been made in design methods since this book was originally issued. Some of these changes arc extensive and some are minor. Some of the examples in this book have changed completely and some remain unchanged. This book continues to be an easy reference for the latest methods of problem solving in Section VIII.

v

James R. Farr Wadsworth, Ohio

Maan H. J awad St. Louis, Missouri

July 2001

ACKNOWLEDGMENTS

We are indebted to many people and organizations for their help in preparing this book. Special thanks are given to the Nooter Corporation, fcHow Committee Members, and to former coworkers for their generous support during the preparation of the manuscript. We also give thanks to Messrs. Greg L. Hollinger and George B. Komara for helping with the manuscript, and to our editor Ray Ramonas at ASME for having great patience and providing valuable suggestions.

vii

CONTENTS

Preface ...................................................................................................................................................................... . Acknowledgments ........................................................... , ............... , .................. ,'., ................. , ................................. . List of Figures ................................................................................................................................................. , ... ", ... . List of Tables ................................................................................... " ...................................................................... .

Chapter 1 Background Infortnation ...................................................................................................................................... . 1.1 Introduction .............................................................................................................. " ... , ... ,., ......... , ....... , ...... . 1.2 Allowable Stresses .................................................................................................................................... .. 1.3 Joint Efficiency Factors .............................................................................................................................. .. 1.4 Brittle Fracture Considerations ................................................................................................................... . 1.5 1.6

Fatigue Requirements .................................................................................................................................. . Pressure Testing of Vessels and Components ........................................................................................... .. 1.6.1 ASME Code Requirements .......................................................................................................... . 1.6.2 What Does a Hydrostatic or Pneumatic Pressure Test Do? ......................................................... . 1.6.3 Pressure Test Requirements for VIll-1 ................................... " .................................................. .. 1.6.4 Pressure Test Requirements for VIlI-2 ............................................ , ........................................... ..

Chapter 2 Cylindrical Shells ...................................................................................................................................... ' ............ . 2.1 Introduction ................................................................................................................................................. .. 2.2 Tensile Forces, VIIl-I ................................................................................................ , ................................ .

2.2.1 Thin Cylindrical Shells ................................................................................................................. . 2.2.2 Thick Cylindrical Shells .................................................... , ........................................................... .

2.3 Axial Compression ...................................................................................................................................... . 2.4 External Pressure ........................................................................................................................................ .

2.4.1 External Pressure for Cylinders with Dolt :2: 10 .......................................................................... . 2.4.2 External Pressure for Cylinders with Dolt < 10 ......................................................................... .. 2.4.3 Empirical Equations ...................................................................................................................... .. 2.4.4 Stiffening Rings .............................................................................................................................. . 2.4.5 Attachment of Stiffening Rings ................... " ................................................................................ .

2.5 Cylindrical Shell Equations, V1I1-2 ........................................................................................................... . 2.6 Miscellaneous Shells ............................ , ...................................................................................................... .

2.6.1 Mitered Cylinders .......................................................................................................................... . 2.6.2 Elliptical Shells .............................................................................................................................. .

Chapter 3 Spherical Shells, Heads, and Transition Sections ............................................................................................. .. 3.1 Introduction ............................................. , .................................................................................................... . 3.2 Spherical Shells and Hemispherical Heads, Vlll-1 .................................................................................... .

3.2.1 Internal Pressure in Spherical Shells and Pressure on Concave Side of Hemispherical Heads .................................................................................................................... .

3.2.2 External Pressure in Spherical Shells and Pressure on Convex Side of Hemispherical Heads .... ,.................................... ...................................... . ......... ", .. , ................. .

3.3 Spherical Shells and Hemispherical Heads, VIII-2 ............................................................................. .

ix

v vii

xiii xvii

2 3 9

19 22 22 22 23 24

27 27 27 27 33 36 42 43 46 47 48 50 53 54 54 55

57 57 57

57

61 64

x Contents

3.4

3.5

3.6 3.7

3.8

Ellipsoidal Heads, VIII-I ........................................................................................................................... .. 3.4.1 Pressure on the Concave Side ............................................................................ " ......................... . 3.4.2 Pressure on the Convex Side ........................................................................................................ .. Torispherical Heads, VIII-I ........................................................................................................................ . 3.5.1 Pressure on the Concave Side ...................................................................................................... .. 3.5.2 Pressure on the Convex Side ......................................................................................................... . Ellipsoidal and Torispherical Heads, VIll~2 ............................................................................................... . Conical Sections, VIII~ 1 .............................................................................................................................. . 3.7.1 Internal Pressure ............................................. , ......................... " .................................................... . 3.7.2 External Pressure .......... , .................................... , .............................................................. , ............. . Conical Sections, VIII-2 ..................................... , ....................... , ............................................................... .

65 65 67 68 68 71 72 74 74 85 95

Chapter 4 Flat Plates, Covers, and Flanges .................. ......................................................................................................... 101 4.1 Introduction ..................................................................................................................................... ,............ 101 4.2 Integral Flat Plates and Covers ......................... ................................................. ........................................ 101

4.2.1 Circular Flat Plates and Covers ...................................................................................................... 101 4.2.2 Noncircular Flat Plates and Covers ................................................................................................ 104

4.3 Bolted Flat Plates, Covers, and Flanges ...................................................................................................... 105 4.3.1 Gasket Requirements, Bolt Sizing, and Bolt Loadings ........................................... ".................... 105

4.4 Flat Plates and Covers With BoIting ............................................................. ,............................................ 106 4.4.1 Blind Flanges & Circular Flat Plates and Covers ......................................................................... 106 4.4.2 Noncircular Flat Plates and Covers ....................................... ........................................................ 107

4.5 Openings in Flat Plates and Covers ............................................................................ ,................................ 107 4.5.1 Opening Diameter Does Not Exceed Half the Plate Diameter ..................................................... 107 4.5.2 Opening Diameter Exceeds Half the Plate Diameter .................................................................... 108

4.6 Bolted Flange Connections With Ring Type Gaskets ................................................................................ 108 4.6.1 Standard Flanges ......................................................................... ................................................... 109 4.6.2 Special Flanges ................................................................................................................................ 118

4.7 Spherically Dished Covers ........................................................................ .................... ............................. 124 4.7.1 Definitions and Terminology ....................................................... ...................... ........................... 125 4.7.2 Types of Dished Covers .............................................................. .................... ............................. 125

Chapter 5 Openings .......................................... ................................. ................................................... ................................... 133 5.1 Introduction .......................... ................................. ................................................. .................................... 133 5.2 Code Bases for Acceptability of Opening ..................................... "............................................................ 133 5.3 Terms and Definitions .................................................................................................................................. 134 5.4 Reinforced Openings-General Requirements ............................................................................................ 134

5.4.1 Replacement Area ........................................................................................................................... 134 5.4.2 Reinforcernent Limits .... ................................................................................................................. 134

5.5 Reinforced Opening Rules, VIII~l ............................................................................. ,................................. 136 5.5.1 Openings With Inherent Compensation ......................................................................................... 136 5.5.2 Shape and Size of Openings ............................................................................................... ,........... 137 5.5.3 Area of Reinforcement Required .................................................................................................... 137 5.5.4 Limits of Reinforcement ................................................................................................................. 140 5.5.5 Area of Reinforcement Available ................................................................ ,.................................. 140 5.5.6 Openings Exceeding Size Limits of Section 5.5.2.2 ..................................................................... 151

5.6 Reinforced Opening Rules, VlII-2 ............................................................................................................... 153 5.6.1 Definitions ......................................................................................................... ............................. 153 5.6.2 Openings Not Requiring Reinforcement Calculations .................. "............................................... 153 5.6.3 Shape and Size of Openings ........................................................................................................... 155 5.6.4 Area of Reinforcement Required ................................................................................ ".................. 155 5.6.5 Limits of Reinforcement ............... ,................................................................................................ 155 5.6.6 Available Reinforcement ................................................................................................................. 157

Contents xi

5,6.7 Strength of Reinforcement Metal .. " .... ,.,."., ....... ,', ...... , ... , ..... , ....... ,., ... " ......... " .. " ..... ,", ....... " .. ' ... ,. 157 5.6.8 Alternative Rules for Nozzle Design , ........... ,................................................................................ 157

5.7 Ligament Efficiency Rules. VIII-l .............................................................................................................. 164

Chapter 6 Special Components, VITI·l ....... ................ ..... ..... ....................... ..... ................. ................... ...... ......... ................... 169 6.1 Introduction ...... ............ ......... ..... ............ ................ ................ ........... ............... ..... ........ ............ .................... 169 6.2 Braced and Stayed Construction .................................................................................................................. 169

6.2.1 Braced and Stayed Surfaces ........................................................................................................... 169 6.2.2 Stays and Staybolts ......................................................................................................................... 172

6.3 Jacketed Vessels ........................................................................................................................................... 173 6.3.1 Types of Jacketed Vessels .............................................................................................................. 174 6.3.2 Design of Closure Member for Jacket to Vessel .... "" ....... ".......................................................... 175 6.3.3 Design of Openings in Jacketed Vessels ....................................................................................... 179

6.4 Half-Pipe Jackets .......................................................................................................................................... 181 6.4.1 Maximum Allowable Internal Pressure in Half-Pipe Jacket ......................................................... 181 6.4.2 Minimum Thickness of Half-Pipe Jacket ....................................................................................... 182

6.5 Vessels of Noncircular Cross Section ......................................................................................................... 186 6.5.1 Types of Vessels ............................................................................................................................. 187 6.5.2 Basis for Allowable Stresses ............................................. ,......................................... ................. 187 6.5.3 Openings in Vessels of Noncircular Cross Section ....................................................................... 187 6.5.4 Vessels of Rectangular Cross Section ............................. " .. " ... ".................................................... 197

Chapter 7 Design of Heat Exchangers ............................ , .............. ,' ..................................................................... , ....... ,......... 201 7.1 Introduction ..................................... , ............. , .................................... , ................ , .............................. ,.......... 201 7.2 Tubesheet Design in U-Tube Exchangers ........................................................................ .......................... 201

7.2.1 Nomenclature ................... ,............................................................................................................... 201 7.2.2 Design Equations for Simply Supported Tubesheets ..................................................................... 207 7.2.3 Design Equations for Integral Construction ............................ ,...................................................... 209 7,2.4 Design Equations for Integral Construction With Tubesheet Extended as a Flange ................... 212

7.3 Fixed Tubesheets .......................................................................................................................................... 213 7.3.1 Nomenclature .................... , .................................... , ......... , .. , ......................................................... ,.. 213 7.3.2 Design Equations .............................................. "............................................................................. 217

7.4 Expansion Joints ........................... ,....................................... ........................................................ 230

Chapter 8 Analysis of Components in VIII~2 ..................... "................................................................................................. 233 8.1 Introduction ...................... ' .. , ................... , .......... , ............ ,., .............. , .............................. , .... , ......... ,............. 233 8.2 Stress Categories .......................... , ........... ,." ..... , ................. " .................. , ............. " ............ , ...... , ...... ,........... 233 8.3 Stress Concentration ................... , ............................ , ..................... ,.............. ............................. ................. 239 8.4 8.5

Combinations of Stresses ................................................ " .............. , ............ , ........... , ......... , .... ,., ................ . Fatigue Evaluation ............... , .................... " ................................................ ..

References ............................ , ............. " .............................................. , ........ , ......... .

Appendices

240 245

249

Appendix A·-Guide to VIII-l Requirements " ....... , ............. " ...... ,. ............. ,. ............... ,......................................... 25] Appendix B-Material Designation ....................................... , .......................................................... ,'..................... 253 Appendix C-Jomt Efficiency Factors ... , ............................ , .... ,............................................... ................. 255 Appendix D-Flange Calculation Sheets ................................................................................................................. 277 Appendix E-Conversion Factors ............................................................................................ ............................... 283

Index ...................................................................................................................................................................... .. 285

REFERENCES

API, 1996, American Petroleum Institute, Recommended Rules for Design and Construction of Large, Welded, Law-Pressure Storage Tanks, API 620, Washington, D,C., API.

ASCE, 1998, American Society of Civil Engineers, Minimum Design Laads for Buildings and Other Structures, ASCE 7-98, New York, ASCE.

ASME, 2001a, American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section VIII, Division 1, Pressure Vessels, New York, ASME.

ASME, 2001b, American Society of Mechanical Engineers, Boiler and Pressure Vessel Code, Section VIII, Division 2, Alternative Rules for Pressure Vessels, New York, ASME.

ASME, 1999, American Society of Mechanical Engineers, B31.3, Chemical Plant and Petroleum Refinery Piping, New York, ASME.

ASME, 1969, American Society of Mechanical Engineers, Criteria of the ASME Boiler and Pressure Vessel Code for Design by Analysis in Sections III and VIII, Division 2, New York, ASME.

ASME, 1968, American Society of Mechanical Engineers, Section VllI-Division 2 of the ASME Boiler and Pressure Vessel Code-Guide to Alternative Rules for Pressure Vessels, New York, ASME.

Beer, F. P., and Johnson, Jr., E. R., 1992, Mechanics of Materials, New York, McGraw Hill.

Bergman, E. 0., 1955, "The Design of Vertical Vessels Subjected to Applied Forces," Transactions of the ASME, New York, ASME.

Flugge, W., 1967, Stresses in the Shells, New York, Springer-Verlag.

Gilbert, N., and Polani, J. R., May 1979, Stability Design Criterion for Vessels Subjected to Concurrent External Pressure and Langitudinal Compressive Loads, New York, ASME.

rCBO, 1997, International Conference of Building Officials, Uniform Building Code, Whittier, CA, rCBO.

Jawad, M. H., 1994, Theory and Design of Plate and Shell Structures, New York, Chapman and Hall.

Jawad, M. H., and Farr, J. R., 1989, Structural Analysis and Design of Process Equipment, New York, John Wiley & Sons.

G+ W Taylor-Bonney, Bulletin 502: Modem Flange Design, 7th Edition, Southfield, MI, G+ W.

Peterson, R. E., 1974, Stress Concentration Factors, New York, John Wiley & Sons.

Prager, W., and Hodge, P. G., 1965, Theory of Perfectly Plastic Solids, New York, John Wiley & Sons.

Shield, R. T., and Drucker, D. C., June 1961, "Design of Thin-Walled Torispherical and Toriconical Pressure Vessel Heads," Journal of Applied Mechanics, New York, ASME.

TEMA, 1999, Tubular Exchanger Manufacturers Association, Inc., Standards of Tubular Exchanger Manufacturers Association, 8th ed., Tarrytown, NY, TEMA.

249

ApPENDIX A

GUIDE TO VIII .. 1 REQUIREMENTS

251

INDEX

A A value, 43-44 Allowable stress, 2-3, 5, 6 ASME Boiler and Pressure Vessel Code,

Section VIII, v, see also Section VIII Assignment of materials to CUI\!es, 10 Axial buckling stress, critical, 39 Axial compression, cylindrical shells

under, 36-42

B B value, 43-44 Beams on Elastic Foundation, 134 Bellows~type expansion joints, 230, 231 Bending moment, 41 Bending stress, 41-42

ligament efficiency for multi-diameter openings for, 193-197

Blind flanges, 106-107 Boiler and Pressure Vessel Code, Section

VIII, ASME, v, see also Section VIII Bolt loads, 106 Bolt sizing, 106 Bolted flanges, 105-106

connections with ring type gaskets, 108-124

Bolted flat head, 12 Bolted flat plates and covers, 105-106 Bolting, flat plates and covers with,

106-107 Bolting rings, 124 Braced and stayed construction, 169-173 Braced and stayed surfaces, 169-172 Brittle fracture, 9-13 Buckling, of cylindrical shells, 42-43 Buckling equation, 38 Buckling stress, critical axial, 39 Butt joints, 6 Butt welded, 5, 7 Butt welded components, II

c C value, 102 Carbon steel plate specifications, 253 Cast Ductile Iron, rules of Part VCD for,

23-24 Cast Iron, rules of Part VCI for, 23

285

Categories, welded joint, 5, 6 Charpy impact-test requirements, 16 Chrome-moly steel forging specifications

SA-182,253 SA-336,254

Chrome-moly steel plate specifications, 253

Circular flat plate, 101 Circumferential membrane stress, 28 Circumferential stress, 34, 70 Closure design details, 175-178 Cold temperatures, 24 Compensation, inherent, openings with,

136 Component analysis in VIII-2, 233-248 Compression

axial, cylindrical shells under, 36-42 cone-ta-shell junction at large end of

cone in, 75-76 cone-ta-shell junction at small end of

cone in, 86-87 Compressive stress, 70 Cone-ta-cylinder junction

large end of inherent reinforcement for, 96 values of Q for, 96

small end of inherent reinforcement for, 98 values of Q for, 99

Cone-ta-shell junction large, 80-81, 89-92 at large end of cone

in compression, 75-76 in tension, 85-86

small, 81-82, 92-94 at small end of cone

in compression, 86-87 in tension, 76-77

Conical sections external pressure on, 85-94 internal pressure on, 74-85 VIII-l,74-94 VIII-2, 95-99

Conical shells, 74 Conversion factors, 283 Comer joint, 12 Corner welded, 5, 7 Corrosion allowance, 31, 32