pressure vessel code guide instructors

8/12/2019 Pressure Vessel Code Guide Instructors

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Overview o f Pressure Vessel Design

Instruc tor s Guide


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CONTACT INFORMATION

ASME Headquarters1-800-THE-ASME

ASME Professional Development

1-800-THE-ASME

Eastern Regional Office Southern Regional Office

8996 Burke Lake Road Suite L102 1950 Stemmons Freeway Suite 5068

Burke, VA 22015-1607 Dallas, TX 75207-3109

703-978-5000 214-800-4900800-221-5536 800-445-2388

703-978-1157 (FAX) 214-746-4902 (FAX)

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1117 S. Milwaukee Avenue 119-C Paul Drive

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Libertyville, IL 60048-5258 415-499-1148

847-680-5493 800-624-9002

800-628-6437 415-499-1338 (FAX)

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Route 22

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845-279-6200

800-628-5981

845-279-7765 (FAX)

You can also find information on these

courses and all of ASME, including ASME

Professional Development, the Vice

President of Professional Development,

and other contacts at the ASME Web

site......

http://www.asme.org

You can also find information on these

courses and all of ASME, including ASME

Professional Development, the Vice

President of Professional Development,

and other contacts at the ASME Web

site......

http://www.asme.org


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Overview of Pressure Vessel Design

By:

Vincent A. Carucci

Carmagen Engineering, Inc.

Copyright 1999 by

All Rights Reserved


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TABLE OF CONTENTS

Abstract 5

Introduction..6

Organizing Unit Responsibilities..7

Instructor Guidelines and Responsibilities.9

Overview of Pressure Vessel Design Outline/

Teaching Plan11

Instructor Notes.13

Appendix A: Reproducible Overheads

Appendix B: Course and Instructor Evaluation Form

Appendix C: Continuing Education Unit (CEU) Submittal Form

Course Improvement Form

Instructors Biography Form


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ABSTRACT

Pressure vessels are typically designed, fabricated, installed, inspected, and tested

in accordance with the ASME Code Section VIII. Section VIII is divided into three

separate divisions. This course outlines the main differences among the divisions.

It then concentrates on and presents an overview of Division I. This course also

discusses several relevant items that are not included in Division I.


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INTRODUCTION

This Overview of Pressure Vessel Design course is part of the ASME International

Career Development Series an educational tool to help engineers and managers

succeed in todays business/engineering world. Each course in this series is a 4-

hour (or half-day) self-contained professional development seminar. The course

material consists of a participant manual and an instructors guide. The participant

manual is a self-contained text for students/participants, while the guide (this

booklet) provides the instructional material designed to be presented by a local

knowledgeable instructor with a minimum of preparation time.

The balance of this instructors guide focuses on:

1. Organizing Unit Responsibilities

2. Instructor Guidelines and Responsibilities

3. Comprehensive teaching materials which may be used as is or adapted

to incorporate experiences and perspective of the instructor.

Welcome to the ASME International Career Development Series! We wish you all

the best in your presentation, operation and delivery of this course.


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Suggested Outline/Teaching Plan

Time,

min.

Major

Interval

Class Segment Sub-Segment

Interval

Sub-SegmentOverheads/Participant

Pages5 Introduction/Logistics

Outline ModuleOV 1Part. 65

10 Introduction

5 Module based primarily on theASME Code Section VIII, Division

1. Divisions 2 and 3 will be brieflydescribed

OV 2Part. 65

10 Main Pressure Vessel Components OV 3-9Part. 67

10 Scope of ASME Code Section VIII

Division 1

Division 2

Division 3

OV 10-13Part. 75

25 General

5 Structure of Section VIII, Division 1 OV 14Part. 78

15 Material Selection Factors

Strength

Corrosion Resistance

Resistance to Hydrogen Attack

Fracture Toughness

Fabricability

OV 15-31Part. 79

20 Materials of Construction

5 Maximum Allowable Stress OV 32-34

Part. 87

10 Exercise 10 Material Selection Based On FractureToughness

OV 35-38Part. 91

10 Break 10

10 Design Conditions and Loadings

Pressure

Temperature

Other Loadings

OV 39-43 Part. 92

25 Design for Internal Pressure

Weld Joints

Cylindrical Shells

Heads

Conical Sections

Sample Problem

OV 44-55 Part. - 98

55 Design

20 Design for External Pressure andCompressive Stresses

Cylindrical Shells Other Components

Sample Problem

OV 56-65 Part. 109


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Suggested Outline/Teaching Plan, continued

Time,

min.

Major

Interval

Class Segment Sub-Segment

Interval

Sub-SegmentOverheads/

ParticipantPages

10 - 50 Major Break Lunch or Major Break

15 Exercise 15 Required Thickness for Internal

Pressure

OV 66-68

Part. - 118

20 Reinforcement of Openings (IncludeSample Problem)

OV 69-84Part. 119

10 Flange Rating (Including Sample

Problem)

OV 85-90

Part. 127

15 Flange Design OV 91-97Part. 131

50 Design(Contd.)

5 Maximum Allowable WorkingPressure (MAWP)

OV 98Part. 138

10 Break

10 Local Loads OV 99

Part. 139

20 Other Design

Considerations

10 Vessel Internals OV 100-102Part. 141

10 Acceptable Welding Details OV 103-106Part. 143

20 Fabrication

10 Postweld Heat Treatment

(PWHT)Requirements

OV 107

Part. 146

10 Inspection OV 108-113Part. 148

15 Inspection andTesting

5 Pressure Testing OV 114-115

Part. 152

10 Closure 10 SummaryQuestionnaire (fill in and collect)CEU Form (hand out individual

responsibility to return)

OV 116Part. - 155


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Instructors Personal Notes

Instructors Outline

1. Course discusses pressure vessel

design and is introductory in nature.

2. Based on ASME Code Section VIII.

3. Preliminary emphasis is on Division

1 but Divisions 2 and 3 are

highlighted.

4. Introduces several items that are notcovered in the ASME Code.

Major Learning Points

Course Introduction

1

OVERVIEW OF

PRESSURE VESSEL DESIGN

By: Vincent A. Carucci

Carmagen Engineering, Inc .


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Instructors Outline

1. The objective: Provide a general

knowledge of design requirements

for pressure vessels.

2. This is not a comprehensive course.

It provides sufficient information for

management personnel to have an

overall understanding of this

subject. Individuals having moredetailed responsibility will receive a

solid starting point to proceed

further.

3. Review outline.

4. Establish schedule.

5. Participation is key:

Questions

Discussion/interaction


Establish course objectives.

Outline course content, a road map.

2

Cours e Overv iew

General

Materials of Construction

Design

Other Design Considerations

Fabrication

Inspection and Testing


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Instructors Outline

1. Describe what a pressure vessel is.

2. Note that pressure vessels are used

in a wide variety of industries. They

can be designed for a wide variety of

conditions and in a broad range of

sizes.


Define pressure vessels.

Identify wide variety of industrial

applications.

3

Pressure Vessels

Containers for fluids under pressure

Used in variety of industries

Petroleum refining

Chemical

Power

Pulp and paper

Food


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Instructors Outline

1. Use this and following overheads to

describe main pressure vessel

components and shapes.

2. Shell is primary component that

contains pressure. Curved shape.

3. Vessel always closed by heads.

4. Components typically weldedtogether.

5. Vessel shell may be cylindrical,

spherical, or conical.

6. Multiple diameters, thicknesses or

materials are possible.

7. Saddle supports used for horizontal

drums.

Spreads load over shell.

One support fixed, other slides.


Main pressure vessel components and

configurations.

4

Hor izonta l Drum o n

Saddle Supp or ts

Figure 2.1

Nozzle

ShellA

A

Head

SaddleSupport

(Fixed)

Saddle Support

(Sliding)

Head

SectionA-A


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Instructors Outline

1. Most heads are curved shape for

strength, thinness, economy.

2. Semi-elliptical shape is most

common head shape.

3. Small vertical drums typically

supported by legs.

Typically maximum 2:1 ratio ofleg length to diameter.

Number, size, and attachment

details depend on loads.



shapes.

5

Vert ica l Drum

on Leg Suppor ts

Figure 2.2

Head

Shell Nozzle

Head

SupportLeg


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Instructors Outline

1. Nozzles used for:

Piping systems

Instrument connections

Manways

Attaching other equipment

2. Ends typically flanged, may bewelded.

3. Sometimes extend into vessel.



shapes.

6

Tal l Vert ical Tow er

Figure 2.3

Trays

Nozzle

Head

Shell

Nozzle

Cone

Shell

Nozzle

NozzleSkirtSupport

Head


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Instructors Outline

1. Skirt supports typically used for tall

vertical vessels:

Cylindrical shell

Typically supported from grade

2. General support design (not just for

skirts)

Design for weight, wind,

earthquake.

Pressure not a factor.

Temperature also a

consideration for material

selection and thermal

expansion.



shapes.

7

Vert ical Reactor

Figure 2.4

Inlet

Nozzle

Head

Shell

UpperCatalyst

Bed

Catalyst Bed

Support Grid

Lower

Catalyst

Bed

Outlet

Collector

Head

Support

Skirt

Outlet

Nozzle


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Instructors Outline

1. Spherical storage vessels typically

supported on legs.

2. Cross-bracing typically used to

absorb wind and earthquake loads.



shapes.

8

Spher ical Pressur ized

Storage Vessel

Figure 2.5

Cross

Bracing

Support

Le g

Shell


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Instructors Outline

1. Vessel size limits for lug supports:

1 10 ft diameter

2:1 to 5:1 height/diameter ratio

2. Vessel located above grade.

3. Lugs bolted to horizontal structure.



configurations.

9

Vert ical Vessel on

Lug Suppor t s

Figure 2.6


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Instructors Outline

1. Section VIII is most widely used

Code.

2. Assures safe design.

3. Three divisions have different

emphasis.


Define scope of ASME Code Section

VIII.

10

Scope of ASME Code

Section VIII

Section VIII used worldwide

Objective: Minimum requirements for safe

construction and operation

Division 1, 2, and 3


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Instructors Outline

1. Review scope of Division 1.

2. Division 1 not applicable below 15

psig.

3. Additional rules required above 3000

psig.

4. Items that are connected to pressure

vessels not covered by Division 1,except for:

Their effect on pressure part.

Welded attachment to pressure

part.


Scope of Division 1

Exclusions from scope

11

Section VIII Divisio n 1

15 psig < P 3000 psig Applies through first connection to pipe

Other exclusions

Internals (except for attachment weld to vessel)

Fired process heaters

Pressure containers integral with machinery

Piping systems


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Instructors Outline

1. Review differences between

Divisions 1 and 2.

2. Division 2 allowable membrane

stress is higher.

3. Division 2 requires more complex

calculations.

4. Division 2 does not permit somedesign details that are permitted in

Division 1.

5. Division 2 requires more stringent

material quality control, fabrication,

and testing requirements.


Differences between Division 1 and 2.

12

Sectio n VIII , Divis ion 2,

Al ternat ive Rules Scope identical to Division 1 but

requirements differ

Allowable stress

Stress calculations

Design

Quality control

Fabrication and inspection

Choice between Divisions 1 and 2 based on

economics


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Instructors Outline

1. Review application of Division 3.

2. Newest Division of Section VIII and

has least applicability.

3. After this point, this course only

addresses Division 1 requirements

when code-specific items are

discussed.


Scope of Division 3

13

Applications over 10,000 psi

Pressure from external source, processreaction, application of heat, combination

of these

Does not establish maximum pressurelimits of Division 1 or 2 or minimum limits

for Division 3.

Div is ion 3, Al ternat ive Rules

High Pressu re Vessels


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Instructors Outline

1. Review Division 1 organization

2. Fabrication methods:

Welded

Forged

Brazed

3. Material classes

Carbon and low-alloy steel

Non-ferrous metals

High alloy steel

Cast iron

Clad and lined material

Ductile iron

Heat treated steels Layered construction

Low-temperature material

4. Highlight several mandatory and

nonmandatory appendices.


Basic organizational structure of

Division 1.

14

Struc ture of Sect io n VIII,

D iv is ion 1 Subsection A

Part UG applies to all vessels

Subsection B

Requirements based on fabrication method

Parts UW, UF, UB

Subsection C

Requirements based on material class

Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT,ULW, ULT

Mandatory and Nonmandatory Appendices


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Instructors Outline

1. ASME Code does not specify

particular materials to use in each

application. Owner must do this.

2. ASME Code specifies permitted

materials and the requirements that

these must meet.


Primary factors that influence pressure

vessel material selection.

15

Material Select ion Facto rs

Strength

Corrosion Resistance

Resistance to Hydrogen Attack

Fracture Toughness

Fabricability


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Instructors Outline

1. Strength: Materials ability to

withstand imposed loading.

2. Higher strength material thinnercomponent.

3. Describe properties that are used to

define strength.


Material strength and pressure vessel

design.

16

Strength

Determines required component thickness

Overall strength determined by:

Yield Strength

Ultimate Tensile Strength

Creep Strength

Rupture Strength


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Instructors Outline

1. Corrosion is thinning of metal.

2. Adding extra component thickness

(i.e., corrosion allowance) is most

common method to address

corrosion.

3. Alloy materials are used in services

where corrosion allowance would be

unreasonably high if carbon steel

were used.


Importance of corrosion resistance in

materials selection.

17

Corros ion Res is tance

Deterioration of metal by chemical action

Most important factor to consider

Corrosion allowance supplies additional

thickness

Alloying elements provide additional

resistance to corrosion


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Instructors Outline

1. Low-temperature H2 attack can

cause cracking.

2. Higher temperature H2 attack causes

through-thickness strength loss and

is irreversible.

3. H2 attack is a function of H2 partial

pressure and design temperature.

Increased alloy content (i.e., Cr)

increases H2 attack resistance.

Reference API-941 for Nelson

Curves.


Hydrogen attack can damage carbon

and low-alloy steel.

18

Resis tance to

Hydrogen A t tack

At 300 - 400F, monatomic hydrogen

forms molecular hydrogen in voids

Pressure buildup can cause steel to crack

Above 600F, hydrogen attack causes

irreparable damage through component

thickness


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Instructors Outline

1. Describe brittle fracture as

equivalent to dropping a piece of

glass.

2. Material selection must ensure that

brittle fracture will not occur.


Brittle fracture and its consequences.

19

Bri t t le Fracture

and Fracture Toughn ess Fracture toughness: Ability of material to

withstand conditions that could cause

brittle fracture

Brittle fracture

Typically at low temperature

Can occur below design pressure

No yielding before complete failure


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Instructors Outline

1. A brittle fracture will occur the first

time the appropriate conditions

occur.

2. Brittle fracture occurs without

warning and is catastrophic.


Three conditions that are required for a

brittle fracture to occur.

20

Bri t t le Fracture and

Fracture Tough ness, cont d

Conditions required for brittle fracture

High enough stress for crack initiation and

growth

Low enough material fracture toughness attemperature

Critical size defect to act as stress

concentration


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Instructors Outline

1. Describe influence of material and

temperature factors on fracture

toughness.

2. Other factors increase brittle fracture

risk.


Primary factors that influence material

fracture toughness.

21

Factor s That Inf luenc e

Fracture Toug hness Fracture toughness varies with:- Temperature

- Type and chemistry of steel

- Manufacturing and fabrication processes

Other factors that influence fracture

toughness:

- Arc strikes, especially if over repaired area

- Stress raisers or scratches in cold formed thick

plate


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Instructors Outline

1. Charpy V-Notch test is most widely

used measure of material fracture

toughness.

2. Describe test set-up.


Charpy V-Notch testing.

22

Charpy V-Notch Test Setup

Starting Position

Hammer

Scale

Pointer

End of swing

Anvil

Specimen

h'

h'


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Instructors Outline

1. ASME Code contains brittle fracture

evaluation procedure.

2. Review components to be included -

only items that relate to structural

integrity of pressure-containing

shell.


Components to consider is ASME Code

brittle fracture evaluation.

23

ASME Code and

Bri t t le Fracture Evaluat ion

Shells

Manways

Heads

Reinforcing pads

Backing stripsthat remain in

place

Nozzles

Tubesheets

Flanges

Flat cover plates

Attachments essential

to structural integrity

that are welded topressure parts

Components to consider


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Instructors Outline

1. Describe the distinction between

MDMT and CET.

MDMT is a materialproperty.

CET is an environmental factor.

2. Important to understand this

distinction.


Two temperatures to be considered in

brittle fracture evaluation.

24

Temp eratures to Con s ider

Minimum Design Metal Temperature

(MDMT)

Lowest temperature at which component has

adequate fracture toughness

Critical Exposure Temperature (CET)

Minimum temperature at which significant

membrane stress will occur


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Instructors Outline

1. Outline ASME procedure.

2. Details described in following

overheads.


Simplified ASME brittle fracture

evaluation procedure.

25

Simpl i f ied ASME

Evaluat ion App roach Material specifications classified into

Material Groups A through D

Impact test exemption curves

For each Material Group

Acceptable MDMT vs. thickness where impact

testing not required

If combination of Material Group andthickness not exempt, then must impact test

at CET


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Instructors Outline

1. Materials are grouped based on

common fracture toughness

properties.

2. Groups A through D move from

worst to best fracture toughness.

3. Point out several common materials.

SA-516 Gr. 65 and 70 are CurveB if not normalized.

Most pipe, fittings and forgings

are Curve B.


Material group classifications for brittle

fracture evaluations.

26

Mater ia l Groups

Table 3.1 (Excerpt)

MATERIAL

GROUP APPLICABLE MATERIALS

Curve A A l l c a r b o n a n d l o w a l l o y s t e el p l a t e s , s t r u c t u ra l s h a p e s , a n d b a r s n o tl i s t e d in Cu rv e s B, C & D

S A-2 1 6 Gr . WCB & WCC, S A-2 1 7 Gr . WC6 , i f n o rma l i z e d a n d t e mp e re do r w a t e r - q u e n c h e d a n d t e m p e r e d

Curve B S A - 2 1 6 G r. W C A , i f n o r m al i z e d a nd t e m p e r ed o r w a t e r -q u e n c h e d a n dt e m p e r e d

S A-2 1 6 Gr . WCB & WCC fo r ma x imu m th i c k n e s s o f 2 i n . , i f p ro d u c e dt o f i n e g r a i n p r a c t i c e a n d w a t e r - q u e n c h e d a n d t e m p e r e d

S A -2 8 5 G r . A & B

S A -4 14 Gr . A

S A -5 1 5 G r . 6 0

S A - 5 1 6 G r . 6 5 & 7 0, i f n o t n or m a l i ze d

E x c e p t f o r c a st s t e e l s , a l l m a t e r ia l s o f C u r v e A i f p r o d u c ed t o f i n e

g ra in p r a c t i c e a n d n o rma l i z e d wh ic h a r e n o t i n c lu d e d in Cu rv e s C & D

A l l p i p e , f i t t i ng s , f o r g i n g, a n d t u b i n g w h i c h a re n o t i n c l u d e d i n C u rv e sC & D


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Instructors Outline

1. Identify other common materials.

SA-516 Gr. 55 and 60 are Curve

C if not normalized.

SA-516 (all grades) is Curve D if

normalized.

2. Highlight points.

Lower strength grades of same

specification have better

fracture toughness.

Normalization improves fracture

toughness.


Material group classifications for brittle

fracture evaluations.

27

Mater ia l Grou ps, contd

Table 3.1 (Excerpt)

MATERIAL

GROUP APPLICABLE MATERIALS

Curve C S A - 1 8 2 G r . 2 1 & 2 2 , i f n o rm a l i z e d a n d t e m p e r e d S A -3 0 2 G r . C & D

S A - 3 3 6 G r . F 2 1 & F 2 2 , i f n o r m a l iz e d a n d t e mp e r e d

S A - 3 8 7 G r . 2 1 & 2 2 , i f n o rm a l i z e d a n d t e m p e r e d

S A - 51 6 G r . 5 5 & 6 0 , i f n o t n o rm a l iz e d

S A -5 3 3 G r . B & C

S A- 66 2 Gr . A

A l l m a t e r i al o f C u r v e B i f p r o d u c e d t o f i n e g r a i n p r a c t i c e a n d

n o r m a l i z e d w h i c h a r e n o t i n c l u d e d i n C u r v e D

Curve D S A- 20 3 S A-537 C l. 1 , 2 & 3

SA-508 Cl . 1 S A - 6 1 2 , i f n o rm a l i z e d

S A -5 16 , i f n o rm al i z e d S A - 6 6 2 , i f no rm a l i z e d

SA-524 Cl . 1 & 2 S A-7 3 8 G r . A

Bolting S e e F i g u r e U C S- 6 6 o f t h e A S M E C o d e S e c t i on V I I I , D i v . 1 , f o r i m p a c t

and Nuts t e s t e x e m p t i o n t e m p e r a t u r e s f o r s p e c i f i e d m a t e r i a l s p e c i f i c a t i o n s


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Instructors Outline

1. Describe relationship between

Material Group, component

thickness, and MDMT.

2. Impact testing not required if point is

at or below curve (i.e., OK if MDMT CET).

3. Example: 1.5 in. thick Group B

material does not require impact

testing if CET 50F.

4. If not exempt, must impact test

material at CET.

5. Exemption means there is enough

experience that material has

adequate fracture toughness without

need for further testing.


Impact test exemption curves.

28

Im pact Test Exemp t ion Curves

for Carbon and Low -Al loy Steel

Figure 3.1

Nominal Thickness, in.

(Limited to 4 in. for Welded Construction)

0.394 1 2 3 4 5

140

120

100

80

60

40

20

0

-20

-40

-55-60

-80

MinimumD

esignMetalTemperature,

F

Impact testing required

D

C

BA


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Instructors Outline

1. Review additional requirements.

2. Note that most flanges will not

require impact testing.


Additional impact test requirements.

29

Add i t ional ASME Code Imp act

Test Requirements

Required for welded construction over 4 in.

thick, or nonwelded construction over 6 in.

thick, if MDMT 65 ksi unless

specifically exempt


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Instructors Outline

1. Review additional requirements.

2. PWHT reduces MDMT by 30Fprovided PWHT not required by

Code and resulting MDMT -55F.

3. Can take MDMT credit if component

thickness greater than needed (i.e.,

calculated stress < allowable stress).


Additional impact test requirements.

30

Add i t ional ASME Code

Impact Test

Requi rements , con t d Not required for impact tested low

temperature steel specifications

May use at impact test temperature

30F MDMT reduction if PWHT P-1 steel

and not required by code

MDMT reduction if calculated stress in. For b

o


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Instructors Outline

Review the additional gasket

information shown.


Information on additional gasket types.

97

Gasket Mater ials

and Con tact Fac ings

Figure 4.22

Gasket Materials and Contact Facings

Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y

Gasket Material Gasket

Factor

m

Min.

Design

Seating

Stress y,

psi

Sketches Facing

Sketch and

Column in

Table 2-5.2

Flat metal, jacketed asbestos filled:Soft aluminum

Soft copper or brassIron or soft steelMonel4% - 6% chromeStainless steels and nickel-base alloys

3.253.50

3.753.503.753.75

55006500

7600800090009000

(1a), (1b),(1c),2, (1d) 2,

(2)2,Column II


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Instructors Outline

1. Emphasize that MAWP is based on

the as-supplied component

thicknesses.

2. Thicknesses used exclude corrosion

allowance and thickness added to

absorb other loads.

3. MAWP is useful to know for potential

future rerate.


MAWP is defined.

98

Maximum Al lowable

Work in g Pressure (MAWP) Maximum permitted gauge pressure at top of

vessel in operating position for designatedtemperature

MAWP Design Pressure Designated Temperature = Design Temperature

Vessel MAWP based on weakest component

Originally based on new thickness less corrosion

allowance

Later based on actual thickness less future corrosion

allowance needed


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Instructors Outline

1. Review the typical external loads

that may be applied.

2. External loads cause local stresses

that must be evaluated.

3. Other industry standards must be

used to evaluate local stresses (e.g.,

WRC 107 and 297).


Externally applied loads must also be

considered in vessel design.

99

Local Loads

Piping system

Platforms, internals, attached equipment

Support attachment


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Instructors Outline

1. Different types of internals are used

to perform various process

functions.

2. Review list of internals.

3. ASME Code does not cover design

of internals. End-user, vessel

vendor, and/or contractor must

develop requirements.


Several types of vessel internals may be

installed.

100

Types o f Vessel Internals

Trays

Inlet Distributor

Anti-vortex baffle

Catalyst bed grid and support beams

Outlet collector

Flow distribution grid

Cyclone and plenum chamber system


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Instructors Outline

1. Potential corrosion of internals

should not be ignored.

2. Corrosion allowance should be

considered in a practical and cost-

effective manner.


Corrosion allowance should be

considered in the design of internals.

102

Cor ros ion A l lowance

For Vessel Internals

Removable internals: CA = CA of shell

Costs less

Easily replaced

Non-removable internals: CA = 2 (CA of shell)

Corrosion occurs on both sides


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115



Instructors Outline

1. Review typical acceptable welding

and fabrication details.

2. Details for openings were previously

reviewed.

3. Highlight thickness taper.

4. Intermediate heads should retain

fillet weld in refinery applications.


ASME Code specifies acceptable

welding and fabrication details.

103

Head-to-Shell Transit ion s

FilletWeld

Butt Weld

Intermediate Head Attachment

th

y

l

ts

Thinnerpart

TangentLine

th

y

l

ts

Thinnerpart

th

y

l

ts

Thinnerpart

Tangent

L ine

th

y

l

ts

Thinnerpart

Figure 6.1


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116



Instructors Outline

Review thickness taper requirements.


ASME Code fabrication details.

104

Typical Shel l Transi t ion s

l

l

y

CL

CL

CLIn all cases, l shall not

be less than 3y.

Figure 6.2


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117



Instructors Outline

Thickness taper may be required in

nozzle neck.



105

Nozzle Neck

Thickness Tapers

Figure 6.3


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118



Instructors Outline

1. Vacuum stiffening ring attachment

details.

2, ASME Code specifies weld spacing,

size, and length.



106

Sti f fener Ring s

In-Line

Intermittent Weld

Staggered

Intermittent Weld

Continuous Fillet Weld On

One Side, Intermittent Weld

On Other Side

Figure 6.4


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119



Instructors Outline

1. ASME Code specifies PWHT

requirements only for relief of

residual stresses.

2. Need for PWHT due to other reasons

must be specified by end-user or

contractor.

Service considerations (e.g.,

wet H2S, caustic)

Weld hardness reduction


ASME Code PWHT requirements.

107

Post Weld Heat Treatment

Restores material properties

Relieves residual stresses

ASME Code PWHT requirements Minimum temperature and hold time

Adequate stress relief

Heatup and cooldown rates


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120



Instructors Outline

Highlight main areas included in

inspection.


ASME Code inspection requirements.

108

Insp ect ion and Test ing

Inspection includes examination of:

Base material specification and quality

Welds

Dimensional requirements

Equipment documentation


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121



Instructors Outline

Review common types of weld defects.


Particular types of weld defects may

occur.

109

Comm on Weld Defects

Undercut

Incomplete Penetration

Lack of Fusion

B et we en Wel d B ead an d Ba se Me ta l B et we en A dj ac en t P as se s

I nc om pl et e F il li ng at Ro ot on On e S id e O nl y I nc om pl et e F il li ng at Ro ot

Internal Undercut

External Undercut

Figure 7.1


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123



Instructors Outline

1. Review NDE methods and types of

defects detected.

2. Review advantages and limitations

of each NDE method.


Different NDE methods are best

suited to detect particular defect

types.

Each NDE method has advantages

and disadvantages.

111

Types of NDENDE TYPE DEFECTS

DETECTED

ADVA NT AGES LI MI TA TI ON S

Radiographic Gas pockets, slag

inclusions,

incompletepenetration, cracks

Produces

permanent record.

Detects small flaws.Most effective for

butt-welded joints.

Expensive.

Not practical for

complex shapes.

Visual Porosity holes, slag

inclusions, weld

undercuts,

overlapping

Helps pinpoint

areas for additional

NDE.

Can only detect

what is clearly

visible.

Liquid Penetrant Weld surface-type

defects: cracks,seams, porosity,

folds, pits,

inclusions,

shrinkage

Used for ferrous

and nonferrousmaterials. Simple

and less expensive

than RT, MT, or UT.

Can only detect

surfaceimperfections.

Magnetic Particle Cracks, porosity,

lack of fusion

Flaws up to in.

beneath surface can

be detected.

Cannot be used on

nonferrous

materials.

Ultrasonic Subsurface flaws:laminations, slag

inclusions

Can be used forthick plates, welds,

castings, forgings.

May be used for

welds where RT not

practical.

Equipment must beconstantly

calibrated.

Figure 7.2


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124



Instructors Outline

Review typical setup for RT inspection.


Typical RT setup.

112

Typic al RT Setup

Test Specimen

Film

X-Ray

X-Ray Tube

Figure 7.3


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125



Instructors Outline

Review how pulse echo UT system can

detect defects.


Typical pulse echo UT system.

113

Pulse Echo UT System

Figure 7.4

A

Transducer

Cable

Flaw

Couplant

B

Test Specimen

Read Out

Base Line

Cathode Ray Tube (CRT)

CB

A

Input-OutputGenerator

C


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126



Instructors Outline

1. Water is a safer test medium than

air. Pneumatic testing should only

be used on an exception basis.

2. Ratio is the lowest value of:


Pressure test is used as final

demonstration of vessel integrity.

)etemperaturdesign(S

)etemperaturtest(S

114

Pressure Test ing

Typically use water as test medium

Demonstrates structural and mechanical

integrity after fabrication and inspection

Higher test pressure provides safety margin

PT= 1.5 P (Ratio)


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127



Instructors Outline

Review additional pressure test design

considerations.


Pressure test considerations.

115

Pressure Test ing ,cont d

Hydrotest pressures must be calculated:

For shop test. Vessel in horizontal position.

For field test. Vessel in final position withuncorroded component thicknesses.

For field test. Vessel in final position and withcorroded component thicknesses.

PTFlange test pressure Stress 0.9 (MSYS) Field test with wind


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128



Instructors Outline

1. Highlight the subjects covered in the

course.

2. Note that much more time is

required for an in-depth discussion

of pressure vessel design. This

course provides a good starting

point to proceed further for those

who need to.

3. Provide the evaluation form for the

class to complete. Collect these and

return them to the sponsoring unit.

4. Distribute the CEU form to the

participants and point out that they

will have to mail it in themselves,

with the required standard fee. All

the information is on the form.


Summarize course.

116

Summary

Materials

Fabrication

Testing

Design

Inspection

Overview of pressure vessel mechanical design

ASME Section VIII, Division 1

Covered


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Appendix AReproducible Overheads


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Appendix BCourse & Instructor Evaluation Form


131/137

131

ASME Career Development Series Course Evaluation

Course Title: ________________________________________________

Location: ___________________________________________________Instructor: __________________________________________________

Please assist us in the evaluation of this program. Answer the following questions by circling only one answerunless otherwise stated. We will be using your feedback to plan future programs. Your assistanceis most appreciated. Please return to instructor as requested.

A. Course Evaluation

Please record your overall reaction to the program by placing a circle around the appropriatenumber on the scale.

10 9 8 7 6 5 4 3 2 1 0

Excellent Good Fair Poor

Please evaluate the course by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location.

1. Course content Relevance of New

matches brochure course notes/ Applicability Knowledge Overall

description workbook to your job Gained Rating

1.1 E G F P 1.2 E G F P 1.3 E G F P 1.4 E G F P 1.5 E G F P

2. What do you think was the best feature of the course?

3. What changes, if any, would you make in the program content and/or format?

4. Can you share with us any comments about this program that we coul use as a quote on our courseliterature?

Optional Information:

Name: _______________________________ Title: _______________________________

Company: ____________________________ City, State: __________________________


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132

B. Instructors Evaluation

Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in theappropriate location

5. Effective Effectiveness Effective Openness to

knowledge of of teaching use of Class Overall

subject matter method class time Participation Rating

1.1 E G F P 1.2 E G F P 1.3 E G F P 1.4 E G F P 1.5 E G F P

C. Facilities

6. How would you rate the meeting site?

7. How would you rate the overnight accommodations (if applicable)?

8. In what other cities would you like to see this course held?

9. Additional Comments:

D. Future Courses and Educational Products (Video, Self Study, Software)

10. What other courses would you like to see sponsored?

11. What educational products would you like to see sponsored by ASME and in what medium?

E. On-Site Company Training12. Would your organization be interested in holding this course or other ASME courses at your

facility? If so, please indicate the area of interest and the contact person. Thank you.

13. Course Name/Topic: _________________________________________________________

14. Contact Name: ________________________________ Phone No.: ___________________


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133

Appendix C

Continuing Education Unit(CEU) Submittal Form

Course Improvement Form


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134

ASME Career Development Series

Continuing Education Unit (CEU) Request Form

Each 4-hour ASME Career Development Series Course earns 0.4 CEU s

PLEASE PRINT AL L YOUR INFORMATION CLEARLY

YOUR CERTI FI CATE WIL L BE PREPARED FROM TH IS FORM

Title of Program: _____________________________________________________

Date Held: __________________________________________________________

Instructor: __________________________________________________________

Location: ___________________________________________________________

Number of CEUs Earned: (0.4 per 4-hour module) ____________

Last Name: __________________________________________

First Name, Middle Initial: ______________________________

Title/Position: ________________________________________

Company: ___________________________________________

Address: ____________________________________________

City: _______________________ State: __ Zip: ____________

Telephone: __________________ Fax: ____________________

Email: _________________________

Please send this form, along with a check made out to ASME

for the standard fee of $15.00 to:

ASME Continuing Education Institute

Three Park Avenue

New York, NY 10016-5990

Your Certificate will be prepared and sent to the address you indicated above.


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135

ASME Career Development SeriesCourse Improvement Form

Important Note: Submission of thi s form is optional. However, we would li ke to soli cit the comments of theI nstructor so that we may conti nu ing improve on the Career Development Seri es. Any instructorswho would l ike to writ e a cour se should indi cate so on thi s form and an authors package wil l be

forwarded to you.

Thank you for helping us with the Career Development Seri es

Name: _________________________________________________________

Address: _______________________________________________________

City/State/Zip: __________________________________________________

Telephone: ______________________________

Fax: ____________________________________

Email: __________________________________

Comments:

Please send this form to:

ASME Continuing Education Institute

Three Park Avenue

New York, NY 10016-5990


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136

ASME Career Development SeriesInstructor s Biography Form

Important Note: Submission of this form is required every time a Career Development

Series Cour se is taugh t. ASME cannot process attendees CEU requests wi thout

this form.

Attachments to this form must include:

1. A biographical sketch of the instructor .

2. Course evaluations f il led out by the parti cipants at the completion of the cour se.

Course: ____________________________________________________

Date Presented: ______________________________________________

Location: ___________________________________________________

Instructor: __________________________________________________

Number of participants: ________________________________________

Sponsoring Unit: _____________________________________________


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