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ASME - Overview of Pressure Vessel Design
ASME - Overview of Pressure Vessel Design
Instructor’s Guide
1
CONTACT INFORMATION
ASME Headquarters
1-800-THE-ASME
http://www.asme.org
http://www.asme.org
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Overview of Pressure Vessel Design
By:
Vincent A. Carucci
Carmagen Engineering, Inc.
Copyright © 1999 by
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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 Plan…………………………………………………………11
Instructor Notes……………………………………………………….13
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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 a mong the divisions.
It then concentrates on and presents an overview of Division I. This course also
discusses several relevant items that are not included in Division I.
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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 today’s 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 instructor’s 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.
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
Overheads/
Time, Major Class Segment Sub-Segment Sub-Segment
Participant
min. Interval Interval
Pages
10 Introduction 5 Introduction/Logistics OV – 1
Outline Module Part. – 65
5 Module based primarily on the OV – 2
ASME Code Section VIII, Division Part. – 65
1. Divisions 2 and 3 will be briefly
described
25 General 10 Main Pressure Vessel Components OV – 3-9
Part. – 67
10 Scope of ASME Code Section VIII OV – 10-13
• Division 1 Part. – 75
• Division 2
• Division 3
5 Structure of Section VIII, Division 1 OV – 14
Part. –78
20 Materials of 15 Material Selection Factors OV – 15-31
Construction • Strength Part. – 79
• Corrosion Resistance
• Resistance to Hydrogen Attack
• Fracture Toughness
• Fabricability
5 Maximum Allowable Stress OV – 32-34
Part. – 87
10 Exercise 10 Material Selection Based On Fracture OV – 35-38
Toughness Part. – 91
10 Break 10
55 Design 10 Design Conditions and Loadings OV – 39-43
• Pressure Part. – 92
• Temperature
• Other Loadings
25 Design for Internal Pressure OV – 44-55
• Weld Joints Part. - 98
• Cylindrical Shells
• Heads
• Conical Sections
Sample Problem
20 Design for External Pressure and OV – 56-65
Compressive Stresses Part. – 109
• Cylindrical Shells
• Other Components
• Sample Problem
11
Suggested Outline/Teaching Plan, continued
Overheads/
Time, Major Class Segment Sub-Segment Sub-Segment
Participant
min. Interval
Interval Pages
10 - 50 Major Break Lunch or Major Break
12
Overview of Pressure Vessel Design
Instructor’s Personal Notes
OVERVIEW OF
PRESSURE VESSEL DESIGN
By: Vincent A. Carucci
Carmagen Engineering, Inc .
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Course Overview
• General
• Materials of Construction
• Design
• Other Design Considerations
• Fabrication
• Inspection and Testing
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Pressure Vessels
• Containers for fluids under pressure
• Used in variety of industries
– Petroleum refining
– Chemical
– Power
– Pulp and paper
– Food
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Horizontal Drum on
Saddle Supports Nozzle
A
Shell
Head Head
SectionA-A
Figure 2.1
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Vertical Drum
on Leg Supports
Head
Shell Nozzle
Head
Support
Leg
5 Figure 2.2
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Tall Vertical Tower
Nozzle
Head
Trays
Shell
Nozzle
Cone
Nozzle
Shell
Nozzle Head
Skirt
Support
6 Figure 2.3
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Vertical Reactor
Inlet
Nozzle
Head
Upper
Catalyst
Bed Shell
Catalyst Bed
Support Grid
Lower
Catalyst
Bed
Outlet
Collector
Head
Outlet
Nozzle
Support
Skirt
7 Figure 2.4
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Spherical Pressurized
Storage Vessel
Shell
Support
Leg
Cross
Bracing
Figure 2.5
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Vertical Vessel on
Lug Supports
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Figure 2.6
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
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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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Section VIII Division 1
• 15 psig < P ≤ 3000 psig
• Applies through first connection to pipe
• Other exclusions
– Internals (except for attachment weld to vessel)
– Fired process heaters
– Pressure containers integral with machinery
– Piping systems
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Section VIII, Division 2,
Alternative 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
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economics
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Division 3, Alternative Rules
High Pressure Vessels
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Structure of Section VIII,
Division 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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• Strength
• Corrosion Resistance
• Resistance to Hydrogen Attack
• Fracture Toughness
• Fabricability
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Strength
• Determines required component thickness
• Overall strength determined by:
– Yield Strength
– Ultimate Tensile Strength
– Creep Strength
– Rupture Strength
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Corrosion Resistance
• Deterioration of metal by chemical action
• Most important factor to consider
• Corrosion allowance supplies additional
thickness
• Alloying elements provide additional
resistance to corrosion
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Resistance to
Hydrogen Attack
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Brittle Fracture
and Fracture Toughness
• Fracture toughness: Ability of material to
withstand conditions that could cause
brittle fracture
• Brittle fracture
– Typically at “low” temperature
– Can occur below design pressure
– No yielding before complete failure
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Brittle Fracture and
Fracture Toughness, cont’d
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Factors That Influence
Fracture Toughness
• Fracture toughness varies with:
- Temperature
- Type and chemistry of steel
- Manufacturing and fabrication processes
• Other factors that influence fracture
toughness:
- Arc strikes, especially if over repaired area
- Stress raisers or scratches in cold formed thick
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plate
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Charpy V-Notch Test Setup
Scale
Starting Position
Hammer
Pointer
h'
Anvil
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
ASME Code and
Brittle Fracture Evaluation
• Components to consider
– Shells – Nozzles
– Manways – Tubesheets
– Heads – Flanges
– Reinforcing pads – Flat cover plates
– Backing strips – Attachments essential
that remain in to structural integrity
place that are welded to
pressure parts
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Temperatures to Consider
• Minimum Design Metal Temperature
(MDMT)
– Lowest temperature at which component has
adequate fracture toughness
• Critical Exposure Temperature (CET)
– Minimum temperature at which significant
membrane stress will occur
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Simplified ASME
Evaluation Approach
• Material specifications classified into
Material Groups A through D
• Impact test exemption curves
– For each Material Group
– Acceptable MDMT vs. thickness where impact
testing not required
• If combination of Material Group and
thickness not exempt, then must impact test
25at CET
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Material Groups
MATERIAL
GROUP APPLICABLE MATERIALS
Curve A • All carbon and low alloy steel plates, structural shapes, and bars not
listed in Curves B, C & D
• SA-216 Gr. WCB & WCC, SA-217 Gr. WC6, if normalized and tempered
or water-quenched and tempered
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Material Groups, cont’d
MATERIAL
GROUP APPLICABLE MATERIALS
Curve C • SA-182 Gr. 21 & 22, if normalized and tempered
• SA-302 Gr. C & D
• SA-336 Gr. F21 & F22, if normalized and tempered
• SA-387 Gr. 21 & 22, if normalized and tempered
• SA-516 Gr. 55 & 60, if not normalized
• SA-533 Gr. B & C
• SA-662 Gr. A
• All material of Curve B if produced to fine grain practice and
normalized which are not included in Curve D
Bolting • See Figure UCS-66 of the ASME Code Section VIII, Div. 1, for impact
and Nuts test exemption temperatures for specified material specifications
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Overview of Pressure Vessel Design
Instructor’s Personal Notes Impact Test Exemption Curves
for Carbon and Low-Alloy Steel
140
120
100
60
C
40
D
20
-20
-40
-55
-60 Impact testing required
-80
0.394 1 2 3 4 5
Nominal Thickness, in.
(Limited to 4 in. for Welded Construction)
Figure 3.1
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Additional ASME Code Impact
Test Requirements
• Required for welded construction over 4 in.
thick, or nonwelded construction over 6 in.
thick, if MDMT < 120°F
• Not required for flanges if temperature
≥ -20°F
• Required if SMYS > 65 ksi unless
specifically exempt
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Additional ASME Code
Impact Test
Requirements, cont’d
• Not required for impact tested low
temperature steel specifications
– May use at impact test temperature
• 30°F MDMT reduction if PWHT P-1 steel
and not required by code
• MDMT reduction if calculated stress <
allowable stress
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Fabricability
• Ease of construction
• Any required special fabrication practices
• Material must be weldable
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Maximum Allowable Stress
• Stress: Force per unit area that resists loads
induced by external forces
• Pressure vessel components designed to
keep stress within safe operational limits
• Maximum allowable stress:
– Includes safety margin
– Varies with temperature and material
• ASME maximum allowable stress tables for
permitted material specifications
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Maximum Allowable
Stress, cont’d
ALLOWABLE STRESS IN TENSION FOR CARBON AND
LOW-ALLOY STEEL
Spec No. Grade Nominal P-No. Group No. Min. Yield Min. Tensile
Composition (ksi) (ksi)
Carbon Steel Plates and Sheets
SA-515 55 C-Si 1 1 30 55
60 C-Si 1 1 32 60
65 C-Si 1 1 35 65
70 C-Si 1 2 38 70
SA-516 55 C-Si 1 1 30 55
60 C-Mn-Si 1 1 32 60
65 C-Mn-Si 1 1 35 65
70 C-Mn-Si 1 2 38 70
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Maximum Allowable
Stress, cont’d
ALLOWABLE STRESS IN TENSION FOR CARBON AND LOW ALLOY STEEL
Max Allowable Stress, ksi (Multiply by 1,000 to Obtain psi)
for Metal Temperature, °F, Not Exceeding
Spec
650 700 750 800 850 900 950 1000 1050 1100 1150 1200 No.
Carbon Steel Plates and Sheets
13.8 13.3 12.1 10.2 8.4 6.5 4.5 2.5 -- -- -- -- SA-515
15.0 14.4 13.0 10.8 8.7 6.5 4.5 2.5 -- -- -- -- SA-515
16.3 15.5 13.9 11.4 9.0 6.5 4.5 2.5 -- -- -- -- SA-515
17.5 16.6 14.8 12.0 9.3 6.5 4.5 2.5 -- -- -- -- SA-515
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Material Selection Based
on Fracture Toughness
Exercise 1
• New horizontal vessel
• CET = - 2°F
• Shell and heads: SA-516 Gr. 70
• Heads hemispherical: ½ in. thick
• Cylindrical shell: 1.0 in. thick
• No impact testing specified
• Is this correct?
• If not correct, what should be done?
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Exercise 1 - Solution
• Must assume SA-516 Gr. 70 not normalized.
Therefore, Curve B material (Ref. Table 3.1).
• Refer to Curve B in Figure 3.1.
– ½ in. thick plate for heads: MDMT = -7°F
– ½ in. thick plate exempt from impact testing since
MDMT < CET
• 1 in. shell plate: MDMT = +31°F
– Not exempt from impact testing
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Exercise 1 - Solution, cont’d
• One approach to correct: Impact test 1 in. plate
at -2°F. If passes, material acceptable.
• Another approach: Order 1 in. plate normalized
– Table 3.1: normalized SA-516 is Curve D material
– Figure 3.1: 1 in. thick Curve D, MDMT = -30°F
– Normalized 1 in. thick plate exempt from impact testing
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Design Conditions
and Loadings
• Determine vessel mechanical design
• Design pressure and temperature, other
loadings
• Possibly multiple operating scenarios to
consider
• Consider startup, normal operation,
anticipated deviations, shutdown
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Design Pressure
PT = Design Pressure at
Top of Vessel
γ = Weight Density of
Liquid in Vessel
H = Height
of Liquid
Figure 4.1
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Temperature Zones
in Tall Vessels
Section 4
(T-Z)
Section 3
(T-Y)
Section 2
(T-X)
Section 1
(T) F
Support Skirt
Grade
Figure 4.2
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Additional Loadings
• Weight of vessel and normal contents
under operating or test conditions
• Superimposed static reactions from weight
of attached items (e.g., motors, machinery,
other vessels, piping, linings, insulation)
• Loads at attached internal components or
vessel supports
• Wind, snow, seismic reactions
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Additional Loadings, cont’d
• Cyclic and dynamic reactions caused by
pressure or thermal variations, equipment
mounted on vessel, and mechanical loadings
• Test pressure combined with hydrostatic
weight
• Impact reactions (e.g., from fluid shock)
• Temperature gradients within vessel
component and differential thermal
expansion between vessel components
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
C C
C
A
A C
B
A D
D A B
D
B
D B
A
B A C
C D
Figure 4.3
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Weld Types
Buttjointsasattainedbydouble-weldingorbyother
1 means which will obtain the same quality of deposited
weld metal on the inside and outside weld surface.
For circumferential
joint only
4 Double-fullfilletlapjoint.
Figure 4.4
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Figure 4.5
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Summary Of ASME
Code Equations
Thickness, Pressure, Stress,
Part tp , in. P, psi S, psi
Pr SE 1t P(r + 0.6t)
Cylindrical shell SE1 − 0.6P tE1
r + 0.6t
Pr 2SEt P(r + 0.2t )
Spherical shell 2SE1 − 0.2P r + 0.2t 2tE
Figure 4.6
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Typical Formed Closure Heads t
R
sf
sf
ID ID
Flanged Hemispherical
t
t
h
h
sf sf
α t α t
sf
r
ID ID
Conical Toriconical
48
Figure 4.7
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Hemispherical
Head to Shell Transition
th th
Thinner Part
Thinner Part
l ≥ 3y
l ≥ 3y
Tangent Line
y y
Length of required taper, l,
may include the width
of the weld
ts ts
Figure 4.8
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 1
Hemispherical
DESIGN INFORMATION
Design Pressure = 250 psig
Design Temperature = 700° F
Shell and Head Material is SA-515
Gr. 60
Corrosion Allowance = 0.125"
4' - 0"
Both Heads are Seamless
60' - 0" Shell and Cone Welds are Double
Welded and will be Spot
Radiographed
The Vessel is in All Vapor Service
Cylinder Dimensions Shown are
Inside Diameters
10' - 0"
6' - 0"
30' - 0"
2:1 Semi-Elliptical
Figure 4.9
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
• P = 250 psig
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 1
Solution, cont’d
• For 6 ft. - 0 in. shell
t = tp + c = 0.747 + 0.125
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 1
Solution, cont’d
• For 4 ft. - 0 in. shell
250 × 24.125
tp = = 0.499 in.
14,400 × 0. 85 − 0. 6 × 250
t = 0.499 + 0.125
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 1
Solution, cont’d
Both heads are seamless, E = 1.0.
Top Head - Hemispherical (Figure 4.6)
Pr 250 × 24.125
tp = = = 0.21 in.
2SE1 − 0.2P 2 × 14,400 × 1 − 0.2 × 250
t = tp + c = 0.21 + 0.125
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 1
Solution, cont’d
• Bottom Head - 2:1 Semi-Elliptical (Figure 4.6)
t = 0.628 + 0.125
t = 0.753 in., including corrosion allowance
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
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
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Design For
External Pressure and
Compressive Stresses, cont’d
• ASME procedures for cylindrical shells,
heads, conical sections. Function of:
– Material – Temperature
– Diameter – Thickness
– Unstiffened length
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Stiffener Rings
Moment Axis of Ring
h/3
L L L L L
L L L L L
h/3
h = Depth of Head
Figure 4.10
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
DESIGN INFORMATION
Design Pressure = Full Vacuum
Design Temperature = 500° F
4' - 0" Shell and Head Material is
SA-285 Gr. B, Yield Stress = 27 ksi
Corrosion Allowance = 0.0625"
Cylinder Dimension Shown
150' - 0"
is Inside Diameter
2:1 Semi-Elliptical
(Typical)
Figure 4.11
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2 - Solution
• Calculate L and Do of cylindrical shell.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
Solution, cont’d
• Determine A.
• Use Figure 4.12, Do /t, and L/Do.
Note: If L/Do > 50, use L/Do = 50. For L/Do < 0.05, use
L/Do = 0.05
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
Solution, cont’d
A = 0.000065
Do/t = 100
.0001
4 5 6 789
D o/t = 125
Do /t = 130 D o/t = 150
D /t = 200
o
3
D o/t = 250 0
00 00 00 800 ,00
= 4 t=5 t = 6 =1
2
/t =
.00001
D o/t = 300 /t / / /t
Do Do Do Do Do
50.0
40.0
35.0
30.0
25.0
20.0
18.0
14.0
10.0
9.0
8.0
7.0
6.0
2.0
1.8
1.6
1.4
1.2
16.0
12.0
5.0
4.0
3.5
3.0
2.5
Length + Outside Diameter = L/Do
L/Do = 37
Factor A
Figure 4.12
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
Solution, cont’d
20,000
GENERAL NOTE: See Table CS-1 for tabular values 18,000
up to 300°F 16,000
500°F 14,000
700°F 12,000
800°F 10,000
FACTOR B
900°F 9,000
8,000
E=29.0 x 106
7,000
E=27.0 x 106
6,000
E=24.5 x 106
5,000
2,500
2,000
2 3 4 5 6 789 2 3 4 5 6 789 2 3 4 5 6789 2 3 4 5 6 789
.00001 .0001 .001 .01 .1
A=0.000065 FACTOR A
Factor B
63 Figure 4.13
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
Solution, cont’d
• Calculate maximum allowable external pressure
2AE
Pa =
3(Do / t )
Where:
E = Young's modulus of elasticity
E = 27 × 106 psi (Figure 4.13) at T = 500°F
P a = 9 psi
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 2
Solution, cont’d
Since Pa < 15 psi, 7/16 in. thickness not sufficient
• Assume new thickness = 9/16 in.,
corroded thickness L = 1/2 in.
Do 48. 875 L
= = 97.75 = 3 7 (as before)
t 0. 5 Do
A = 0.000114
2 × 0.000114 × 27 × 10 6
Pa = = 15. 7 psi
3 × 130. 33
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Exercise 2 - Required
Thickness for Internal Pressure
• Inside Diameter - 10’ - 6”
• Design Pressure - 650 psig
• Design Temperature - 750°F
• Shell & Head Material - SA-516 Gr. 70
• Corrosion Allowance - 0.125 in.
• 2:1 Semi-Elliptical heads, seamless
• 100% radiography
• Vessel in vapor service
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Exercise 2 - Solution
• For shell tp =
Pr
SE 1 − 0 .6P
P = 650 psig
r = 0.5 × D + CA
= (0.5 × 126) + 0.125 = 63.125 in.
• S = 16,600 psi, Figure 3.3 for SA-516 Gr. 70
• E = 1.0, Figure 4.8 for 100% radiography
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Exercise 2 - Solution, cont’d
Add corrosion allowance
tp = 2.53 + 0.125 = 2.655 in.
• For the heads
PD
tp =
2 SE − 0. 2P
68
tp = 2.23 + 0.125 = 2.355 in.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Reinforcement of Openings
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Cross Sectional View of
Nozzle Opening
Dp
tn Rn
t rn
2.5t or 2.5t n + te te
Use smaller value tr
t c
2.5t or 2.5t n h
Use smaller value d
d or R n + tn + t d or R n + tn + t
Figure 4.14
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Nozzle Design Configurations
(a)
Full Penetration Weld
With Integral Reinforcement (a-1) (a-2) (a-3)
Separate Reinforcement Plates Added
(f-1) (f-3)
(f-2)
(f-4) (g)
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Figure 4.15
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Additional Reinforcement
• Necessary if insufficient excess thickness
• Must be located within reinforcement zone
• Allowable stress of reinforcement pad
should be ≥ that of shell or head
• Additional reinforcement sources
– Pad
– Additional thickness in shell or lower part of
nozzle
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3
DESIGN INFORMATION
Design Pressure = 300 psig
Design Temperature = 200° F
Shell Material is SA-516 Gr. 60
Nozzle Material is SA-53 Gr. B, Seamless
Corrosion Allowance = 0.0625"
Vessel is 100% Radiographed
Nozzle does not pass through Vessel Weld Seam
NPS 8 Nozzle
(8.625" OD)
0.5" Thick
Figure 4.16
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 - Solution
• Calculate required reinforcement area, A
A = dtrF
Where:
d = Finished diameter of circular opening, or
finished dimension of nonradial opening in
plane under consideration, in.
tr = Minimum required thickness of shell using
E = 1.0, in.
F = Correction factor, normally 1.0
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate diameter, d.
d = Diameter of Opening – 2 (Thickness +
Corrosion Allowance)
d = 8.625 – 1.0 + .125 = 7.750 in.
• Calculate required shell thickness, t r (Figure 4.6)
tr = 0.487 in.
• Assume F = 1.0
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate A
A = dtr F
A = (8.625 - 1.0 + 0.125) × 0.487 × 1
= 3.775 in.2
• Calculate available reinforcement area in vessel
shell, A 1, as larger of A 11 or A1 2
A1 1 = (E lt - Ftr)d
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A1 2 = 2 (Elt-Ftr)(t + tn)
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
Where:
E l = 1.0 when opening is in base plate away from welds,
or when opening passes through circumferential joint
in shell (excluding head to shell joints).
E l = ASME Code joint efficiency when any part of opening
passes through any other welded joint.
F = 1 for all cases except integrally reinforced nozzles
inserted into a shell or cone at angle to vessel
longitudinal axis. See Fig. UG-37 for this special
case.
tn = Nominal thickness of nozzle in corroded condition, in.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
A 11 = (Elt - Ftr)d = (0.5625 - 0.0625 - 0.487) × 7.75 = 0.1 in.2
A 12 = 2 (Elt - Ftr ) (t + t n)
= 0.0243 in. 2
Therefore,
A1 = 0.1 in.2 available reinforcement in shell
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate reinforcement area available in nozzle wall, A2,
as smaller of A21 or A22.
A21 = (tn-tr n) 5t
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
Where:
te = 0 if no reinforcing pad.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate required nozzle thickness, trn (Figure 4.6)
Pr
t rn =
SE1 − 0. 6P
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate A2.
A21 = (tn - trn)5t = (0.5 - 0.0625 - 0.0784) × 5 (0.5625 - 0.0625)
= 0.898 in.2
A22 = 2 (tn - t rn) (2.5 tn + te)
= 2 (0.5 - 0.0625 - 0.0784) [2.5 × (0.5 - 0625) + 0]
= 0.786 in.2
Therefore,
A2 = 0.786 in.2 available reinforcement in nozzle.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Determine total available reinforcement area, A T;
compare to required area.
AT = A1 + A2 = 0.1 + 0.786 = 0.886 in.2
AT < A, nozzle not adequately reinforced, reinforcement
pad required.
• Determine reinforcement pad diameter, Dp.
A5 = A - AT
A5 = (3.775 - 0.886) = 2.889 in.2
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 3 -
Solution, cont’d
• Calculate Dp
te = 0.5625 in. (reinforcement pad thickness)
A 5 = [Dp - (d + 2 t n)] te
2.889 = [Dp - (7.75 + 2(0.5 - 0.0625)] 0.5625
Dp = 13.761 in.
• Confirm Dp within shell reinforcement zone, 2d
2d = 2 × 7.75 = 15.5 in.
Therefore, Dp = 13.761 in. acceptable
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Flange Rating
• Based on ASME B16.5
• Seven classes
(150, 300, 400, 600, 900, 1,500, 2,500)
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Figure 4.17
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Pressure - Temperature Ratings
Material
1.1 1.2 1.3
Group No.
Classes 150 300 400 150 300 400 150 300 400
Temp., °F
-20 to 100 285 740 990 290 750 1000 265 695 925
200 260 675 900 260 750 1000 250 655 875
300 230 655 875 230 730 970 230 640 850
400 200 635 845 200 705 940 200 620 825
500 170 600 800 170 665 885 170 585 775
600 140 550 730 140 605 805 140 534 710
650 125 535 715 125 590 785 125 525 695
700 110 535 710 110 570 755 110 520 690
750 95 505 670 95 505 670 95 475 630
800 80 410 550 80 410 550 80 390 520
850 65 270 355 65 270 355 65 270 355
900 50 170 230 50 170 230 50 170 230
950 35 105 140 35 105 140 35 105 140
1000 20 50 70 20 50 70 20 50 70
Figure 4.18
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 4
Determine Required Flange Rating
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 4 - Solution
• Identify flange material specification
SA-105
• From Figure 4.17, determine Material Group No.
Group 1.1
• From Figure 4.18 with design temperature and
Material Group No. determined in Step 3
– Intersection of design temperature with Material
Group No. is maximum allowable design pressure for
the flange Class
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Sample Problem 4 -
Solution, cont’d
– Table 2 of ASME B16.5, design information for all
flange Classes
– Select lowest Class whose maximum allowable
design pressure ≥ required design pressure.
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Flange Design
• Bolting requirements
– During normal operation (based on design
conditions)
– During initial flange boltup (based on stress
necessary to seat gasket and form tight seal
W
Am =
S
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Flange Loads and
Moment Arms
Flange
Ring
Gasket
t h
A hG W
C
hT hD
g1
HT
G
HD B g0
HG
Flange Hub
Figure 4.19
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Stresses in Flange Ring
and Hub
• Calculated using:
– Stress factors (from ASME code)
– Applied moments
– Flange geometry
• Calculated for:
– Operating case
– Gasket seating case
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Flange Design and
In-Service Performance
Factors affecting design and performance
• ASME Code m and y parameters.
• Specified gasket widths.
• Flange facing and nubbin width, w
• Bolt size, number, spacing
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
ASME Code m and y Factors
Min.
Facing Sketch
Gasket Design
and Column in
Gasket Type and Material Factor, Seating
ASME Table 2-5.2
m Stress y,
(Figure 4.21)
psi
Figure 4.20
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
ASME Code Gasket Widths
Facing Sketch Basic Gasket Seating Width bo
(Exaggerated)
Column I Column II
N N
(1a) N N
N 2 2
N
(1b)
w
T
w+ T w+ N
(1c)
N
w ≤N ; max
w + T ; w + N max 2 4
w
T
2 4
N
(1d) w ≤N
HG HG
G hG G hG
O.D. Contact Face
b C Gasket
L Face
Figure 4.21
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Gasket Materials
and Contact Facings
Gasket Materials and Contact Facings
Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y
Gasket Material Gasket Min. Sketches Facing
Factor Design Sketch and
m Seating Column in
Stress y, Table 2-5.2
psi
Flat metal, jacketed asbestos filled: 3.25 5500 (1a), (1b),
Soft aluminum 3.50 6500 (1c),2, (1d) 2,
Soft copper or brass 3.75 7600 (2)2,
Iron or soft steel 3.50 8000 Column II
Monel 3.75 9000
4% - 6% chrome 3.75 9000
Stainless steels and nickel-base alloys
Figure 4.22
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Maximum Allowable
Working Pressure (MAWP)
Maximum permitted gauge pressure at top of
vessel in operating position for designated
temperature
• MAWP ≥ Design Pressure
• Designated Temperature = Design Temperature
• Vessel MAWP based on weakest component
– Originally based on new thickness less corrosion
allowance
– Later based on actual thickness less future corrosion
98 allowance needed
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Local Loads
• Piping system
• Support attachment
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
ASME Code and
Vessel Internals
• Loads applied from internals on vessel to be
considered in design
101
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Corrosion Allowance
For Vessel Internals
• Removable internals: CA = CA of shell
– Costs less
– Easily replaced
102
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Head-to-Shell Transitions
th th
Thinner part
Thinner part
l l
Tangent
y Line
y
ts t
s
th th
y Tangent y
Line
Thinner part
l
Thinner part
l
t t
s s
Fillet
Weld
Butt Weld
Figure 6.1
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
CL CL
In all cases, l shall not
be less than 3y.
y
C
L
Figure 6.2
104
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Nozzle Neck
Thickness Tapers
Figure 6.3
105
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Stiffener Rings
Figure 6.4
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Post Weld Heat Treatment
• Restores material properties
• Relieves residual stresses
• ASME Code PWHT requirements
– Minimum temperature and hold time
– Adequate stress relief
– Heatup and cooldown rates
107
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
• Welds
• Dimensional requirements
• Equipment documentation
108
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Common Weld Defects
Lack of Fusion
Incomplete Penetration
ExternalUndercut
Internal Undercut
Undercut
Figure 7.1
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Weld Defects
Presence of defects:
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Types of NDE
NDE TYPE DEFECTS ADVANTAGES LIMITATIONS
DETECTED
Radiographic Gas pockets, slag Produces Expensive.
inclusions, permanent record. Not practical for
incomplete Detects small flaws. complex shapes.
penetration, cracks Most effective for
butt-welded joints.
Visual Porosity holes, slag Helps pinpoint Can only detect
inclusions, weld areas for additional what is clearly
undercuts, NDE. visible.
overlapping
Liquid Penetrant Weld surface-type Used for ferrous Can only detect
defects: cracks, and nonferrous surface
seams, porosity, materials. Simple imperfections.
folds, pits, and less expensive
inclusions, than RT, MT, or UT.
shrinkage
Magnetic Particle Cracks, porosity, Flaws up to ¼ in. Cannot be used on
lack of fusion beneath surface can nonferrous
be detected. materials.
Ultrasonic Subsurface flaws: Can be used for Equipment must be
laminations, slag thick plates, welds, constantly
inclusions castings, forgings. calibrated.
May be used for
welds where RT not
practical.
Figure 7.2
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Typical RT Setup
X-Ray Tube
X-Ray
Film
Test Specimen
Figure 7.3
112
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Pulse Echo UT System
Cathode Ray Tube (CRT)
A C
B Read Out
BaseLine
Input-Output Cable
Generator
Transducer
Couplant
Test Specimen
Flaw
Figure 7.4
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Pressure Testing
• Typically use water as test medium
• Demonstrates structural and mechanical
integrity after fabrication and inspection
• Higher test pressure provides safety margin
• PT = 1.5 P (Ratio)
114
S( test temperatur e)
S ( design temperatur e)
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
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Overview of Pressure Vessel Design
Instructor’s Personal Notes
Summary
• Overview of pressure vessel mechanical design
• ASME Section VIII, Division 1
• Covered
– Materials – Design
– Fabrication – Inspection
– Testing
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128
Appendix A
Reproducible Overheads
Appendix B
Course & Instructor Evaluation Form
ASME Career Development Series Course Evaluation
A. Course Evaluation
Please record your overall reaction to the program by placing a circle around the appropriate
number on the scale.
Please evaluate the course by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location.
3. What changes, if any, would you make in the program content and/or format?
4. Can you share with us any comments about this program that we coul use as a quote on our course
literature?
Optional Information:
Name: _______________________________ Title: _______________________________
Company: ____________________________ City, State: __________________________
131
B. Instructor’s Evaluation
Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in the
appropriate location
C. Facilities
6. How would you rate the meeting site?
8. In what other cities would you like to see this course held?
9. Additional Comments:
11. What educational products would you like to see sponsored by ASME and in what medium?
132
Appendix C
133
ASME Career Development Series
Continuing Education Unit (CEU) Request Form
Each 4-hour ASME Career Development Series Course earns 0.4 CEU’s
Please send this form, along with a check made out to ASME
for the standard fee of $15.00 to:
ASME Continuing Education Institute
Three Park Avenue
New York, NY 10016-5990
Your Certificate will be prepared and sent to the address you indicated above.
134
ASME Career Development Series
Course Improvement Form
Important Note: Submission of this form is optional. However, we would like to solicit the comments of the
Instructor so that we may continuing improve on the Career Development Series. Any instructors
who would like to write a course should indicate so on this form and an authors package will be
forwarded to you.
Name: _________________________________________________________
Address: _______________________________________________________
City/State/Zip: __________________________________________________
Telephone: ______________________________
Fax: ____________________________________
Email: __________________________________
Comments:
135
ASME Career Development Series
Instructor’s Biography Form
Important Note: Submission of this form is required every time a Career Development
Series Course is taught. ASME cannot process attendees’ CEU requests without
this form.
Course: ____________________________________________________
Location: ___________________________________________________
Instructor: __________________________________________________
136
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