ASME e - Learn - Final - Sec VIII-2 PDF

ASME Section VIII, Division 2
Design And Fabrication Of

Pressure Vessels
1
Table of Contents
MODULE 1: Introduction And General Requirements
MODULE 2: Data Reports And Stamping
MODULE 3: Materials Requirements
MODULE 4: Material Toughness Requirements
MODULE 5: Design By Rule Requirements
MODULE 6: Design For Internal Pressure
MODULE 7: Design For External Pressure And Buckling
MODULE 8: Design Rules For Openings
MODULE 9: Design By Analysis Requirements
MODULE 10: Fabrication Requirements
MODULE 11: Inspection And Examination Requirements
MODULE 12: Pressure Testing And Over-pressure Protection Requirements
2
Course Description
• Covers Section VIII, Division 2, of the ASME Boiler &
Pressure Vessel Code
• Includes major topics related to construction of
pressure vessels
• Focuses on new design and analysis requirements
introduced in 2007 Edition of the Code
– Includes history of (and basis for) the rules
• Details complexity of new design formulas

– Importance of understanding design rules to apply them
properly
3
Module 1: Introduction and
General Requirements
4
Module 1: Learning Objectives
• At the conclusion of Module 1, participants will be able
to:
– Describe the scope and contents of the ASME Boiler & Pressure
Vessel Code
– Describe the background and scope of Section VIII, Division 2
– Identify the responsibilities of the User, the Manufacturer, and the
Inspector
– Describe the required contents and certification requirements of
the User’s Design Specification and the Manufacturer’s Design
Report
– Name the system of Units used by this Code
and how to apply them
5
Introduction
• B&PV Code consists of 12 Sections and 2 Code Case books (one for nuclear and one
for non-nuclear)
– Normally referred to as the ASME Code
• Code Cases are either additional rules or alternative rules to those of the Code
• Entire set of Code books is re-published every three years

– New “Addenda” published every year
– Includes the revisions and additions approved by the Committee
• New Edition or Addenda may be used as soon as it is published

– Becomes mandatory 6 months after date of publication
–
• Code Committee also issues “Interpretations” of the Code Rules
• Code users may contact Committee to request interpretation of the requirements of a

particular paragraph
6
Sections of ASME Code
• I Rules for Construction of Power Boilers
• II Materials
• III Nuclear
• IV Rules for Construction of Heating Boilers
• V Nondestructive Examination
• VI Recommended Rules for the Care and
Operation of Heating Boilers
• VII Recommended Guidelines for the Care of
Power Boilers
7
Sections of ASME Code (Continued)
• VIII Rules for Construction of Pressure Vessels
– Division 1
– Division 2 – Alternative Rules
– Division 3 – Alternative Rules for Construction of High Pressure
Vessels
• IX Welding and Brazing Qualifications
• X Fiber reinforced Plastic Pressure Vessels
• XI Rules for In-service Inspection of Nuclear Power Plant
Components
• XII Rules for Construction and Continued Service of
Transport Tanks
8
Code Forward
• Key points
– “Construction” comprises materials, design, fabrication, examination, inspection,
testing, certification, & pressure relief
– Codebook not a “handbook” (provides minimum requirements)
– Rules may be supplemented by good practice and jurisdictional requirements
– Code neither requires nor prohibits use of computer programs
– Code does not fully address tolerances
– Code only specifies tolerances that validate the design rules
– Rules do not approve, recommend, or endorse any proprietary or specific design
9
Units
• Construction
– U.S. Customary, SI or any other set may be used
• Design
– Single set of units must be used for all aspects
• Data Reports & Name Plates Entries

– Must be in units consistent with fabrication drawings
• Informative Annex 1.C

– Provides guidance re: use of units & suggested conversion factors
• Tables and figures

– Provided in both sets of units
10
Comparison With Division 1
• Division 2 rules
– Are intended to be just as safe
– Have higher allowable stresses
– Have more rigorous design/analysis requirements
– Have higher fabrication costs
• Owner decides which rules to use

– Div 1 or Div 2
– Usually based on cost of vessel
11
Comparison With Old Division 2
• New Division 2 rules
– Base “joint efficiency” on degree of RT
– Provide partial NDE option
– Offer alternatives to P.E. certification
– Incorporate allowable stresses in creep range from
Division 1
– Allow design temperatures in the creep range
12
Organization of Division 2
• Part 1 – General Requirements
• Part 2 – Responsibilities and Duties
• Part 3 – Materials Requirements
• Part 4 – Design by Rule Requirements
• Part 5 – Design by Analysis requirements
• Part 6 – Fabrication requirements
• Part 7 – Inspection and Examination requirements
• Part 8 – Pressure Testing Requirements
• Part 9 – Overpressure Protection
• “Informative” annexes non-mandatory
• “Normative” annexes mandatory
13
Scope of the Code
• Definition of Pressure vessels
– Containers for containment of pressure, either internal or external
• List of Excluded vessels

– Vessels within scope of other Sections
– Fired process tubular heaters
– Integral parts of rotating or reciprocating mechanical devices
– Piping components
– Components such as strainers, mixers, separators, provided the pressure containing parts
are considered piping.
– Vessels in water service for certain combinations of P and T
– Hot water supply storage tanks
– Vessels with an internal or external pressure not exceeding 15 psi.
– Vessels with an inside diameter not exceeding 6”.
– Pressure vessels for human occupancy (can use PVHO-1 Code)
• Exception
– Excluded vessels may be constructed and stamped to Div 2 if all requirements are met
14
Geometric Scope
• Where piping, other PVs or devices connect to vessel
– First circumferential welded joint, the first threaded joint, or face
of first flange
• First sealing surface of propriety connections or fittings
• Non-pressure parts
– Subject to specific non-pressure requirements only
• Pressure retaining covers and their fasteners for
openings
– Such as manholes
15
Responsibilities & Duties
• Three parties involved with construction of a
Code stamped vessel
– User
– Manufacturer
– Inspector
16
User Responsibilities & Duties
• Prepare and provide User’s Design Specification
(UDS)
– Provides basis for design and construction
– Specifies effective Code Edition and Addenda
– Must be certified in accordance with Annex 2.A of
Codebook
– Sample certification statement added
17
Minimum UDS Requirements**
• Location of installation
• Jurisdictional authority
• Environmental loads such as wind or earthquake
• The lowest one day mean temperature
• Vessel identification
• Service fluid and density
• Vessel configuration including openings and method of support
• Design conditions including design temperature, design pressure, minimum design metal
temperature (MDMT), dead and live loads
• Operating conditions including operating pressure, operating temperature, Fluid transients and
flow
• Cyclic conditions and number of associated cycles
• Materials of construction and service related requirements for them
• Corrosion and/or erosion allowance
• All loads and load cases
• Overpressure protection requirements
• ** This is not a complete list
18
Manufacturer Responsibilities & Duties
• Assure structural and pressure retaining integrity
of the vessel
• Meet all Code and UDS requirements
• Ensure work quality of sub-contractors
• Prepare and provide Manufacturer’s Design
Report (MDR)
• This is not a complete list
19
Manufacturer’s Design Report (MDR)
• Minimum requirements
– Final as-built drawings
– The actual material specifications
– Design calculations and analysis
– Results of any fatigue analysis
– Any assumptions used for design
Not a complete list
• Must be certified in accordance with Annex 2.A of

Codebook
20©
Inspector Duties
• Assure all Code requirements are met
• Conduct the following inspections (from Annex

7.A of the Code):
– Inspect materials for compliance, markings and
traceability
– Assure all heat treatments are properly performed
– Assure all welding and NDE meet Code
– Witness pressure test
– Verify name plate markings
21
Module 1: Review Activity
• What are additional rules or alternative rules to the Code rules
known as?
• How many Sections does the B&PV Code contain?
• Match the following parties with their responsibilities or duties:

• User
• Manufacturer
• Inspector
• Assures that all Code requirements are met by other parties, in the
construction of the vessel
• Prepares and provides a UDS
• Assures structural and pressure retaining integrity
of the vessel
22
Module 1: Review Activity (Continued)
• Name at least six items that must be included in
the User’s Design Specification
• Name five items that must be included in the

Manufacturer’s Design Report
• What system of Units may be used for

construction to this Code?
23
Module 2: Data Report and
Stamping
24
• At the conclusion of Module 2, the participants
will be able to:
– Identify the requirements for obtaining an ASME Code
stamp
– Name the key features to address in a quality control
program
– Complete a Manufacturer’s Data Report
– Describe Code stamp and name plate markings
25
Code Stamps
• To Apply Stamp
– Manufacturer must obtain stamp and Certificate of Authorization from
ASME
– Proper Division 2 Code stamp is “U2”
– Safety relief equipment must have “UV” stamp
• To Obtain Certificate of Authorization

– Apply to ASME
– Have contract with Authorized Inspection Agency
– Pass ASME team administered survey
– Prepare Quality Control program
• Quality Control program requirements

– Summarized in Annex 2.E
26
Data Reports
• Completed by Manufacturer once fabrication is finished
– Use form A-1 for overall vessel
– Use form A-2 for part supplied by a Manufacturer other than the
vessel Manufacturer
• Copies should be sent to:
– The User
– The Inspector, if requested
– Jurisdiction, if required
– A file copy to be kept by the Manufacturer, for a minimum of 3
years
– Filed with the National Board (recommended)
• Form A-3 is Supplementary Sheet
– Use if information does not fit on forms A-1 and A-2
27
Data Reports
28
Data Reports
29
Stamping
• Proper stamp for a Division 2 vessel is the “U2”
• Code symbol may be directly applied to vessel wall
• Stamp is applied to name plate, then name plate is attached to vessel
• As a minimum, the following markings must be included on the name plate:

– The name of the Manufacturer
– The Manufacturer’s serial number
– The MAWP and the coincident design temperature. More than one combination
of MAWP and design temperature may be marked
– The MAEWP, if applicable
– The MDMT (Minimum Design Metal Temperature)
– The year built
– Method of construction (“W”, for welded – “F”, for forged – “WL”, for welded
layered
– Extent of heat treatment
30
Sample Name Plate
31
1. Name 3 requirements for obtaining a Code stamp
2. Name 5 things that need to be addressed in a Quality Control program
3. What is the Data Report Form for documenting a fabricated part?
4. What parties are required to sign the Data Reports?
5. Who gets a copy of the Data Report?
6. Stamping is done prior to hydrotest. True or false?
7. It is required to show the vessel materials on the name plate. True or False?
8. To obtain a Code stamp, the Manufacturer must have an agreement with an

Authorized Inspection Agency. True or False?
32
Module 3: Materials
Requirements
33
• At the conclusion of Module 3, the participants will be
able to:
– Describe the allowable materials and their requirements for

construction to Division 2
– Identify criteria used to establish allowable stresses and the

design margin on ultimate tensile strength
– Distinguish between the allowable stresses for different codes
– Describe the contents of the data tables in Annexes 3.D, 3.E &
3.F of the Code
34
Permitted Materials
• Material allowed for construction of pressure parts are
listed in Tables of Annex 3.A
– Also in the allowable stress Tables of Section II, Part D
• Also applies to materials for non-pressure parts welded
to pressure parts, unless classified as “minor attachment”
• Welding materials must also be those listed, with some
exceptions
• List of materials in new Division 2 much more extensive
than old Division 2
35
Additional Material Requirements
• Plate material may be ordered to the design
thickness under-thickness tolerance does not
have to be accounted for).
• For pipe or tube product forms, the under-
thickness allowed by the specification is
generally 12 ½ % and must be accounted for in
design.
• There are a number of supplementary
requirements for materials of various categories
• All Ferrous materials must meet the
requirements of paragraph 3.3.
36
Material Requirements (Continued)
• All plate and forging material 2” thick and greater
must be UT examined
• New requirements for MT or PT of machined
surfaces of forgings have been added
• New requirements added for hubs machined
from plates
• Test specimen for materials must be subjected
to same heat treatment as vessel
37
Basis for Stress Allowables
• The stress allowables (below the creep temperature) in all
international Codes, for most materials, are set to not exceed the
lower of the following:
– 2/3 of the minimum specified yield strength
– The minimum specified ultimate tensile strength divided by a Design
Factor, (DF)
• The first limit is universal in all major codes
• The value of DF varies from one Code to another
• The DF started as 5.0 for Div. 1, in 1914
• In 1942, this factor was dropped to 4.0
• The European Codes using DF values between 2.0 and 3.0
• DF in Div. 1 reduced to 3.5, in 1999
• Division 2, was first published in 1963, with a DF of 3.0
• DF in Div. 2 was reduced to 2.4, in 2007
38
Material Properties
• Annex 3.D references Tables “y-1’ and “U” of Section II for the
values of yield strength and ultimate tensile strength, as a function of
temperature
– This Annex also provides “Strength Parameters”, which enables the user
to generate a typical stress-strain curve for any material and calculate
the tangent Modulus
• Annex 3.D allows generating a cyclic stress-strain curve for elastic-
plastic fatigue analysis
• Annex 3.E references tables (in II-D) for a number of Physical
Properties including Young’s Modulus, Coefficient of Thermal
Expansion, Thermal Conductivity, Thermal Diffusivity
• Annex 3.F provides the design fatigue curves (formulas) for elastic
fatigue analysis (smooth bar)
– This Annex also provides parameters for generation of the welded joint
design fatigue curves (master curve or structural stress approach)
39
1. Where are the materials allowed for Code construction listed?
2. For pressure boundary materials, only those materials in the tables may
be used, without exception. True or False?
3. Materials for attachments to pressure boundary are not limited to those
listed in the tables. True or False?
4. To re-certify a material to another specification, the two material
specifications must be identical. True or False?
5. What are the two material properties that generally control allowable
stresses, below the creep temperature?
6. Name 3 major differences between Division 1 and Division 2.
7. What is the design margin on ultimate tensile strength, in Division 2?
8. What would be a good source for values of the Modulus of Elasticity, as a
function of temperature?
40
Module 4: Material Toughness
Requirements
41
will be able to:
– Describe the basis for toughness requirements
– Assess the need for impact testing of various
materials
– Name key methods for exemption from impact testing
– Identify impact testing requirements
42
Toughness Requirements for Carbon & Low
Alloy
• Charpy V-notch (CVN) impact test required, unless exempted by the rules
• The toughness requirements applicable to all shells, heads, nozzles, and attachments
essential to the structural integrity of the vessel.
• The impact testing exemption curves and required toughness curves have been
revised and refined
• There are now two separate sets of impact exemption and toughness requirement
curves, for as-welded and for PWHT’d (or not welded) components
• Rules assure proper selection of materials to have adequate toughness at the coldest
temperature specified (MDMT)
• Figures 3.7 and 3.8 are to be used for as-welded and PWHT’d components,
respectively
• The abscissa of these Figures is “Nominal Governing Thickness”, which may not be
the same as the actual nominal thickness
43
Alloy (Continued)
• The governing thickness of a component is the largest of the following
definitions that apply to that component. The definition of “governing
thickness” is as follows:
– For butt joints (except those in flat heads and tube sheets), the thickness of the
weld, defined as the thinner of the parts joined
– For corner, fillet, or lap welded joints, the thinner of the two parts joined
– For welded flat heads and tube sheets, the largest weld (as defined above) or the
thickness divided by 4, whichever is larger
– For castings, the largest nominal thickness
– For flat non-welded parts (such as bolted flanges, tube sheets, and flat heads),
the thickness divided by 4
– For a non-welded dished head, the greater of flat flange thickness divided by 4 or
the minimum thickness of dished portion
44
Alloy (Continued)
• For the purpose of impact testing exemption, all Carbon and Low Alloy materials have
been grouped into four classifications and assigned to curves A, B, C, or D on Figures
3.7 and 3.8. The classification of a particular material may be determined by the use
of the table that follows these Figures and is included here.
• Once the governing thickness and the material classification have been established
for a component, the need for impact testing can be determined from Figures 3.7 and
3.8. The ordinate of these curves, marked “Minimum Design Metal Temperature” is
the exemption temperature, the coldest temperature to which the component may be
subjected without the need for impact testing. This temperature is to be compared
with the MDMT specified in the UDS. If the specified MDMT is not colder than this
exemption temperature, the material need not be impact tested.
• Based on available data and experience, it has been established that the use of this
particular material is safe at temperatures not colder than this exemption temperature.
Figures 3.7 and 3.8 provide the general rule. Each component of a vessel must be
evaluated based on its classification and governing thickness. A number of exceptions
are applicable to these general rules and all paragraphs under 3.11.2 must be studied
by the Code user. The following paragraphs explain some of such exceptions and
modifications.
45
Alloy (Continued)
• For impact testing exemption, all Carbon and Low Alloy materials
have been grouped into four classifications and assigned to curves
A, B, C, or D
• The classification of a particular material may be determined by the

use of the table included here
• The ordinate of Fig. 3.7 &3.8, marked “Minimum Design Metal

Temperature” is the exemption (from impact testing) temperature
• This temperature is to be compared with the MDMT specified in the

UDS. If the specified MDMT is not colder than this exemption
temperature, the material need not be impact tested
• A number of exceptions are applicable to these general rules
46
Alloy (Continued)
• For the following 3 cases, the impact testing exemption
rules do not apply and impact testing must be done:
– If the governing thickness (defined later) at any welded joint on
the material or the thickness of a non-welded part exceeds 4”,
and MDMT is colder than 90F
– Materials having specified minimum yield strength greater than

65 ksi.
– Welded parts not subject to PWHT, having a governing thickness

exceeding 1.5”
47
Alloy (Continued)
• For the following, impact testing is not required:
– Materials with a thickness not exceeding 0.099” (2.5mm), for
MDMT not colder than -55F
– For components made from NPS 4 pipe or smaller (and for

equivalent size of tubes), of P-No. 1 materials, and for MDMT not
colder than -155F, if the thickness does not exceed a value
between 0.099” and 0.25 inch (depending on the Specified
Minimum Yield Strength (SMYS) of the material)
– ASME B16.5 flanges, ASME B16.47 flanges, and long weld neck
flanges meeting the dimensional requirements of ASME B16.5,
for MDMT not colder than -20F, if heat treated, and for MDMT not
colder than 0F, if as-forged
48
Toughness Requirements for
Carbon & Low Alloy (Continued)
49
50
51
Toughness Requirements for Carbon
& Low Alloy (Continued)
52
53
Alloy (Continued)
• The curves of Figures 3.7 and 3.8 applicable if
the general membrane tensile stress is equal to
the allowable stress
• If the calculated stress is less than the allowable,
credit may be taken to lower the exemption or
impact testing temperature
• The credit depends on the value of Rts, defined
as the ratio of calculated primary membrane
tensile stress to the allowable (or the required
thickness to the nominal corroded thickness)
54
©
Alloy (Continued)
• The amount of credit is obtained from Figures 3.12 and 3.13
(included here)
• For materials with minimum specified yield strength greater than 65
ksi, these Figures are not applicable and a formula is given for
calculating the credit
• If the reduction results in an exemption temperature of colder than
-55F, the material must still be impact tested, if the value of Rts is
more than 0.24
• For values of Rts not exceeding 0.24, the resulting exemption
temperature can be as cold as -155F.
• The credit obtained for Rts being less than 1.0 can also be used for
materials which are required to be impact tested by specifications
55
56
57
58
Alloy (Continued)
• Paragraph 3.1.4 provides exemption rules for high alloy
steels
• The most common grades of austenitic Chromium-Nickel
stainless steel (Types 304, 304L, 316, 316,L, 321, and
347), are exempt from impact testing down to -320F
• Austenitic-ferritic duplex steels up to 3” thick, Ferritic
Chromium stainless steels up to 1/8” thick, and
martensitic chromium stainless steels up to ¼” tick are
exempt down to -20F
• The materials not specifically exempted must always be
impact tested
• When certain heat treatments are performed on stainless
steel materials, impact testing becomes mandatory
59
Impact Testing Requirements
• Any material not exempt from impact testing, must be impact tested
• Impact testing is generally done with Charpy V-notch (CVN) specimen, in accordance with SA-370
• The CVN specimen (see sketch) is 55 mm long and 10 mm on each side, with a standard notch
and cooled to a temperature no warmer than the MDMT
• The amount energy required to break the specimen is an indication of the toughness
• Another indication is the mills of lateral expansion (see sketch)
• There are requirements for the location and direction of the specimens, depending on material
grouping
• Three specimens from each plate or forging or piece of pipe are to be tested. The required energy
values or mills of lateral expansion is the average value for the three specimens. The minimum
value shall not be less than 2/3 of this required average value
• The required average energy values, for Carbon and low alloy steels, are obtained from Figures
3.3 and 3.4
60
61
62
63
1. Toughness requirements for Carbon steels do not differentiate between as-
welded and heat treated joints. True or False?
2. Toughness rules of Divisions 1 and 2 are identical. True or False?
3. Non-welded Carbon steels, over 1 ½” thick, must always be impact tested.

True or False?
4. All Caron and low alloy steels are classified in to 6 categories. True or
False?
5. A “Curve A” material has more toughness than a “Curve D” material. True or

False?
6. The exemption from testing of a material always depends on the actual

nominal thickness. True or False?
64
7. What is the definition of a “nominal Governing Thickness”?
8. Materials required to be impact tested by the material specification

do not have to meet impact testing requirements of this Code. True
or False?
9. If a component is stressed to a value less than the allowable stress,

it must be tested at a lower temperature. True or False?
10. The impact testing exemption temperature of high alloy materials

does not depend on thickness. True or False?
11. ANSI Standard flanges do not have to be impact tested at an MDMT

of -40F. True or False?
65
Module 5: Design by Rules
Requirements
66
able to:
– Describe the background of the design rules
– Distinguish between “design by rule” and “design by analysis”
– Define key weld categories
– Name key weld joint types
– Compose a sketch for acceptable welded joints
– Describe the components for which Division 2 has design rules
– Distinguish the major differences between old and new Division 2
design rules
67
General Design Requirements
• This Code offers 2 options for design of a vessel:
– Design by Rule, in accordance with the rules of Part 4
– Design by Analysis, in accordance with the rules of Part 5
• Design rules are provided for commonly used shapes, details, and loadings
• If design rules are not available for a certain geometry, detail or loading design by
analysis may be used
• This new Code allows the establishment of the required design thickness by analysis
rules of part 5. This is a major change in philosophy from the old Division 2
• With some minor exceptions, the minimum vessel shell thickness allowed is 1/16”
• This Code specifically requires that allowances be provided for fabrication (forming)
operations that results in reduction of thickness
• All design equations and figures are in the corroded condition. Corrosion allowance
must be added to design thickness
68
• The new Division 2 introduces the term MAWP (Maximum Allowable
Working Pressure), similar to that of Division 1 (The old Division 2
did not have such a term)
• The MAWP may be set to be the same as the design pressure
specified by the User or may be calculated as the maximum
pressure that every element of the vessel can support
• The design temperature (specified by the User) shall not be less
than the mean metal temperature expected coincidentally with the
corresponding maximum pressure
• The loads that must be considered in design shall include (but not
limited to) those in Table 4.1.1, shown here. The load combinations
that must be considered are those (but not limited to) shown in Table
4.1.2, shown here.
69
70
71
• The design formulas satisfy the following
Pm ≤ S
Pm + Pb ≤ 1.5S
– Primary membrane stress is “Pm”
– Primary bending stress is “Pb”
– Specified minimum yield strength is “Sy”
72
• For the hydrotest condition, the stresses can not
exceed the following limits:
• For pneumatic, allowables are lower
73
©
Design Of Welded Joints
• Several acceptable weld joint design details are
provided, for various locations
• Some of these details have been brought in from
Division 1
• Any of these details may be used for “Design by Rule”
• All requirements associated with each detail must be
complied with
• Some (but not all) of such details are shown here
74
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76
77
• The concept of weld category categorizes welds
depending on location for convenience
• The definitions of various categories are in Table 4.2.1
and the locations shown in Figure 4.2.1
• Any joint that does not fit one of the categories defined
here is a “non category” weld.
78
79
80
• The weld joint type defines the type of a weld between pressure
and/or non-pressure parts
• This is independent of the location of the weld
• The “weld joint efficiency”, to be defined later, depends on the type
of weld, as well as degree on NDE
• The following is the definition of some related terms and various
weld joint types
81
82
83
• The design formulas contain a term “E”, defined as “weld joint
efficiency”
• Division 2 prior to 2007 Edition did not allow anything less than
100% RT and did not have a joint efficiency
• The weld joint efficiency is a multiplier applied to the stress
allowable, to account for the fact that the weld may not be as good
as the base material
• The value of “E” depends on the material type, the type of the weld
and the degree of NDE
• This Code only allows full NDE (E = 1.0) or partial NDE (E = 0.85)
• Over a certain thickness, depending on the type of material, the
Code requires full NDE and certain weld joint types
• There are limitations on the use of weld joint types other than 1
84
Covered Design Rules
• The design rules for commonly used shells and
for openings are covered in detail later
• The following is a summary of the rules for some
specific components
• Design rules for various flat heads provided. The
required thickness of circular flat head attached
by welding is the following:
85
• Where,
– D is the inside diameter
– Sho is the allowable stress for head material
– “E” is the weld joint efficiency for a weld within the head, if any
– “C” is a constant which depends on method of attachment and is
obtained from Table 4.6.1
• Formulas are also provided for circular flat heads
attached by bolting and for rectangular flat heads
• Rules have been added for integral flat heads with a
centrally located opening
86
• Detailed design rules are included for spherically dished bolted
covers
• Rules have been added for quick actuating closures
• New rules have been added for braced and stayed surfaces (similar
to Div.1)
• Rules are included for determining the ligament efficiency of multiple
openings that have a regular pattern. Use of ligament efficiency is an
alternative to nozzle reinforcement. The calculated ligament
efficiency is used in the design thickness formula, in lieu of the joint
efficiency
• Design rules have been added for jacketed vessels (similar to Div.1)
• Rules for design of noncircular vessels have been added (similar to
Div. 1)
• Rules for layered vessels have been kept and expanded
87
• Option provided for evaluating vessels which are outside the
tolerance limits
• Analysis of out-of-tolerance provides the Manufacturer with some
flexibility (May only be exercised with Owner’s agreement)
• The analysis may be in accordance with Part 5 of this Division or
assessment methods of API 579-1/ASME FFS-1
• If latter used, a Remaining Strength Factor (RSF) must be
calculated, in accordance with the rules of this document (“RSF” is
the ratio of the load to failure of the vessel or component with the
flaw to the load to failure without the flaw)
• “RSF” can not be less than 0.95, unless a lower value (not less than
0.9) is agreed to between the Manufacturer and User
88
• Detailed methodology for evaluating local thin areas (LTA) provided
• A “thin area is defined as that part of a vessel shell which has a

thickness less than the calculated minimum required thickness
• For assessment of “LTA”, the use of API-579-1/ASME FFS-1 is

allowed
• The calculated “RSF” shall not be less than 0.98, unless a lower
value is agreed to between the User and the Manufacturer (not less
than 0.90)
• Local thin areas must have a blend radius, as shown below.
89
• Rules added for design of supports and attachments. The types of

supports covered include saddles, skirts, lugs and leg type
• Several commonly used details are provided and “good practice”

suggestions offered
• Detailed design rules are provided for saddle supports, based on

Zick method
• An alternative to these rules is design by analysis, in accordance

with Part 5.
90
• Paragraph 4-16 contains rules for design of flanged joints
• The rules for design of flanged connection with ring type gaskets
essentially the same as those of Division 1
• An alternative to these design rules is design by analysis rules of
Part 5
• This paragraph covers integral and loose type flanges. The term
“optional type” is no longer used
• The Pressure Vessel Research Council (PVRC) has been working
on developing more refined and comprehensive rules
• Flange design is a very detailed and time consuming process
• Use ANSI standard flange, if possible
• If a custom flange has to be designed, use of a computer program is
recommended
91
• Rules for design of clamped connections
provided (same as Div.1)
• Paragraph 4.18 provides rules for design of
shell-and-tube heat exchangers (same as Part
UHX in Div. 1)
• Paragraph 4.19 provides new design rules for
thin-walled expansion joints, in heat exchangers
92
1. A nozzle attachment weld is Category C. True or False?
2. A Type 2 joint is better than a Type 1 joint. True or False?
3. The category of a weld depends on the location. True or False?
4. What is the category of nozzle to shell attachment welds?
5. Design formulas and sketches are for the vessel in new condition. True or False?
6. New Division 2 contains design rules for more components than the old. True or False?
7. Name some of the weld seams that are considered Category A.
8. Sketch three commonly used nozzle attachment details.
9. Define a Type 2 weld
93
Module 6: Design for Internal
Pressure
94
able to:
– Identify required fabrication tolerances
– Compose a design for cylindrical and conical shells, subject to
internal pressure
– Compose a design for spherical shells and formed heads,
subject to internal pressure
– Compose a design for flat heads and covers
– Describe key methods for design due to combination loadings
95
Design For Internal Pressure
• Rules provided for common shapes subject to internal pressure alone and in
combination with axial force, overturning moment and torsional moment
• For those shapes for which design rules not provided, the analysis rules of
Part 5 must be used
• To validate the design rules, certain fabrication tolerances have to be met
• One tolerance that must be met for all shells in the completed vessel is the
ovality (or out-of-round) tolerance of 1% (The difference between maximum
and minimum inside diameters at any cross section shall not exceed 1%)
• For formed heads, the inner surface of a torispherical, toriconical,
hemispherical, or ellipsoidal head shall not deviate outside of the specified
shape by more than 1.25% of vessel diameter nor inside the specified shape
by more than 0.625%.
• Provides an option for evaluating tolerances exceeding these values
96
• The minimum required thickness of a cylindrical shell subject to
internal pressure, P, is:
• Where,
– “D” is the vessel inside diameter
– “S” is the stress allowable at design temperature
– “E” is the joint efficiency
• To apply this formula, calculate x = P/SE. Then take a natural log of
x, which is “e’ to the power of x
97
• The minimum required thickness of a conical shell, such as that
shown below, subject to internal pressure must be determined using
the following equation:
98
• The minimum required thickness of a spherical shell or
hemi spherical head, subject to internal pressure, must
be calculated by the following equation:
99
• The minimum thickness of tori-spherical heads subjected to internal
pressure, having the same thickness for crown and knuckle regions,
shall be calculated with the following procedure: (consistent with that
of Code Case 2260 for Division 1)
100
101
102
103
104
105
106
107
108
• Tori-spherical heads with different crown and knuckle thickness are
allowed (Division 1 does not allow). The knuckle thickness
calculated as above and dome thickness calculated by spherical
shell formula
109
• The minimum required thickness of an ellipsoidal head
subject to internal pressure shall be calculated using the
above procedure, with the following substitutions for r
and L
110
• For cone-cylinder junctions a totally new procedure, using limit analysis, has
been included
• This procedure, although more refined and accurate than those of Division 1
or the old Division 2, is cumbersome and tedious to apply by hand
• Step by step procedures are provided in paragraph 4.3.11, which easily lend
themselves to computer programming
• These procedures cover junctions with a flare or knuckle, as well as
junctions without such transition
• Formulas are provided for applied axial force and moment as well as for
internal pressure
• Some limitations are specified on the range of geometric parameter
111
• When in addition to internal pressure any of the following loads are to be
designed for, the formulas of paragraph 4.3.10 must be used
– Net section axial force
– Cross section bending moment
– Torsional moment
• Rules are provided for cylindrical, conical, and spherical shells
• Rules applicable only for regions of the shell at least 2.5 square root of RT
away from any major structural discontinuity
• These rules do not take shear forces in to account
• The following is a sketch of such supplemental loads (rules in the Code)
112
113
1. The Code has all needed tolerances for any vessel. True or False?
2. The local deviation from true circular form is to validate rules for internal pressure. True or False?
3. Design by analysis is allowed, only if design rules are not provided. True or False?
4. What is the required design thickness of a cylindrical shell with R = 100”, P = 50 psi, allowable
stress = 20,000 psi, and joint efficiency = 1.0?
5. A hemi-spherical head is about the same thickness as the cylindrical vessel. True or False?
6. The choice of the type of head is up to the Inspector. True or False?
7. The Code does not allow ellipsoidal heads with different thickness knuckle and dome. True or
False?
8. Name two key fabrication tolerance requirements.
114
9. The design thickness of a conical shell depends on what factors?
10. The diameter used in the design formula for a flat cover is the diameter of the cover. T or F?
11. What is the minimum design thickness of a spherical shell, with the following specified
requirements:
Diameter D = 60 in.
Pressure P = 200psi
Joint Efficiency E = 0.85
Allowable S = 20,000 psi
12. What is the minimum required thickness for a cylindrical shell, with the following specified
requirements:
Diameter D = 48 in.
Pressure P = 200 psi
Joint Efficiency E = 1.0
Allowable stress S = 20,000psi
115
Module 7: Design for External
Pressure and Buckling
116
will be able to:
– Describe buckling as a mode of failure
– Compose a design for cylindrical and conical shell,
subject to external pressure and axial compression
– Compose a design for spherical shells and formed
heads, subject to external pressure
– Describe key methods for design due to combinations
of loading contributing to buckling
– Identify local buckling considerations around openings
117
Design For External Pressure And Buckling
• The buckling rules of Paragraph 4.4 are new and totally different from those of
Division 1 and the old Division 2
• These rules are mostly consistent with the rules of Code Case 2286
• They are based on the test data and the analytical work presented in WRC Bulletins
406 and 462
• New rules will always result in more economical designs
• Range of applicability to much thinner shell, D/t of 2000
• Based on elastic stability theory, modified by knockdown factors that account for
effects of imperfections, boundary conditions, material non-linearity and residual
stresses
• The design factor used in the elastic buckling range is 2.0 and linearly reduced to 1.5
when the mode of failure becomes yielding
118
Design For External Pressure And
Buckling
• Most of the test data used was for Carbon and low alloy materials
• For other materials, for buckling in the inelastic range, the Tangent Modulus
is used, to account for non-linearities
• Annex 3.D provides a method for calculating the Tangent Modulus from a
master stress-strain curve
• Alternatively, this value may be obtained from the old external pressure
curves, which are still in Section II, Part D
• These rules provide some guidance on how to treat local compressive

membrane stresses. When such localized stresses extend over one half the
buckling node for a certain shell, there is adequate room to form a local
buckle. This distance is approximately 1.2 square root of DT of the shell.
Therefore, it is recommended that the local value of the stress extending
over a larger distance be conservatively assumed to be a general stress.
119
Buckling
• Buckling rules are based on the shell tolerances allowed.
Shells having larger imperfections may have a
significantly less resistance to buckling
• Shells subjected to external pressure must meet the
same tolerances on out of roundness as those for
internal pressure
• In addition a tolerance on local deviation from true
circular form, e, must be met, to prevent local buckling
• This is measured by the use of a template having the
exact nominal radius
• The length of the template can be determined from a
formula in the Code
120
Buckling
• The maximum allowable local deviation is the
following:
121
Buckling
• Another tolerance introduced is a straightness tolerance,
ex, for cylindrical and conical shells subject to axial
compression
• This deviation from a straight line must be measured with
a template have a length equal to Lx
• The maximum allowed deviation and the length of the
template shall be the following:
122
123
Buckling
• For spherical shells and formed heads, subject
to external pressure, the tolerances for such
shells under internal pressure shall be me
• In addition, the maximum local deviation from
true circular form shall not exceed the shell
thickness
• If shell imperfections exceed the above
tolerances, There are rules for reducing the
allowable external pressure of shells with such
out-of-tolerance.
124
• The required thickness of a cylindrical shell subjected to external pressure shall be
determined using the following procedure:
• “L” is the length of the shell between the lines of support

• A line of support can be anything that keeps the shell round
• The shell may only buckle in between such lines of support, which may be a “small
stiffening ring” or a “bulkhead”
• The use of “bulkheads” on a vessel reduces the required moment of inertia for “small
stiffening rings”
• Assume a “bulkhead” at 1/3 the depth of the head, regardless of the type of head
• A cone cylinder junction may act as a bulkhead, if it has adequate moment of inertia about
a vertical axis
• Some geometric restraints are provided for sizing the stiffeners
125
Cylindrical and Conical Shells
126
127
128
129
130
• The rules for sizing stiffeners have been very much refined and are much
less conservative than the old rules
• The equations for sizing both types of stiffeners are rather long and tedious
to apply by hand
• It is suggested that a computer program or spread sheet be used for sizing
stiffeners
• The choices of increasing the shell thickness vs. adding stiffeners made on
an economics basis
• The required thickness of a conical shell subjected to external pressure shall
be determined using the same procedure as that shown above, for
cylindrical shells, using the effective cone length and diameter
131
• The required thickness of a spherical shell or

hemispherical head subject to external pressure shall be
calculated using the following procedure:
132
133
(Use above equations)
134
135
• The required thickness of a torispherical head with uniform thickness
subjected to external pressure shall be determined using the above
equations, by substituting the outside dome radius for Ro
• Torispherical shells with different dome and knuckle thicknesses are
allowed, but must be designed in accordance with the analysis rules of Part
5.
• The required thickness of an ellipsoidal head (height = ho) determined using
the above equations for a spherical shell, by substituting KoDo for Ro, where,
136
• The allowable axial compressive membrane stress of a cylinder due

to an axial compressive load alone, Fxa shall be calculated by the
following procedure:
137
138
• Allowables for column buckling are also provided

• The rules will indicate whether column buckling is likely prior to shell
buckling
• Formulas, similar to above are provided for axial buckling due to
overturning moment
• Formulas provided for shear buckling
• Interaction relationships provided for any combinations of above
loadings
139
1. The buckling rules of this Code are similar to those in Division 1. True or False?
2. What factors does the allowable compressive stress of a cylinder under axial compression depend
on?
3. What is the definition of the “length” of a cylindrical shell subject to external pressure?
4. There is no interaction between axial compression and external pressure on a cylinder. True or
False?
5. An ellipsoidal head, subject to external pressure, will buckle in the knuckle first. True or False?
6. A shell with a larger radius is more resistant to buckling than a shell of smaller radius, other factors
being the same. True or False?
7. Describe the difference between buckling and rupture modes of failure.
8. Design thickness of a cylinder under axial compression does not depend on length. True or False?
9. Large openings in cylindrical shells under axial compression do not need reinforcing around the
opening. True or False?
140
Module 8: Design Rules for
Openings
141
will be able to:
– Define key requirements regarding nozzle geometry
and methods of attachment
– Describe the background of the new methodology for
design of openings and the basis for these rules
– Compose a design of nozzles in shells and heads,
subject to internal and external pressure
– Compose a design of nozzles in flat heads
– Identify all other requirements for proper design and
details of openings and their reinforcement
142
Nozzle Geometry and Attachment Methods
• Design rules for opening totally new, based on

Bildy beams on elastic foundation theory
• Good correlation with test results
• If rules not provided for certain geometry or
loading; or whenever the designer chooses,
design by analysis (Part 5) may be used
• Applicable to round and elliptical (aspect ratio
net exceeding 1.5) opening subject to internal or
external pressure
143
Nozzle Geometry and Attachment Methods
• Minimum nozzle neck thickness specified in tabular form

(equivalent of UG-45) (not applicable to inspection
openings)
• Many attachment details provided. Some (not all) of
Division 1 and old Division 2 included. See examples
below
• For nozzle external loadings, 3 methods recommended:
– WRC Bulletin 107
– WRC Bulletin 297
– FEA
144
Nozzles in Cylindrical and Conical Shells
• The procedure for design of a radial nozzle in a

cylindrical shell subject to pressure is much
more complicated than old methods
• Iterative method very time consuming. Computer
program use recommended
• The method accounts for stiffening effects of
nozzle neck, resulting in more economical
designs
• The following sketches shows terminology
145
146
147
Nozzles in Cylindrical and Conical
Shells
• For an assumed reinforcement, the local primary
membrane stresses are calculated. For internal
pressure, compared with 1.5SE (E is joint
efficiency). For external pressure, compared with
a buckling allowable
• Equations provided for hillside nozzles in
cylindrical shells
• Procedure for nozzles in conical shells similar to
cylindrical shells, with a few substitutions.
148
Nozzles in Spherical Shells and Formed
Heads
• Procedure for design of nozzles in spherical shells and formed
heads similar to cylinders
• Long detailed formulas are provided to calculate the effective radius,
the limits of reinforcement along the shell and perpendicular to the
shell
• Any excess thickness (over that required for pressure, by design
formulas) within these boundaries is counted as effective area
resisting pressure forces
• An average stress over this area, which represent local primary
membrane stress is calculated and limited to the appropriate
allowables
• The formulas for calculating the forces are built in to the procedure
• Formulas are provided for calculating the maximum allowable
working pressure (MAWP) of a certain nozzle junction, for rating
149
Nozzles in Spherical Shells and Formed
Heads
• Design of openings in flat heads is different
• Maximum forces at the intersection calculated and used to calculate
the maximum local primary membrane stress, then limited to 1.5S
• This iterative procedure provides for design of nozzles that penetrate
the flat heads and for those abutting the head (paste on nozzles)
• For flat heads, the internal pressure and external pressure are the
same. Flat plates subjected to pressure do not fail by buckling
• An alternative to the nozzle reinforcement rules, for a centrally
located nozzle on a flat head, is the rules of paragraph 4.6.4 (Integral
Flat Head with a Centrally Located Opening
150
Other Requirements Regarding Openings
• Rules provided for multiple openings

• If a pair of openings is spaced so that their limits of
reinforcement do not overlap, there will be no interaction
between them
• If the limits do overlap, new shorter limits for each nozzle
are calculated, so that the do not overlap
• These new limits are used to satisfy the reinforcement
requirements for each nozzle
• The following sketch shows this procedure, graphically:
151
152
• For three or more closely spaced nozzles, the above procedure must
be repeated between each pair
• If the limit along the ligament between each pair of openings is less
than the sum of the limits of reinforcement for those two nozzles,
new limits are calculated to prevent such overlap
• This procedure is shown graphically, in the following sketch:
153
154
• Rules provided for verifying the strength of nozzle attachment welds
• These calculations assure that the welds are sufficient to resist the
discontinuity forces calculated in the respective nozzle reinforcing
procedure
• Equations provided for both integrally reinforced and pad reinforced
nozzles
• These rules also cover the attachment welds of nozzles to flat heads
• Following methods used for external loadings
155
• WRC Bulletin 107 has been used for several decades and provides some
reasonable estimate of the stresses in the vessel shell
• This method may be applied to nozzles (or other loaded attachments) in
cylindrical, conical, spherical shells and formed heads
• For attachments to cylindrical or conical shells, this method of analysis
assumes an unpenetrated shell subject to distributed pressure over the
loaded area
• Nozzle neck thickness is not accounted for. Effect of nozzle neck thickness
on stresses in the shell very significant
156
• For cylinders, R/t limited to 600
• Diameter of the opening limited to 0.25 to 0.30 times the
diameter of the vessel shell
• Results provided in the form of curves for calculating
membrane and bending stresses at different locations
around the nozzle
• Stresses due to various loadings must be added at
several locations
157
• WRC Bulletin 297, based on shallow shell theory, models the
intersection discreetly
• Handles Cylinder-Cylinder intersections only
• Provides maximum membrane and bending stresses on the nozzle
neck as well as on the shell
• This Bulletin may be used for R/T values up to 2000
• Nozzle diameter to shell diameter ratio limited to 0.3 to 0.35
• Result presented in the form of curves
158
• Most detailed analysis of the intersection by finite

element analysis (FEA)
• The method and details and choice of mesh are left to
the designer and results may vary
• Has no limitations on the range of geometric values
159
• An alternative to performing the FEA, for openings with

large diameter ratio is the method of WRC Bulletin 497
• The results of this Bulletin are based on a parametric
FEA
• This Bulletin provides the stresses at the intersection due
to both external loadings and pressure
160
• Stresses due to external loadings must be added to those due to
pressure
• If the methods of Bulletin 107 or 297 are used, formulas of WRC
Bulletin 368 may be used to calculate pressure stresses
• This Bulletin based on parametric study using the same theory as
Bulletin 297
• The sum of the stresses due to all loading combinations must be
categorized into various categories and limited to the applicable
allowable
161
• The requirements for inspection openings are in

paragraph 4.5.16
• All pressure vessels, with some minor exceptions, must
have an access opening
• An access opening may be a manhole, a hand hole or an
instrument hole, depending on the vessel diameter
162
• Vessels with diameters between 12” and 18” may have

two inspection openings of not less than NPS 1 ½
• For vessels with diameters between 18” and 36”, either
two handholes (4”x6” minimum) or a manhole may be
used
• For vessels over 36” diameter, a manhole must be
provided
• The minimum size of a manhole is either 16” round or
12” x16” elliptical
• Such size openings are too small for personnel access
and the owner should consider requiring a larger size
163
• Paragraph 4.5.17 has some rules for design of opening

subject to compressive stresses
• If compressive stresses due to external pressure only,
the reinforcement rules assure that no buckling occurs
• For axial compression due to uniform axial compression
and axial compression due to an overturning moment,
rules are provided that cover openings with diameters
that do not exceed 25% of vessel diameter or 80% of
ring spacing for stiffened vessels
164
• These rules simply require a certain amount of area to be

added at the intersection, within certain limits
• For vessels subject to both external pressure and axial
compression, the rules for each individual loading must
be met
165
1. Nozzle design rules of this Code are totally different from those of Division 1.
True or False?
2. Nozzle design rules can not be superseded by analysis. True or False?
3. What are the three recommended design methods for nozzle external
loadings?
4. Who is PVRC and what does it do?
5. Nozzle attachments for vessels subject to external pressure are designed

for rupture. True or False?
6. The nozzle neck thickness can not be less than the minimum thickness of
what?
166
Module 9: Design by Analysis
Requirements
167
• At the conclusion of Module 9, the participants will be able to:
– Assess when to use design by analysis rules

– Describe the background and advantages of various analysis methods
– Distinguish between stresses of different categories
– Classify stresses
– Name key modes of failure and different theories of failure
– Conduct an elastic stress analysis
– Describe limit analysis and elastic-plastic analysis options and
limitations of each
– Identify key requirements for buckling analysis
– Describe key methods for exemption from fatigue analysis rules
– Identify key methods of fatigue analysis
– Conduct an elastic fatigue analysis
168
General Analysis Requirements
• Design by analysis rules of Part 5 may be used as an
alternative to deign rules of Part 4
• When Part 4 does not provide design rules for a certain
geometry or loading Part 5 must be used
• Rules provided to address each mode of failure
individually
• The failure modes addressed include plastic collapse,
local failure, buckling and fatigue
• Procedures are also provided for design by experimental
methods and for fracture mechanics evaluations
169
• For some failure modes, a number of different
evaluation methods are offered
• With a few minor exceptions, the analysis rules
of Part 5 may be used only if the design
temperature does not exceed creep temperature
• For components which meet the fatigue
exemption rules, the elastic stress analysis
method may be used, up to the highest
temperature for which allowables are listed
170
• The detailed analysis procedure is left to the
designer
• Provides some guidelines and rules on modeling
details, load combinations, stress
categorizations and acceptance criteria
• All applicable loads and loading combinations
must be accounted for
• The following Table lists the load cases that, as
a minimum, must be addressed:
171
172
173
• The procedures for protection against plastic
collapse mode of failure is provided in paragraph
5.2
• For this mode of failure, three different
alternative analysis methods are allowed:
– Elastic stress analysis
– Limit load analysis
– Elastic-plastic analysis.
174
Elastic Stress Analysis Method
• The elastic stress analysis method (similar to that which was in the old
Division 2, in Section III and in a number of other Codes), is the simplest
and most widely used method
• This method is based on equivalent stresses calculated assuming that the
stress-strain curve remains elastic beyond the proportional limit
• The calculated equivalent stress does not have a physical significance,
beyond proportional limit. It calculated strain multiplied by “E”
• Main difference between new procedure and old Division 2 is that the old
rules used the Maximum Shear Stress theory (Tresca) calculating “Stress
Intensity”
• New Code uses “equivalent stress” using the Maximum Distortion Energy
(Von Mises) theory
• Von Mises more accurate representation of material behavior but the
formulas more complex than those used for the Tresca method
175
• The “equivalent stress”, using the Von Mises yield criterion, is

obtained by the use of the following formula (the 3 principal stresses
must fist be calculated from the stress components at the point):
176
177
178
179
180
181
Examples of Stress Classification
(Continued)
182
Stress Categories and Limits of Equivalent
Stress
183
• For comparison with allowable stresses, results of elastic stress analysis may have to
be linearized to get equivalent membrane and bending stresses
• This is particularly true if the stress results have been obtained from FEA
• If shell elements are used, the membrane and bending stresses are directly obtained
from the output
• For any other type of element, the stresses through the thickness must be converted
to equivalent membrane and bending
• Equivalent membrane stress is that average stress through the thickness having a net
force equal to that of the calculated stress
• Equivalent bending stress is a linear through thickness distribution having a net

through thickness bending moment equal to that produced by the actual distribution
• Peak stress components can be obtained directly by subtracting the membrane plus
bending stress from the total surface stress
184
Stress Integration Method
• The use of stress integration method is shown by the
following figure:
185
Stress Integration Method
• Once the equivalent stresses of different categories have
been computed, they must be assessed for acceptability,
in accordance with the following procedure. The notation
used in the following paragraph is the same as that of the
old Division 2, as well as that of many other Codes.
186
Assessing for Acceptability: Step 1
187
188
189
Assessing for Acceptability: Steps 4&5
190
Limit-Load Analysis
• The second method of analysis, to protect against
rupture and plastic collapse, is limit-load analysis
• The displacements and strains indicated by this analysis
have no physical meaning
• The theory of limit analysis defines a lower bound to the
limit load of a structure as the solution of a numerical
model with the following properties:
191
Limit-Analysis Theory: Numerical Model
Properties
192
Component Acceptability Criteria
193
Elastic-Plastic Analysis
• The third method allowed for protection against plastic collapse is elastic-plastic
analysis
• The allowable load on the component is established by applying a design factor to the
calculated plastic collapse load (design factors are applied to each load)
• This method provides a more accurate assessment by modeling actual material
behavior (need stress-strain curve)
• The plastic collapse load may be obtained from a FEA
• The effects of geometric non-linearities (large deflections) must be included
• The plastic collapse load is the load that causes overall structural instability (solution
will not converge)
• The load combinations and load factors used for this analysis are shown in Table 5.5,
below
194
Elastic-Plastic Analysis
195
Protection Against Local Failure
• In addition to protection against plastic collapse, the local failure
criteria must be met
• Two analysis methods provided; elastic analysis and elastic-plastic
analysis.
• Using the elastic method, it must be shown that the sum of local
primary membrane plus bending principal stresses (S1 + S2 + S3)
does not exceed 4S
• This assures prevention of large local deformation when stresses
are the same sign and have large magnitudes
• The elastic plastic method is more accurate but more involved
• The load case combinations for this analysis are shown in Table 5.5,
shown above
196
Protection Against Buckling
• For compressive stress field protection against
buckling must be demonstrated
• The design factor to be used depends on the

type of buckling analysis performed
• Three methods of analysis are covered; elastic,

elastic-plastic, and collapse analysis including
geometric non-linearities
197
• In addition to applying a design factor (safety
margin), a capacity reduction factor must be
applied to the analysis results, to account for the
effects of imperfections, residual stresses, etc
• The following reduction factors, called Beta, are

suggested for various loadings:
198
199
Protection Against Fatigue Failure
• A fatigue evaluation must be performed to determine if
the operation must be considered cyclic
• Screening criteria are provided in Paragraph 5.5.2 to
determine if a complete fatigue analysis is required
• Three methods are provided for exempting a component
from fatigue analysis
• These methods are similar to those of paragraph AD-160
in the old Division 2, with some minor revisions
• One significant addition to the rules is that fatigue
exemption is not allowed, if the number of cycles, of any
range, exceed one million
200
• Old rules assumed there was an “endurance limit”, below
which fatigue damage is insignificant (the cycles having a
range less than a certain value did not have to be
accounted)
• Fatigue exemption and fatigue analysis are performed for
a single point on the vessel and not the entire vessel
• One component of vessel may be exempt from fatigue
analysis while another may not
• How many points to evaluate and what points to pick are
left to the designer
201
• The points chosen must be those where the highest local (peak)
stresses are expected
• One screening criteria for exempting a vessel (or component) from

fatigue analysis is that of “Experience with comparable equipment
operating under similar conditions”
• Determined by the User, based on successful experience, over “a

sufficient time frame” with comparable equipment in comparable
service
• When making this evaluation, the harmful effects of such things as

fillet welded attachments, threaded connections, partial penetration
welds must be considered.
202
Fatigue Screening Criteria: “Method A”
• The second screening criteria, referred to as “Method A”,
may be used for materials having tensile strength not
exceeding 80 ksi
• For this method a number of conservative assumptions

have been made to arrive at a simple procedure
• The effective number of thermal cycles is determined by

multiplying the actual number of such cycles by a factor
that depends on the range of temperature excursion
203
• The values of these multipliers are shown in Table 5.8
• The procedure is outlined below:
204
205
206
207
Fatigue Screening Criteria: “Method B”
• The third criteria, referred to as “Method B”, does not
have a limitation on strength of the material
• This method is less conservative than Method A and
considerably more complicated
• To apply his method, a thermal analysis may be needed
to arrive at temperature changes between adjacent
points and the range of such temperature changes
• The stresses due to external loading are also needed
• To perform Method B may be nearly as much work as
performing a full fatigue analysis.
• If none of the above screening criteria is met, a fatigue
analysis is required
208
Fatigue Analysis
• Three methods of fatigue analysis are offered
• The first method is an elastic fatigue analysis, using equivalent
elastic stresses
• This is same as the old method in Appendix 5 of Division 2 (as well
as a number of other Codes)
• This method uses fatigue curves generated by the use of smooth bar
specimens tested by strain control
• The effects of any stress concentrations due to welds, surface
roughness, etc. must be included in the calculated peak stresses
• The effect of mean stresses (stresses which do not fluctuate, such
as dead load) have been built into these curves
209
Fatigue Analysis
• These curves were generated by multiplying the strain values of test
by a value of assumed Modulus of Elasticity, to establish the plotted
equivalent stress
• If the analysis has used different Modulus of Elasticity, to arrive at
equivalent elastic stresses, a correction to the calculated stresses
must be made
• The correction factor is the ratio of value specified on the applicable
curve to the value used for calculating stresses
• A master fatigue curve equation is in Annex 3.F. Parameters are
provided for groups of materials (curves will be added later)
• Each curve indicates a maximum temperature, not to be exceeded.
This is the creep temperature for that grouping of materials.
210
Fatigue Analysis
• The stresses used for fatigue evaluation consist of the sum of
primary plus secondary plus peak stresses
• These stresses may be directly obtained from a fine meshed FEA
• FEA results, using elastic analysis, include the theoretical stress
concentration factor (SCF), which may be conservative
• Must use fatigue strength reduction factor, defined below, which is
usually less than stress concentration factor
• If the mesh is not fine enough, not all stress concentrating effects will
be included in the results
• The offsetting effects of these two inaccuracies must be considered
by an experienced analyst
• Fatigue strength reduction factor is applied to account for local
discontinuities
• Tables 5.11 and 5.12, shown below, provide some recommended
values for welded joints
211
Weld Surface Fatigue-Strength-
Reduction Factors
212
Weld Surface Fatigue-Strength-Reduction
Factors
• Using theoretical stress concentration factor generally produces
conservative results (sometimes overly conservative)
• Attempt should be made to obtain and use a Fatigue Strength
Reduction Factor, FSRF
• While the SCF can be obtained analytically, the FSRF for any
particular detail must be obtained by test
• FSRC for any detail with a local discontinuity is the factor by which
the fatigue curve drops as a result of the discontinuity
• If for “n” cycles the stress amplitude to cause fatigue is “X” for
component without local discontinuity and X/3 for component with a
local discontinuity, FSRF is 3 (remains about same for any “n”)
213
Range of Effective Stress
• To arrive at the maximum range, a number of critical areas must be
chosen
• Maximum calculated stresses at any location or cross section must
be used
• At the locations chosen, the range of effective stress must be
calculated, from the range of each stress component
• The range is defined as the difference between the maximum value
and minimum value of each stress component
• Tensile stresses are considered positive and compressive stresses
negative
• Range calculated by comparing the stress value at any one load
combination with every other load combination
• A zero stress case should always be included
214
Elastic Fatigue Curves
• Elastic fatigue curves are plotted with equivalent elastic
stress amplitude as the vertical axis
• Definition of amplitude is half the range
• To enter the curves, the calculated range of equivalent
stress must be multiplied by the ratio of the Modulus of
Elasticity shown on the curve to that used for analysis
and the resulting number divided by two
• Get the number of allowable cycles by horizontally
moving to the curve and dropping vertically
215
• If two or more types of operating cycles are specified, the Miner’s
law of linear damage is used
• This law does not account for sequence of various cycles and the
interaction effects between the various cycles (Although not
rigorously correct, the effects are small)
• The allowable number of cycles determined from the fatigue curve,

for each type of cycle
• The ratio of the actual number of cycles, n, to the allowable number,

N, is the partial fatigue damage, “u”, for that particular cycle
• To be acceptable,
n1/N1 + n2/N2 + n3/N3 + ……= u1 + u2 + +u3… ≤ 1.0
216
• The 2007 Edition of Division 2 does not include
the graph of the fatigue curves (will be added
later)
• Annex 3.F provides formulas for calculating the
allowable number of cycles for any calculated
equivalent stress amplitude
• A representative curve from the old Division 2 is
included here (the same as new)
• These curves have been extended to
100,000,000,000 cycles.
217
218
Elastic-Plastic Fatigue Analysis
• The second option, for fatigue analysis, is elastic-plastic
analysis
• More accurate but much more complicated
• The elastic-plastic properties (cyclic stress strain curve)
of the material are needed
219
Structural Stress Method
• The third option is a newly developed procedure called Structural Stress
Method or master curve method
• This method is directly applicable to welded joints without the need for
calculating the peak stresses
• Structural stresses can simply be calculated (elastic analysis) and used
• Structural stresses can usually be calculated by hand. If FEA used, results
are not mesh sensitive
• The universal fatigue curve (equation 3.F.3 in Annex 3.F) is the same for all
details and for all materials and temperatures
• The effects of materials, weld details, etc. are incorporated by the use of
adjustment factors
• This method can only be used by agreement between the User and the
Manufacturer
• Limited to temperatures below creep
220
• The method is a statistical method, requiring
experimental data (or experience)
• It is suggested that 99% Prediction Interval be
used, unless otherwise agreed by User and
Manufacturer
• If a fatigue improvement method (such as
grinding, TIG dressing, peening) is applied,
credit (value specified by Code) may be taken
through a factor
221
• If detrimental effects of the environment (product
inside) are significant, a penalty factor may be
applied (needs to be specified by User)
• The effect of temperature is accounted for by a
reduction factor equal to the ratio of the tangent
modulus (at the average temperature of cycle
being considered) to the value of Elastic
Modulus at room temperature for Carbon steels
222
1. Can analysis be used to determine minimum design thickness?
2. What is the slope of stress-strain diagram for elastic analysis?
3. What is the assumption regarding stress-strain diagram, in limit analysis?
4. What is the primary advantage of elastic-plastic analysis?
5. Can FEA results be used directly to determine the buckling value of shell structures?
6. What are the various methods of fatigue analysis, covered by this Code?
7. Explain Miner’s law of linear damage.
223
Module 10: Fabrication
Requirements
224
able to:
– Identify general fabrication requirements
– Describe the welding requirements
– Assess when PWHT is needed, at what temperature, and for
how long
– Identify key PWHT procedures and their limitations
– Describe material groupings and specific requirements for each
group
– Identify specific requirements related to various methods of
construction
225
General Fabrication Requirements
• Fabrication requirements are in Part 6
• For the details and specific values Code
paragraphs must be studied
• All materials used for the vessel pressure
boundary must be traceable to Certified Material
Test Reports (CMTR). This can be done by:
• Transferring markings when a material is cut
• A coded system
• Marking each piece on the as-built drawing
226
• Repair of materials is “fabrication”; requires
qualified procedure, qualified welder, inspection
• May be performed by vessel Manufacturer or the
material manufacturer with the approval of the
vessel Manufacturer
• Any welding on materials subject to all Code
rules (qualified welders qualified procedures,
etc.)
227
• Forming of materials may be by any method which does not unduly
impair material
• Materials may lose some thickness during the forming; a forming
allowance must be included
• Another consideration for forming is the maximum surface strain
• If the material is strained too much, cracking may occur, during
fabrication or service
• Formulas provided for calculating the maximum surface strain
• If this strain is higher than a certain value, the material must be
post-form heat treated or hot formed
• Some forming tolerances have also been introduced.
228
• Requirements regarding base metal preparation have
been included:
– Visual examination of all materials
– Surface examination of cut edges (over a certain thickness) and
nozzle openings (over a certain size)
– UT of the edge of flat covers
– Cutting requirements
– Shearing requirements
• Fitting and alignment requirements included and some
tolerances specified. Includes suggested means for
maintaining alignment during welding
229
Welding Requirements
• Welding Fabrication requirements spelled out in detail
• These are similar to the requirements of Part UW in
Division 1
• Acceptable welding processes listed
• Each Manufacturer is responsible to generate his own
qualified welding procedures
• All welders must be employed by and be qualified by the
Manufacturer, with some exceptions
• Record keeping requirements are included
230
Welding Requirements
• Precautions to be taken prior to welding include
identification, handling, and storing of all welding
materials
• No welding may be performed when the metal
temperature is colder than 0 degree F.
• Specific requirements for various weld joint types
specified
• Include weld penetration, limits on reduction in thickness
due to welding, weld reinforcement
• Rules provided for repair of weld defects
• Specific requirements for some materials
231
Heat Treatment Requirements
• Preheat and Post Weld Heat Treat (PWHT) requirements
specified
• These requirements are tied to the material P-number
(which is a measure of weldability)
• The P-number and Group number are listed in the stress
allowable tables of Section II, Part D, as well as in
Section IX
• Except for preheat requirements of Section IX, preheat is
not mandatory
• However recommendations are made for preheat, which
would result in somewhat better welds
232
• The PWHT requirements are much more
extensive and detailed than those of Division 1
(or old Division 2)
• The need for PWHT depends on the P-number
and nominal thickness
• The definition of nominal thickness governing
PWHT is in paragraph 6.4.2.7, and must be
carefully studied
233
• The following are some examples of nominal thickness (for determining PWHT):
– For full penetration butt welds, the depth of the weld, exclusive of weld reinforcement
– For groove welds, the depth of the groove
– For fillet weld, the throat dimension (if used in conjunction with a groove weld, the larger of
groove depth or throat)
– For stud weld, the diameter of stud
– When welding parts of unequal thickness, the thinner of the two butt welded parts
– For nozzles, the greater of the thickness of the neck or shell
– For attachment of non-pressure parts, the thickness of the weld
• Note that some of these definitions are different from those of Division 1 and old
Division 2
234
• The thickness over which PWHT is mandatory is
shown in tables, for each P-number
• These tables also specify the minimum
temperature and time
• Table 6.8, for P-1 materials, is shown below
235
236
• When materials of two different P-numbers are joined, the higher
temperature and hold time shall be used
• Except for a few materials, Code does not specify maximum
temperature and time
• If an entire vessel is heat treated in a furnace, the greatest nominal
thickness of any part determines the hold time
• Manufacturer must assure PWHT does not adversely affect material
• Any heat treatment used for the production weld must be simulated
in the weld procedure qualification
• Manufacturer must determine when heat treatment above and
beyond those required by Code are needed
237
• Paragraph 6.4.3 specifies a number of procedures for
PWHT and limitations of each
• The term “soak band” is defined as the volume of metal
required to meet or exceed the minimum PWHT
temperature
• This is to assure that the entire heat affected zone (HAZ)
gets the benefits of the heat treatment
• As a minimum, the soak band shall include the weld and
the HAZ
• The width of HAZ is specified as lesser of nominal
thickness or 2” on either side of the widest part of weld
238
• One method of PWHT is heating the entire vessel in a
furnace
• Maximum heating and cooling rates are specified,
depending on the material and thickness
• If vessel is too long, it can be heat treated in more than
one heat
• In such a case, the middle 5’ length of vessel need to be
heat treated twice
• This method also requires adequate insulation, so that
the axial gradient is not harmful
• A vessel too large to be put in a furnace may be heated
internally. Care must be taken to avoid harmful gradient
239
• Parts of vessels may also be heat treated individually
• The welds joining the parts must be locally treated
• Local heating of nozzles and attachments is permitted
(heating an entire band around the vessel no longer
required)
• Temperature must be reduced, in the circumferential
direction, so there is “no harmful gradient”
• This depends on shell radius, thickness, strength,
proximity to a restraint etc.
240
Requirements for Material Groupings and
Construction
• With minor exceptions, vessels or parts of vessels that
have been heat treated must again be treated after any
welded repair
• Care must be taken to assure that all weld defects have
been identified and repaired, prior to PWHT
• For some materials, the Code requires that the specified
NDE be performed after PWHT
• In such cases, it may be cost effective for the
Manufacturer to perform the NDE prior to PWHT and
again after PWHT, to avoid costly second PWHT
241
Construction
• Part 6 includes specific requirements for certain
groupings of materials or for certain method of
construction
• These requirements are similar to those in
Subsection B (specific material requirements)
and Subsection C (requirements for methods of
fabrication), in Division 1
• But, these rules are much more extensive and
detailed than those of Division 1
242
Construction
• Paragraph 6.5 specifies requirements for clad or
overlay welded materials
• Similar to Part UCL of Division 1
• Various methods are described with limitations
• Rules are also provided for cladding material
included in design thickness
• Welding requirements for overlay are specified
243
Construction
• Paragraph 6.6 has the specific requirements for
high strength quench and tempered materials
• These are materials with high strength achieved
by heat treatment
• Because of their high strength, these materials
are very difficult to work with
• The weld details allowed for these materials very
limited and mostly full penetration
• Care must be taken in subjecting these materials
to high temperatures
244
• May soften and lose strength

©
Construction
• Paragraph 6.7 has specific requirements for
forged construction
• Similar to Part UF of Division 1
• These rules generally apply to forged bottles for
transport of pressurized gases and are limited to
a few Manufacturers
245
Construction
• Paragraph 6.8 has special requirements for
layered vessels
• Similar to Part ULW of Division 1
• Layered vessels which consist of many layers
• Each layer applies a pre-compression in the
previous layers
• Due to costly fabrication, not many produced
today
246
1. Section VIII has rules for qualification of weld procedures. True or False?
2. Explain the relationship between Section VIII and Section IX
3. The need for PWHT depends on thickness. True or False?
4. Explain P-number
5. What are the different methods for PWHT?
6. Define the “soak band” and what it consists of
7. The Code does not allow a local PWHT. True or False?
8. What is accomplished by PWHT?
247
Module 11: Inspection and
Examination Requirements
248
will be able to:
– Describe the background for inspection and
examination requirements
– Apply the rules for examination of welded joints.
– Assess joint efficiency
– Identify key methods of NDE and how to determine
the acceptance criteria for each
249
General Inspection And Examination
Requirements
• Inspection and non-destructive examination
(NDE) requirements are in Part 7
• The term “inspection” refers to the activities of
the A.I.
• To verify the soundness of welds and materials
by such operations as RT, UT, MT or PT is
referred to as “examination”
• The word “testing” refers to pressurizing the
vessel and to testing of specimens for properties.
250
Inspection And Examination
• Detailed responsibilities of the Manufacturer and duties
of A.I. listed in Annex 7.A
• Manufacturer has primary responsibility to assure all
NDE and testing requirements met
• Manufacturer certifies all NDE operators and keeps their
certification records
• The Inspector must make inspections to assure all Code
required NDE performed and acceptance criteria met
• He also has the duty to monitor the Manufacturer’s
Quality Control System
251
• Manufacturer has certain material and part
verification responsibilities including:
– Verification of material identification
– Dimensional check of component parts
– Assuring such parts conform to the required form and
curvature
– Verification of heat treatment
252
Examination of Welded Joints
• NDE requirements of this Code much more refined and
complex than Division 1
• For required NDE and joint efficiency, welded joints
assigned to various Examination Groups, in Table 7.1
• Category depends on material and the fabrication
complexity associated with that material, maximum
thickness, and welding process
• Examination group is subdivided into sub-groups “a” and
“b”, depending on crack sensitivity
• For examination group and sub-group, Table 7.2
indicates required NDE for each joint category and the
joint efficiency for each degree of NDE and type of weld
253
254
255
256
• RT and UT are interchangeable, with a few exceptions
• For joint thickness less than ½”, UT may not be used
• Different weld joints assigned to different examination
groups, and the joint efficiency determined for design
calculations
• If less than 100% NDE performed, some requirements
apply to the location of spots examined
• Category A and B welds for which fatigue analysis is
mandatory must receive 100% volumetric examination
• Category C, D and E weld not exempt from fatigue
analysis must receive surface examination
257
Examination Methods and Acceptance
Criteria
• A summary of various NDE methods allowed
and reference to acceptance criteria are in Table
7.5
• The referenced paragraphs must be studied in
detail for characterization of flaws and
determining acceptability
• This Table also has a reference to the detailed
procedures, mostly in Section V
258
259
1. Define “inspection”, “examination”, and “testing”
2. What are the primary methods of volumetric
examination?
3. All NDE operators must be certified by the
Manufacturer. True or False?
4. The NDE acceptance criteria are in Section V. True or
False?
5. What are some the things that the A.I. must witness?
260
Module 12: Pressure Testing and
Over-pressure Protection
Requirements
261
able to:
– Describe key pressure testing requirements and the timing for
such test
– Distinguish between hydrotest and pneumatic test
– Identify limitations on and precautions for pneumatic testing
– Apply key methods to assess minimum test pressures
– Reproduce the minimum metal temperature during test
– Identify the requirements for protection against over-pressure
– Describe the alternatives for protection against over-pressure
262
General Testing Requirements
• All stamped vessels must pass a pressure test (over-
pressure) after completion of all fabrication
• If vessel is welded on after the pressure test, it must be
re-tested
• The only operations allowed after test are those that can
not be done prior to test
• All examinations must also be done prior to test, except
those required to be performed after the test
• The pressure test is to proof test the completed vessel
and to detect any leaks
• There are other benefits such as reduction of residual
stresses, blunting of notches, and cold pre-stressing
263
• The Code requires the test be done hydrostatically (with
a liquid, usually water), except for any of the following
cases:
– The weight of the fluid may distort vessel or support
– Traces of liquid can not be tolerated on internals
– Brittle fracture is not a credible mode of failure under test
conditions (this is new)
– The test is monitored by acoustic emission examination
– A pneumatic (using a gas, usually air) or combined hydro-
pneumatic test may be used, for any of the above cases
264
• Vessels designed for vacuum or partial vacuum
must be tested at an internal pressure not less
than 1.43 times the design external pressure
• New requirements added for pressure gages
and calibration of such gages
• The gage is required to be connected directly to
the vessel and be readily visible to the operator
265
Pressure Testing And Over-pressure
Protection
• A number of precautions added
• Vents at the top of the vessel are required, to
purge air pockets, for hydrotest
• Painting or coating of the vessel is now allowed,
prior to hydrotest, unless the vessel is to operate
with a lethal gas inside
• The concern is that the paint or coating may
mask small leaks.
266
Hydrostatic Testing
• Except for a few specific cases, the minimum
hydrostatic test pressure must be the greater of
the following:
267
Hydrostatic Testing
• The ST/S is the lowest ratio of the stress allowable at test
temperature to allowable at design temperature, for all materials
within pressure boundary
• The first formula above was included to make this Division compliant
with the European Pressure Equipment Directive (PED)
• The effect of temperature on the strength of materials during the

operation is not accounted for
• Second formula familiar ASME form, except the multiplier reduced to

1.25, to account for design margin reduction to 2.4.
268
Hydrostatic Testing
• Test pressure is at top of the vessel
• Hydrostatic pressure of the liquid must be
accounted for in design
• Allowable stresses for test condition covered in
design paragraphs
• For tall vessels tested vertically, the hydrostatic
test case may control design
269
Hydrostatic Testing
• The above minimum value of test pressure may
be exceeded by calculations, by agreement
between the User and Manufacturer
• The pressure test shall be the lowest calculated
allowable pressure for any component of the
vessel
• For such calculations, any corrosion allowance
may be included in the thickness value
270
Hydrostatic Testing
• The minimum metal temperature during hydrotest shall
be 30F above the MDMT of the vessel (this used to be
recommended, now it is mandatory)
• Need not be warmer than 120F
• It must be noted that this is metal temperature and the
fluid temperature may have to be warmer
• Adequate time must be allowed for the metal, through
the thickness, to come up to this temperature
271
Hydrostatic Testing
• Over-pressure held for an agreed upon period of time
(the Code does not specify)
• Personnel may not approach the vessel, under over-
pressure
• Pressure dropped to MAWP and vessel inspected for
deformation and leakage
• The acceptance criteria for test is visual examination by
the Inspector for leaks and for permanent deformation
• Leaks through welded joints must be corrected and the
vessel re-tested
• Visual permanent deformation may be cause for rejection
of the vessel, at the discretion of the Inspector
272
Pneumatic Testing
• With minor exceptions, minimum required pneumatic test pressure
is:
• Allowable stresses for pneumatic test in design paragraphs

• A higher calculated test pressure may be used, based on nominal
thickness including corrosion allowance, by agreement
273
Pneumatic Testing
• Multiplier lower than hydrotest because of
• Gases being compressible, energy is stored and
failure much more catastrophic
• A number of precautions must be taken,
including:
– Slow pressurization
– Control by acoustic emission
– Clearing all personnel within a certain distance
274
• Over-pressure protection requirements are in Part 9
• These rules establish the type, quantity, relieving capacity and

settings of relief devices
• Rules provided for installation of the devices
• Pressure relief equipment not a part of the stamped vessel and not
normally provided by Manufacturer
• All vessels must be provided with pressure relief
• These would normally be mechanical devices
• Such devices need not be installed directly on vessel
275
• Pressure relieving capacity requirements same as
Division 1
• A 10% overpressure allowed for vessels with one relief
device
• 16% allowed for vessels with multiple devices
• Code Case 2211, over-pressure protection by system
design incorporated in Division 2
• If it can be shown that the system is designed such that
an over-pressure is not possible, a mechanical device
need not be used
• For guidelines on application of these rules see WRC
Bulletin 498
276
1. What does an over-pressure test accomplish?
2. The pressure test must be performed after stamping. True or False?
3. Under what conditions pneumatic testing is permitted?
4. What are some of the precautions for pneumatic testing?
5. What is the minimum pressure for hydrotest?
6. What are the required metal temperatures during hydrotest?
277
7. The “hydrotest pressure” is at the bottom of the vessel. True or
False?
8. The Code does not allow pressure relief by system design. True
or False?
9. Relief capacity of a relief device must be such that the pressure
never exceeds MAWP. True or False?
10. Are the relief equipment a part of the stamped vessel?
11. Who is responsible for providing the relief device?
278
Further Reading
• Welding Research Council (WRC) Bulletin 435,
“Evaluation of Design Margins for Section VIII,
Div. 1 and 2, of ASME Code”, by E. Upitis and K.
Mokhtarian, September 1998.
• ASME PCC-1, Guidelines for Pressure Boundary
Bolted Flange Joint Assembly”
• ASME PCC-2, “Repair of Pressure Equipment
and Piping”
279
Further Reading
• WRC Bulletin 107, “Local Stresses in Spherical
and Cylindrical Shells”
• WRC Bulletin 297, “Local Stresses in Cylindrical
Shells Due to External Loadings”
• WRC Bulletin 368, “Stresses in Intersecting
Cylinders subjected to pressure”
• WRC Bulletin 497, “Large Diameter Ratio Shell
Intersections”
280
Further Reading
• WRC Bulletin 501, “Design of Torispherical and
Ellipsoidal Heads”
• WRC Bulletin 498, “Guidelines for Application of
Code Case 2211”
• WRC Bulletin 474, “Master S-N Method for
fatigue evaluation of welded components”
• WRC Bulletin 464, “Guidelines for Sizing of
Vessels by Limit Analysis”
281
Further Reading
• WRC Bulletin 462, “Commentary on the
Alternative Rules for Determining allowable
compressive stresses for Cylinders, Cones,
Spheres, and Formed Heads”
• WRC Bulletin 444, “Buckling Criteria for
Torispherical Heads Under Internal Pressure”
• WRC Bulletin 364, “New Design Curves for
Torispherical Heads”
• WRC Bulletin 432, “Fatigue Strength Reduction
and Stress Concentration Factors”
• WRC Bulletin 429, “3D Stress Criteria
©
Guidelines for Application”

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ASME Section VIII, Division 2

Design And Fabrication Of

• Details complexity of new design formulas

• Entire set of Code books is re-published every three years

• New Edition or Addenda may be used as soon as it is published

• Code users may contact Committee to request interpretation of the requirements of a

– Codebook not a “handbook” (provides minimum requirements)

– Rules may be supplemented by good practice and jurisdictional requirements

– Code neither requires nor prohibits use of computer programs

– Code does not fully address tolerances

– Code only specifies tolerances that validate the design rules

– Rules do not approve, recommend, or endorse any proprietary or specific design

• Data Reports & Name Plates Entries

• Informative Annex 1.C

• Tables and figures

– Have higher allowable stresses

– Have more rigorous design/analysis requirements

– Have higher fabrication costs

• Owner decides which rules to use

• List of Excluded vessels

• ** This is not a complete list

• This is not a complete list

Not a complete list

• Must be certified in accordance with Annex 2.A of

• Conduct the following inspections (from Annex

• How many Sections does the B&PV Code contain?

• Match the following parties with their responsibilities or duties:

• Name five items that must be included in the

• What system of Units may be used for

• To Obtain Certificate of Authorization

• Quality Control program requirements

• Code symbol may be directly applied to vessel wall

• Stamp is applied to name plate, then name plate is attached to vessel

• As a minimum, the following markings must be included on the name plate:

2. Name 5 things that need to be addressed in a Quality Control program

3. What is the Data Report Form for documenting a fabricated part?

4. What parties are required to sign the Data Reports?

5. Who gets a copy of the Data Report?

6. Stamping is done prior to hydrotest. True or false?

8. To obtain a Code stamp, the Manufacturer must have an agreement with an

– Describe the allowable materials and their requirements for

– Identify criteria used to establish allowable stresses and the

– Distinguish between the allowable stresses for different codes

– For castings, the largest nominal thickness

• The classification of a particular material may be determined by the

• The ordinate of Fig. 3.7 &3.8, marked “Minimum Design Metal

• This temperature is to be compared with the MDMT specified in the

• A number of exceptions are applicable to these general rules

– Materials having specified minimum yield strength greater than

– Welded parts not subject to PWHT, having a governing thickness

– For components made from NPS 4 pipe or smaller (and for

• Another indication is the mills of lateral expansion (see sketch)

2. Toughness rules of Divisions 1 and 2 are identical. True or False?

3. Non-welded Carbon steels, over 1 ½” thick, must always be impact tested.

5. A “Curve A” material has more toughness than a “Curve D” material. True or

6. The exemption from testing of a material always depends on the actual

7. What is the definition of a “nominal Governing Thickness”?

8. Materials required to be impact tested by the material specification

9. If a component is stressed to a value less than the allowable stress,

10. The impact testing exemption temperature of high alloy materials

11. ANSI Standard flanges do not have to be impact tested at an MDMT

• For pneumatic, allowables are lower

• A “thin area is defined as that part of a vessel shell which has a