PV Elite and CodeCalc

Verification and Quality Assurance Manual

Version 2020 (22.0)
November 2019
Copyright
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PV Elite and CodeCalc Verification and Quality Assurance Manual 2

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PV Elite and CodeCalc Verification and Quality Assurance Manual 3

 Introduction

Contents
Introduction .................................................................................................................................................. 6

Hexagon PPM Quality Assurance .............................................................................................................. 7

Software Purpose.................................................................................................................................... 7
Disclaimer ............................................................................................................................................... 7
Intellectual Property Statement ............................................................................................................... 8
Management/Organization ...................................................................................................................... 8
PV Elite Development ............................................................................................................................. 8
User Documentation ............................................................................................................................... 8
Product Support ...................................................................................................................................... 9
Software Issue Tracking/Resolution ....................................................................................................... 9

Software Verification ................................................................................................................................. 10

Test Control........................................................................................................................................... 10
Beta Tests ............................................................................................................................................. 11
PV Elite Test Jobs ................................................................................................................................. 12
Corrective Action Standard ................................................................................................................... 12
Post-Development Procedures ............................................................................................................. 13
Distribution Control ............................................................................................................................... 13

CodeCalc QA Checks ................................................................................................................................ 14

Introduction ........................................................................................................................................... 14
Shell and Head Checks ........................................................................................................................ 15
Nozzle Checks ...................................................................................................................................... 17
Flange Checks ...................................................................................................................................... 19
Cone Checks......................................................................................................................................... 22
Floating Heads Checks ......................................................................................................................... 23
Horizontal Vessel Checks ..................................................................................................................... 25
Leg and Lug .......................................................................................................................................... 25
TEMA Tubesheets Checks ................................................................................................................... 27
WRC 107 Checks.................................................................................................................................. 28
Pipe and Pad Checks ........................................................................................................................... 29
Base Ring Checks ................................................................................................................................ 29
Half-Pipe Check .................................................................................................................................... 30
Large Opening Checks ......................................................................................................................... 31
Rectangular Vessel Checks .................................................................................................................. 33

PV Elite Sample Benchmark Problem Sets............................................................................................. 36

Problem 1 - Natural Frequency Calculation .......................................................................................... 37
Problem 2 - Example of Stiffening Ring Calculation ............................................................................. 41
Problem 3 - Nozzle Reinforcement, Weld Strength, Weld Size ............................................................ 47
Problem 4 - Vessel under Internal and External Pressure on Legs ...................................................... 64
Problem 5 - Vertical Vessel with Wind and Seismic Loads .................................................................. 79
Problem 6a - ASME Section VIII Division 1 Sample Comparisons ...................................................... 93
Problem 6b - ASME Section VIII Division 2 Sample Comparisons ...................................................... 97

PV Elite and CodeCalc Verification and Quality Assurance Manual 4

 Introduction

Problem 7 - EN-13445 Nozzle Reinforcement.................................................................................... 105

Index ......................................................................................................................................................... 111

PV Elite and CodeCalc Verification and Quality Assurance Manual 5

SECTION 1

Introduction
The PV Elite®/CodeCalc® Verification and Quality Assurance Manual provides a standard set of
PV Elite/CodeCalc jobs that are used in verifying both the operation of the software and the
accuracy of the result for each release of the PV Elite/CodeCalc package. The examples
presented in this manual are a representative cross-section of the jobs run by Hexagon PPM.
The jobs selected for this manual compare the PV Elite/CodeCalc output with results published
in industry journals and with results from other software products. The PV Elite/CodeCalc output
is (also) verified with hand and/or MathCad™ calculations.
The component-analysis part of PV Elite is called CodeCalc. CodeCalc-specific results can be
found in the Software Verification section of this manual. In all other sections, the software is
referred to simply as PV Elite.
This manual consists of two major sections: Hexagon PPM Quality Assurance and Software
Verification.
ƒ Hexagon PPM Quality Assurance describes the quality assurance procedures employed by
Hexagon PPM to ensure that PV Elite is producing correct results.
ƒ Software Verification explains a series of benchmark jobs that you can use to confirm
software accuracy. These jobs compare PV Elite output to published results, to output from
similar software, or to hand calculations. For each job in this section, a brief description of
the job and any special considerations are discussed. Following the discussion is a
graphical representation of the system with selected result comparisons. Because of the
volume of output, important results like required thickness, maximum allowable working
pressure (MAWP), and stress are listed in tables. Users interested in the entire output can
re-analyze the jobs as necessary.
The PV Elite development team is constantly testing and adding new test jobs to the QA
benchmark problem set. Currently, there are more than 800 test jobs run which test thousands
of different calculations. It is impractical to include all of these tests in this manual. As new
Quality Assurance procedures are published, they will be incorporated into the QA methods
employed by Hexagon PPM. Users with questions, comments, or suggestions are encouraged
to contact Hexagon PPM to discuss future revisions to this document. User requests for new
features are always welcome. By working with the user, the PV Elite development staff will
continue to develop a product that best meets the demands of pressure-vessel design and
analysis users.

PV Elite and CodeCalc Verification and Quality Assurance Manual 6

SECTION 2

Hexagon PPM Quality Assurance

Software quality assurance is generally a speculative pursuit because, no matter how much
testing is performed, the next test may reveal an error in the software. The goal of any quality
assurance standard is to perform enough testing to achieve such a level of confidence in the
software that errors are rare and unlikely. With this objective in mind, several organizations have
published guidelines for use in software quality assurance.

In This Section
Software Purpose .......................................................................... 7
Disclaimer ...................................................................................... 7
Intellectual Property Statement...................................................... 8
Management/Organization ............................................................ 8
PV Elite Development .................................................................... 8
User Documentation ...................................................................... 8
Product Support ............................................................................. 9
Software Issue Tracking/Resolution .............................................. 9

Software Purpose
PV Elite is a package of twenty applications that work together to design and analyze pressure
vessels and heat exchangers. The purpose of the software is to provide the mechanical
engineer with easy-to-use, technically sound, well-documented calculations that will expedite
and simplify vessel-design and re-rating tasks. The software also provides recent,
industry-accepted analyses of the designs.
Calculations in PV Elite are based on the latest editions of national codes such as the ASME
Boiler and Pressure Vessel Code, or other relevant industry standards that are not covered
directly by ASME VIII-1, VIII-2 or other codes.

Disclaimer
The PV Elite and CodeCalc Verification and Quality Assurance Manual is intended to
demonstrate Hexagon PPM quality assurance procedures. ASME inspections do not require the
tests and material discussed in this manual. Hexagon PPM is not responsible for qualifying or
validating user designs and calculations. Calculations are the responsibility of the Manufacturer
as discussed in ASME Section VIII, Div. 1 U-2(b). For additional information, refer to ASME
Section VIII, Div. 1 UG-90(b), UG-90(c), 10-5 and 10-15.

PV Elite and CodeCalc Verification and Quality Assurance Manual 7

 Hexagon PPM Quality Assurance

Intellectual Property Statement

This manual and its contents should be considered proprietary. This material should not be
copied or distributed to other parties without the expressed written consent of Hexagon PPM.

Management/Organization
At Hexagon PPM, the Chief Technology Officer/Architect, Product Owner, Product Development
Manager, and Quality Assurance Manager oversee the development and testing of the software
product. Software development team members include: engineers, software developers, and a
technical writer. All members of the development team support customers and test the software
prior to each release. Specialized technical support representatives work closely with the
development team. In addition, an on-staff, certified Nuclear Quality Assurance (NQA) lead
auditor oversees the quality assurance program followed by the team.

PV Elite Development
Hexagon PPM is wholly responsible for all software made available to the public that bears the
Hexagon label on the distribution media.
Changes to PV Elite are made by or with the consent of the Product Manager. Additional
members of the software team include engineers, who interact at the same level and
communicate directly with the product manager. Therefore, all software issues can be brought to
the attention of the Product Manager quickly and easily.
Software engineers each bring a different kind of expertise to the team and write routines for
specialized functions in the software. For example, the source code to perform structural steel
checks may be written by an engineer at Hexagon PPM whose educational background permits
him to do this efficiently.
All members of the development staff provide customer support for PV Elite, directly or
indirectly. One member of the team is tasked with quality assurance procedures for each
release.

User Documentation
The PV Elite user has online access to documentation spanning all facets of the software,
including all of the ancillary processors and interfaces. The standard PV Elite documentation set
consists of the following documents:
ƒ PV Elite User's Guide
ƒ CodeCalc User's Guide
ƒ Quick Start Guide
These documents can be accessed from the Help tab in PV Elite. The PV Elite documentation
accompanies each new version of the program and is supplied in both PDF and online help
formats.
Contact information for Hexagon PPM is included in these documents, as well as displayed in
the help system, and in a variety of other locations in the software. We encourage users

PV Elite and CodeCalc Verification and Quality Assurance Manual 8

 Hexagon PPM Quality Assurance

experiencing problems or confusion with the software to reference the documentation first, and
then contact us for further resolution and suggestions.

Product Support
Hexagon PPM welcomes input/suggestions from our users. Users having problems with our
software may freely contact Hexagon PPM through our customer support system, which is found
on our company website and on the News Feed tab in PV Elite.
Our Technical Support staff may ask users with a numerical/computational issue in PV Elite to
submit the job to Hexagon PPM. This allows our support staff to identify the problem and locate
the cause, and then contact the user for resolution.

Software Issue Tracking/Resolution

PV Elite supports standard practices for tracking released software issues, including:
ƒ Incorporating user feedback directly back into the development process.
ƒ Notifying users regarding hot fix or service pack updates issued throughout development
ƒ Following software release criteria based on issue review and prioritization.

PV Elite and CodeCalc Verification and Quality Assurance Manual 9

SECTION 3

Software Verification
This section describes the test methods through which PV Elite software team performs Quality
Assurance testing on PV Elite. In addition, the section describes test methods that you can
implement to validate your PV Elite program data against industry-standard benchmarks.

In This Section
Test Control ................................................................................... 10
Beta Tests ...................................................................................... 11
PV Elite Test Jobs ......................................................................... 12
Corrective Action Standard ............................................................ 12
Post-Development Procedures ...................................................... 13
Distribution Control ........................................................................ 13

Test Control
Currently in the United States there is no organization that formally establishes the credibility of
pressure-vessel analysis software. Therefore, software suppliers take on this responsibility.
Generally, there are two ways to establish that any software product is performing correctly:
ƒ Comparing product results to hand calculations.
ƒ Comparing results to previously verified results from an external source.
If these methods compare favorably to software-generated results, then the software is
assumed to be performing as expected. If the results do not compare favorably, the PV Elite
development team identifies the differences and corrects the problem.

Testing Process
Before a new version of PV Elite is released, the development personnel perform alpha-level
testing throughout the delivery cycle in a process called "continuous delivery". This means that
every month-long development cycle, items are worked on, tested, and verified before the item
is considered done. This involves checking the Fortran/C++ or assembler code and running of
basic test problems designed to test the functionality of the feature addition, error and abort
conditions, and so forth. Next, the development staff generates a series of alpha jobs that:
ƒ Test new features against existing software.
ƒ Run tests against industry standard programs, such as Compress™ and VVD™ teams.
ƒ Suggest to customers that they independently compare the results of PV Elite against their
own in-house program or spreadsheets.
ƒ Test new features against hand calculations.
ƒ Test new features against published literature, such as the ASME VIII-1, PTB-3, and other
codes.
ƒ Test the interaction between new features and features already existing in the software.

PV Elite and CodeCalc Verification and Quality Assurance Manual 10