BASICS OF

PRESSURE VESSEL
FABRICATION

B. DUTTA
16/11/19
 WHAT IS PRESSURE VESSEL
A Pressure Vessel is a closed container designed to hold gas /
liquid at a pressure substantially different from the gauge
pressure.

TYPES OF PRESSURE VESSEL

BASED ON TEMP.
1.Low Temp. Vessels (≤ -20°C)
2.Normal Temp. Vessels (-20°C to 150°C)
3.Medium Temp. Vessels (150°C to 450)
4.High Temp. Vessels (≥ 450°C)
BASED ON DESIGN PR.
1.Low Pr. Vessels (0.1MPa to 1.6MPa)
2.Medium Pr. Vessels (1.6MPa to 10MPa)
3.High Pr. Vessels (10MPa to 100MPa)
4.Very High Pr. Vessels (≥ 100MPa)

BASED ON CONSTRUCTION BASED ON USAGE MODE

1.Single Wall Vessel 1.Fixed Pr. Vessels
2.Multi Wall Vessel 2.Mobile Pr. Vessels
3.Cladded Vessel
4.Overlayed Vessel

B. DUTTA
16/11/19
 INDUSTRIAL USE OF PRESSURE VESSEL

•Fertilizer Industries

•Chemical Industries

•Petrochemical Industries

•Steel Plant Industries

•Indian Navy

•Nuclear Power Corporation

•Indian Space Research Organization

B. DUTTA
16/11/19
 ASME SECTIONS FOR PRESSURE VESSEL

SECTION-I POWER BOILERS

PART-A FERROUS MATERIALS
PART-B NON-FERRUOUS MATERIALS
SECTION-II
PART-C SPECIFICATION FOR WELDING, RODS, ELECTRODES ETC.
PART-D PROPERTIES (METRIC & CUSTOMERY)
SECTION-III NUCLEAR CODES
SECTION-IV HEATING BOILERS
SECTION-V NDE
DIVISION-I RULES FOR CONSTRUCTION OF PV
SECTION-VIII DIVISION-II ALTERNATIVE RULES
DIVISION-III ALTERNATIVE RULES FOR CONSTRUCTION OF HIGH PV
SECTION-IX WELDING & BRAZING

B. DUTTA
16/11/19
 CERTIFICATIONS REQUIRED FOR PRESSURE VESSEL
A Pressure Vessel manufacturer has to obtain following
certifications from ASME :

U : For pressure vessels as per ASME Sec. VIII Div. 1

U2 : For pressure vessels as per ASME Sec. VIII Div. 2
U3 : For pressure vessels as per ASME Sec. VIII Div. 3
S : For Steam Boilers

B. DUTTA
16/11/19
 MATERIALS USED TO MAKE PRESSURE VESSEL
•BQ grade plate - SA 516 Grade 55, 60, 65, 70
•Stainless Steel
•Aluminium
•Titanium

SA 516 material is Carbon Steel Pressure Vessel Plates for

Moderate and Lower Temperature Services.

S : ASME material

A : Ferrous material (as per Section II Part A)

516 : "516" is just an identifier for CS pressure vessel plate

material. It has no technical significance.

55, 60,65 70 : Min. Tensile strength B. DUTTA

16/11/19
 DIFFERENT PARTS OF A PRESSURE VESSEL

FLANGE
REINFORCEMENT
SHELL PAD
NOZZLE

DISHED END
CIRCUMFERENTIA
L SEAM (C/S)

SADDLE

LONGITUDINAL
SEAM (L/S)
B. DUTTA
16/11/19
MANUFACTURING
PRESSURE VESSEL

Making of Shell

B. DUTTA
16/11/19
1 Check the of 4

4 Units
s
corners of the shell

nit
5U
plate after cutting

3 Units

2 Check diagonal TOLERANCE

L - + 1 mm / M,
Max. 3 mm.,
K2 W
K1
W - + 1 mm / M,
Max. 3 mm
L
K1 - K2 = + 1 mm / M,
Max. + 5 mm

3 WEP (Weld Edge

Preparation) & DP of
WEP

B. DUTTA
16/11/19
4 Rolling in flat condition
before rolling to make
shell

5 Rolling to form shell

6 Fit-up with PTC (if

customer asks for) &
Spiders

B. DUTTA
16/11/19
7 L/S welding Adopt sequence
welding ( I/S – O/S ) to
control Peak in or
Peak out

8 Re-rolling &
Ovality correction

9 DP/UT/RT of L/S
joint

B. DUTTA
16/11/19
10 Shell to Shell
fit-up

V V V V
11 C/S welding

12 DP/UT/RT of
C/S joint

B. DUTTA
16/11/19
 MAX. OVALITY ALLOWED IN SHELL
ID Allowed gap
Peak in /
ID/4 out

ID MATCHING < 152 0.8 MM

< 305

MP
1.2 MM
D/

TE
4
TE

< 457
D/4
M
P

1.6 MM
PEAK OUT PEAK IN < 610 2.4
MM <
ID/4 914 3.2 MM
< 1219
What is Ovality and % Ovality? 4.0 MM
Ovality = ID max - ID min < 1524 4.8
MM <
% Ovality = (Ovality X 100) / 1905 5.6 MM
Nominal Dia.
< 2133 B.6.4
DUTTA
Nominal Dia = Measured Circ. /  MM 16/11/19
<
 MAX. OFF-SET ALLOWED IN BUTT JOINTS

Long Seam Circ. Seam t=

≤12.7mm 1/4th t 1/4th t Nominal
thickness
12.7mm ≥ 19mm 3.2 mm 1/4th t
19mm ≥ 38mm 3.2 mm 4.8 mm
38mm ≥ 51mm 3.2 mm 1/8th t
1/16th t. 1/8th t.
≥ 51mm
Max. 10 mm Max. 19mm

Aim For Half Of The Permissible Off Set At Set Up Stage

B. DUTTA
16/11/19
 MANUFACTURING
PRESSURE VESSEL

Making of Dished Ends

B. DUTTA
16/11/19
 MAJOR 3 TYPES OF DISHED END

Ellipsoidal

Torispherical

Hemispherical
B. DUTTA
16/11/19
 ELLIPSOIDAL & TORISPHERICAL HEAD DIMENSIONS
Do  = External head diameter
Di = Internal head diameter
CR = Crown radius
KR = Knuckle radius
SF = Straight flange height
DH = Depth of dishing
Thi = Total internal head height
t = Wall thickness
WL = Welding Line
TL = Tangent Line                        
Ellipsoidal head 2:1 Ellipsoidal head 1.9 : 1 Torispherical head
Di = Do – 2t = Do – 2t = Do – 2t
CR = 0.9Di = Di / 1.16 = Do
KR = 0.17Di = Di / 5.39 = 0.1Do
SF = 3.5t or per request = 3.5t or per request = 3.5t or per request
THi = SF + DH = SF + DH = SF + DH

B. DUTTA
16/11/19
 ELLIPSOIDAL & TORISPHERICAL HEAD DIMENSIONS

Ellipsoidal head 2:1 means that inside diameter is 2 x

inside depth of head as per UG-32 (C).

HEMISPHERICAL HEAD DIMENSIONS

Hemispherical head
Di = Do – 2t
CR = Do
KR = 0.1Do
SF = 3.5t or per request
DH = 0.1935Do – 0.455t
B. DUTTA
THi = SF + DH 16/11/19
1 Blank cutting for D/E

2 Forming

3 Inspection (1) Dimension

(2) DP / RT
(3) SR

4 Trimming to size & WEP

5 DP of Bevel edge

6 Fitting D/E with Shell

7 Welding & NDT

B. DUTTA
16/11/19
 INSPECTION METHOD OF DISHED ENDS
Keep Equal Template – 20 mm Less In Size Try To Match
Gap Tan Line
Trimming Line Keep Equal Gap
Tan
Line
Centre Line

Transfer Trimming Line, Tan

Measure Gap At Every 6’’
Line & Centre Line On D’
Intervals
Shed End

Repeat Marking & Checking Along the Full Circumference

at Every 300 mm apart by the template as shown.
B. DUTTA
16/11/19
 MANUFACTURING
PRESSURE VESSEL

Making of Nozzle joints

B. DUTTA
16/11/19
 TYPES OF PRESSURE VESSEL FLANGES

Weld Neck
Flange

Slip On
Flange

Socket weld
Flange

Lap joint
Flange

B. DUTTA
16/11/19
 TYPES OF PRESSURE VESSEL FLANGES

Threaded
Flange

Blind
flange

B. DUTTA
16/11/19
 PRESSURE RATING OF FLANGES
Forged steel flanges, ASME B16.5, are made in seven primary
Pressure Classes
150,  300,  400,  600,  900,  1500 & 2500

Different nomenclatures are used to indicate a Pressure Class.

For example: 150 Lb or 150 Lbs or 150# or Class 150, all are
means the same.

As temperature increases, the pressure rating of the flange

decreases. For example a Class 150 flange is rated to approximately,

270 PSIG at ambient conditions,

180 PSIG at approximately 400°F,
150 PSIG at approximately 600°F,
75 PSIG at approximately 800°F
B. DUTTA
16/11/19
 DIFFERENCE BETWEEN TUBES & PIPES

TUBES PIPES
Tubes are typically ordered to OD and Pipes are typically ordered using the
Wall thickness or to OD & ID or to ID and Nominal Pipe Size (NPS) standard by
Wall thickness. specifying a nominal diameter and
schedule number (wall thickness).

Tubes are used in structural applications
so the OD becomes the important
dimension.
Pipes are normally used to transport
gasses or liquids making it important to
know the capacity that how much can
flow through the pipe, hence ID becomes
the important dimension.

Tubes can come in different shapes such Pipe is always round

as square, rectangular and cylindrical

Example : Tube of size Ǿ1” OD x 6mm Example : Pipe of size 1”NB Sch. 80
WT

B. DUTTA
16/11/19
NPS TABLE OF PIPES

B. DUTTA
16/11/19
MANUFACTURING
PRESSURE VESSEL

Fitting of Nozzles
(1) Radial fitting
(2) Off-set fitting
B. DUTTA
16/11/19
RADIAL NOZZLE FITTING OFF-SET NOZZLE FITTING
Off-set distance

Nozzle
projection
Nozzle
projection

LINEAR OFF-SET ANGULAR OFF-SET

Off-set distance

Nozzle
projection

Nozzle
B. DUTTA
projection Off-set angle 16/11/19
 NOZZLE SET-UP METHOD

SET THROUGH SET ON

B. DUTTA
16/11/19
 REINFORCEMENT PADS

Reinforcement Pads are generally used to

give strengthening to parent material, on
which R-pad is applied.

A vent hole is made on the R-pad which serves a

couple of purposes :

1) it relieves any gas pressure that may develop

when welding the pad to the nozzle or branch.
2) it is threaded so that it can be pressure tested to
check for leaks.
3) it serves as a "telltale" if the weld underlying it
develops a leak.
4) it prevents any build-up of pressure should the
underlying weld develops a leak. B. DUTTA
16/11/19
1 Nozzle to flanges
fitting

2 Nozzles to flanges
welding

3 Orientation
marking for
nozzles & making
cut out

B. DUTTA
16/11/19
4 WEP and DP on
nozzle cut outs

5 Fitting of Nozzles,
welding and NDT

6 Fitting of
Reinforcement pads,
welding and NDT

B. DUTTA
16/11/19
MANUFACTURING
PRESSURE VESSEL

Important points of
Welding

B. DUTTA
16/11/19
 PRE-HEATING

Pre-heating is heating the base metal around welding

joint before welding

Preheating of the base metal is necessary for the

following reasons: -

•To evolve out the hydrogen from the metal,

•To reduce thermal stresses developed during welding,

•To reduce shrinkage stresses developed during welding,

• To remove the moisture from the metal and the gases

generated during welding,

•To lower the cooling rate B. DUTTA

16/11/19
 PWHT

Post Weld Heat Treatment is heating the welding joint

and the HAZ after the last pass welding is completed.
PWHT of the weld joint & HAZ is necessary for the
following reasons: -

•To lower the cooling rate of the weld joint & HAZ,

•To evolve out the hydrogen from the weld pool to prevent
HIC,

•To reduce thermal stresses developed during welding,

•To reduce shrinkage stresses developed during welding

• To remove the gases generated during welding

B. DUTTA
16/11/19
 PWHT

•Post heating also lowers the hardness of the welding joint

and HAZ, and promotes ductility.

•Post heating also does stress relieving partially.

B. DUTTA
16/11/19
 PRESSURE VESSEL WELD JOINT CATEGORIES
Category A: Category B:
(1) All longitudinal welds in shell and (1) All circumferential welds in shell and
nozzles. nozzles
(2) All welds in heads, (2) Head to shell weld joint (other than
(3) Head to shell weld joint (in case of Hemispherical)
Hemispherical DE)

Category C : Category D :
Flange welds Nozzle attachment welds

B. DUTTA
16/11/19
 MAX. REINFORCEMENT ALLOWED AS PER UW-35

Max. Reinforcement
Material Thickness
Long Seam Circ. Seam

Below 2.4 mm 0.8 mm 2.4 mm

2.4 to 4.8 mm incl 1.6 mm 3.2 mm

Over 4.8 to 13 mm incl 2.4 mm 4.0 mm

Over 13 to 25 mm incl 2.4 mm 4.8 mm

Over 25 to 51 mm incl 3.2 mm 5.0 mm

Over 51 to 76 mm 4.0 mm 6.0mm

Over 76 to 127 mm 6.0 mm 6.0 mm

Over 127 mm 8.0 mm 8.0 mm

B. DUTTA
16/11/19
 RADIOGRAPHY TEST IN PRESSURE VESSEL

Radiography Test

FULL SPOT
1. 100% 1. One spot shall be examined for each 50 ft.
radiography increment of weld. The minimum length of spot
2. Acceptance shall be 6 in. (150 mm).
criteria UW-51 2. For failure of any spot, two additional spots
radiography to be done in the same weld increment
at locations away from the original spot.
3. If either of the two additional spots failed, the
entire increment of weld represented shall be
rejected. The entire rejected weld shall be removed
and the joint shall be rewelded.
4. The location of the spot shall be chosen by the
Inspector.
5. Acceptance criteria UW-52

B. DUTTA
16/11/19
MANUFACTURING
PRESSURE VESSEL

Stress Relieving

B. DUTTA
16/11/19
 STRESS RELIEVING

Stress Relieving is done to remove or to reduce the

residual stresses generated by forming/ welding 
GAS/OIL FIRED

ELECTRICAL
FURNCE

FURNCE
STRESS RELIEVE
INDUCTION

VIBRATION
FURNCE

B. DUTTA
16/11/19
 STRESS RELIEVING

700                                            
TIME vs TEMPERATURE GRAPH
650                                            
600                   C      D                   
500                                            
450                                            
400                                            
350                                            
TEMPERATURE (°C)

300          B                          
E        
250             A
  B : Uncontrolled heating from Room temp. to 300°C
                             
200   B C : Controlled heating @60°C /hr from 300°C to 600°C
                                         
150   C D : Soaking period 3hrs. at 600°C
                                         
100   D E : Controlled cooling @50°C /hr from 600°C to 300°C
                                         
E F : Uncontrolled cooling from 300°C to Room temp.
50   A                                         F
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

TIME (Hr.) B. DUTTA

16/11/19
 STRESS RELIEVING

SOAKING
700                      PERIOD
                     
650                                            
600                   C      D                   
500                                 CONTROLLED
           
COOLING
450           CONTROLLED
                                 
HEATING
400                                            
TEMPERATURE

350                                            
300          B                          E        
250                                            
200 UNCONTROLLED
                                           
HEATING UNCONTROLLED
150                                   COOLING
         
100                                            
50   A                                         F
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

TIME B. DUTTA
16/11/19
MANUFACTURING
PRESSURE VESSEL

Hydrotest

B. DUTTA
16/11/19
 HYDRAUTEST PRECAUTIONS
1 Pipe fittings are to be used must of high pressure
ratings (5,000 to 10,000 PSI)

2 Fasteners to be used must be of high tensile grade

3 Only Calibrated pressure gauges are to be used.

The upper range graduation on PG should be min.

1.5 times, max. 4 times of test pressure.

Ideally it should be twice the test pressure

4 Use water with correct PPM as Chlorine particles

affect the anti-corrosive properties of the vessel
• 25 PPM or Less for SS Vessel
• 80 PPM or Less for CS Vessel
B. DUTTA
16/11/19
5 Adequate arrangement to be Keep inlet nozzle of water at top and
made for venting the air, drain nozzle at bottom
trapped inside the vessel

6 Tightening of covers to be done

on sequential way

7 Correct pump selection to be

done for pressuring the vessel
--- whether High pressure –
Low discharge or Low pressure
– High discharge. Please note
that High discharge pump shall
not be used for vessels with <
10m3 volume

B. DUTTA
16/11/19
8 Raise the pressure till 50% of test pressure & then increase the pressure
in increments of 10% of test pressure

9 Stop pumping for 5 minutes after each increment of 10% raise in

pressure

10 When test pressure is reached, stop pumping, connect inlet gauge to

pressure line and hold for 30min and observe vessel from distance

11 If any leakage is observed through gasket connection, repeat the test

after depressurize the vessel and tighten the studs/nuts

12 If any leakage is observed from weld joint or parent metal, drain the
water, repair the leak repeat the test

B. DUTTA
16/11/19
HYDROTEST - LAYOUT

B. DUTTA
16/11/19
HYDROTEST - LAYOUT

B. DUTTA
16/11/19
If you focus on RESULTS, you will never
change.

If you focus on CHANGE, you will get

results.