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Pressure Vessel Design
Pressure Vessel Design
Pressure Vessel Design
Instructors Guide
CONTACT INFORMATION
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Overview of Pressure Vessel Design By: Vincent A. Carucci Carmagen Engineering, Inc.
Copyright 1999 by
TABLE OF CONTENTS
Abstract 5 Introduction..6 Organizing Unit Responsibilities..7 Instructor Guidelines and Responsibilities.9 Overview of Pressure Vessel Design Outline/ Teaching Plan11 Instructor Notes.13 Appendix A: Reproducible Overheads Appendix B: Course and Instructor Evaluation Form Appendix C: Continuing Education Unit (CEU) Submittal Form Course Improvement Form Instructors Biography Form
ABSTRACT
Pressure vessels are typically designed, fabricated, installed, inspected, and tested in accordance with the ASME Code Section VIII. Section VIII is divided into three separate divisions. This course outlines the main differences a mong the divisions. It then concentrates on and presents an overview of Division I. This course also discusses several relevant items that are not included in Division I.
INTRODUCTION
This Overview of Pressure Vessel Design course is part of the ASME International Career Development Series an educational tool to help engineers and managers succeed in todays business/engineering world. Each course in this series is a 4hour (or half-day) self-contained professional development seminar. The course material consists of a participant manual and an instructors guide. The participant manual is a self-contained text for students/participants, while the guide (this booklet) provides the instructional material designed to be presented by a local knowledgeable instructor with a minimum of preparation time. The balance of this instructors guide focuses on: 1. 2. 3. Organizing Unit Responsibilities Instructor Guidelines and Responsibilities Comprehensive teaching materials which may be used as is or adapted to incorporate experiences and perspective of the instructor.
Welcome to the ASME International Career Development Series! We wish you all the best in your presentation, operation and delivery of this course.
10
25
General
10 10
5 20 Materials of Construction 15
25
OV 44-55 Part. - 98
20
11
50
Design (Contd.)
20 10 15 5
10 20
10 10
20
Fabrication
10 10
15
10 5
10
Closure
10
12
Instructors Outline
1. Course discusses pressure vessel design and is introductory in nature. 2. Based on ASME Code Section VIII. 3. Preliminary emphasis is on Division 1 but Divisions 2 and 3 are highlighted. 4. Introduces several items that are not covered in the ASME Code.
13
Instructors Outline
1. The objective: Provide a general knowledge of design requirements for pressure vessels. 2. This is not a comprehensive course. It provides sufficient information for management personnel to have an overall understanding of this subject. Individuals having more detailed responsibility will receive a solid starting point to proceed further. 3. Review outline. 4. Establish schedule. 5. Participation is key: Questions Discussion/interaction
14
Pressure Vessels
Containers for fluids under pressure Used in variety of industries Petroleum refining Chemical Power Pulp and paper Food
3
Instructors Outline
1. Describe what a pressure vessel is. 2. Note that pressure vessels are used in a wide variety of industries. They can be designed for a wide variety of conditions and in a broad range of sizes.
15
SectionA-A
Figure 2.1
4
Instructors Outline
1. Use this and following overheads to describe main pressure vessel components and shapes. 2. Shell is primary component that contains pressure. Curved shape. 3. Vessel always closed by heads. 4. Components typically welded together. 5. Vessel shell may be cylindrical, spherical, or conical. 6. Multiple diameters, thicknesses or materials are possible. 7. Saddle supports used for horizontal drums. Spreads load over shell. One support fixed, other slides.
16
Head
Support Leg
Figure 2.2
Instructors Outline
1. Most heads are curved shape for strength, thinness, economy. 2. Semi-elliptical shape is most common head shape. 3. Small vertical drums typically supported by legs. Typically maximum 2:1 ratio of leg length to diameter. Number, size, and attachment details depend on loads.
17
Cone
Nozzle Shell
Nozzle
Figure 2.3
Instructors Outline
1. Nozzles used for: Piping systems Instrument connections Manways Attaching other equipment
18
Shell
Lower Catalyst Bed Outlet Collector Head Outlet Nozzle Support Skirt
Figure 2.4
Instructors Outline
1. Skirt supports typically used for tall vertical vessels: Cylindrical shell Typically supported from grade
2. General support design (not just for skirts) Design for weight, wind, earthquake. Pressure not a factor. Temperature also a consideration for material selection and thermal expansion.
19
Support Leg
Cross Bracing
Figure 2.5
8
Instructors Outline
1. Spherical storage vessels typically supported on legs. 2. Cross-bracing typically used to absorb wind and earthquake loads.
20
Figure 2.6
Instructors Outline
1. Vessel size limits for lug supports: 1 10 ft diameter 2:1 to 5:1 height/diameter ratio
21
10
Instructors Outline
1. Section VIII is most widely used Code. 2. Assures safe design. 3. Three divisions have different emphasis.
22
11
Instructors Outline
1. Review scope of Division 1. 2. Division 1 not applicable below 15 psig. 3. Additional rules required above 3000 psig. 4. Items that are connected to pressure vessels not covered by Division 1, except for: Their effect on pressure part. Welded attachment to pressure part.
23
12
Instructors Outline
1. Review differences between Divisions 1 and 2. 2. Division 2 allowable membrane stress is higher. 3. Division 2 requires more complex calculations. 4. Division 2 does not permit some design details that are permitted in Division 1. 5. Division 2 requires more stringent material quality control, fabrication, and testing requirements.
24
Instructors Outline
1. Review application of Division 3. 2. Newest Division of Section VIII and has least applicability. 3. After this point, this course only addresses Division 1 requirements when code-specific items are discussed.
25
Subsection C
Requirements based on material class Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT, ULW, ULT
14
Instructors Outline
1. Review Division 1 organization 2. Fabrication methods: Welded Forged Brazed
3. Material classes Carbon and low-alloy steel Non-ferrous metals High alloy steel Cast iron Clad and lined material Ductile iron Heat treated steels Layered construction Low-temperature material
26
15
Instructors Outline
1. ASME Code does not specify particular materials to use in each application. Owner must do this. 2. ASME Code specifies permitted materials and the requirements that these must meet.
27
Strength
Determines required component thickness Overall strength determined by:
Yield Strength Ultimate Tensile Strength Creep Strength Rupture Strength
16
Instructors Outline
1. Strength: Materials ability to withstand imposed loading. 2. Higher strength material thinner component. 3. Describe properties that are used to define strength.
28
Corrosion Resistance
Deterioration of metal by chemical action Most important factor to consider Corrosion allowance supplies additional thickness Alloying elements provide additional resistance to corrosion
17
Instructors Outline
1. Corrosion is thinning of metal. 2. Adding extra component thickness (i.e., corrosion allowance) is most common method to address corrosion. 3. Alloy materials are used in services where corrosion allowance would be unreasonably high if carbon steel were used.
29
Instructors Outline
1. Low-temperature H 2 attack can cause cracking. 2. Higher temperature H 2 attack causes through-thickness strength loss and is irreversible. 3. H2 attack is a function of H 2 partial pressure and design temperature. Increased alloy content (i.e., Cr) increases H 2 attack resistance. Reference API-941 for Nelson Curves.
30
Instructors Outline
1. Describe brittle fracture as equivalent to dropping a piece of glass. 2. Material selection must ensure that brittle fracture will not occur.
31
Instructors Outline
1. A brittle fracture will occur the first time the appropriate conditions occur. 2. Brittle fracture occurs without warning and is catastrophic.
32
21
Instructors Outline
1. Describe influence of material and temperature factors on fracture toughness. 2. Other factors increase brittle fracture risk.
33
Pointer
h'
22
Instructors Outline
1. Charpy V-Notch test is most widely used measure of material fracture toughness. 2. Describe test set-up.
34
Nozzles Tubesheets Flanges Flat cover plates Attachments essential to structural integrity that are welded to pressure parts
Instructors Outline
1. ASME Code contains brittle fracture evaluation procedure. 2. Review components to be included only items that relate to structural integrity of pressure-containing shell.
35
Temperatures to Consider
Minimum Design Metal Temperature (MDMT)
Lowest temperature at which component has adequate fracture toughness
24
Instructors Outline
1. Describe the distinction between MDMT and CET. MDMT is a material property. CET is an environmental factor.
36
If combination of Material Group and thickness not exempt, then must impact test at CET
25
Instructors Outline
1. Outline ASME procedure. 2. Details described in following overheads.
37
Material Groups
APPLICABLE MATERIALS
All carbon and low alloy steel plates, structural shapes, and bars not listed in Curves B, C & D SA-216 Gr. WCB & WCC, SA-217 Gr. WC6, if normalized and tempered or water-quenched and tempered
Curve B
SA-216 Gr. WCA, if normalized and tempered or water-quenched and tempered SA-216 Gr. WCB & WCC for maximum thickness of 2 in., if produced to fine grain practice and water-quenched and tempered SA-285 Gr. A & B SA-414 Gr. A SA-515 Gr. 60 SA-516 Gr. 65 & 70, if not normalized Except for cast steels, all materials of Curve A if produced to fine grain practice and normalized which are not included in Curves C & D
All pipe, fittings, forging, and tubing which are not included in Curves C & D
Instructors Outline
1. Materials are grouped based on common fracture toughness properties. 2. Groups A through D move from worst to best fracture toughness. 3. Point out several common materials. SA-516 Gr. 65 and 70 are Curve B if not normalized. Most pipe, fittings and forgings are Curve B.
38
APPLICABLE MATERIALS
SA-182 Gr. 21 & 22, if normalized and tempered SA-302 Gr. C & D SA-336 Gr. F21 & F22, if normalized and tempered SA-387 Gr. 21 & 22, if normalized and tempered SA-516 Gr. 55 & 60, if not normalized SA-533 Gr. B & C SA-662 Gr. A All material of Curve B if produced to fine grain practice and normalized which are not included in Curve D SA-203 SA-508 Cl. 1 SA-516, if normalized SA-524 Cl. 1 & 2 SA-537 Cl. 1, 2 & 3 SA-612, if normalized SA-662, if normalized SA-738 Gr. A
Curve D
See Figure UCS-66 of the ASME Code Section VIII, Div. 1, for impact test exemption temperatures for specified material specifications
Instructors Outline
1. Identify other common materials. SA-516 Gr. 55 and 60 are Curve C if not normalized. SA-516 (all grades) is Curve D if normalized.
2. Highlight points. Lower strength grades of same specification have better fracture toughness. Normalization improves fracture toughness.
39
Figure 3.1
28
Instructors Outline
1. Describe relationship between Material Group, component thickness, and MDMT. 2. Impact testing not required if point is at or below curve (i.e., OK if MDMT CET). 3. Example: 1.5 in. thick Group B material does not require impact testing if CET 50 F. 4. If not exempt, must impact test material at CET. 5. Exemption means there is enough experience that material has adequate fracture toughness without need for further testing.
40
29
Instructors Outline
1. Review additional requirements. 2. Note that most flanges will not require impact testing.
41
30F MDMT reduction if PWHT P-1 steel and not required by code MDMT reduction if calculated stress < allowable stress
30
Instructors Outline
1. Review additional requirements. 2. PWHT reduces MDMT by 30 F provided PWHT not required by Code and resulting MDMT -55 F. 3. Can take MDMT credit if component thickness greater than needed (i.e., calculated stress < allowable stress).
42
Fabricability
Ease of construction Any required special fabrication practices Material must be weldable
31
Instructors Outline
Describe fabricability.
43
Instructors Outline
1. Discuss the use of allowable stress in determining vessel component design. 2. Section II, Part D, Appendix I contains allowable stress criteria for materials other than bolting. 3. Section II, Part D contains allowable stress tables.
44
Plate - Low Alloy Steels SA-387 2 Cl.1 1/2Cr-1/2Mo 2 Cl.2 1/2Cr-1/2Mo 12 Cl.1 1Cr-1/2Mo 12 Cl.2 1Cr-1/2Mo 11 Cl.1 1 1/4Cr-1/2Mo-Si 11 Cl.2 1 1/4Cr-1/2Mo-Si 22 Cl.1 2 1/4Cr-1Mo 22 Cl.2 2 1/4Cr-1Mo
Instructors Outline
1. Describe information contained in first section of table. 2. Information is grouped by material chemistry and material form.
45
Plate-Low Alloy Steels (Cont'd) ----SA-387 ----SA-387 4.5 2.8 1.8 1.1 SA-387 4.5 2.8 1.8 1.1 SA-387 4.2 2.8 1.9 1.2 SA-387 4.2 2.8 1.9 1.2 SA-387 5.7 3.8 2.4 1.4 SA-387 5.1 3.2 2.0 1.2 SA-387
Instructors Outline
1. Review allowable stress vs. design temperature. 2. Most ferritic materials have a constant allowable stress at temperatures through 650F.
46
New horizontal vessel CET = - 2F Shell and heads: SA-516 Gr. 70 Heads hemispherical: in. thick Cylindrical shell: 1.0 in. thick No impact testing specified Is this correct? If not correct, what should be done?
Instructors Outline
1. This independent Exercise gives the Participants practice in material selection based on fracture toughness. 2. Review the given information together. 3. Allow approximately 10 minutes for the Participants to solve the problem. Then review the solution with them.
47
Exercise 1 - Solution
Must assume SA-516 Gr. 70 not normalized. Therefore, Curve B material (Ref. Table 3.1). Refer to Curve B in Figure 3.1.
in. thick plate for heads: MDMT = -7 F in. thick plate exempt from impact testing since MDMT < CET
36
Instructors Outline
1. Review difference between normalized and non-normalized material with respect to fracture toughness. 2. Review MDMT determination in each case. 3. Note difference between MDMT and CET in each case.
48
37
Instructors Outline
1. Review possible solutions for the 1 in. plate.
49
38
Instructors Outline
1. Review rationale for which option to select.
50
Instructors Outline
1. Review conditions to be considered. 2. Worst case operating scenario determines mechanical design.
51
Design Pressure
P T = Design Pressure at Top of Vessel
H = Height of Liquid
Figure 4.1
40
Instructors Outline
1. May have internal of external pressure, or both at different times. 2. Must have margin between maximum operating pressure at top of vessel and design pressure. 3. Hydrostatic pressure of operating liquid (if present) must be considered at corresponding vessel elevation.
52
Section 2 (T-X)
Figure 4.2
41
Instructors Outline
1. Margin required between operating temperature and design temperature. 2. Maximum design temperature needed to determine allowable stress and thermal expansion considerations. 3. CET needed for material selection considering brittle fracture. 4. There may be a wide temperature variation between the bottom and top of a tall tower.
53
Additional Loadings
Weight of vessel and normal contents under operating or test conditions Superimposed static reactions from weight of attached items (e.g., motors, machinery, other vessels, piping, linings, insulation) Loads at attached internal components or vessel supports Wind, snow, seismic reactions
42
Instructors Outline
1. Highlight other loads that must be considered in the mechanical design. 2. These other loads may govern the mechanical design in local areas.
54
Instructors Outline
1. Review these additional other loads.
55
D B A
Figure 4.3
44
Instructors Outline
1. Review the ASME Code Weld Joint Categories. 2. Only specific weld types may be used in each category.
56
Weld Types
1 Buttjointsasattainedbydouble-weldingorbyother means which will obtain the same quality of deposited weld metal on the inside and outside weld surface. Backing strip, if used, shall be removed after completionofweld. Single-welded butt joint with backing strip which remainsinplaceafterwelding. 2
Double-fullfilletlapjoint.
5 6
Figure 4.4
45
Instructors Outline
1. Review the different weld types. 2. Limited applications for Types 3 through 6.
57
Figure 4.5
46
Instructors Outline
1. Weld joint efficiency, E, is a measure of weld quality and accounts for stress concentrations. 2. E is needed in component thickness calculations. 3. Review information in table. 4. Note that corrosion allowance was previously discussed.
58
SE 1t r + 0.6t
2SEt r + 0.2t 2SEt D + 0.2t SEt 0.885L + 0.1t 2SEt cos D + 1.2t cos
Spherical shell 2:1 Semi - Elliptical head Torispherical head with 6% knuckle Conical Section ( = 30)
P(r + 0.2t ) 2tE P(D + 0.2t ) 2tE P (0.885L + 0.1t ) tE P(D + 1.2t cos ) 2tE cos
Figure 4.6
47
Instructors Outline
1. Circumferential stress governs minimum required component thickness in most cases. 2. Longitudinal stress may govern local thickness in some cases (e.g., under wind or earthquake loads). 3. Review ASME Code equations for internal pressure design. May calculate required thickness, permitted pressure, component stress. Must account for corrosion allowance.
59
sf ID Conical r ID Toriconical
48
Figure 4.7
Instructors Outline
1. Review the different head types. 2. The 2:l semi-elliptical head is the most common.
60
l 3y
Tangent Line y
l 3y
ts
Figure 4.8
49
Instructors Outline
1. Required thickness of a hemispherical head is about half that of the connected cylindrical shell. 2. Must have a tapered thickness transition in the head to end up matching the shell thickness.
61
Sample Problem 1
Hemispherical DESIGN INFORMATION Design Pressure = 250 psig Design Temperature = 700 F Shell and Head Material is SA-515 Gr. 60 Corrosion Allowance = 0.125" Both Heads are Seamless Shell and Cone Welds are Double Welded and will be Spot Radiographed The Vessel is in All Vapor Service Cylinder Dimensions Shown are Inside Diameters 4' - 0" 60' - 0"
10' - 0"
2:1 Semi-Elliptical
Figure 4.9
50
Instructors Outline
1. Sample Problem 1 illustrates calculation of required shell and head thicknesses for internal pressure. 2. Review the given information. 3. Review the problem solution with the Participants.
62
tp =
Pr SE1 0. 6P
Welds spot radiographed, E = 0.85 (Figure 4.5) S = 14,400 psi for SA- 515/Gr. 60 at 700F (Figure 3.2) P = 250 psig
51
Instructors Outline
1. Review the relevant equation for a cylindrical shell. 2. Note the sources used for the various parameters.
63
Instructors Outline
1. The corrosion allowance must be added to obtain the inside radius. 2. The corrosion allowance must be added to the calculated thickness.
64
= 0.499 in.
Instructors Outline
1. The calculation is repeated for the other cylindrical shell section.
65
tp =
54
Instructors Outline
1. Review the relevant equation for a hemispherical head. 2. Note the sources for the relevant parameters and how corrosion allowance is accounted for.
66
tp =
55
Instructors Outline
1. Review the relevant equation for a semi-elliptical head. 2. Note the sources for the relevant parameters and how corrosion allowance is accounted for.
67
56
Instructors Outline
1. Buckling of a shell under external pressure or compressive forces is analogous to column buckling under a compressive force. 2. Addition of stiffener rings reduces effective buckling length.
68
57
Instructors Outline
1. Highlight the main parameters that affect buckling strength. 2. ASME Code has design procedure for each type of shell or head.
69
Stiffener Rings
Moment Axis of Ring h/3
Figure 4.10
58
Instructors Outline
1. Stiffener rings reduce the buckling length of a shell and may be either inside or outside. 2. Stiffener rings are not used for heads.
70
Sample Problem 2
DESIGN INFORMATION Design Pressure = Full Vacuum Design Temperature = 500 F Shell and Head Material is SA-285 Gr. B, Yield Stress = 27 ksi Corrosion Allowance = 0.0625" Cylinder Dimension Shown is Inside Diameter
4' - 0"
150' - 0"
Figure 4.11
59
Instructors Outline
1. Sample Problem 2 illustrates procedure for calculation of required cylindrical shell thickness for external pressure. 2. The problem does not cover all aspects of the general procedure since it is geometry-specific. 3. Review the given information. 4. Review the problem solution with the participants.
71
Instructors Outline
1. Corroded shell diameter and thickness are used in the calculations. 2. The unstiffened length of the shell must include part of the head depth.
72
61
Instructors Outline
1. Factor A is determined based only on geometry. 2. Note the source of Factor A.
73
Do /t = 130
D o/t = 300 50.0 40.0 35.0 30.0 25.0 20.0 18.0 14.0 16.0
10.0 9.0
8.0
7.0
6.0
2.0 1.8
1.6 1.4
12.0
5.0
4.0
3.5 3.0
L/Do = 37
Instructors Outline
1. Note how Factor A is determined from these curves. 2. After determine Factor A, go to applicable material chart.
2.5
1.2
D o/t = 250
74
E=29.0 x 106 E=27.0 x 106 E=24.5 x 106 E=22.8 x 106 E=20.8 x 106
A=0.000065
63
Instructors Outline
1. Different material charts are used for different material types. This is chart used for most carbon and lowalloy steels. 2. If A is under curves: Move up to intersect with temperature line. Move right to get B. B is then used to calculate allowable external pressure.
75
Pa =
Where:
2AE 3(Do / t )
Instructors Outline
1. Pa is calculated using indicated equation because A is not under curves. 2. Must use E from curves at design temperature.
76
A = 0.000114
L = 3 7 (as before) Do
Pa =
65
Instructors Outline
1. Since P a < 15 psi, must either increase shell thickness or add stiffeners to decrease L. 2. Problem illustrates results if increase thickness. 3. Choice of whether to increase thickness or add stiffeners depends on cost.
77
Inside Diameter - 10 - 6 Design Pressure - 650 psig Design Temperature - 750F Shell & Head Material - SA-516 Gr. 70 Corrosion Allowance - 0.125 in. 2:1 Semi-Elliptical heads, seamless 100% radiography Vessel in vapor service
Instructors Outline
1. This independent Exercise gives the Participants practice in determining required vessel thicknesses for internal pressure. 2. Review the given information together. 3. Allow approximately 15 minutes for the Participants to solve the problem. Then review the solution with them. 4. Note that this Exercise may be skipped and assigned as homework if available class time is an issue.
78
Exercise 2 - Solution
For shell
tp = Pr SE 1 0 .6P
P = 650 psig r = 0.5 D + CA = (0.5 126) + 0.125 = 63.125 in. S = 16,600 psi, Figure 3.3 for SA-516 Gr. 70 E = 1.0, Figure 4.8 for 100% radiography
650 63. 125 = 2. 53 in. (16,600 1 .0 ) (0 .6 650)
tp =
67
Instructors Outline
1. Note the relevant equation for the cylindrical shell and the appropriate parameters. 2. Note how corrosion allowance is accounted for.
79
tp =
Instructors Outline
1. Note the relevant equation for the heads and the appropriate parameters. 2. Note how corrosion allowance is accounted for.
80
Reinforcement of Openings
Simplified ASME rules - Area replacement Metal used to replace that removed:
-
69
Instructors Outline
1. Simplified ASME rules do not require stress calculations. Use area replacement approach. 2. Metal removed must be replaced by equivalent metal.
81
Figure 4.14
70
Instructors Outline
1. Review cross-sectional view of region and associated nomenclature. 2. Note the different areas involved in the calculations and the reinforcement zone in the nozzle and shell.
82
(b)
(c)
(d)
(e)
(f-1)
(f-3)
71
Figure 4.15
Instructors Outline
1. Note the different nozzle design details that may be used. 2. The actual detail used in each case depends on the design conditions and the needed reinforcement.
83
Additional Reinforcement
Necessary if insufficient excess thickness Must be located within reinforcement zone Allowable stress of reinforcement pad should be that of shell or head Additional reinforcement sources
Pad Additional thickness in shell or lower part of nozzle
72
Instructors Outline
1. The method used to provide additional reinforcement depends on the particular situation. 2. The ASME Code specifies circumstances where nozzle reinforcement evaluation is not needed. The opening is considered to be inherently reinforced in these cases.
84
Sample Problem 3
DESIGN INFORMATION Design Pressure = 300 psig Design Temperature = 200 F Shell Material is SA-516 Gr. 60 Nozzle Material is SA-53 Gr. B, Seamless Corrosion Allowance = 0.0625" Vessel is 100% Radiographed Nozzle does not pass through Vessel Weld Seam
Figure 4.16
73
Instructors Outline
1. Sample Problem 3 illustrates evaluation of an opening for adequate reinforcement. 2. Review the given information. 3. Review the problem solution with the Participants.
85
Instructors Outline
1. Required replacement area is based on the cross-sectional area removed. 2. Calculated using the required shell thickness, not the actual.
86
Instructors Outline
1. Corrosion allowance is accounted for. 2. tr is calculated using the appropriate shell equation.
87
A1 2 = 2 (Elt-Ftr)(t + tn)
Instructors Outline
1. Required area is calculated using the previously calculated parameters. 2. Two equations must be checked to determine the reinforcement area available in the shell.
88
Instructors Outline
Review the relevant parameters.
89
Instructors Outline
Available shell reinforcement area is determined.
90
79
Instructors Outline
Available reinforcement area in the nozzle is determined by checking two equations.
91
Required thickness of nozzle wall, in. Radius of nozzle, in. 0 if no reinforcing pad. Reinforcing pad thickness if one installed, in. Defined in Figure UG-40 for self-reinforced nozzles, in.
Instructors Outline
Review the relevant parameters.
92
t rn =
Pr SE1 0. 6P
t rn =
81
Instructors Outline
Calculate required thickness using the equation for a cylinder.
93
Instructors Outline
1. The available reinforcement in the nozzle is determined. 2. Note that in this case, the nozzle has much more excess metal available than the shell.
94
Instructors Outline
1. The nozzle is not adequately reinforced because it does not have enough reinforcement available. 2. The problem now proceeds to determine the required dimensions of a reinforcement pad. Note, however, that the additional reinforcement could also be added by using a thicker nozzle or by using a thicker shell section near the nozzle.
95
Instructors Outline
1. The reinforcement pad thickness was assumed to be equal to the shell thickness. This is common practice. 2. A final check is made to ensure that the reinforcement pad is within the reinforcement zone.
96
Instructors Outline
1. ASME B16.5 provides standard flange dimensional details. 2. Flange strength is based on dimensions and material used.
97
Castings
Spec. No. Grade
Plates
Spec. No. Grade
1.1
1.2
-LF2 ----LF3
70 70 Cl.1 --B E
Figure 4.17
86
Instructors Outline
1. Acceptable flange materials are grouped based on similarities in strength. 2. The Material Group is determined based on the specified material.
98
Figure 4.18
87
Instructors Outline
1. This table combines information for three Material Groups for illustrative purposes. 2. Review the information in this table and how it is used to determine the appropriate flange rating.
99
88
Instructors Outline
1. Sample Problem 4 illustrates how to determine flange rating. 2. Review the given information. 3. Review the problem solution with the Participants.
100
Instructors Outline
Review the problem solution.
101
At 700F, Material Group 1.1: Lowest Class that will accommodate 275 psig is Class 300. At 700F, Class 300 flange of Material Group 1.1: Maximum design pressure = 535 psig.
90
Instructors Outline
1. Use the lowest flange class that is suitable for the design conditions. Flange cost increases as the class increases. 2. A given flange class is good for a range of temperature/pressure combinations for a particular Material Group.
102
Flange Design
Bolting requirements During normal operation (based on design conditions) During initial flange boltup (based on stress necessary to seat gasket and form tight seal
Am =
91
W S
Instructors Outline
1. Division 1 Appendix 2 procedure for custom-designed flanges. 2. Used if flange size not covered by ASME B16.5 or ASME B16.47. 3. Typical application is girth flange for shell-and-tube heat exchanger.
103
Figure 4.19
92
Instructors Outline
1. Applied loads act at different flange locations. 2. Flange moments are calculated for the operating and gasket seating cases.
104
Instructors Outline
1. Various stresses are calculated for each case and must be kept within allowable limits. 2. Flange dimensions are adjusted as needed to meet allowable stresses (e.g., increase thickness, change hub dimensions, etc.). 3. Equipment suppliers use computer programs to optimize flange design to be least weight (i.e., lowest cost).
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Instructors Outline
1. Flange is designed for specific gasket type, dimensions, and facing details. Changing any of these after flange is fabricated (e.g., gasket type) can adversely affect in-service performance. 2. TEMA specifies minimum gasket width and bolt spacing criteria.
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Flat metal, jacketed asbestos filled: Soft aluminum Soft copper or brass Iron or soft steel Monel 4-6% chrome Stainless steels and nickel-base alloys Solid flat metal: Soft aluminum Soft copper or brass Iron or soft steel Monel or 4-6% chrome Stainless steels and nickel-base alloys
Figure 4.20
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Instructors Outline
1. This is an excerpt from Table 2-5.1. 2. Review the variation in m and y with gasket type.
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N 2
N 2
(1b)
w T N
(1c)
w
w N
T
w + T ; w + N max 2 4
w+ T w+ N ; max 2 4
(1d)
w N
HG G O.D. Contact Face b hG G HG hG Gasket C L Face
Figure 4.21
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Instructors Outline
1. This is an excerpt from Table 2-5.2. 2. Review the flange facings shown.
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Flat metal, jacketed asbestos filled: Soft aluminum Soft copper or brass Iron or soft steel Monel 4% - 6% chrome Stainless steels and nickel-base alloys
Figure 4.22
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Instructors Outline
Review the additional gasket information shown.
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Instructors Outline
1. Emphasize that MAWP is based on the as-supplied component thicknesses. 2. Thicknesses used exclude corrosion allowance and thickness added to absorb other loads. 3. MAWP is useful to know for potential future rerate.
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Local Loads
Piping system Platforms, internals, attached equipment Support attachment
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Instructors Outline
1. Review the typical external loads that may be applied. 2. External loads cause local stresses that must be evaluated. 3. Other industry standards must be used to evaluate local stresses (e.g., WRC 107 and 297).
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Instructors Outline
1. Different types of internals are used to perform various process functions. 2. Review list of internals. 3. ASME Code does not cover design of internals. End-user, vessel vendor, and/or contractor must develop requirements.
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Instructors Outline
Discuss ASME requirements for loads applied to vessel and welding to pressure parts.
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Instructors Outline
1. Potential corrosion of internals should not be ignored. 2. Corrosion allowance should be considered in a practical and costeffective manner.
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Head-to-Shell Transitions
th Thinner part th Thinner part y t
s
l y
Tangent Line
ts
th
th
y l
Thinner part
Tangent Line
y l Thinner part t
s
Fillet Weld
Figure 6.1
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Instructors Outline
1. Review typical acceptable welding and fabrication details. 2. Details for openings were previously reviewed. 3. Highlight thickness taper. 4. Intermediate heads should retain fillet weld in refinery applications.
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l l
C L
Figure 6.2
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Instructors Outline
Review thickness taper requirements.
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Figure 6.3
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Instructors Outline
Thickness taper may be required in nozzle neck.
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Stiffener Rings
Figure 6.4
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Instructors Outline
1. Vacuum stiffening ring attachment details. 2, ASME Code specifies weld spacing, size, and length.
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Instructors Outline
1. ASME Code specifies PWHT requirements only for relief of residual stresses. 2. Need for PWHT due to other reasons must be specified by end-user or contractor. Service considerations (e.g., wet H 2S, caustic) Weld hardness reduction
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Base material specification and quality Welds Dimensional requirements Equipment documentation
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Instructors Outline
Highlight main areas included in inspection.
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Lack of Fusion
Incomplete Penetration
ExternalUndercut
Internal Undercut
Undercut
Figure 7.1
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Instructors Outline
Review common types of weld defects.
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Instructors Outline
Review why weld defects can reduce vessel integrity.
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Types of NDE
NDE TYPE Radiographic DEFECTS DETECTED Gas pockets, slag inclusions, incomplete penetration, cracks Porosity holes, slag inclusions, weld undercuts, overlapping Weld surface-type defects: cracks, seams, porosity, folds, pits, inclusions, shrinkage Cracks, porosity, lack of fusion Subsurface flaws: laminations, slag inclusions ADVANTAGES Produces permanent record. Detects small flaws. Most effective for butt-welded joints. Helps pinpoint areas for additional NDE. LIMITATIONS Expensive. Not practical for complex shapes. Can only detect what is clearly visible. Visual
Liquid Penetrant
Used for ferrous Can only detect and nonferrous surface materials. Simple imperfections. and less expensive than RT, MT, or UT. Flaws up to in. beneath surface can be detected. Can be used for thick plates, welds, castings, forgings. May be used for welds where RT not practical. Cannot be used on nonferrous materials. Equipment must be constantly calibrated.
Figure 7.2
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Instructors Outline
1. Review NDE methods and types of defects detected. 2. Review advantages and limitations of each NDE method.
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X-Ray
Film
Test Specimen
Figure 7.3
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Instructors Outline
Review typical setup for RT inspection.
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Cable
B C
Flaw
Figure 7.4
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Instructors Outline
Review how pulse echo UT system can detect defects.
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Pressure Testing
Typically use water as test medium Demonstrates structural and mechanical integrity after fabrication and inspection Higher test pressure provides safety margin PT = 1.5 P (Ratio)
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Instructors Outline
1. Water is a safer test medium than air. Pneumatic testing should only be used on an exception basis. 2. Ratio is the lowest value of:
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Instructors Outline
Review additional pressure test design considerations.
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Summary
Overview of pressure vessel mechanical design ASME Section VIII, Division 1 Covered
Materials Fabrication Testing Design Inspection
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Instructors Outline
1. Highlight the subjects covered in the course. 2. Note that much more time is required for an in-depth discussion of pressure vessel design. This course provides a good starting point to proceed further for those who need to. 3. Provide the evaluation form for the class to complete. Collect these and return them to the sponsoring unit. 4. Distribute the CEU form to the participants and point out that they will have to mail it in themselves, with the required standard fee. All the information is on the form.
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Appendix A
Reproducible Overheads
Appendix B
Course & Instructor Evaluation Form
Fair
Please evaluate the course by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location. 1. Course content Relevance of New matches brochure course notes/ Applicability Knowledge Overall description workbook to your job Gained
Rating
1.1 E G F P 2.
1.2 E G F P
1.3 E G F P
1.4 E G F P 1.5 E G F P
3.
What changes, if any, would you make in the program content and/or format?
4.
Can you share with us any comments about this program that we coul use as a quote on our course literature?
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B.
Instructors Evaluation Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in the appropriate location Effective knowledge of subject matter Effectiveness Effective of teaching use of Class method class time Openness to Overall Participation Rating
5.
1.1 E G F P C. 6. 7. 8. 9.
1.2 E G F P
1.3 E G F P
1.4 E G F P 1.5 E G F P
Facilities How would you rate the meeting site? How would you rate the overnight accommodations (if applicable)? In what other cities would you like to see this course held? Additional Comments:
D. 10.
Future Courses and Educational Products (Video, Self Study, Software) What other courses would you like to see sponsored?
11.
What educational products would you like to see sponsored by ASME and in what medium?
E. 12.
On-Site Company Training Would your organization be interested in holding this course or other ASME courses at your facility? If so, please indicate the area of interest and the contact person. Thank you. Course Name/Topic: _________________________________________________________ Contact Name: ________________________________ Phone No.: ___________________
13. 14.
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Appendix C
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ASME Career Development Series Continuing Education Unit (CEU) Request Form
Each 4-hour ASME Career Development Series Course earns 0.4 CEUs PLEASE PRINT ALL YOUR INFORMATION CLEARLY YOUR CERTIFICATE WILL BE PREPARED FROM THIS FORM Title of Program: _____________________________________________________ Date Held: __________________________________________________________ Instructor: __________________________________________________________ Location: ___________________________________________________________ Number of CEUs Earned: (0.4 per 4-hour module) ____________ Last Name: __________________________________________ First Name, Middle Initial: ______________________________ Title/Position: ________________________________________ Company: ___________________________________________ Address: ____________________________________________ City: _______________________ State: __ Zip: ____________ Telephone: __________________ Fax: ____________________ Email: _________________________ Please send this form, along with a check made out to ASME for the standard fee of $15.00 to: ASME Continuing Education Institute Three Park Avenue New York, NY 10016-5990 Your Certificate will be prepared and sent to the address you indicated above.
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Important Note: Submission of this form is optional. However, we would like to solicit the comments of the Instructor so that we may continuing improve on the Career Development Series. Any instructors who would like to write a course should indicate so on this form and an authors package will be forwarded to you. Thank you for helping us with the Career Development Series Name: _________________________________________________________ Address: _______________________________________________________ City/State/Zip: __________________________________________________ Telephone: ______________________________ Fax: ____________________________________ Email: __________________________________ Comments:
Please send this form to: ASME Continuing Education Institute Three Park Avenue New York, NY 10016-5990
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Important Note: Submission of this form is required every time a Career Development Series Course is taught. ASME cannot process attendees CEU requests without this form. Attachments to this form must include: 1. A biographical sketch of the instructor. 2. Course evaluations filled out by the participants at the completion of the course.
Course: ____________________________________________________ Date Presented: ______________________________________________ Location: ___________________________________________________ Instructor: __________________________________________________ Number of participants: ________________________________________ Sponsoring Unit: _____________________________________________
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