pressure vessel code guide instructors
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Overview o f Pressure Vessel Design
Instruc tor s Guide
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CONTACT INFORMATION
ASME Headquarters1-800-THE-ASME
ASME Professional Development
1-800-THE-ASME
Eastern Regional Office Southern Regional Office
8996 Burke Lake Road Suite L102 1950 Stemmons Freeway Suite 5068
Burke, VA 22015-1607 Dallas, TX 75207-3109
703-978-5000 214-800-4900800-221-5536 800-445-2388
703-978-1157 (FAX) 214-746-4902 (FAX)
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1117 S. Milwaukee Avenue 119-C Paul Drive
Building B, Suite 13 San Rafael, CA 94903-2022
Libertyville, IL 60048-5258 415-499-1148
847-680-5493 800-624-9002
800-628-6437 415-499-1338 (FAX)
847-680-6412 (FAX)
Northeast Regional Office International Regional Office
326 Clock Tower Commons 1-800-THE-ASME
Route 22
Brewster, NY 10509-9241
845-279-6200
800-628-5981
845-279-7765 (FAX)
You can also find information on these
courses and all of ASME, including ASME
Professional Development, the Vice
President of Professional Development,
and other contacts at the ASME Web
site......
http://www.asme.org
You can also find information on these
courses and all of ASME, including ASME
Professional Development, the Vice
President of Professional Development,
and other contacts at the ASME Web
site......
http://www.asme.org
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Overview of Pressure Vessel Design
By:
Vincent A. Carucci
Carmagen Engineering, Inc.
Copyright 1999 by
All Rights Reserved
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TABLE OF CONTENTS
Abstract 5
Introduction..6
Organizing Unit Responsibilities..7
Instructor Guidelines and Responsibilities.9
Overview of Pressure Vessel Design Outline/
Teaching 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
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ABSTRACT
Pressure vessels are typically designed, fabricated, installed, inspected, and tested
in accordance with the ASME Code Section VIII. Section VIII is divided into three
separate divisions. This course outlines the main differences among the divisions.
It then concentrates on and presents an overview of Division I. This course also
discusses several relevant items that are not included in Division I.
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INTRODUCTION
This Overview of Pressure Vessel Design course is part of the ASME International
Career Development Series an educational tool to help engineers and managers
succeed in todays business/engineering world. Each course in this series is a 4-
hour (or half-day) self-contained professional development seminar. The course
material consists of a participant manual and an 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. Organizing Unit Responsibilities
2. Instructor Guidelines and Responsibilities
3. 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.
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Suggested Outline/Teaching Plan
Time,
min.
Major
Interval
Class Segment Sub-Segment
Interval
Sub-SegmentOverheads/Participant
Pages5 Introduction/Logistics
Outline ModuleOV 1Part. 65
10 Introduction
5 Module based primarily on theASME Code Section VIII, Division
1. Divisions 2 and 3 will be brieflydescribed
OV 2Part. 65
10 Main Pressure Vessel Components OV 3-9Part. 67
10 Scope of ASME Code Section VIII
Division 1
Division 2
Division 3
OV 10-13Part. 75
25 General
5 Structure of Section VIII, Division 1 OV 14Part. 78
15 Material Selection Factors
Strength
Corrosion Resistance
Resistance to Hydrogen Attack
Fracture Toughness
Fabricability
OV 15-31Part. 79
20 Materials of Construction
5 Maximum Allowable Stress OV 32-34
Part. 87
10 Exercise 10 Material Selection Based On FractureToughness
OV 35-38Part. 91
10 Break 10
10 Design Conditions and Loadings
Pressure
Temperature
Other Loadings
OV 39-43 Part. 92
25 Design for Internal Pressure
Weld Joints
Cylindrical Shells
Heads
Conical Sections
Sample Problem
OV 44-55 Part. - 98
55 Design
20 Design for External Pressure andCompressive Stresses
Cylindrical Shells Other Components
Sample Problem
OV 56-65 Part. 109
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Suggested Outline/Teaching Plan, continued
Time,
min.
Major
Interval
Class Segment Sub-Segment
Interval
Sub-SegmentOverheads/
ParticipantPages
10 - 50 Major Break Lunch or Major Break
15 Exercise 15 Required Thickness for Internal
Pressure
OV 66-68
Part. - 118
20 Reinforcement of Openings (IncludeSample Problem)
OV 69-84Part. 119
10 Flange Rating (Including Sample
Problem)
OV 85-90
Part. 127
15 Flange Design OV 91-97Part. 131
50 Design(Contd.)
5 Maximum Allowable WorkingPressure (MAWP)
OV 98Part. 138
10 Break
10 Local Loads OV 99
Part. 139
20 Other Design
Considerations
10 Vessel Internals OV 100-102Part. 141
10 Acceptable Welding Details OV 103-106Part. 143
20 Fabrication
10 Postweld Heat Treatment
(PWHT)Requirements
OV 107
Part. 146
10 Inspection OV 108-113Part. 148
15 Inspection andTesting
5 Pressure Testing OV 114-115
Part. 152
10 Closure 10 SummaryQuestionnaire (fill in and collect)CEU Form (hand out individual
responsibility to return)
OV 116Part. - 155
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 notcovered in the ASME Code.
Major Learning Points
Course Introduction
1
OVERVIEW OF
PRESSURE VESSEL DESIGN
By: Vincent A. Carucci
Carmagen Engineering, Inc .
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 moredetailed responsibility will receive a
solid starting point to proceed
further.
3. Review outline.
4. Establish schedule.
5. Participation is key:
Questions
Discussion/interaction
Major Learning Points
Establish course objectives.
Outline course content, a road map.
2
Cours e Overv iew
General
Materials of Construction
Design
Other Design Considerations
Fabrication
Inspection and Testing
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Define pressure vessels.
Identify wide variety of industrial
applications.
3
Pressure Vessels
Containers for fluids under pressure
Used in variety of industries
Petroleum refining
Chemical
Power
Pulp and paper
Food
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 weldedtogether.
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.
Major Learning Points
Main pressure vessel components and
configurations.
4
Hor izonta l Drum o n
Saddle Supp or ts
Figure 2.1
Nozzle
ShellA
A
Head
SaddleSupport
(Fixed)
Saddle Support
(Sliding)
Head
SectionA-A
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 ofleg length to diameter.
Number, size, and attachment
details depend on loads.
Major Learning Points
Main pressure vessel components and
shapes.
5
Vert ica l Drum
on Leg Suppor ts
Figure 2.2
Head
Shell Nozzle
Head
SupportLeg
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Nozzles used for:
Piping systems
Instrument connections
Manways
Attaching other equipment
2. Ends typically flanged, may bewelded.
3. Sometimes extend into vessel.
Major Learning Points
Main pressure vessel components and
shapes.
6
Tal l Vert ical Tow er
Figure 2.3
Trays
Nozzle
Head
Shell
Nozzle
Cone
Shell
Nozzle
NozzleSkirtSupport
Head
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Main pressure vessel components and
shapes.
7
Vert ical Reactor
Figure 2.4
Inlet
Nozzle
Head
Shell
UpperCatalyst
Bed
Catalyst Bed
Support Grid
Lower
Catalyst
Bed
Outlet
Collector
Head
Support
Skirt
Outlet
Nozzle
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Spherical storage vessels typically
supported on legs.
2. Cross-bracing typically used to
absorb wind and earthquake loads.
Major Learning Points
Main pressure vessel components and
shapes.
8
Spher ical Pressur ized
Storage Vessel
Figure 2.5
Cross
Bracing
Support
Le g
Shell
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Vessel size limits for lug supports:
1 10 ft diameter
2:1 to 5:1 height/diameter ratio
2. Vessel located above grade.
3. Lugs bolted to horizontal structure.
Major Learning Points
Main pressure vessel components and
configurations.
9
Vert ical Vessel on
Lug Suppor t s
Figure 2.6
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Section VIII is most widely used
Code.
2. Assures safe design.
3. Three divisions have different
emphasis.
Major Learning Points
Define scope of ASME Code Section
VIII.
10
Scope of ASME Code
Section VIII
Section VIII used worldwide
Objective: Minimum requirements for safe
construction and operation
Division 1, 2, and 3
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Scope of Division 1
Exclusions from scope
11
Section VIII Divisio n 1
15 psig < P 3000 psig Applies through first connection to pipe
Other exclusions
Internals (except for attachment weld to vessel)
Fired process heaters
Pressure containers integral with machinery
Piping systems
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 somedesign details that are permitted in
Division 1.
5. Division 2 requires more stringent
material quality control, fabrication,
and testing requirements.
Major Learning Points
Differences between Division 1 and 2.
12
Sectio n VIII , Divis ion 2,
Al ternat ive Rules Scope identical to Division 1 but
requirements differ
Allowable stress
Stress calculations
Design
Quality control
Fabrication and inspection
Choice between Divisions 1 and 2 based on
economics
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Scope of Division 3
13
Applications over 10,000 psi
Pressure from external source, processreaction, application of heat, combination
of these
Does not establish maximum pressurelimits of Division 1 or 2 or minimum limits
for Division 3.
Div is ion 3, Al ternat ive Rules
High Pressu re Vessels
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Overview of Pressure Vessel Design
Instructors Personal Notes
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
4. Highlight several mandatory and
nonmandatory appendices.
Major Learning Points
Basic organizational structure of
Division 1.
14
Struc ture of Sect io n VIII,
D iv is ion 1 Subsection A
Part UG applies to all vessels
Subsection B
Requirements based on fabrication method
Parts UW, UF, UB
Subsection C
Requirements based on material class
Parts UCS, UNF, UHA, UCI, UCL, UCD, UHT,ULW, ULT
Mandatory and Nonmandatory Appendices
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Primary factors that influence pressure
vessel material selection.
15
Material Select ion Facto rs
Strength
Corrosion Resistance
Resistance to Hydrogen Attack
Fracture Toughness
Fabricability
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Strength: Materials ability to
withstand imposed loading.
2. Higher strength material thinnercomponent.
3. Describe properties that are used to
define strength.
Major Learning Points
Material strength and pressure vessel
design.
16
Strength
Determines required component thickness
Overall strength determined by:
Yield Strength
Ultimate Tensile Strength
Creep Strength
Rupture Strength
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Importance of corrosion resistance in
materials selection.
17
Corros ion Res is tance
Deterioration of metal by chemical action
Most important factor to consider
Corrosion allowance supplies additional
thickness
Alloying elements provide additional
resistance to corrosion
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Low-temperature H2 attack can
cause cracking.
2. Higher temperature H2 attack causes
through-thickness strength loss and
is irreversible.
3. H2 attack is a function of H2 partial
pressure and design temperature.
Increased alloy content (i.e., Cr)
increases H2 attack resistance.
Reference API-941 for Nelson
Curves.
Major Learning Points
Hydrogen attack can damage carbon
and low-alloy steel.
18
Resis tance to
Hydrogen A t tack
At 300 - 400F, monatomic hydrogen
forms molecular hydrogen in voids
Pressure buildup can cause steel to crack
Above 600F, hydrogen attack causes
irreparable damage through component
thickness
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Brittle fracture and its consequences.
19
Bri t t le Fracture
and Fracture Toughn ess Fracture toughness: Ability of material to
withstand conditions that could cause
brittle fracture
Brittle fracture
Typically at low temperature
Can occur below design pressure
No yielding before complete failure
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. A brittle fracture will occur the first
time the appropriate conditions
occur.
2. Brittle fracture occurs without
warning and is catastrophic.
Major Learning Points
Three conditions that are required for a
brittle fracture to occur.
20
Bri t t le Fracture and
Fracture Tough ness, cont d
Conditions required for brittle fracture
High enough stress for crack initiation and
growth
Low enough material fracture toughness attemperature
Critical size defect to act as stress
concentration
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Describe influence of material and
temperature factors on fracture
toughness.
2. Other factors increase brittle fracture
risk.
Major Learning Points
Primary factors that influence material
fracture toughness.
21
Factor s That Inf luenc e
Fracture Toug hness Fracture toughness varies with:- Temperature
- Type and chemistry of steel
- Manufacturing and fabrication processes
Other factors that influence fracture
toughness:
- Arc strikes, especially if over repaired area
- Stress raisers or scratches in cold formed thick
plate
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Charpy V-Notch test is most widely
used measure of material fracture
toughness.
2. Describe test set-up.
Major Learning Points
Charpy V-Notch testing.
22
Charpy V-Notch Test Setup
Starting Position
Hammer
Scale
Pointer
End of swing
Anvil
Specimen
h'
h'
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Components to consider is ASME Code
brittle fracture evaluation.
23
ASME Code and
Bri t t le Fracture Evaluat ion
Shells
Manways
Heads
Reinforcing pads
Backing stripsthat remain in
place
Nozzles
Tubesheets
Flanges
Flat cover plates
Attachments essential
to structural integrity
that are welded topressure parts
Components to consider
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Describe the distinction between
MDMT and CET.
MDMT is a materialproperty.
CET is an environmental factor.
2. Important to understand this
distinction.
Major Learning Points
Two temperatures to be considered in
brittle fracture evaluation.
24
Temp eratures to Con s ider
Minimum Design Metal Temperature
(MDMT)
Lowest temperature at which component has
adequate fracture toughness
Critical Exposure Temperature (CET)
Minimum temperature at which significant
membrane stress will occur
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Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Outline ASME procedure.
2. Details described in following
overheads.
Major Learning Points
Simplified ASME brittle fracture
evaluation procedure.
25
Simpl i f ied ASME
Evaluat ion App roach Material specifications classified into
Material Groups A through D
Impact test exemption curves
For each Material Group
Acceptable MDMT vs. thickness where impact
testing not required
If combination of Material Group andthickness not exempt, then must impact test
at CET
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 CurveB if not normalized.
Most pipe, fittings and forgings
are Curve B.
Major Learning Points
Material group classifications for brittle
fracture evaluations.
26
Mater ia l Groups
Table 3.1 (Excerpt)
MATERIAL
GROUP APPLICABLE MATERIALS
Curve A A l l c a r b o n a n d l o w a l l o y s t e el p l a t e s , s t r u c t u ra l s h a p e s , a n d b a r s n o tl i s t e d in Cu rv e s B, C & D
S A-2 1 6 Gr . WCB & WCC, S A-2 1 7 Gr . WC6 , i f n o rma l i z e d a n d t e mp e re do r w a t e r - q u e n c h e d a n d t e m p e r e d
Curve B S A - 2 1 6 G r. W C A , i f n o r m al i z e d a nd t e m p e r ed o r w a t e r -q u e n c h e d a n dt e m p e r e d
S A-2 1 6 Gr . WCB & WCC fo r ma x imu m th i c k n e s s o f 2 i n . , i f p ro d u c e dt o f i n e g r a i n p r a c t i c e a n d w a t e r - q u e n c h e d a n d t e m p e r e d
S A -2 8 5 G r . A & B
S A -4 14 Gr . A
S A -5 1 5 G r . 6 0
S A - 5 1 6 G r . 6 5 & 7 0, i f n o t n or m a l i ze d
E x c e p t f o r c a st s t e e l s , a l l m a t e r ia l s o f C u r v e A i f p r o d u c ed t o f i n e
g ra in p r a c t i c e a n d n o rma l i z e d wh ic h a r e n o t i n c lu d e d in Cu rv e s C & D
A l l p i p e , f i t t i ng s , f o r g i n g, a n d t u b i n g w h i c h a re n o t i n c l u d e d i n C u rv e sC & D
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Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Material group classifications for brittle
fracture evaluations.
27
Mater ia l Grou ps, contd
Table 3.1 (Excerpt)
MATERIAL
GROUP APPLICABLE MATERIALS
Curve C S A - 1 8 2 G r . 2 1 & 2 2 , i f n o rm a l i z e d a n d t e m p e r e d S A -3 0 2 G r . C & D
S A - 3 3 6 G r . F 2 1 & F 2 2 , i f n o r m a l iz e d a n d t e mp e r e d
S A - 3 8 7 G r . 2 1 & 2 2 , i f n o rm a l i z e d a n d t e m p e r e d
S A - 51 6 G r . 5 5 & 6 0 , i f n o t n o rm a l iz e d
S A -5 3 3 G r . B & C
S A- 66 2 Gr . A
A l l m a t e r i al o f C u r v e B i f p r o d u c e d t o f i n e g r a i n p r a c t i c e a n d
n o r m a l i z e d w h i c h a r e n o t i n c l u d e d i n C u r v e D
Curve D S A- 20 3 S A-537 C l. 1 , 2 & 3
SA-508 Cl . 1 S A - 6 1 2 , i f n o rm a l i z e d
S A -5 16 , i f n o rm al i z e d S A - 6 6 2 , i f no rm a l i z e d
SA-524 Cl . 1 & 2 S A-7 3 8 G r . A
Bolting S e e F i g u r e U C S- 6 6 o f t h e A S M E C o d e S e c t i on V I I I , D i v . 1 , f o r i m p a c t
and Nuts t e s t e x e m p t i o n t e m p e r a t u r e s f o r s p e c i f i e d m a t e r i a l s p e c i f i c a t i o n s
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Overview of Pressure Vessel Design
Instructors Personal Notes
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 50F.
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.
Major Learning Points
Impact test exemption curves.
28
Im pact Test Exemp t ion Curves
for Carbon and Low -Al loy Steel
Figure 3.1
Nominal Thickness, in.
(Limited to 4 in. for Welded Construction)
0.394 1 2 3 4 5
140
120
100
80
60
40
20
0
-20
-40
-55-60
-80
MinimumD
esignMetalTemperature,
F
Impact testing required
D
C
BA
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41
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Review additional requirements.
2. Note that most flanges will not
require impact testing.
Major Learning Points
Additional impact test requirements.
29
Add i t ional ASME Code Imp act
Test Requirements
Required for welded construction over 4 in.
thick, or nonwelded construction over 6 in.
thick, if MDMT 65 ksi unless
specifically exempt
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42
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Review additional requirements.
2. PWHT reduces MDMT by 30Fprovided PWHT not required by
Code and resulting MDMT -55F.
3. Can take MDMT credit if component
thickness greater than needed (i.e.,
calculated stress < allowable stress).
Major Learning Points
Additional impact test requirements.
30
Add i t ional ASME Code
Impact Test
Requi rements , con t d Not required for impact tested low
temperature steel specifications
May use at impact test temperature
30F MDMT reduction if PWHT P-1 steel
and not required by code
MDMT reduction if calculated stress in. For b
o
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109
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review the additional gasket
information shown.
Major Learning Points
Information on additional gasket types.
97
Gasket Mater ials
and Con tact Fac ings
Figure 4.22
Gasket Materials and Contact Facings
Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y
Gasket Material Gasket
Factor
m
Min.
Design
Seating
Stress y,
psi
Sketches Facing
Sketch and
Column in
Table 2-5.2
Flat metal, jacketed asbestos filled:Soft aluminum
Soft copper or brassIron or soft steelMonel4% - 6% chromeStainless steels and nickel-base alloys
3.253.50
3.753.503.753.75
55006500
7600800090009000
(1a), (1b),(1c),2, (1d) 2,
(2)2,Column II
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110
Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
MAWP is defined.
98
Maximum Al lowable
Work in g Pressure (MAWP) Maximum permitted gauge pressure at top of
vessel in operating position for designatedtemperature
MAWP Design Pressure Designated Temperature = Design Temperature
Vessel MAWP based on weakest component
Originally based on new thickness less corrosion
allowance
Later based on actual thickness less future corrosion
allowance needed
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111
Overview of Pressure Vessel Design
Instructors Personal Notes
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).
Major Learning Points
Externally applied loads must also be
considered in vessel design.
99
Local Loads
Piping system
Platforms, internals, attached equipment
Support attachment
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112
Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Several types of vessel internals may be
installed.
100
Types o f Vessel Internals
Trays
Inlet Distributor
Anti-vortex baffle
Catalyst bed grid and support beams
Outlet collector
Flow distribution grid
Cyclone and plenum chamber system
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114
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Potential corrosion of internals
should not be ignored.
2. Corrosion allowance should be
considered in a practical and cost-
effective manner.
Major Learning Points
Corrosion allowance should be
considered in the design of internals.
102
Cor ros ion A l lowance
For Vessel Internals
Removable internals: CA = CA of shell
Costs less
Easily replaced
Non-removable internals: CA = 2 (CA of shell)
Corrosion occurs on both sides
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115
Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
ASME Code specifies acceptable
welding and fabrication details.
103
Head-to-Shell Transit ion s
FilletWeld
Butt Weld
Intermediate Head Attachment
th
y
l
ts
Thinnerpart
TangentLine
th
y
l
ts
Thinnerpart
th
y
l
ts
Thinnerpart
Tangent
L ine
th
y
l
ts
Thinnerpart
Figure 6.1
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116
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review thickness taper requirements.
Major Learning Points
ASME Code fabrication details.
104
Typical Shel l Transi t ion s
l
l
y
CL
CL
CLIn all cases, l shall not
be less than 3y.
Figure 6.2
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117
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Thickness taper may be required in
nozzle neck.
Major Learning Points
ASME Code fabrication details.
105
Nozzle Neck
Thickness Tapers
Figure 6.3
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118
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Vacuum stiffening ring attachment
details.
2, ASME Code specifies weld spacing,
size, and length.
Major Learning Points
ASME Code fabrication details.
106
Sti f fener Ring s
In-Line
Intermittent Weld
Staggered
Intermittent Weld
Continuous Fillet Weld On
One Side, Intermittent Weld
On Other Side
Figure 6.4
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119
Overview of Pressure Vessel Design
Instructors Personal Notes
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 H2S, caustic)
Weld hardness reduction
Major Learning Points
ASME Code PWHT requirements.
107
Post Weld Heat Treatment
Restores material properties
Relieves residual stresses
ASME Code PWHT requirements Minimum temperature and hold time
Adequate stress relief
Heatup and cooldown rates
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120
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Highlight main areas included in
inspection.
Major Learning Points
ASME Code inspection requirements.
108
Insp ect ion and Test ing
Inspection includes examination of:
Base material specification and quality
Welds
Dimensional requirements
Equipment documentation
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121
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review common types of weld defects.
Major Learning Points
Particular types of weld defects may
occur.
109
Comm on Weld Defects
Undercut
Incomplete Penetration
Lack of Fusion
B et we en Wel d B ead an d Ba se Me ta l B et we en A dj ac en t P as se s
I nc om pl et e F il li ng at Ro ot on On e S id e O nl y I nc om pl et e F il li ng at Ro ot
Internal Undercut
External Undercut
Figure 7.1
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123
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
1. Review NDE methods and types of
defects detected.
2. Review advantages and limitations
of each NDE method.
Major Learning Points
Different NDE methods are best
suited to detect particular defect
types.
Each NDE method has advantages
and disadvantages.
111
Types of NDENDE TYPE DEFECTS
DETECTED
ADVA NT AGES LI MI TA TI ON S
Radiographic Gas pockets, slag
inclusions,
incompletepenetration, cracks
Produces
permanent record.
Detects small flaws.Most effective for
butt-welded joints.
Expensive.
Not practical for
complex shapes.
Visual Porosity holes, slag
inclusions, weld
undercuts,
overlapping
Helps pinpoint
areas for additional
NDE.
Can only detect
what is clearly
visible.
Liquid Penetrant Weld surface-type
defects: cracks,seams, porosity,
folds, pits,
inclusions,
shrinkage
Used for ferrous
and nonferrousmaterials. Simple
and less expensive
than RT, MT, or UT.
Can only detect
surfaceimperfections.
Magnetic Particle Cracks, porosity,
lack of fusion
Flaws up to in.
beneath surface can
be detected.
Cannot be used on
nonferrous
materials.
Ultrasonic Subsurface flaws:laminations, slag
inclusions
Can be used forthick plates, welds,
castings, forgings.
May be used for
welds where RT not
practical.
Equipment must beconstantly
calibrated.
Figure 7.2
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124
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review typical setup for RT inspection.
Major Learning Points
Typical RT setup.
112
Typic al RT Setup
Test Specimen
Film
X-Ray
X-Ray Tube
Figure 7.3
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125
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review how pulse echo UT system can
detect defects.
Major Learning Points
Typical pulse echo UT system.
113
Pulse Echo UT System
Figure 7.4
A
Transducer
Cable
Flaw
Couplant
B
Test Specimen
Read Out
Base Line
Cathode Ray Tube (CRT)
CB
A
Input-OutputGenerator
C
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126
Overview of Pressure Vessel Design
Instructors Personal Notes
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:
Major Learning Points
Pressure test is used as final
demonstration of vessel integrity.
)etemperaturdesign(S
)etemperaturtest(S
114
Pressure Test ing
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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127
Overview of Pressure Vessel Design
Instructors Personal Notes
Instructors Outline
Review additional pressure test design
considerations.
Major Learning Points
Pressure test considerations.
115
Pressure Test ing ,cont d
Hydrotest pressures must be calculated:
For shop test. Vessel in horizontal position.
For field test. Vessel in final position withuncorroded component thicknesses.
For field test. Vessel in final position and withcorroded component thicknesses.
PTFlange test pressure Stress 0.9 (MSYS) Field test with wind
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128
Overview of Pressure Vessel Design
Instructors Personal Notes
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.
Major Learning Points
Summarize course.
116
Summary
Materials
Fabrication
Testing
Design
Inspection
Overview of pressure vessel mechanical design
ASME Section VIII, Division 1
Covered
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Appendix AReproducible Overheads
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Appendix BCourse & Instructor Evaluation Form
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131
ASME Career Development Series Course Evaluation
Course Title: ________________________________________________
Location: ___________________________________________________Instructor: __________________________________________________
Please assist us in the evaluation of this program. Answer the following questions by circling only one answerunless otherwise stated. We will be using your feedback to plan future programs. Your assistanceis most appreciated. Please return to instructor as requested.
A. Course Evaluation
Please record your overall reaction to the program by placing a circle around the appropriatenumber on the scale.
10 9 8 7 6 5 4 3 2 1 0
Excellent Good Fair Poor
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 1.2 E G F P 1.3 E G F P 1.4 E G F P 1.5 E G F P
2. What do you think was the best feature of the course?
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 courseliterature?
Optional Information:
Name: _______________________________ Title: _______________________________
Company: ____________________________ City, State: __________________________
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132
B. Instructors Evaluation
Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in theappropriate location
5. Effective Effectiveness Effective Openness to
knowledge of of teaching use of Class Overall
subject matter method class time Participation Rating
1.1 E G F P 1.2 E G F P 1.3 E G F P 1.4 E G F P 1.5 E G F P
C. Facilities
6. How would you rate the meeting site?
7. How would you rate the overnight accommodations (if applicable)?
8. In what other cities would you like to see this course held?
9. Additional Comments:
D. Future Courses and Educational Products (Video, Self Study, Software)
10. 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. On-Site Company Training12. 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.
13. Course Name/Topic: _________________________________________________________
14. Contact Name: ________________________________ Phone No.: ___________________
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133
Appendix C
Continuing Education Unit(CEU) Submittal Form
Course Improvement Form
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134
ASME Career Development Series
Continuing Education Unit (CEU) Request Form
Each 4-hour ASME Career Development Series Course earns 0.4 CEU s
PLEASE PRINT AL L YOUR INFORMATION CLEARLY
YOUR CERTI FI CATE WIL L BE PREPARED FROM TH IS 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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135
ASME Career Development SeriesCourse Improvement Form
Important Note: Submission of thi s form is optional. However, we would li ke to soli cit the comments of theI nstructor so that we may conti nu ing improve on the Career Development Seri es. Any instructorswho would l ike to writ e a cour se should indi cate so on thi s form and an authors package wil l be
forwarded to you.
Thank you for helping us with the Career Development Seri es
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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ASME Career Development SeriesInstructor s Biography Form
Important Note: Submission of this form is required every time a Career Development
Series Cour se is taugh t. ASME cannot process attendees CEU requests wi thout
this form.
Attachments to this form must include:
1. A biographical sketch of the instructor .
2. Course evaluations f il led out by the parti cipants at the completion of the cour se.
Course: ____________________________________________________
Date Presented: ______________________________________________
Location: ___________________________________________________
Instructor: __________________________________________________
Number of participants: ________________________________________
Sponsoring Unit: _____________________________________________
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