Pressure Vessels Field Manual

Common

Operating

Problems

and Practical Solutions

Maurice Stewart

Oran T. Lewis

AMSTERDAM

NEW YORK

BOSTON

OXFORD

SAN FRANCISCO
Gulf Professional

HEIDELBERG

PARIS

SINGAPORE

Publishing

is an

LONDON

SAN DIEGO

SYDNEY

Imprint

TOKYO

of Elsevier

G P
P IK

Contents

Chapter

1:

History and Organization of Codes

Overview

Use of Pressure Vessels and

History

Equipment

of Pressure Vessel Codes in the United States

Organization of

the ASME Boiler and Pressure Vessel Code

2
4

Section I: Power Boilers

Section II: Materials

Section III: Rules for Construction of Nuclear Power

Plant Components
Section IV:

Heating

Boilers

Section V: Nondestructive Examination

Section VI: Recommended Rules for the Care

and

Operation of Heating Boilers

Section VII: Recommended Guidelines for

the Care of Power Boilers

Section VIII

Section IX:

Welding and Brazing Qualifications

Section X: Fiber-Reinforced Plastic Pressure Vessels

Section XI: Rules for In-Service

Inspection

10
10

of

Nuclear Power Plant Components

Section XII: Rules for the Construction and

11

Continued Service of

11

Organization

Updating

Transport

Tanks

of Code Committee

and Interpreting the Code

12
12

Addenda

12

New Edition of the Code

12

Code Cases

13

Code Interpretations

13

ASME Code

"U"

Stamps

Stamp

13
14

vi

Contents

"UM"

15

Stamp

National Board of Boiler and Pressure Vessel

Inspectors

15

Organization of the ANSI/ASME B31 Code for

Pressure

15

Piping

B31.1: Power

Piping
Piping
B31.4: Pipeline Transportation Systems for
Liquid Hydrocarbons and Other Liquids
B31.5: Refrigeration Piping and Heat Transfer

16

B31.3: Process

16

Components

18

17

B31.8: Gas Transmission and Distribution

Piping Systems
B31.9: Building Services Piping
B31.11:

18
18
19

Slurry Transportation Piping Systems

B31.12: Hydrogen Piping and Pipelines

20

ANSI/ASME B31 Piping Code Committee

20

Some Other Pressure Vessel Codes and Standards

in the United States

20

Worldwide Pressure Vessel Codes

21

Australia

21

Belgium

22

China

22

France

22

Germany

22

Italy

22

Japan

22

Netherlands

23

Sweden

23

United

23

ASME

Kingdom

Code,

Section VIII, Division 1 versus Division 2

Division 1

24

Division 2
Criteria, ASME

Design
Scope

Structure

23
23

Code,

Section VIII, Division 1

24
24
25

Contents

vii

Allowable Stresses

26

Material

27

Specifications

32

Inspection Openings
Pressure Relief Devices

Cryogenic and

33

Low-Temperature

Vessels

Testing, Inspection, and Stamping

Design Criteria,

33
34

ASME Code, Section VIII, Division 2

38

Structure

39

Allowable Stresses

39

Materials and Tests

41

Responsibilities
ASME Code, Section

43
IX:

Welding

44

ASME Code

Requirements
Welding Procedure Specifications (WPS)

44

and Procedure Qualification Records (PQR)

44

Post-Weld Heat Treatment (PWHT)

45

ASME Code, Section I, Power Boilers

45

and Limitations

45

Scope

Allowable Stresses
Fabrication, Inspection,
Additional

46

and Tests

Requirements Employed by

47
Users in
48

Critical Service
Additional Requirements

Chapter

2: Materials of Construction

48

49

Overview

49

Material Selection

49

General Considerations

49

Corrosion

50

Strength

50

Example

53

Material Cost
Nonferrous

57

Alloys

58

General Considerations

58

Aluminum

58

Alloys

viii

Contents

Copper and Copper Alloys

61

Nickel and

61

High-Nickel Alloys

Titanium and Zirconium

Ferrous

62

Alloys

65

Alloys

65

General Considerations

Code,

ASME

Section

VIII, Division

Categories

65
67

Heat Treatment of Steels

General Considerations

67

Various Heat Treatments of Carbon Steel

69

70

Brittle Factors

General Considerations

70

Charpy V-Notch Test (Cv)

70

Drop-Weight Test (DWT)

Fracture-Analysis Diagram (FAD)

73

Example

77

Example 3
Theory of Brittle
Fracture

78
Fracture

Example

83
83
Fracture

Section VIII, Division 1 Criteria

Embrittlement

Hydrogen Decarburization
Hydrogen Attack

Chapter

84
85

Code,

Hydrogen

78

Theory

Hydrostatic Testing
Factors Influencing Brittle
ASME

74

3: Materials Selection for Pressure

Vessels

86
90

90
92

95

Overview

95

Selection of Materials for Service Conditions

95

General Considerations

Design

95

Factors

Typical Selections
Application Criteria
Materials

95

99
for Common Pressure Vessel
102

Contents

Summary

of

Temperature

Limitations

Selection of Materials for Brittle Fracture Prevention

ix

111
112

General Considerations

112

More Considerations

113

Design

to Prevent Brittle Fracture

114

Steels for New Construction of

Selecting

Pressure Vessels

121

Guidelines for Preventing Brittle Fracture in

129

Existing Equipment
General Considerations

Determining

Chapter

129

MPTs

129

4: Mechanical
Vessels

Design of Pressure
133

Overview

133

General Considerations

133

Owner's, User's, and Manufacturer's

Responsibilities

134

ASME Code, Section VIII

134

ASME Code, Section VIII, Division 1

134

ASME Code, Section VIII, Division 2

137

Determining Design

Conditions

139

General Considerations

139

Design

Pressure: Overview

Design

Pressure: ASME

Design

Pressure: ASME Code, Section VIII, Division 2

Code,

140
Section VIII, Division 1

External Pressure

Design Temperature:

145
146

ASME Code, Section VIII,

Division 1

146

Design Temperature:

ASME Code, Section VIII,

Division 2

Wind and

140

151

Earthquake Design

152

Corrosion Allowance

153

External and Internal Loads

153

Mechanical

Design

Overview

157
157

Contents

Design Summary
Design for Internal

165
Pressure

167

Example

168

Design for
Example

External Pressure

170
173

Example
Example
Example
Example

177
177
178
of Internal/External Pressure

Openings
Example 1

Design

and Nozzle Reinforcement

Reinforcement Calculations

179
184
194

Example

2 Reinforcement Calculations

198

Example

3 Reinforcement Calculations

200

Reinforcement of Openings for External Pressure

Bolted Flanged Connections

202

Minimum Wall Thickness and Nominal Plate Sizes

210

Design of Welded

211

Chapter

5:

Joints

Fabrication, Welding, and

In-Shop Inspection

202

217

Overview

217

Plate Materials

218

Overview

218

ASME Code Requirements

Fabricator Considerations

219

Forming of Shell and Head Components

General Considerations
Cylindrical

Shell

Ring Courses

Heads

220
220
220
223

Nozzles

225

Integrally Reinforced Nozzles

Built-Up Nozzles
Fabrication Welds

Longitudinal

219

Welds

Nozzle Welds

225
226
228
228
231

Contents

Girth Welds

233

Skirt Attachment Weld

235

Post-Weld Heat Treatment

(PWHT)

236

Processes and Procedures

Welding

Welding

237

Processes

237

Consumables

247

Preheat and

Interpass Temperature Control

Post-Weld Heat Treatment (PWHT)
Welding Procedure Qualification

Welding

Procedure Review

Welder Performance

264
275

Qualification

290

General Considerations
of

252
257

283

In-Shop Inspection
Degree

xi

290

Inspection
Choosing the Appropriate Degree

291

Guidelines for

of Inspection for Pressure Vessels

294

Inspection Tasks
Case Study 1: Construction and Inspection of

297

Replacement Flare

Knockout DrumMost

Appropriate Inspection Level: Degree 5

Case Study 2: Construction and Inspection
of

Replacement Flue

Gas CoolerMost

Appropriate Inspection

Chapter

298

Level:

Degree

6: In-Service Inspection by
Nondestructive Examination (NDE)

328

347

Overview

347

General Considerations

347

Materials for Construction

348

Inspection Program

348

Nondestructive Examination (NDE) Techniques

Design for Inspection

348
349

Jurisdiction Requirements
ASME Code, Section VIII Requirements

349

Jurisdiction

350

Code and

Requirements

349

xii

Contents

API 510: Pressure Vessel

Inspection Code
Inspection Code (NB Code)
Authorized Inspector versus ASNT-Certified

350

National Board

352
NDE

Technician

352

Forms of Deterioration

353

General Considerations

353

Internal Corrosion

353

External Corrosion

355

Thermal

Aging

356

General Considerations

356

Fatigue

359

Stress-Corrosion (Environmental)

Cracking

360

Internal Erosion

361

Hydrogen Attack
Hydrogen Blistering

362

Creep

and

362

Stress-Rupture

Cracks

363

Analysis of In-Service Inspection Data

364

General Considerations

364

Internal Corrosion

364

External Corrosion

368

Thermal Aging

368

Fatigue

368

Stress-Corrosion (Environmental) Cracking

369

Internal Erosion

370

Attack

Hydrogen
Hydrogen Blisters
Creep and Stress Rupture
Fitness-for-Service Analysis

370
371
371
372

Introduction

372

Background
Information

373

Required

for Fitness-for-Service

Procedures for Fitness-for-Service

Analysis

Analysis

Outline of the Procedure

Required Inspection

at

377

377

the Next Scheduled Shutdown

Nondestructive Examination (NDE)

376

Techniques

385
385

Contents

xiii

General Considerations

385

Visual Examination (VT)

385

Examination (PT)

Dye-Penetrant
Magnetic Particle

387

Examination (MT)

Ultrasonic Examination

391
399

(UT)

Crack

Sizing
Radiographic

Chapter

7:

413
Examination (RT)

417

Repair, Alteration, and Re-rating

Overview

425
425

Code and Jurisdiction

426

Requirements

ASME Code

426

Jurisdictional Requirements
National Board

Inspection

Code

427
versus

API 510

Repairs

427
437

General Considerations

431

Design of the Repair

Planning and Approval

438

Organization Making
Replacement Parts

the

443

Repair

444
445

Repair Welding

445

Post-Weld Heat Treatment (PWHT)

446

Inspection and Hydrotest

Approval of Repairs, Documentation, and

447

Nameplate

449

Alteration

450

General Considerations

450

Planning and Approval

Organization Making Alterations
Materials, Replacement Parts, Welding, PWHT,

451

and Inspection

452

Hydrotest

after Alterations

451

452

of Alterations, Documentation, and

Approval
Nameplate
Re-Rating

453
454

xiv

Contents

General Considerations

454

Organization Making Re-Rating

454

Calculations

455

Information Required

456

Approval of Re-Rating, Documentation, and

Nameplate
Index

457

471