Pressure Vessel Design ASME Guide

Overview of Pressure Vessel Design
Instructor’s Guide
1
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2
By:
Vincent A. Carucci
Carmagen Engineering, Inc.
Copyright © 1999 by
All Rights Reserved
3
TABLE OF CONTENTS
Abstract………………………………………………………………… 5
Introduction…………………………..…………………………………6
Organizing Unit Responsibilities……………………………………..7
Instructor Guidelines and Responsibilities………………………….9
Overview of Pressure Vessel Design Outline/
Teaching Plan…………………………………………………………11
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
Instructor’s Biography Form
4
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.
5
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 today’s 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 instructor’s 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 instructor’s 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.
6
7
8
9
10
Suggested Outline/Teaching Plan
Overheads/
Time, Major Class Segment Sub-Segment Sub-Segment
Participant
min. Interval Interval
Pages
10 Introduction 5 Introduction/Logistics OV – 1
Outline Module Part. – 65
5 Module based primarily on the OV – 2
ASME Code Section VIII, Division Part. – 65
1. Divisions 2 and 3 will be briefly
described
25 General 10 Main Pressure Vessel Components OV – 3-9
Part. – 67
10 Scope of ASME Code Section VIII OV – 10-13
• Division 1 Part. – 75
• Division 2
• Division 3
5 Structure of Section VIII, Division 1 OV – 14
Part. –78
20 Materials of 15 Material Selection Factors OV – 15-31
Construction • Strength Part. – 79
• Corrosion Resistance
• Resistance to Hydrogen Attack
• Fracture Toughness
• Fabricability
5 Maximum Allowable Stress OV – 32-34
Part. – 87
10 Exercise 10 Material Selection Based On Fracture OV – 35-38
Toughness Part. – 91
10 Break 10
55 Design 10 Design Conditions and Loadings OV – 39-43
• Pressure Part. – 92
• Temperature
• Other Loadings
25 Design for Internal Pressure OV – 44-55
• Weld Joints Part. - 98
• Cylindrical Shells
• Heads
• Conical Sections
Sample Problem
20 Design for External Pressure and OV – 56-65
Compressive Stresses Part. – 109
• Cylindrical Shells
• Other Components
• Sample Problem
11
Suggested Outline/Teaching Plan, continued
Overheads/
Time, Major Class Segment Sub-Segment Sub-Segment
Participant
min. Interval
Interval Pages
10 - 50 Major Break Lunch or Major Break
15 Exercise 15 Required Thickness for Internal OV – 66-68

Pressure Part. - 118
50 Design 20 Reinforcement of Openings (Include OV – 69-84

(Cont’d.) Sample Problem) Part. – 119
10 Flange Rating (Including Sample OV – 85-90
Problem) Part. – 127
15 Flange Design OV – 91-97
Part. – 131
5 Maximum Allowable Working OV – 98
Pressure (MAWP) Part. – 138
10 Break
20 Other Design 10 Local Loads OV – 99
Considerations Part. – 139
10 Vessel Internals OV – 100-102
Part. – 141
20 Fabrication 10 Acceptable Welding Details OV – 103-106
Part. – 143
10 Postweld Heat Treatment OV – 107
(PWHT)Requirements Part. – 146
15 Inspection and 10 Inspection OV – 108-113

Testing Part. – 148
5 Pressure Testing OV – 114-115
Part. – 152
10 Closure 10 Summary OV – 116
Questionnaire (fill in and collect) Part. - 155
CEU Form (hand out – individual
responsibility to return)
12
Instructor’s Personal Notes
OVERVIEW OF
PRESSURE VESSEL DESIGN
By: Vincent A. Carucci
Carmagen Engineering, Inc .
Instructor’s Outline Major Learning Points

1. Course discusses pressure vessel Course Introduction
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
Course Overview
• General
• Materials of Construction
• Design
• Other Design Considerations
• Fabrication
• Inspection and Testing
2

1. The objective: Provide a general • Establish course objectives.
knowledge of design requirements
• Outline course content, a road map.
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

1. Describe what a pressure vessel is. • Define pressure vessels.
2. Note that pressure vessels are used • Identify wide variety of industrial
in a wide variety of industries. They applications.
can be designed for a wide variety of
conditions and in a broad range of
sizes.
15
Horizontal Drum on
Saddle Supports Nozzle
A
Shell
Head Head
Saddle Support Saddle Support

(Sliding) (Fixed)
SectionA-A
Figure 2.1
4

1. Use this and following overheads to Main pressure vessel components and
describe main pressure vessel configurations.
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
Vertical Drum
on Leg Supports
Head
Shell Nozzle
Head
Support
Leg
5 Figure 2.2

1. Most heads are curved shape for Main pressure vessel components and
strength, thinness, economy. shapes.
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
Tall Vertical Tower
Nozzle
Head
Trays
Shell
Nozzle
Cone
Nozzle
Shell
Nozzle Head
Skirt
Support
6 Figure 2.3

1. Nozzles used for: Main pressure vessel components and
shapes.
• Piping systems
• Instrument connections
• Manways
• Attaching other equipment
2. Ends typically flanged, may be
welded.
3. Sometimes extend into vessel.
18
Vertical Reactor
Inlet
Nozzle
Head
Upper
Catalyst
Bed Shell
Catalyst Bed
Support Grid
Lower
Catalyst
Bed
Outlet
Collector
Head
Outlet
Nozzle
Support
Skirt
7 Figure 2.4

1. Skirt supports typically used for tall Main pressure vessel components and
vertical vessels: shapes.
• 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
Spherical Pressurized
Storage Vessel
Shell
Support
Leg
Cross
Bracing
Figure 2.5
8

1. Spherical storage vessels typically Main pressure vessel components and
supported on legs. shapes.
2. Cross-bracing typically used to
absorb wind and earthquake loads.
20
Vertical Vessel on
Lug Supports
9
Figure 2.6

1. Vessel size limits for lug supports: Main pressure vessel components and
configurations.
• 1 – 10 ft diameter
• 2:1 to 5:1 height/diameter ratio
2. Vessel located above grade.
3. Lugs bolted to horizontal structure.
21
Scope of ASME Code
Section VIII
• Section VIII used worldwide
• Objective: Minimum requirements for safe
construction and operation
• Division 1, 2, and 3
10

1. Section VIII is most widely used Define scope of ASME Code Section
Code. VIII.
2. Assures safe design.
3. Three divisions have different
emphasis.
22
Section VIII Division 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
11

1. Review scope of Division 1. • Scope of Division 1
2. Division 1 not applicable below 15 • Exclusions from scope
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
Section VIII, Division 2,
Alternative 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
12
economics

1. Review differences between Differences between Division 1 and 2.
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
Division 3, Alternative Rules
High Pressure Vessels
• Applications over 10,000 psi

• Pressure from external source, process
reaction, application of heat, combination
of these
• Does not establish maximum pressure
limits of Division 1 or 2 or minimum limits
for Division 3.
13

1. Review application of Division 3. Scope 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
Structure of Section VIII,
Division 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
14

1. Review Division 1 organization Basic organizational structure of
Division 1.
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.
26
Material Selection Factors
• Strength
• Corrosion Resistance
• Resistance to Hydrogen Attack
• Fracture Toughness
• Fabricability
15

1. ASME Code does not specify Primary factors that influence pressure
particular materials to use in each vessel material selection.
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

1. Strength: Material’s ability to Material strength and pressure vessel
withstand imposed loading. design.
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

1. Corrosion is thinning of metal. Importance of corrosion resistance in
materials selection.
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
Resistance to
Hydrogen Attack
• At 300 - 400°F, monatomic hydrogen

forms molecular hydrogen in voids
• Pressure buildup can cause steel to crack
• Above 600°F, hydrogen attack causes
irreparable damage through component
thickness
18

1. Low-temperature H 2 attack can Hydrogen attack can damage carbon
cause cracking. and low-alloy steel.
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
Brittle Fracture
and Fracture Toughness
• 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
19

1. Describe brittle fracture as Brittle fracture and its consequences.
equivalent to dropping a piece of
glass.
2. Material selection must ensure that
brittle fracture will not occur.
31
Brittle Fracture and
Fracture Toughness, cont’d
• Conditions required for brittle fracture

– High enough stress for crack initiation and
growth
– Low enough material fracture toughness at
temperature
– Critical size defect to act as stress
concentration
20

1. A brittle fracture will occur the first Three conditions that are required for a
time the appropriate conditions brittle fracture to occur.
occur.
2. Brittle fracture occurs without
warning and is catastrophic.
32
Factors That Influence
Fracture Toughness
• 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
21
plate

1. Describe influence of material and Primary factors that influence material
temperature factors on fracture fracture toughness.
toughness.
2. Other factors increase brittle fracture
risk.
33
Charpy V-Notch Test Setup
Scale
Starting Position
Hammer
Pointer
End of swing h'

Specimen
h'
Anvil
22

1. Charpy V-Notch test is most widely Charpy V-Notch testing.
used measure of material fracture
toughness.
2. Describe test set-up.
34
ASME Code and
Brittle Fracture Evaluation
• Components to consider
– Shells – Nozzles
– Manways – Tubesheets
– Heads – Flanges
– Reinforcing pads – Flat cover plates
– Backing strips – Attachments essential
that remain in to structural integrity
place that are welded to
pressure parts
23

1. ASME Code contains brittle fracture Components to consider is ASME Code
evaluation procedure. brittle fracture evaluation.
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
• Critical Exposure Temperature (CET)
– Minimum temperature at which significant
membrane stress will occur
24

1. Describe the distinction between
Two temperatures to be considered in
MDMT and CET.
brittle fracture evaluation.
• MDMT is a material property.
• CET is an environmental factor.
2. Important to understand this
distinction.
36
Simplified ASME
Evaluation Approach
• 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 and
thickness not exempt, then must impact test
25at CET

1. Outline ASME procedure. Simplified ASME brittle fracture
evaluation procedure.
2. Details described in following
overheads.
37
Material Groups
MATERIAL
GROUP APPLICABLE MATERIALS
Curve A • 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
Table 3.1 (Excerpt)

26

1. Materials are grouped based on Material group classifications for brittle
common fracture toughness fracture evaluations.
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
Material Groups, cont’d
MATERIAL
GROUP APPLICABLE MATERIALS
Curve C • 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
Curve D • SA-203 • SA-537 Cl. 1, 2 & 3

• SA-508 Cl. 1 • SA-612, if normalized
• SA-516, if normalized • SA-662, if normalized
• SA-524 Cl. 1 & 2 • SA-738 Gr. A
Bolting • See Figure UCS-66 of the ASME Code Section VIII, Div. 1, for impact
and Nuts test exemption temperatures for specified material specifications
Table 3.1 (Excerpt)

27

1. Identify other common materials. Material group classifications for brittle
fracture evaluations.
• 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
Instructor’s Personal Notes Impact Test Exemption Curves
for Carbon and Low-Alloy Steel
140
120
100
Minimum Design Metal Temperature, F

A B
80
60
C
40
D
20
-20
-40
-55
-60 Impact testing required
-80
0.394 1 2 3 4 5
Nominal Thickness, in.
(Limited to 4 in. for Welded Construction)
Figure 3.1
28

1. Describe relationship between Impact test exemption curves.
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
Additional ASME Code Impact
Test Requirements
• Required for welded construction over 4 in.
thick, or nonwelded construction over 6 in.
thick, if MDMT < 120°F
• Not required for flanges if temperature
≥ -20°F
• Required if SMYS > 65 ksi unless
specifically exempt
29

1. Review additional requirements. Additional impact test requirements.
2. Note that most flanges will not
require impact testing.
41
Additional ASME Code
Impact Test
Requirements, cont’d
• Not required for impact tested low
temperature steel specifications
– May use at impact test temperature
• 30°F MDMT reduction if PWHT P-1 steel
and not required by code
• MDMT reduction if calculated stress <
allowable stress
30

1. Review additional requirements. Additional impact test 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

Describe fabricability. Definition of fabricability.
43
Maximum Allowable Stress
• Stress: Force per unit area that resists loads
induced by external forces
• Pressure vessel components designed to
keep stress within safe operational limits
• Maximum allowable stress:
– Includes safety margin
– Varies with temperature and material
• ASME maximum allowable stress tables for
permitted material specifications
32

1. Discuss the use of allowable stress • Description of allowable stress.
in determining vessel component
• ASME Code allowable stress tables
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
Maximum Allowable
Stress, cont’d
ALLOWABLE STRESS IN TENSION FOR CARBON AND
LOW-ALLOY STEEL
Spec No. Grade Nominal P-No. Group No. Min. Yield Min. Tensile
Composition (ksi) (ksi)
Carbon Steel Plates and Sheets
SA-515 55 C-Si 1 1 30 55
60 C-Si 1 1 32 60
65 C-Si 1 1 35 65
70 C-Si 1 2 38 70
SA-516 55 C-Si 1 1 30 55
60 C-Mn-Si 1 1 32 60
65 C-Mn-Si 1 1 35 65
70 C-Mn-Si 1 2 38 70
Plate - Low Alloy Steels

SA-387 2 Cl.1 1/2Cr-1/2Mo 3 1 33 55
2 Cl.2 1/2Cr-1/2Mo 3 2 45 70
12 Cl.1 1Cr-1/2Mo 4 1 33 55
12 Cl.2 1Cr-1/2Mo 4 1 40 65
11 Cl.1 1 1/4Cr-1/2Mo-Si 4 1 35 60
11 Cl.2 1 1/4Cr-1/2Mo-Si 4 1 45 75
22 Cl.1 2 1/4Cr-1Mo 5 1 30 60
22 Cl.2 2 1/4Cr-1Mo 5 1 45 75
ASME Maximum Allowable Stress (Table 1A Excerpt)

Figure 3.2
33

1. Describe information contained in ASME Code allowable stress tables.
first section of table.
2. Information is grouped by material
chemistry and material form.
45
Maximum Allowable
Stress, cont’d
ALLOWABLE STRESS IN TENSION FOR CARBON AND LOW ALLOY STEEL
Max Allowable Stress, ksi (Multiply by 1,000 to Obtain psi)
for Metal Temperature, °F, Not Exceeding
Spec
650 700 750 800 850 900 950 1000 1050 1100 1150 1200 No.
Carbon Steel Plates and Sheets
13.8 13.3 12.1 10.2 8.4 6.5 4.5 2.5 -- -- -- -- SA-515
15.0 14.4 13.0 10.8 8.7 6.5 4.5 2.5 -- -- -- -- SA-515
16.3 15.5 13.9 11.4 9.0 6.5 4.5 2.5 -- -- -- -- SA-515
17.5 16.6 14.8 12.0 9.3 6.5 4.5 2.5 -- -- -- -- SA-515
13.8 13.3 12.1 10.2 8.4 6.5 4.5 2.5 -- -- -- -- SA-516

15.0 14.4 13.0 10.8 8.7 6.5 4.5 2.5 -- -- -- -- SA-516
16.3 15.5 13.9 11.4 9.0 6.5 4.5 2.5 -- -- -- -- SA-516
17.5 16.6 14.8 12.0 9.3 6.5 4.5 2.5 -- -- -- -- SA-516
Plate-Low Alloy Steels (Cont'd)

13.8 13.8 13.8 13.8 13.8 13.3 9.2 5.9 -- -- -- -- SA-387
17.5 17.5 17.5 17.5 17.5 16.9 9.2 5.9 -- -- -- -- SA-387
13.8 13.8 13.8 13.8 13.4 12.9 11.3 7.2 4.5 2.8 1.8 1.1 SA-387
16.3 16.3 16.3 16.3 15.8 15.2 11.3 7.2 4.5 2.8 1.8 1.1 SA-387
15.0 15.0 15.0 15.0 14.6 13.7 9.3 6.3 4.2 2.8 1.9 1.2 SA-387
18.8 18.8 18.8 18.8 18.3 13.7 9.3 6.3 4.2 2.8 1.9 1.2 SA-387
15.0 15.0 15.0 15.0 14.4 13.6 10.8 8.0 5.7 3.8 2.4 1.4 SA-387
17.7 17.2 17.2 16.9 16.4 15.8 11.4 7.8 5.1 3.2 2.0 1.2 SA-387
ASME Maximum Allowable Stress (Excerpt), cont'd

Figure 3.2, cont'd
34

1. Review allowable stress vs. design ASME Code allowable stress tables.
temperature.
2. Most ferritic materials have a
constant allowable stress at
temperatures through 650°F.
46
Material Selection Based
on Fracture Toughness
Exercise 1
• New horizontal vessel
• CET = - 2°F
• Shell and heads: SA-516 Gr. 70
• Heads hemispherical: ½ in. thick
• Cylindrical shell: 1.0 in. thick
• No impact testing specified
• Is this correct?
• If not correct, what should be done?
35

1. This independent Exercise gives the Participant Exercise 1 covering fracture
Participants practice in material toughness.
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.
– ½ in. thick plate for heads: MDMT = -7°F
– ½ in. thick plate exempt from impact testing since
MDMT < CET
• 1 in. shell plate: MDMT = +31°F
– Not exempt from impact testing
36

1. Review difference between Solution to Participant Exercise.
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
Exercise 1 - Solution, cont’d
• One approach to correct: Impact test 1 in. plate
at -2°F. If passes, material acceptable.
• Another approach: Order 1 in. plate normalized
– Table 3.1: normalized SA-516 is Curve D material
– Figure 3.1: 1 in. thick Curve D, MDMT = -30°F
– Normalized 1 in. thick plate exempt from impact testing
37

1. Review possible solutions for the Solution to Participant Exercise.
1 in. plate.
49

• Choice of option based on cost, material
availability, whether likely that 1 in. thick non-
normalized plate would pass impact testing
38

1. Review rationale for which option to Solution to Participant Exercise 1.
select.
50
Design Conditions
and Loadings
• Determine vessel mechanical design
• Design pressure and temperature, other
loadings
• Possibly multiple operating scenarios to
consider
• Consider startup, normal operation,
anticipated deviations, shutdown
39

1. Review conditions to be considered. Design conditions and loadings to be
considered in pressure vessel
2. Worst case operating scenario
mechanical design.
determines mechanical design.
51
Design Pressure
PT = Design Pressure at
Top of Vessel
γ = Weight Density of
Liquid in Vessel
H = Height
of Liquid
PBH = Design Pressure of

Bottom Head
Figure 4.1
40

1. May have internal of external Design pressure as a mechanical
pressure, or both at different times. design condition.
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
Temperature Zones
in Tall Vessels
Section 4
(T-Z)
Section 3
(T-Y)
Section 2
(T-X)
Section 1
(T) F
Support Skirt
Grade
Figure 4.2
41

1. Margin required between operating Design temperature as a mechanical
temperature and design temperature. design condition.
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

1. Highlight other loads that must be Loadings other than pressure and
considered in the mechanical temperature must also be considered.
design.
2. These other loads may govern the
mechanical design in local areas.
54
Additional Loadings, cont’d
• Cyclic and dynamic reactions caused by
pressure or thermal variations, equipment
mounted on vessel, and mechanical loadings
• Test pressure combined with hydrostatic
weight
• Impact reactions (e.g., from fluid shock)
• Temperature gradients within vessel
component and differential thermal
expansion between vessel components
43

1. Review these additional other loads. Additional other loadings to consider.
55
Weld Joint Categories
C C
C
A
A C
B
A D
D A B
D
B
D B
A
B A C
C D
Figure 4.3
44

1. Review the ASME Code Weld Joint ASME Code defines welded joints by
Categories. category.
2. Only specific weld types may be
used in each category.
56
Weld Types
Buttjointsasattainedbydouble-weldingorbyother
1 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

2 remainsinplaceafterwelding.
For circumferential
joint only
3 Single-welded butt joint without backing strip.
4 Double-fullfilletlapjoint.
5 Single-full fillet lap joint with plug welds.
6 Single-full fillet lap joint without plug welds.
Figure 4.4
45

1. Review the different weld types. ASME Code defines specific weld types
that may be used.
2. Limited applications for Types 3
through 6.
57
Weld Joint Efficiencies
Joint Acceptable Joint Categories Degree of

Type Radiographic Examination
Full Spot None
1 A, B, C, D 1.00 0.85 0.70
2 A, B, C, D (See ASME Code for limitations) 0.90 0.80 0.65
3 A, B, C NA NA 0.60
4 A, B, C (See ASME Code for limitations) NA NA 0.55
5 B, C (See ASME Code for limitations) NA NA 0.50
6 A, B, (See ASME Code for limitations) NA NA 0.45
Figure 4.5
46

1. Weld joint efficiency, E, is a measure Weld joint efficiency vs. Joint Type,
of weld quality and accounts for Category, Radiographic Examination.
stress concentrations.
2. E is needed in component thickness
calculations.
3. Review information in table.
4. Note that corrosion allowance was
previously discussed.
58
Summary Of ASME
Code Equations
Thickness, Pressure, Stress,
Part tp , in. P, psi S, psi
Pr SE 1t P(r + 0.6t)
Cylindrical shell SE1 − 0.6P tE1
r + 0.6t
Pr 2SEt P(r + 0.2t )
Spherical shell 2SE1 − 0.2P r + 0.2t 2tE
2:1 PD 2SEt P(D + 0.2t )

Semi - Elliptical 2SE − 0.2P D + 0.2t 2tE
head
0.885PL SEt P (0.885L + 0.1t )
Torispherical head SE − 0.1P 0.885L + 0.1t tE
with 6% knuckle
PD 2SEt cos α P(D + 1.2t cos α)

Conical Section
( α = 30°)
2 cos α (SE − 0.6P) D + 1.2t cos α 2tE cos α
Figure 4.6
47

1. Circumferential stress governs ASME Code equations for various
minimum required component components under internal pressure.
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
Typical Formed Closure Heads t
R
sf
sf
ID ID
Flanged Hemispherical
t
t
h
h
sf sf
Elliptical Flanged and Dished

(torispherical)
α t α t
sf
r
ID ID
Conical Toriconical
48
Figure 4.7

1. Review the different head types. Different types of closure heads may be
used.
2. The 2:l semi-elliptical head is the
most common.
60
Hemispherical
Head to Shell Transition
th th
Thinner Part
Thinner Part
l ≥ 3y
l ≥ 3y
Tangent Line
y y
Length of required taper, l,
may include the width
of the weld
ts ts
Figure 4.8
49

1. Required thickness of a Thickness transition at a hemispherical
hemispherical head is about half that head.
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"
4' - 0"
Both Heads are Seamless
60' - 0" 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
10' - 0"
6' - 0"
30' - 0"
2:1 Semi-Elliptical
Figure 4.9
50

1. Sample Problem 1 illustrates Sample Problem to illustrate calculation
calculation of required shell and of required thickness for internal
head thicknesses for internal pressure.
pressure.
2. Review the given information.
3. Review the problem solution with
the Participants.
62
Sample Problem 1 - Solution
• Required thickness for internal pressure of cylindrical

shell (Figure 4.6):
Pr
tp =
SE1 − 0. 6P
• Welds spot radiographed, E = 0.85 (Figure 4.5)
• S = 14,400 psi for SA- 515/Gr. 60 at 700°F (Figure 3.2)
• P = 250 psig
51

1. Review the relevant equation for a Sample Problem 1 solution.
cylindrical shell.
2. Note the sources used for the
various parameters.
63
Sample Problem 1
Solution, cont’d
• For 6 ft. - 0 in. shell
r = 0.5D + C = 0.5 × 72 + 0.125 = 36.125 in.

Pr 250 × 36.125
tp = =
S E1 − 0.6P 14,400 × 0.85 − 0.6 × 250 = 0.747 in.
t = tp + c = 0.747 + 0.125
t = 0.872 in., including corrosion allowance
52

1. The corrosion allowance must be Sample Problem 1 solution.
added to obtain the inside radius.
2. The corrosion allowance must be
added to the calculated thickness.
64
Sample Problem 1
Solution, cont’d
• For 4 ft. - 0 in. shell
r = 0.5 × 48 + 0.125 = 24.125 in.
250 × 24.125
tp = = 0.499 in.
14,400 × 0. 85 − 0. 6 × 250
t = 0.499 + 0.125

53

1. The calculation is repeated for the Sample Problem 1 solution.
other cylindrical shell section.
65
Sample Problem 1
Solution, cont’d
Both heads are seamless, E = 1.0.
Top Head - Hemispherical (Figure 4.6)
r = 24 + 0.125 = 24.125 in.
Pr 250 × 24.125
tp = = = 0.21 in.
2SE1 − 0.2P 2 × 14,400 × 1 − 0.2 × 250
t = tp + c = 0.21 + 0.125

54

hemispherical head.
2. Note the sources for the relevant
parameters and how corrosion
allowance is accounted for.
66
Sample Problem 1
Solution, cont’d
• Bottom Head - 2:1 Semi-Elliptical (Figure 4.6)
D = 72 + 2 × 0.125 = 72.25 in.

PD 250 × 72 .25
tp = = = 0.628 in.
2SE − 0.2P 2 × 14,400 × 1 − 0.2 × 250
t = 0.628 + 0.125
55

semi-elliptical head.
2. Note the sources for the relevant
parameters and how corrosion
allowance is accounted for.
67
Design For External
Pressure and Compressive
Stresses
• Compressive forces caused by dead
weight, wind, earthquake, internal vacuum
• Can cause elastic instability (buckling)
• Vessel must have adequate stiffness
– Extra thickness
– Circumferential stiffening rings
56

1. Buckling of a shell under external Different procedures are used to design
pressure or compressive forces is for external pressure or compressive
analogous to column buckling under loads.
a compressive force.
2. Addition of stiffener rings reduces
effective buckling length.
68
Design For
External Pressure and
Compressive Stresses, cont’d
• ASME procedures for cylindrical shells,
heads, conical sections. Function of:
– Material – Temperature
– Diameter – Thickness
– Unstiffened length
57

1. Highlight the main parameters that Parameters that affect compressive
affect buckling strength. strength.
2. ASME Code has design procedure
for each type of shell or head.
69
Stiffener Rings
Moment Axis of Ring
h/3
L L L L L
L L L L L
h/3
h = Depth of Head
Figure 4.10
58

1. Stiffener rings reduce the buckling Use and location of stiffener rings.
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
4' - 0" Shell and Head Material is
SA-285 Gr. B, Yield Stress = 27 ksi
Cylinder Dimension Shown
150' - 0"
is Inside Diameter
2:1 Semi-Elliptical
(Typical)
Figure 4.11
59

1. Sample Problem 2 illustrates Sample Problem to illustrate calculation
procedure for calculation of required of required cylindrical shell thickness
cylindrical shell thickness for for external pressure.
external pressure.
2. The problem does not cover all
aspects of the general procedure
since it is geometry-specific.
the participants.
71
• Calculate L and Do of cylindrical shell.
L = Tangent Length + 2 × 1/3 (Head Depth)

L = 150 × 12 + 2/3 × (48/4) = 1,808 in.
Do = 48 + 2 × 7/16 = 48.875 in.
• Determine L/Do and Do/t

Account for corrosion allowance:
t = 7/16 – 1/16 = 6/16 = 0.375 in.

Do/t = 48.875 / 0.375 = 130
L/Do = 1808 / 48.875 = 37
60

1. Corroded shell diameter and Sample Problem 2 solution.
thickness are used in the
calculations.
2. The unstiffened length of the shell
must include part of the head depth.
72
Sample Problem 2
Solution, cont’d
• Determine A.
• Use Figure 4.12, Do /t, and L/Do.
Note: If L/Do > 50, use L/Do = 50. For L/Do < 0.05, use
L/Do = 0.05
61

1. Factor A is determined based only Sample Problem 2 solution.
on geometry.
2. Note the source of Factor A.
73
Sample Problem 2
Solution, cont’d
A = 0.000065
Do/t = 100
.0001
4 5 6 789
D o/t = 125
Do /t = 130 D o/t = 150
D /t = 200
o
3
D o/t = 250 0
00 00 00 800 ,00
= 4 t=5 t = 6 =1
2
/t =
.00001
D o/t = 300 /t / / /t
Do Do Do Do Do
50.0
40.0
35.0
30.0
25.0
20.0
18.0
14.0
10.0
9.0
8.0
7.0
6.0
2.0
1.8
1.6
1.4
1.2
16.0
12.0
5.0
4.0
3.5
3.0
2.5
Length + Outside Diameter = L/Do
L/Do = 37
Factor A
Figure 4.12
62

1. Note how Factor A is determined Sample Problem 2 solution.
from these curves.
2. After determine Factor A, go to
applicable material chart.
74
Sample Problem 2
Solution, cont’d
20,000
GENERAL NOTE: See Table CS-1 for tabular values 18,000
up to 300°F 16,000
500°F 14,000
700°F 12,000
800°F 10,000
FACTOR B
900°F 9,000
8,000
E=29.0 x 106
7,000
E=27.0 x 106
6,000
E=24.5 x 106
5,000
E=22.8 x 106 4,000

E=20.8 x 106 3,500
3,000
2,500
2,000
2 3 4 5 6 789 2 3 4 5 6 789 2 3 4 5 6789 2 3 4 5 6 789
.00001 .0001 .001 .01 .1
A=0.000065 FACTOR A
Factor B
63 Figure 4.13

1. Different material charts are used for Sample Problem 2 solution.
different material types. This is
chart used for most carbon and low-
alloy 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.
3. Since A is to left of curves in our
case, must use alternate procedure.
75
Sample Problem 2
Solution, cont’d
• Calculate maximum allowable external pressure
2AE
Pa =
3(Do / t )
Where:
E = Young's modulus of elasticity
E = 27 × 106 psi (Figure 4.13) at T = 500°F
P a = 9 psi
64

1. Pa is calculated using indicated Sample Problem 2 solution.
equation because A is not under
curves.
2. Must use E from curves at design
temperature.
76
Sample Problem 2
Solution, cont’d
Since Pa < 15 psi, 7/16 in. thickness not sufficient
• Assume new thickness = 9/16 in.,
corroded thickness L = 1/2 in.
Do 48. 875 L
= = 97.75 = 3 7 (as before)
t 0. 5 Do
A = 0.000114
2 × 0.000114 × 27 × 10 6
Pa = = 15. 7 psi
3 × 130. 33
65

1. Since P a < 15 psi, must either Sample Problem 2 solution.
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
Exercise 2 - Required
Thickness for Internal Pressure
• Inside Diameter - 10’ - 6”
• Design Pressure - 650 psig
• Design Temperature - 750°F
• Shell & Head Material - SA-516 Gr. 70
• Corrosion Allowance - 0.125 in.
• 2:1 Semi-Elliptical heads, seamless
• 100% radiography
• Vessel in vapor service
66

1. This independent Exercise gives the Participant Exercise 2 covering required
Participants practice in determining thickness for internal pressure.
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

tp = = 2. 53 in.
(16,600 ×1 .0 ) − (0 .6 × 650)
67

1. Note the relevant equation for the Exercise 2 solution.
cylindrical shell and the appropriate
parameters.
2. Note how corrosion allowance is
accounted for.
79
Add corrosion allowance
tp = 2.53 + 0.125 = 2.655 in.
• For the heads
PD
tp =
2 SE − 0. 2P
650 (126 × 0 . 9) + 0 . 250

tp = = 2 . 23 in.
(2 × 16, 600) − (0 . 2 × 650 )
Add corrosion allowance
68
tp = 2.23 + 0.125 = 2.355 in.

1. Note the relevant equation for the Exercise 2 solution.
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:
- Must be equivalent in metal area
- Must be adjacent to opening
69

1. Simplified ASME rules do not require Openings must be reinforced to
stress calculations. Use “area account for metal removed.
replacement” approach.
2. Metal removed must be replaced by
equivalent metal.
81
Cross Sectional View of
Nozzle Opening
Dp
tn Rn
t rn
2.5t or 2.5t n + te te
Use smaller value tr
t c
2.5t or 2.5t n h
Use smaller value d
d or R n + tn + t d or R n + tn + t
Use larger value Use larger value
For nozzle wall inserted For nozzle wall abutting

through the vessel wall the vessel wall
Figure 4.14
70

Region near opening and nomenclature.
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
Nozzle Design Configurations
(a)
Full Penetration Weld
With Integral Reinforcement (a-1) (a-2) (a-3)
Separate Reinforcement Plates Added
(b) (c) (d) (e)
Full Penetration Welds to Which Separate Reinforcement Plates May be Added
(f-1) (f-3)
(f-2)
(f-4) (g)
Self - Reinforced Nozzles
71
Figure 4.15

1. Note the different nozzle design Typical nozzle configurations.
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

1. The method used to provide Requirements for additional
additional reinforcement depends on reinforcement.
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
Shell Material is SA-516 Gr. 60
Nozzle Material is SA-53 Gr. B, Seamless
Vessel is 100% Radiographed
Nozzle does not pass through Vessel Weld Seam
NPS 8 Nozzle
(8.625" OD)
0.5" Thick
0.5625" Thick Shell, 48" Inside Diameter
Figure 4.16
73

1. Sample Problem 3 illustrates Sample Problem to illustrate evaluation
evaluation of an opening for of nozzle reinforcement.
adequate reinforcement.
the Participants.
85
• Calculate required reinforcement area, A
A = dtrF
Where:
d = Finished diameter of circular opening, or
finished dimension of nonradial opening in
plane under consideration, in.
tr = Minimum required thickness of shell using
E = 1.0, in.
F = Correction factor, normally 1.0
74

1. Required replacement area is based Sample Problem 3 solution.
on the cross-sectional area removed.
2. Calculated using the required shell
thickness, not the actual.
86
Sample Problem 3 -
Solution, cont’d
• Calculate diameter, d.
d = Diameter of Opening – 2 (Thickness +
Corrosion Allowance)
d = 8.625 – 1.0 + .125 = 7.750 in.
• Calculate required shell thickness, t r (Figure 4.6)
tr = 0.487 in.
• Assume F = 1.0
75

1. Corrosion allowance is accounted Sample Problem 3 solution.
for.
2. tr is calculated using the appropriate
shell equation.
87
Sample Problem 3 -
Solution, cont’d
• Calculate A
A = dtr F
A = (8.625 - 1.0 + 0.125) × 0.487 × 1
= 3.775 in.2
• Calculate available reinforcement area in vessel
shell, A 1, as larger of A 11 or A1 2
A1 1 = (E lt - Ftr)d
76
A1 2 = 2 (Elt-Ftr)(t + tn)

1. Required area is calculated using Sample Problem 3 solution.
the previously calculated
parameters.
2. Two equations must be checked to
determine the reinforcement area
available in the shell.
88
Sample Problem 3 -
Solution, cont’d
Where:
E l = 1.0 when opening is in base plate away from welds,
or when opening passes through circumferential joint
in shell (excluding head to shell joints).
E l = ASME Code joint efficiency when any part of opening
passes through any other welded joint.
F = 1 for all cases except integrally reinforced nozzles
inserted into a shell or cone at angle to vessel
longitudinal axis. See Fig. UG-37 for this special
case.
tn = Nominal thickness of nozzle in corroded condition, in.
77

Review the relevant parameters. Sample Problem 3 solution.
89
Sample Problem 3 -
Solution, cont’d
A 11 = (Elt - Ftr)d = (0.5625 - 0.0625 - 0.487) × 7.75 = 0.1 in.2
A 12 = 2 (Elt - Ftr ) (t + t n)
= 2(0.5625-0.0625-0.487) × (0.5625-0.0625+0.5 -0.0625)
= 0.0243 in. 2
Therefore,
A1 = 0.1 in.2 available reinforcement in shell
78

Available shell reinforcement area is Sample Problem 3 solution.
determined.
90
Sample Problem 3 -
Solution, cont’d
• Calculate reinforcement area available in nozzle wall, A2,
as smaller of A21 or A22.
A21 = (tn-tr n) 5t
A22 = 2 (t n-tr n) (2.5 tn + t e)
79

Available reinforcement area in the Sample Problem 3 solution.
nozzle is determined by checking two
equations.
91
Sample Problem 3 -
Solution, cont’d
Where:
trn = Required thickness of nozzle wall, in.
r = Radius of nozzle, in.
te = 0 if no reinforcing pad.
te = Reinforcing pad thickness if one installed, in.
te = Defined in Figure UG-40 for self-reinforced

nozzles, in.
80

Review the relevant parameters. Sample Problem 3 solution.
92
Sample Problem 3 -
Solution, cont’d
• Calculate required nozzle thickness, trn (Figure 4.6)
Pr
t rn =
SE1 − 0. 6P
300 (3. 8125 + 0. 0625)

t rn = = 0. 0784 in.
15,000 × 1 − 0. 6 × 300
81

Calculate required thickness using the Sample Problem 3 solution.
equation for a cylinder.
93
Sample Problem 3 -
Solution, cont’d
• Calculate A2.
A21 = (tn - trn)5t = (0.5 - 0.0625 - 0.0784) × 5 (0.5625 - 0.0625)
= 0.898 in.2
A22 = 2 (tn - t rn) (2.5 tn + te)
= 2 (0.5 - 0.0625 - 0.0784) [2.5 × (0.5 - 0625) + 0]
= 0.786 in.2
Therefore,
A2 = 0.786 in.2 available reinforcement in nozzle.
82

1. The available reinforcement in the Sample Problem 3 solution.
nozzle is determined.
2. Note that in this case, the nozzle has
much more excess metal available
than the shell.
94
Sample Problem 3 -
Solution, cont’d
• Determine total available reinforcement area, A T;
compare to required area.
AT = A1 + A2 = 0.1 + 0.786 = 0.886 in.2
AT < A, nozzle not adequately reinforced, reinforcement
pad required.
• Determine reinforcement pad diameter, Dp.
A5 = A - AT
A5 = (3.775 - 0.886) = 2.889 in.2
83

1. The nozzle is not adequately Sample Problem 3 solution.
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
Sample Problem 3 -
Solution, cont’d
• Calculate Dp
te = 0.5625 in. (reinforcement pad thickness)
A 5 = [Dp - (d + 2 t n)] te
2.889 = [Dp - (7.75 + 2(0.5 - 0.0625)] 0.5625
Dp = 13.761 in.
• Confirm Dp within shell reinforcement zone, 2d
2d = 2 × 7.75 = 15.5 in.
Therefore, Dp = 13.761 in. acceptable
84

1. The reinforcement pad thickness Sample Problem 3 solution.
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
Flange Rating
• Based on ASME B16.5
• Identifies acceptable pressure/temperature combinations
• Seven classes
(150, 300, 400, 600, 900, 1,500, 2,500)
• Flange strength increases with class number
• Material and design temperature combinations without

pressure indicated not acceptable
85

1. ASME B16.5 provides standard The flange rating establishes
flange dimensional details. acceptable temperature/pressure
combinations and is based on ASME
2. Flange strength is based on
B16.5
dimensions and material used.
97
Material Specification List
Material Groups Product Forms

Material Nominal
Group Designation Forgings Castings Plates
Number Steel
Spec. No. Grade Spec. No. Grade Spec. No. Grade
1.1 Carbon A105 -- A216 WCB A515 70
A350 LF2 -- -- A516 70
C-Mn-Si -- -- -- -- A537 Cl.1
1.2 Carbon -- -- A216 WCC -- --
-- -- A352 LCC -- --
2 ½ Ni -- -- A352 LC2 A203 B
3 ½ Ni A350 LF3 A352 LC3 A203 E
ASME B16.5, Table 1a, Material Specification List (Excerpt)
Figure 4.17
86

1. Acceptable flange materials are Flange Material Group Number is based
grouped based on similarities in on material specification and product
strength. form.
2. The Material Group is determined
based on the specified material.
98
Pressure - Temperature Ratings
Material
1.1 1.2 1.3
Group No.
Classes 150 300 400 150 300 400 150 300 400
Temp., °F
-20 to 100 285 740 990 290 750 1000 265 695 925
200 260 675 900 260 750 1000 250 655 875
300 230 655 875 230 730 970 230 640 850
400 200 635 845 200 705 940 200 620 825
500 170 600 800 170 665 885 170 585 775
600 140 550 730 140 605 805 140 534 710
650 125 535 715 125 590 785 125 525 695
700 110 535 710 110 570 755 110 520 690
750 95 505 670 95 505 670 95 475 630
800 80 410 550 80 410 550 80 390 520
850 65 270 355 65 270 355 65 270 355
900 50 170 230 50 170 230 50 170 230
950 35 105 140 35 105 140 35 105 140
1000 20 50 70 20 50 70 20 50 70
Figure 4.18
87

1. This table combines information for Pressure/temperature rating is a
three Material Groups for illustrative function of Material Group and design
purposes. temperature.
2. Review the information in this table
and how it is used to determine the
appropriate flange rating.
99
Sample Problem 4
Determine Required Flange Rating
Pressure Vessel Data:

Shell and Heads: SA-516 Gr.70
Flanges: SA-105
Design Temperature: 700°F
Design Pressure: 275 psig
88

1. Sample Problem 4 illustrates how to Sample Problem to illustrate
determine flange rating. determining flange rating.
the Participants.
100
• Identify flange material specification
SA-105
• From Figure 4.17, determine Material Group No.
Group 1.1
• From Figure 4.18 with design temperature and
Material Group No. determined in Step 3
– Intersection of design temperature with Material
Group No. is maximum allowable design pressure for
the flange Class
89

Review the problem solution. Sample Problem 4 solution.
101
Sample Problem 4 -
Solution, cont’d
– Table 2 of ASME B16.5, design information for all
flange Classes
– Select lowest Class whose maximum allowable
design pressure ≥ required design pressure.
• At 700°F, Material Group 1.1: Lowest Class that

will accommodate 275 psig is Class 300.
• At 700°F, Class 300 flange of Material Group
1.1: Maximum design pressure = 535 psig.
90

1. Use the lowest flange class that is Sample Problem 4 solution.
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
W
Am =
S
91

1. Division 1 Appendix 2 procedure for ASME procedure must be used for
custom-designed flanges. 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
Flange Loads and
Moment Arms
Flange
Ring
Gasket
t h
A hG W
C
hT hD
g1
HT
G
HD B g0
HG
Flange Hub
Figure 4.19
92

1. Applied loads act at different flange Various flange loads are applied on
locations. corresponding moment arms.
2. Flange moments are calculated for
the operating and gasket seating
cases.
104
Stresses in Flange Ring
and Hub
• Calculated using:
– Stress factors (from ASME code)
– Applied moments
– Flange geometry
• Calculated for:
– Operating case
– Gasket seating case
93

1. Various stresses are calculated for • Flange stresses are calculated and
each case and must be kept within compared to allowable values.
allowable limits.
• Both operating and gasket seating
2. Flange dimensions are adjusted as cases must be checked.
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).
105
Flange Design and
In-Service Performance
Factors affecting design and performance
• ASME Code m and y parameters.
• Specified gasket widths.
• Flange facing and nubbin width, w
• Bolt size, number, spacing
94

1. Flange is designed for specific Various parameters affect flange design
gasket type, dimensions, and facing and performance.
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.
106
ASME Code m and y Factors
Min.
Facing Sketch
Gasket Design
and Column in
Gasket Type and Material Factor, Seating
ASME Table 2-5.2
m Stress y,
(Figure 4.21)
psi
Flat metal, jacketed asbestos filled:

Soft aluminum 3.25 5,500
Soft copper or brass 3.50 6,500
(1a), (1b), (1c),
Iron or soft steel 3.75 7,600
(1d); (2);
Monel 3.50 8,000
Column II
4-6% chrome 3.75 9,000
Stainless steels and nickel-base alloys 3.75 9,000
Solid flat metal:

Soft aluminum 4.00 8,800
Soft copper or brass 4.75 13,000 (1a), (1b), (1c),
Iron or soft steel 5.50 18,000 (1d); (2), (3), (4),
Monel or 4-6% chrome 6.00 21,800 (5); Column I
Stainless steels and nickel-base alloys 6.50 26,000
Figure 4.20
95

1. This is an excerpt from Table 2-5.1. • Gasket m and y factors are based
on gasket type.
2. Review the variation in m and y with
gasket type. • Gasket type also affects gasket
width used in calculations.
107
ASME Code Gasket Widths
Facing Sketch Basic Gasket Seating Width bo
(Exaggerated)
Column I Column II
N N
(1a) N N
N 2 2
N
(1b)
w
T
w+ T  w+ N
(1c)
N
w ≤N ; max
w + T ;  w + N max  2  4 
 
w
T
2  4 
N
(1d) w ≤N
HG HG
G hG G hG
O.D. Contact Face
b C Gasket
L Face
For b o > ¼ in. For b o< ¼in.
ASME Code Gasket Widths (Table 2-5.2 excerpt)
Figure 4.21
96

1. This is an excerpt from Table 2-5.2. The gasket width used in the
calculations depends on the type of
2. Review the flange facings shown.
flange facing.
108
Gasket Materials
and Contact Facings
Gasket Materials and Contact Facings
Gasket Factors m for Operating Conditions and Minimum Design Seating Stress y
Gasket Material Gasket Min. Sketches Facing
Factor Design Sketch and
m Seating Column in
Stress y, Table 2-5.2
psi
Flat metal, jacketed asbestos filled: 3.25 5500 (1a), (1b),
Soft aluminum 3.50 6500 (1c),2, (1d) 2,
Soft copper or brass 3.75 7600 (2)2,
Iron or soft steel 3.50 8000 Column II
Monel 3.75 9000
4% - 6% chrome 3.75 9000
Stainless steels and nickel-base alloys
Figure 4.22
97

Review the additional gasket Information on additional gasket types.
information shown.
109
Maximum Allowable
Working Pressure (MAWP)
Maximum permitted gauge pressure at top of
vessel in operating position for designated
temperature
• 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
98 allowance needed

1. Emphasize that MAWP is based on MAWP is defined.
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.
110
Local Loads
• Piping system
• Platforms, internals, attached equipment
• Support attachment
99

1. Review the typical external loads Externally applied loads must also be
that may be applied. considered in vessel design.
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).
111
Types of Vessel Internals

• Trays
• Inlet Distributor
• Anti-vortex baffle
• Catalyst bed grid and support beams
• Outlet collector
• Flow distribution grid
• Cyclone and plenum chamber system
100

1. Different types of internals are used Several types of vessel internals may be
to perform various process installed.
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.
112
ASME Code and
Vessel Internals
• Loads applied from internals on vessel to be
considered in design
• Welding to pressure parts must meet ASME

Code
101

Discuss ASME requirements for loads ASME Code requires that internals be
applied to vessel and welding to considered only to extent of their effect
pressure parts. on pressure shell.
113
Corrosion Allowance
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
102

1. Potential corrosion of internals Corrosion allowance should be
should not be ignored. considered in the design of internals.
2. Corrosion allowance should be
considered in a practical and cost-
effective manner.
114
Head-to-Shell Transitions
th th
Thinner part
Thinner part
l l
Tangent
y Line
y
ts t
s
th th
y Tangent y
Line
Thinner part
l
Thinner part
l
t t
s s
Fillet
Weld
Butt Weld
Intermediate Head Attachment
Figure 6.1
103

1. Review typical acceptable welding ASME Code specifies acceptable
and fabrication details. 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.
115
Typical Shell Transitions
CL CL
In all cases, l shall not
be less than 3y.
y
C
L
Figure 6.2
104

Review thickness taper requirements. ASME Code fabrication details.
116
Nozzle Neck
Thickness Tapers
Figure 6.3
105

Thickness taper may be required in ASME Code fabrication details.
nozzle neck.
117
Stiffener Rings
In-Line Continuous Fillet Weld On

Intermittent Weld One Side, Intermittent Weld
Staggered On Other Side
Intermittent Weld
Figure 6.4
106

1. Vacuum stiffening ring attachment ASME Code fabrication details.
details.
2, ASME Code specifies weld spacing,
size, and length.
118
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
107

1. ASME Code specifies PWHT ASME Code PWHT requirements.
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
119
Inspection and Testing

Inspection includes examination of:
• Base material specification and quality
• Welds
• Dimensional requirements
• Equipment documentation
108

Highlight main areas included in ASME Code inspection requirements.
inspection.
120
Common Weld Defects
Between Weld Bead and Base Metal Between Adjacent Passes
Lack of Fusion
Incomplete Filling at Root on One Side Only Incomplete Filling at Root
Incomplete Penetration
ExternalUndercut
Internal Undercut
Undercut
Figure 7.1
109

Review common types of weld defects. Particular types of weld defects may
occur.
121
Weld Defects
Presence of defects:
• Reduces weld strength below that required

• Reduces overall strength of fabrication
• Increases risk of failure
110

Review why weld defects can reduce Presence of unacceptable weld defects
vessel integrity. reduces vessel integrity.
122
Types of NDE
NDE TYPE DEFECTS ADVANTAGES LIMITATIONS
DETECTED
Radiographic Gas pockets, slag Produces Expensive.
inclusions, permanent record. Not practical for
incomplete Detects small flaws. complex shapes.
penetration, cracks Most effective for
butt-welded joints.
Visual Porosity holes, slag Helps pinpoint Can only detect
inclusions, weld areas for additional what is clearly
undercuts, NDE. visible.
overlapping
Liquid Penetrant Weld surface-type Used for ferrous Can only detect
defects: cracks, and nonferrous surface
seams, porosity, materials. Simple imperfections.
folds, pits, and less expensive
inclusions, than RT, MT, or UT.
shrinkage
Magnetic Particle Cracks, porosity, Flaws up to ¼ in. Cannot be used on
lack of fusion beneath surface can nonferrous
be detected. materials.
Ultrasonic Subsurface flaws: Can be used for Equipment must be
laminations, slag thick plates, welds, constantly
inclusions castings, forgings. calibrated.
May be used for
welds where RT not
practical.
Figure 7.2
111

1. Review NDE methods and types of • Different NDE methods are best
defects detected. suited to detect particular defect
types.
2. Review advantages and limitations
of each NDE method. • Each NDE method has advantages
and disadvantages.
123
Typical RT Setup
X-Ray Tube
X-Ray
Film
Test Specimen
Figure 7.3
112

Review typical setup for RT inspection. Typical RT setup.
124
Pulse Echo UT System
Cathode Ray Tube (CRT)
A C
B Read Out
BaseLine
Input-Output Cable
Generator
Transducer
Couplant
Test Specimen
Flaw
Figure 7.4
113

Review how pulse echo UT system can Typical pulse echo UT system.
detect defects.
125
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)
114

1. Water is a safer test medium than Pressure test is used as final
air. Pneumatic testing should only demonstration of vessel integrity.
be used on an exception basis.
2. “Ratio” is the lowest value of:
S( test temperatur e)
S ( design temperatur e)
126
Pressure Testing, cont’d

Hydrotest pressures must be calculated:
• For shop test. Vessel in horizontal position.
• For field test. Vessel in final position with
uncorroded component thicknesses.
• For field test. Vessel in final position and with
corroded component thicknesses.
• PT ≤ Flange test pressure
• Stress ≤ 0.9 (MSYS)
• Field test with wind
115

Review additional pressure test design Pressure test considerations.
considerations.
127
Summary
• Overview of pressure vessel mechanical design
• ASME Section VIII, Division 1
• Covered
– Materials – Design
– Fabrication – Inspection
– Testing
116

1. Highlight the subjects covered in the Summarize course.
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.
128
Appendix A
Reproducible Overheads
Appendix B
Course & Instructor Evaluation Form
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 answer
unless otherwise stated. We will be using your feedback to plan future programs. Your assistance
is 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 appropriate
number on the scale.
10 9 876 543 210

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 course
literature?
Optional Information:
Name: _______________________________ Title: _______________________________
Company: ____________________________ City, State: __________________________
131
B. Instructor’s Evaluation
Please evaluate the instructor(s) by circling E (excellent), G (good), F (fair), or P (poor) in the
appropriate 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 Training

12. 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.: ___________________
132
Appendix C
Continuing Education Unit

(CEU) Submittal Form
133
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 ALL YOUR INFORMATION CLEARLY

YOUR CERTIFICATE WILL BE PREPARED FROM THIS FORM
Title of Program: _____________________________________________________

Date Held: __________________________________________________________
Instructor: __________________________________________________________
Location: ___________________________________________________________
Number of CEU’s 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.
134
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
135
Instructor’s Biography Form
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: _____________________________________________
136
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Pressure Vessel Design ASME Guide

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Overview of Pressure Vessel Design

ASME Professional Development

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Appendix A: Reproducible Overheads

The balance of this instructor’s guide focuses on:

1. Organizing Unit Responsibilities

15 Exercise 15 Required Thickness for Internal OV – 66-68

50 Design 20 Reinforcement of Openings (Include OV – 69-84

15 Inspection and 10 Inspection OV – 108-113

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Saddle Support Saddle Support

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

• Applications over 10,000 psi

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

• At 300 - 400°F, monatomic hydrogen

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

• Conditions required for brittle fracture

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

End of swing h'

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Curve B • SA-216 Gr. WCA, if normalized and tempered or water-quenched and

Table 3.1 (Excerpt)

Instructor’s Outline Major Learning Points

Curve D • SA-203 • SA-537 Cl. 1, 2 & 3

Table 3.1 (Excerpt)

Instructor’s Outline Major Learning Points

Minimum Design Metal Temperature, F

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Plate - Low Alloy Steels

ASME Maximum Allowable Stress (Table 1A Excerpt)

Instructor’s Outline Major Learning Points

13.8 13.3 12.1 10.2 8.4 6.5 4.5 2.5 -- -- -- -- SA-516

Plate-Low Alloy Steels (Cont'd)

ASME Maximum Allowable Stress (Excerpt), cont'd

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points

Instructor’s Outline Major Learning Points