Pressure Vessels Field Manual

Pressure Vessels Field Manual

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Pressure Vessels Field ManualCommon Operating Problems and Practical SolutionsMaurice Stewart Oran T. Lewis

AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE SYDNEY TOKYO Gulf Professional Publishing is an Imprint of Elsevier

Gulf Professional Publishing is an imprint of Elsevier 225 Wyman Street, Waltham, MA 02451, USA The Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GB, UK 2013 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher's permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this eld are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. Library of Congress Cataloging-in-Publication Data Stewart, Maurice. Pressure vessels eld manual: common operating problems and practical solutions / Maurice Stewart and Oran T. Lewis. p. cm. Includes bibliographical references. ISBN 978-0-12-397015-2 1. Pressure vesselsMaintenance and repairHandbooks, manuals, etc. 2. Pressure vesselsMaintenance and repairStandardsUnited StatesHandbooks, manuals, etc. 3. Pressure vesselsInspectionHandbooks, manuals, etc. 4. Pressure vesselsInspectionUnited StatesHandbooks, manuals, etc. 5. BoilersMaintenance and repairHandbooks, manuals, etc. 6. BoilersMaintenance and repairStandardsUnited States Handbooks, manuals, etc. 7. BoilersInspectionHandbooks, manuals, etc. 8. BoilersInspectionUnited StatesHandbooks, manuals, etc. 9. ASME boiler & pressure vessel code. I. Lewis, Oran T. II. Title. TS283.S74 2012 681'.76041dc23 2012026721 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. For information on all Gulf Professional Publishing publications visit our website at http://store.elsevier.com 09 10 11 12 10 9 8 7 6 5 4 3 2 1

Printed in the United States of America

ContentsChapter 1: History and Organization of CodesOverview Use of Pressure Vessels and Equipment History of Pressure Vessel Codes in the United States Organization of the ASME Boiler and Pressure Vessel Code 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 Qualications Section X: Fiber-Reinforced Plastic Pressure Vessels Section XI: Rules for In-Service Inspection of Nuclear Power Plant Components Section XII: Rules for the Construction and Continued Service of Transport Tanks Organization of Code Committee Updating and Interpreting the Code Addenda New Edition of the Code Code Cases Code Interpretations ASME Code Stamps U Stamp

11 1 2 4 4 5 6 6 7 7 8 8 10 10 11 11 12 12 12 12 13 13 13 14v

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UM Stamp National Board of Boiler and Pressure Vessel Inspectors Organization of the ANSI/ASME B31 Code for Pressure Piping B31.1: Power Piping B31.3: Process Piping B31.4: Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids B31.5: Refrigeration Piping and Heat Transfer Components B31.8: Gas Transmission and Distribution Piping Systems B31.9: Building Services Piping B31.11: Slurry Transportation Piping Systems B31.12: Hydrogen Piping and Pipelines ANSI/ASME B31 Piping Code Committee Some Other Pressure Vessel Codes and Standards in the United States Worldwide Pressure Vessel Codes Australia Belgium China France Germany Italy Japan Netherlands Sweden United Kingdom ASME Code, Section VIII, Division 1 versus Division 2 Division 1 Division 2 Design Criteria, ASME Code, Section VIII, Division 1 Scope Structure

15 15 15 16 16 17 18 18 18 19 20 20 20 21 21 22 22 22 22 22 22 23 23 23 23 23 24 24 24 25

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Allowable Stresses Material Specications Inspection Openings Pressure Relief Devices Cryogenic and Low-Temperature Vessels Testing, Inspection, and Stamping Design Criteria, ASME Code, Section VIII, Division 2 Structure Allowable Stresses Materials and Tests Responsibilities ASME Code, Section IX: Welding ASME Code Requirements Welding Procedure Specications (WPS) and Procedure Qualication Records (PQR) Post-Weld Heat Treatment (PWHT) ASME Code, Section I, Power Boilers Scope and Limitations Allowable Stresses Fabrication, Inspection, and Tests Additional Requirements Employed by Users in Critical Service Additional Requirements

26 27 32 33 33 34 38 39 39 41 43 44 44 44 45 45 45 46 47 48 48

Chapter 2: Materials of ConstructionOverview Material Selection General Considerations Corrosion Strength Example 1 Material Cost Nonferrous Alloys General Considerations Aluminum Alloys

4949 49 49 50 50 53 57 58 58 58

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Copper and Copper Alloys Nickel and High-Nickel Alloys Titanium and Zirconium Alloys Ferrous Alloys General Considerations ASME Code, Section VIII, Division 1 Categories Heat Treatment of Steels General Considerations Various Heat Treatments of Carbon Steel Brittle Factors General Considerations Charpy V-Notch Test (Cv) Drop-Weight Test (DWT) Fracture-Analysis Diagram (FAD) Example 2 Example 3 Theory of Brittle Fracture Fracture Theory Hydrostatic Testing Factors Inuencing Brittle Fracture Example 4 ASME Code, Section VIII, Division 1 Criteria Hydrogen Embrittlement Hydrogen Decarburization Hydrogen Attack

61 61 62 65 65 65 67 67 69 70 70 70 73 74 77 78 78 83 83 84 85 86 90 90 92

Chapter 3: Materials Selection for Pressure VesselsOverview Selection of Materials for Service Conditions General Considerations Design Factors Typical Selections Application Criteria for Common Pressure Vessel Materials

9595 95 95 95 99 102

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Summary of Temperature Limitations Selection of Materials for Brittle Fracture Prevention General Considerations More Considerations Design to Prevent Brittle Fracture Selecting Steels for New Construction of Pressure Vessels Guidelines for Preventing Brittle Fracture in Existing Equipment General Considerations Determining MPTs

111 112 112 113 114 121 129 129 129

Chapter 4: Mechanical Design of Pressure VesselsOverview General Considerations Owners, Users, and Manufacturers Responsibilities ASME Code, Section VIII ASME Code, Section VIII, Division 1 ASME Code, Section VIII, Division 2 Determining Design Conditions General Considerations Design Pressure: Overview Design Pressure: ASME Code, Section VIII, Division 1 Design Pressure: ASME Code, Section VIII, Division 2 External Pressure Design Temperature: ASME Code, Section VIII, Division 1 Design Temperature: ASME Code, Section VIII, Division 2 Wind and Earthquake Design Corrosion Allowance External and Internal Loads Mechanical Design Overview

133133 133 134 134 134 137 139 139 140 140 145 146 146 151 152 153 153 157 157

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Design Summary Design for Internal Pressure Example Design for External Pressure Example Example Example Example Example of Internal/External Pressure Design Openings and Nozzle Reinforcement Example 1 Reinforcement Calculations Example 2 Reinforcement Calculations Example 3 Reinforcement Calculations Reinforcement of Openings for External Pressure Bolted Flanged Connections Minimum Wall Thickness and Nominal Plate Sizes Design of Welded Joints

165 167 168 170 173 177 177 178 179 184 194 198 200 202 202 210 211

Chapter 5: Fabrication, Welding, and In-Shop InspectionOverview Plate Materials Overview ASME Code Requirements Fabricator Considerations Forming of Shell and Head Components General Considerations Cylindrical Shell Ring Courses Heads Nozzles Integrally Reinforced Nozzles Built-Up Nozzles Fabrication Welds Longitudinal Welds Nozzle Welds

217217 218 218 219 219 220 220 220 223 225 225 226 228 228 231

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Girth Welds Skirt Attachment Weld Post-Weld Heat Treatment (PWHT) Welding Processes and Procedures Welding Processes Consumables Preheat and Interpass Temperature Control Post-Weld Heat Treatment (PWHT) Welding Procedure Qualication Welding Procedure Review Welder Performance Qualication In-Shop Inspection General Considerations Degree of Inspection Guidelines for Choosing the Appropriate Degree of Inspection for Pressure Vessels Inspection Tasks Case Study 1: Construction and Inspection of Replacement Flare Knockout DrumdMost Appropriate Inspection Level: Degree 5 Case Study 2: Construction and Inspection of Replacement Flue Gas CoolerdMost Appropriate Inspection Level: Degree 9

233 235 236 237 237 247 252 257 264 275 283 290 290 291 294 297

298

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Chapter 6: In-Service Inspection by Nondestructive Examination (NDE)Overview General Considerations Materials for Construction Inspection Program Nondestructive Examination (NDE) Techniques Design for Inspection Code and Jurisdiction Requirements ASME Code, Section VIII Requirements Jurisdiction Requirements

347347 347 348 348 348 349 349 349 350

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API 510: Pressure Vessel Inspection Code National Board Inspection Code (NB Code) Authorized Inspector versus ASNT-Certied NDE Technician Forms of Deterioration General Considerations Internal Corrosion External Corrosion Thermal Aging General Considerations Fatigue Stress-Corrosion (Environmental) Cracking Internal Erosion Hydrogen Attack Hydrogen Blistering Creep and Stress-Rupture Cracks Analysis of In-Service Inspection Data General Considerations Internal Corrosion External Corrosion Thermal Aging Fatigue Stress-Corrosion (Environmental) Cracking Internal Erosion Hydrogen Attack Hydrogen Blisters Creep and Stress Rupture Fitness-for-Service Analysis Introduction Background Information Required for Fitness-for-Service Analysis Procedures for Fitness-for-Service Analysis Outline of the Procedure Required Inspection at the Next Scheduled Shutdown Nondestructive Examination (NDE) Techniques

350 352 352 353 353 353 355 356 356 359 360 361 362 362 363 364 364 364 368 368 368 369 370 370 371 371 372 372 373 376 377 377 385 385

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General Considerations Visual Examination (VT) Dye-Penetrant Examination (PT) Magnetic Particle Examination (MT) Ultrasonic Examination (UT) Crack Sizing Radiographic Examination (RT)

385 385 387 391 399 413 417

Chapter 7: Repair, Alteration, and Re-ratingOverview Code and Jurisdiction Requirements ASME Code Jurisdictional Requirements National Board Inspection Code versus API 510 Repairs General Considerations Design of the Repair Planning and Approval Organization Making the Repair Replacement Parts Repair Welding Post-Weld Heat Treatment (PWHT) Inspection and Hydrotest Approval of Repairs, Documentation, and Nameplate Alteration General Considerations Planning and Approval Organization Making Alterations Materials, Replacement Parts, Welding, PWHT, and Inspection Hydrotest after Alterations Approval of Alterations, Documentation, and Nameplate Re-Rating

425425 426 426 427 427 431 431 438 443 444 445 445 446 447 449 450 450 451 451 452 452 453 454

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General Considerations Organization Making Re-Rating Calculations Information Required Approval of Re-Rating, Documentation, and Nameplate

454 454 455 456 457

Index

471

History and Organization of Codes