US Pressure Vessels Codes Walter Sperko

8/9/2019 US Pressure Vessels Codes Walter Sperko

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Notice All statements by the speaker represent his

opinion alone and do not necessarily representthe position of the ASME Boiler and Pressure

Vessel Code Committee. All requests for

interpretations or other inquiries relative to ASME Code and Standards should be

addressed to the Secretary, ASME Boiler and

Pressure Vessel Code Committee, ASMEInternational, Three Park Avenue, New York, NY

10016-5990.


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Industrial Revolution

Steam became a prime mover fortransportation, factories, space

heating

1905, Brockton, MA

R. B. Grover Shoe Factory

Why do we have Codes. . .


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The boiler ripped open and shot through thebuilding with the force of 300 kilos of dynamite

causing structural damage to the building. The roof collapsed and floors buckled.

Fire was fed by a broken natural gas line.

Wooden building went burned down andseveral buildings adjacent also burned.

100 escaped, 58 died and 117 were injured.

March 20, 1905, 7:30 AM


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SS Sultana built in 1863 was powered by 4 boilers

mounted side by side and interconnected with a

common header

April 21 1865 stopped in Vicksburg Miss. for a hastyrepair patch on one boiler

Released from Confederate prison camps, 2,400

Union solders bribed their way on to the ship.

With a legal capacity of 376 the SS Sultana was

severely overcrowded. All berths were full and both

decks were completely packed

SS Sultana April 27, 1865


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To overcome the river current the 4 boilerswere pushed to exceed their maximum

working pressures

2:00 A.M. April 27, 3 of her 4 boilers explodeddamaging a good portion of the ship.

Hot coals from the boilers turned the

remaining superstructure into an inferno

SS Sultana


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Brockton shoe factory explosion promptedMassachusetts to establish a Board on Boiler

Rules which published rules in 1908. Ohio

passed similar (but different rules). And the race was on.

By 1911, 10 states and 19 cities had adopted

some form of boiler rules. All were different. States were unable to compromise (OURS is

better!), so boilers built for one jurisdiction could

not be installed in others

Historical Background


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• ASME was a recognized boiler standardsdeveloper, having published the boiler PerformanceTest Code in 1884. Boiler Code Committee wasformed in 1911 to prepare a uniform code that could

be adopted by local jurisdictions for safe design,manufacture and testing of steam boilers.

• The first edition of this safety code was published in1914 (Boiler Code). 5 X 8 format, 119 pages

• The Boiler Code was expanded to include pressurevessels in 1928 (P&PV Code).

• Section IX (Welding) was added in 1941

Historical Background


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IV Rules for Construction of Heating Boilers

V Nondestructive ExaminationVI Recommended Rules for the Care and Operation of Heating

Boilers

VII Recommended Guidelines for the Care of Power Boilers

VIII Rules for Construction of Pressure Vessels

Division 1

Division 2 -- Alternative Rules

Division 3 -- Alternative Rules for Construction of

High Pressure Vessels

IX Welding and Brazing QualificationsX Fiber-Reinforced Plastic Pressure Vessels

XI Rules for Inservice Inspection of Nuclear Power Plant

Components

XII Transport Tanks

BOILER AND PRESSURE VESSEL CODE


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ASME CODES

When is an ASME Code required to be fol lowed?

1) By law. These codes were written to be adopted into lawto protect the public.

• Boiler Code is law in 49 States and all of Canada.

• Pressure Vessel Code is law in about 43 states and all

of Canada.• Section III is law by CFR and Canadian Regulations.

• Piping Codes are generally not adopted by law except

for Boiler External Piping (part of ASME Section I)

National Board (www.nationalboard.org) has a publication

listing adoptions. See:

http://www.nationalboard.org/SiteDocuments/NB-370.pdf


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All jurisdictions have provisions to allow deviation from meeting ASME requirements.

Boilers and Pressure Vessels built to BS 5500, JIS, EN 13445, etc. can be evaluated for equivalence to ASME and accepted by jurisdiction.

National Board has already prepared comparisons of other major boiler and pressure vessel standards to ASME, so getting approval of such items is not a big deal.

State Specials


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ASME CODES

When is an ASME Code required to be fol lowed?

2) By contract:

• When the code is not imposed by law, Owners

and their engineers will elect to follow the Code

and impose it on fabricators and contractors.• Most commonly occurs with piping since piping

codes are not typically adopted by law.

• Also occurs with pressure vessels when Pressure

Vessel Code is not adopted by law.

3) Just to establish industry-accepted practices (Most

commonly found with ASME Section IX. -- Due

diligence)


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Rules for Construction of Pressure Vessels

Division 1 General

Division 2 Alternative Rules

Division 3 Alternative Rules for Construction

of

High

Pressure

Vessels

ASME Section VIII


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All ASME Construction must be done by a

holder of an ASME “Certificate of Authorization” to build

specific

components

(i.e. manufacturer must have an ASME “Code Stamp”)

ASME Section VIII Conformity Assessment


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To get a Code Stamp, the manufacturer must have a Quality Control Program that has been

audited

by

ASME.

Construction

of

a

component is required as part of the audit.

Third‐party auditing by a National Board

Certified

Inspector

(“Code

Inspector”)

is

ongoing during any ASME manufacturing or construction.

ASME Section VIII Conformity Assessment


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Division 1 Division 2 Division 3

to

establish

design

requirements:∙ need for corrosion allowances,∙ definition of lethal services,∙ need for PWHT,∙ need for piping, valves, instruments,

and

fittings

if

steam

generated or water heated∙ degree of NDE

to

provide

UDS

for

each

vessel:∙ installation site∙ vessel identification∙ controlling dimensions∙ design conditions∙ operating conditions∙ design fatigue life∙ materials of

construction∙ loads and load cases∙ overpressure protection∙ additional requirements (2.2.2.2)

to

provide

UDS

for

each

vessel:∙ vessel identification,∙ vessel configuration,∙ controlling dimensions,∙ design criteria∙ operating conditions,∙ contained fluid data,∙ materials selection,∙

loadings,∙ useful operating life expected,,∙ fatigue analysis,∙ overpressure protection,∙ additional requirements,∙ installation site.


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No Design Specification required, no PE required.

User Design Specification shall be certified in

accordance with Appendix 2A by a PE or Engineer

other

than

the

PE

or E who certifies the

Manufacturer’s

Design Report

User Design Specification shall be certified in

accordance with Appendix 2A by a PE or Engineer

other

than

the

PE

or E who certifies the

Manufacturer’s

Design Report


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∙ design by formulae

∙ design by rule∙ design by analysis

∙ complete detailed analysis, including a fatigue

and

fracture

mechanics analysis


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(a) internal or external design pressure

(P) internal or external MAWP,static head from

liquid or bulk materials

(a) internal or external pressure, at

coincident temperature


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Dead weight of the vessel, contents, and appurtenances at the location of interest, including the following:• Weight of vessel including internals, supports (e.g.

skirts, lugs, saddles, and legs), and appurtenances (e.g. platforms, ladders, etc.)

• Weight of vessel contents under operating and test

conditions,

• Refractory linings, insulation• Static reactions from the weight of attached

equipment,

such

as

motors,

machinery,

other

vessels,

and piping• Cyclic loads, thermal gradients• Wind, Snow, Ice, seismic• Impact loads, deflagration


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(UG‐4) It is recommended that the USER or his designated agent assure himself that materials usedfor the construction of the vessels will be suitable for the intended service with respect to

retention ofsatisfactory mechanical properties, and resistance to corrosion,

erosion,

oxidation,

and

other deterioration during the intended service life.

The Manufacturer shall ensure all requirements of thematerial specification, and all special requirements of Part 3 of this Division, that are to be fulfilled by the materials manufacturer

have been complied with. The Manufacturer shall accomplish this by obtaining CofC or MTR.

The materialsmanufacturer shall certify that all requirements of the applicable materials specification in Sec. II, allspecial requirements of Part KM which are to be fulfilled by the materials

manufacturer and allsupplementary materialrequirements specified by the User's

Design

Specification

have beencomplied with.


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(UG‐84(h)(2)) Welding procedure impact tests shall be made when required by UCS‐67, UHT‐82, or UHA‐ 51.

3.11.2.10 a) For welded construction,the Welding Procedure Qualificationshall include impact tests of welds and

heat

affected

zones

when required bythe following provisions: b)

through

e)

(KT‐220) Impact tests shall be required on weld and heat affected zones for all welding procedure qualifications. When

tensile

specimens

are required by Section IX, the yieldstrength shall also be

determined,

usingthe method required for the base metal...


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Sec. IX QW‐304.1 Examination. Welds made in test coupons for performancequalification may be examined by visual

and

mechanical

examinations ... or by volumetric examination for the

process

(es)

and

mode of arc transfer specified inQW‐304.

Sec. IX QW‐304.1 Examination. Welds made in test coupons for performancequalification may be examined by visual

and

mechanical

examinations ... or by volumetric examination for the

process

(es)

and

mode of arc transfer specified inQW‐304.

(KF‐215)(a) Mechanical testing isrequired for all performance qualificationtests; qualification by NDE is not

permitted....


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(UG‐84(i)(2)) Vessel (production)impact test plates shall be made for all

joints for which impact tests are required

for

the

welding

procedure...

(3.11.8.4) When the base material isrequired to be impact tested,

impact tests of welds and heat affected zones shall

be

made

for

Category A and Bjoints in accordance with paragraph

3.11.8.2

for

each

qualified weldingprocedure used on each vessel.

(KT‐230)Impact tests of welds andHAZ's shall be made in accordance with

KT‐210 for each qualified weldingprocedure used on

each

vessel.


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(UG‐84(i)(3)(a) For each vessel, one test plate

shall

be

made

for

each weldingprocedure used

for

joints

of

Categories A and B, unless the vessel is one of severalas defined in(b) or (c) below.

(UG‐84(i)(3)(a) For each vessel, one test plate

shall

be

made

for

each weldingprocedure used

for

joints

of

Categories A and B, unless the vessel is one of severalas defined in(b) or (c) below.

One production run test plate from one of the

heats

of

materials

used for Category A and B

weld

joints...


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ASME Requires Production Run Test Plates

when Impact testing is required

39

Category A joint


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(a) Full Radiography(b) Spot Radiography(c) No Radiography

UT substitution for RT permitted

All finished welds shall besubject to nondestructive

examinationdepending on Examination Group

selected

in

paragraph 7.4.2 and the JointCategory and Weld

Type

as

defined

inparagraph 4.2.

The entire length of all Category A, B, Cand D weld joints shall be

ultrasonicallyexamined in accordance with KE‐

300.


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The Manufacturer shall distribute the Manufacturer’s Data Report as indicated below.a) Furnish a copy of the Manufacturer’s Data Report to

the

user

and,

upon

request,

to

the

Inspector;b) Submit a copy of the Manufacturer’s Data Report to the appropriate enforcement authority in the jurisdiction

in

which

the

vessel

is

to

be

installed

where

required

by

law;c) Keep a copy of the Manufacturer’s Data Report on file in a safe repository for at least 3 years;


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Nameplate(a) Certification Mark with U, U2, U3 Designator (b) Certified by: (name of Mfr.)

(c)

MAWP

at

coincident

max.

designmetal temperature(d) MDMT at coincident MAWP

(e)

MFG

SER(f) Year built(g) Code Edition (and Addenda)(h) Construction type: F, W, WL(i) HT or PHT(j) USER (if inspected by)


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Using

ASME

Meeting

PED

ASME Section VIII runs from pretty mundane to pretty sophisticated.

Can I build to it and export to Europe?

What

Guidance

is

available?How Expensive is Compliance?


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ASME has published several things on meeting PED. Do a search on ASME.ORG on “PED” and you get the following:

Guide for ASME Stamp Holders for Section VIII Division 1 Vessels and the Pressure Equipment Directive

ASME Section I Power Boilers ‐ PED Guide: Supplement to Guide for ASME Stamp Holders Use of Section I to Meet EC Pressure Equipment

Directive (97/23/EC)

ASME

Guides


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STP‐PT

‐007

COMPARISON OF

PRESSURE

VESSEL

CODES ASME SECTION VIII AND EN13445

Technical, Commercial, and Usage

Comparison Design

Fatigue

Life

Comparison

ASME

Assistance


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Hazard

Analysis


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Category I No intervention by the NB (Notified Body)

Category II No intervention by the NB at Design phase, but surveillance by the NB during production phase or surveillance by the NB of QA system (D1, E1)

Category III Design examination by the NB and final assessment of the equipment . Surveillance of the QA system

Category IV Increased intervention of the NoBo

Conformity

Assessment


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Welding


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Welding


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(a) All pressure equipment above the thresholds mentioned in Article 3 of the PED (i.e., classified in Hazard Category I, II, III, or IV) must comply with all these ESR. They concern the various steps of the construction: design, material selection, fabrication, inspection, and safety devices.

(b) These ESR are generally formulated in general terms of safety objectives, such as, “Pressure Equipment must be constructed in such a way to ensure its safety in reasonable foreseeable conditions.”

Essential

Safety

Requirements


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The PED does not provide the means to achieve these requirements; this is the role of the Harmonized Standards. Some quantitative

requirements are provided by PED §7 of Annex I, which “apply as a general rule.” Manufacturers can depart from these

quantitative

requirements,

but

they

must

convince the NB that “they have taken appropriate measures to achieve an

equivalent

overall

level

of

safety.”

Essential

Safety

Requirements


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(c) It is the role of CEN Harmonized Standards (harmonized to the PED), such as draft Unfired Pressure Vessel (Pr. EN 13445,), to quantify each of these requirements. As a consequence, this gives them a presumption of conformity to the PED). However, use of these Harmonized Standards

is

not

compulsory.

The

Manufacturer

may

construct

it

pressure vessel using any Code or Standard but must be able to demonstrate to the NB that the vessel complies with each of the ESR of PED Annex I. Or, the Manufacturer must

show that it has used a quantitative requirement different from the Harmonized Standards, provided an equivalent level of safety is achieved.

Essential

Safety

Requirements


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(d)

The

Manufacturer

is

free

to

use

one

of

the

following

three

options to prove that this Equipment complies with the ESR:

(1) use of the EN Harmonized Standard, which will give presumption of conformity to the ESR

(2) use of a recognized Code like ASME Boiler and Pressure Vessel Code, CODAP, etc. (supplemented by additional requirements to ensure compliance with the PED).

(3) by applying directly the ESR and providing calculation sheets, carrying out tests, etc.

In options 2 and 3, the Manufacturer will have to convince the NB of its compliance with the ESR.

Essential

Safety

Requirements


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(e) The stringency of some of these ESR depend on the Hazard Category of the Equipment, especially:

(1) approval of welding operating procedures

(Annex I‐§3.12 of the PED) (2) approval of welders (Annex I‐§3.12 of the PED)

(3) approval of nondestructive test personnel

(Annex I‐§3.13 of the PED)

(4) types of material certificate (Annex I‐§4.3 of the PED)

Essential

Safety

Requirements


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(a) Before a material can be used in Pressure

Equipment,

it

must

comply

with

the

applicable

Essential Safety Requirements (ESR) specified in PED Annex I‐§4 (also see Chapter VI, para. 2.1.4 of this Guide):

(1) The material must have appropriate properties for all foreseeable operating and test conditions.

(2)

It

must

be

sufficiently

ductile:

14%

minimum

elongation for steel.

(3) It must have sufficient notch toughness: 27 J at

20°C

(or

20

ft‐

lbs at

68°F)

for

steel.

Materials


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(4) It must be sufficiently chemically resistant to

the

fluid

contained

in

the

pressure

equipment. (5) It must not be significantly affected by aging.

(6) It must be suitable for the intended processing

procedures

during

manufacture

of

the

pressure

equipment.

(7) It must be selected to avoid undesirable effects

when

various

materials

are

joined. (8) It must be suitable for such application during

the scheduled lifetime unless replacement is

foreseen.

Materials


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(b) For selecting a material for Pressure Equipment, the Manufacturer has three options:

(1) Use material specification taken from an EN Material Harmonized Standard. Materials taken from these

Standards

are

presumed

to

conform

to

the

ESR

and

there will be no inspection from the NB.

(2) Use material covered by European Approval for Materials (EAM) as explained below. This procedure is only applicable for materials intended for repeated use.

(3) Use of material covered by a Particular Material

Approval.

This

procedure

is

applicable

for

new

Materials


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(a) The PED provides for the involvement of an NB to assess the conformity of the Equipment to the specifications of the PED.

(b) These NBs must comply with various requirements in terms of technical competence, organization, independence, etc. (See PED, Annex IV). They are

designated

by

the

official

authorities

of

each

Member

State, who notify the references of these bodies to the Commission of the European Communities. The

Commission

publishes

the

list

of

the

NB

in

the

OJEC.

Notified

Bodies


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(a) The Manufacturer may select any of the NB from this list.

(b) According to the PED, the approval of joint procedures, joint operators (particularly welders) and non destructive testing operators may, in some cases, be performed by Recognized Third‐Party Organizations (PED Article 13). These entities must comply with criteria similar to those of the NB.

Notified

Bodies


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For pressure equipment in Categories II, III and IV, qualification of welders and welding operators must meet the requirements of EN 287 and qualification of welding procedures the requirements of EN 288. (EN 287 and EN 288 are European harmonized standards). The welder, welding operator and welding procedure qualifications must be approved by a Notified Body or an approved third party organization. To carry out

these approvals, the third party must perform (or have performed) examinations and tests as set out in the approved European harmonized standards or

equivalent examinations and tests.

Welding


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Details

of

the

Document


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Details

of

the

Document


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It is possible to design and build vessels to ASME Sections I and VIII and meet PED requirements

Welding

Procedures

and

welders

have

to

be

qualified

to EN standards in the presence of an Notified Body.

Summary


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