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    Welcome To: Training Program On GUIDED TOUR OF ASME Codes

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    Andri Konyoa Konyoa
    The document provides an introduction and agenda for a training program on the ASME Boiler and Pressure Vessel Codes, which establish standards and guidelines for designing, fabricating, and inspecting pressure vessels and boilers. It discusses the objectives and system of the ASME codes, and gives an overview of Section VIII Division 1, which governs pressure vessels. The training will cover the requirements of the codes as well as examples of pressure vessel design.

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    Welcome To: Training Program On GUIDED TOUR OF ASME Codes

    Uploaded by

    Andri Konyoa Konyoa
    139 views120 pages
    The document provides an introduction and agenda for a training program on the ASME Boiler and Pressure Vessel Codes, which establish standards and guidelines for designing, fabricating, and inspecting pressure vessels and boilers. It discusses the objectives and system of the ASME codes, and gives an overview of Section VIII Division 1, which governs pressure vessels. The training will cover the requirements of the codes as well as examples of pressure vessel design.

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    Training Program ASME Code

    Original Title

    Asmesecviiidiv1icb 150415010927 Conversion Gate01

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    The document provides an introduction and agenda for a training program on the ASME Boiler and Pressure Vessel Codes, which establish standards and guidelines for designing, fabricating, and inspecting pressure vessels and boilers. It discusses the objectives and system of the ASME codes, and gives an overview of Section VIII Division 1, which governs pressure vessels. The training will cover the requirements of the codes as well as examples of pressure vessel design.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    139 views120 pages

    Welcome To: Training Program On GUIDED TOUR OF ASME Codes

    Uploaded by

    Andri Konyoa Konyoa
    The document provides an introduction and agenda for a training program on the ASME Boiler and Pressure Vessel Codes, which establish standards and guidelines for designing, fabricating, and inspecting pressure vessels and boilers. It discusses the objectives and system of the ASME codes, and gives an overview of Section VIII Division 1, which governs pressure vessels. The training will cover the requirements of the codes as well as examples of pressure vessel design.

    Copyright:

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    of 120

    Welcome to

    Training Program on GUIDED TOUR OF ASME


    CODES

    Presented by

    P. S. KULKARNI
    Agenda - session 1

    • This session will provide:


    – An introduction to Codes and
    Standards
    – Objectives of Codes/ Standards.
    – ASME Code System.
    – Introduction To ASME Sec. VIII-1
    • Approximate duration – 8.0 Hours
    WHY ADOPT CODES ?

    Collective Knowledge
    and Experience
    2C

    Credibility
    CODE

    Safety
    (Plant, Personnel, People)

    2S
    Standardization
    Common pressure vessel codes

    • ASME Sec VIII Div 1 and Div 2

    • BS 5500

    • IS 2825

    • Ad Merk Blatter (German)

    • AFNOR (French)
    ASME Codes
    Issued by : American society of mechanical Engineers, New
    York.

    Issue freq. : New edition every 3 years, on 1st July


    latest edition was on 1st July 04.

    Addenda : In-between revisions, issued yearly


    also on 1st July.

    2004 Edn. & '04 add. --- 1st July '04


    2005 Addenda --- 1st July '05
    2006 Addenda --- 1st July '06
    Again new edition - 2007 (1st July)

    Applicability : Edition & Addendas effective 6 months from date of issue


    (i.e. 1st Jan of next year)
    ASME SEC. VIII DIV. 1

    Pressure vessels within scope:

    • Vessels designed for pressures above 15 psig and not


    exceeding 3000 psi.

    • Vessels having inside diameter above 6 in.

    • Unfired steam boilers, evaporators,


    Heat exchangers
    ASME Sec. VIII div.1--Excluded from scope

    • Vessels covered by other sections

    • Pressure containers which are integral


    part of rotating machinery.

    • Piping system & components beyond


    battery limits.

    • Vessels for human occupancy


    ASME Boiler & Pressure Vessel Codes

    ASME Codes give stipulations and guidelines for the design,


    materials, manufacture and testing of pressure vessels. These are
    issued by the American Society of Mechanical Engineers, New York.

    The codes were first issued in 1915. Since then, many changes have
    been made and new sections added to the code as need arose. It is
    a LIVE code and is revised and updated periodically. It keeps pace
    with time and is responsive to its users.
    CODE SYSTEM
    In its present from the ASME Code System is a follows

    • Section I Power Boilers.

    • Section II Material specifications.

     Part A Ferrous materials,


     Part B Non Ferrous Materials
     Part C Welding rods, electrodes,
    filler metals.
     Part D Material properties.
    CODE SYSTEM
    • Section III Nuclear Power Plant Components.
    Section IV Heating Boilers.
    • Section V Non destructive Examinations.
    • Section VI Care and operation of Heating Boilers.
    • Section VII Rules for care of Power Boilers.
    • Section VIII Division 1 - Pressure Vessels
    Division 2 Alternative Rules ( Pr. Vessel)
    Division 3 Rules for constructive of High
    Pressure Vessels.
    • Section IX Welding and Brazing Qualifications.
    CODE SYSTEM, cont’d

    Section X Fiber glass reinforced Plastic Pressure


    Vessels.

    Section XI Rules for in service inspection of Nuclear


    Power Plant Components.
    APPLICABILITY

    The editions and addenda become applicable after


    six months from date of issue. Thus, 1st Jan. 2000,
    the construction of Pressure Vessels shall be as per
    1998 edition and 1999 addenda. However, for old
    contracts spilling over beyond 1st Jan 2000, the old
    applicable edition and addenda are valid.
    CODE INTERPRETATION

    ASME issue written replies know as "Interpretations" to


    the inquiries concerning technical aspects of the code
    .These are issued twice in a year (July and December) and
    are sent to "Edition - subscribers" as up-date service.
    CODE CASES
    Boiler and Pressure Vessels committee meets regularly to
    consider

    Proposed additions and revisions to the code. At the same


    time it may formulate code cases to clarify ' Intent' of
    existing requirements. These are published as code Case
    books. It is published along with new editions and
    supplements are automatically sent to subscribers of code
    case book till new edition ispublished.
    ASME Sec. VIII Div. 1 has five different parts

    Part 1 : UG – General requirements (Design requirements)

    Part 2 : Material Specific Requirements


    UCS – Carbon steel & low alloy steel
    UHA – High alloy steels
    UNF – Non ferrous metallurgy

    Part 3 : Fabrication method specific requirements


    UW – Welded construction
    UF – Forging construction

    Part 4 : Mandatory Appendices &

    Part 5 : Non mandatory Appendices


    Types of vessels

    • Cylindrical – Horizontal or Vertical

    • Spherical
    Steps in design -1
    • Find service conditions & metallurgy.
    • Ensure ductility at service conditions
    • Calculate thickness required (TR).
    Steps in design -2
    • Design thickness = TR + Corr Allow
    • Roundup to commercially available thickness
    to get nominal thickness
    • Find MAWP from nominal thickness
    Solve a problem
    Calculate the minimum thickness of a cylindrical shell of inside diameter
    4000mm, tan to tan length of 8300mm and a design pr. of 100 Kg/sq cmg.

    Design temperature of the vessel is 343 C

    Material of construction – ASTM A 516 Gr 70

    Allowable stress of vessel at 343 C = 16500 psi

    Corrosion allowance = 3.0 mm

    Efficiency of the weld joint – 1.0


    24
    25
    26
    UW – 3 : WELD JOINTS CATEGORIES.
    UW – 3 : WELD JOINTS CATEGORIES.

    Category A :

    1 Longitudinal weld joints in main shell or nozzles.


    2 Any welded joints in spherical shell.
    3. Any welded joints in Dished Head.
    4. Circumferential Seam , Hemisph. head to shell.
    UW – 3 : WELD JOINTS CATEGORIES.

    Category B :

    1 Circumferential seam in main shell, or nozzle


    2 Circumferential seam connecting formed head (other
    than hemi-spherical head) to shell.
    UW – 3 : WELD JOINTS CATEGORIES. Contd.

    Category C :

    • Weld joints connecting flanges, tube sheets, flat


    head to main shell or Nozzles
    (Flange Welds)

    Category D:

    • Welds joining communicating chamber or nozzle


    to the main shell / heads.
    (Attachment Welds).
    Types of ends
    FLAT HEADS :
    – For low pressures up to 5 kg/sqcm
    FORMED HEADS :
    – Torispherical
    • Generally used up to 15 kg/sqcm
    – Ellipsoidal
    • Generally used between 15 to 25 kg/sqcm
    – Hemispherical
    • Generally used above 25 kg/sqcm.
    CONICAL HEADS : for Special purposes.
    35
    FORMED HEADS
    For spherical shells / head :
    t = P x R / (2SE - 0.2P) ….for Thickness
    P = 2SEt / (R + 0.2t)….for MAWP

    For Ellipsoidal Heads : ( 2 : 1 type)


    t = P x D / (2SE - 0.2P) ….for Thickness
    P = 2SEt / (D + 0.2t) ….for MAWP
    For Torisph. Heads : (L = Crown Rad., r = 0.06 x L)
    t, = 0.885 x P x L / (SE - 0.1P)… for Thickness
    P = SEt / ( 0.885L + 0.1 t ) … for MAWP
    UW-11 :RT and UT EXAMINATIONS
    Full Radiography is required in following cases :

    • All butt welds of vessels for lethal substances

    • If thickness exceeds given in table UCS-57, UHA - 33,

    • Butt welds of unfired boilers, with design pr. > 50 psi.

    • For all other vessels, All cat. A welds full radiography .


    Cat. B & C welds which intersect the Cat. A welds shall be
    spot radiographed.

    • Radiography is not required of category B and C butt


    welds in nozzles less than NPS 10 or 1 1/8 in. thick.
    UW-11 :RT and UT EXAMINATIONS…contd.

    1 Spot Radiography : Spot RT of Butt joints if


    design efficiency is selected for spot radiography.

    2 No Radiography : No RT of weld joints if design efficiency is


    selected for no radiography or vessel is designed for external
    pressure

    3 Ultrasonic examination : May be substituted for RT only for


    the final closure seam of a pressure vessel.
    41
    v
    v
    v

    42
    43
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    46
    UW – 12 :WELDED JOINT TYPES
    UW – 12 :WELDED JOINT EFFICIENCY

    RT – 1 : Full Radiography ( E=1) :


    Full length radiography of all butt welds
    RT – 2 : Full Radiography ( E=1):
    Cat – A: Full length radiography
    Cat – B: Spot RT per [UW – 11 (a) 5 (b)]

    RT – 3 : Spot radiography ( E= 0.85)


    RT – 4 : No radiography ( E= 0.7)
    Some key points:
    55
    Out of roundness of Shell

    Difference between the maximum and minimum inside diameter measured at


    any cross section of the vessel shall not exceed 1% of the nominal diameter at
    that cross section under consideration.
    The diameter can be measured from either inside or outside. If measured from
    outside shall be corrected for the thickness at that cross section.
    57
    NOZZLE REINFORCEMENT
    Required area of Reinforcement = d X tr

    d= Diameter of finished opening


    tr = Required thickness of shell or head.

    Reinforcement is waived off for single openings if:

    1. finished opening size is 3 1/2" or less diameter in shell or head of


    thickness 3/8" or less; or

    2. finished opening size 2 3/8" or less diameter


    in shell or head of thickness over 3/8";
    UCS-66 : IMPACT TESTING
    1 MDMT - Thickness point falls on or above the relevant
    curve. Impact test is not required
    (Curve UCS – 66 )

    2 Impact test is must, if MDMT < 120 deg F, and:


    Thickness Of welded part > 4”
    Thickness for Non-welded part > 6”

    3 Test normally required for MDMT < -55 deg. F


    64
    65
    66
    67
    68
    69
    70
    71
    IMPACT TESTING EXEMPTION -- UG-20 (f) :

    Impact test exempt for if,


    Materials are P No 1, Gr. No. 1 and 2
    1. Materials of curve A : thickness < 0.5 inch
    2. Materials curve B, C, D : thickness < 1.0 inch
    3. Hydrostatic test performed as required
    4. Design temp = -20 deg F to 650deg.F
    5. No cyclic or thermal shock loading
    IMPACT TESTINGEXEMPTION…….contd.

    1 UCS-68 (c) : If PWHT is performed when not a Code


    requirement, reduction of 30 deg. F (17 0C) in impact testing
    exemption temp.(from Fig UCS-66) may be given for P No. 1
    materials

    2 If coincident ratio is < 1, Reduction to exemption temperature


    may be given as per UCS-66.1
    74
    75
    76
    77
    78
    79
    80
    81
    82
    83
    84
    UW-40 : POST-WELD HEAT TREATMENT
    • PWHT is Code Requirement if thickness exceeds
    those given in tables for respective materials .

    • Furnace PWHT method is preferred .

    • Min. Overlap for PWHT in multiple heats = 5 ft.

    • Local PWHT : Min Soak Band = weld width + Lesser of


    2’’ or t. and it shall extend full 360 deg for circ. Joint

    • PWHT temperature is higher of the two for dissimilar metal joints


    UCS-56: POST-WELD HEAT TREATMENT

    · Max. Loading temp in furnace = 800 deg .F

    · Max. heating rate 400 deg F/hr/inch of thickness.

    · Soaking period as per UCS-56 tables.

    · Temp difference between hottest and coldest


    parts of vessel shall not exceed 150 deg .F

    · Max. cooling rate = 500 deg .F /hr/inch of thk.

    · Max. offloading temp = 800 deg. F

    · Still air cooling permitted below 800 deg .F.


    88
    89
    90
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    92
    93
    94
    95
    96
    Summary of NDT
    NDE OF PRESSURE VESSELS
    Selection of a particular NDT technique :

    Applicable NDT methods / Welding Discontinuities

    Applicable NDT Methods


    Discontinuities
    RT T PT MT VT ET
    Porosity √ * √a *b √a *

    Slag Inclusion √ √ NA *b NA *

    Incomplete fusion * √ NA *b NA *

    Incomplete Penetration √ √ NA * NA *

    Undercut √ * * * √ *

    Overlap * √ √ * *
    NA
    Cracks * √ √a √b √a √

    Laminations √
    NA √a,c √b,c √a,c NA
    Applicable NDT methods for Weld joint types

    NDT Methods

    Joints

    RT UT PT MT VT ET

    Butt √ √ √ √ √ √

    Corner * √ √ √ √ *

    T * √ √ √ √ *

    Lap * * √ √ √ *
    Note to NDT Table

    a. Surface

    b. Surface and slightly subsurface

    c. Weld preparation or edge of base metal

    √ Applicable method

    * Marginal applicability depending on other factors.


    101
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    UG-99 : HYDROSTATIC TEST
    • Hydrostatic Test pr. = 1.3 X MAWP X stress ratio
    Stress ratio = Stress at test temp./Stress at design temp.

    • Min. Inspection pressure = Test pressure / 1.3

    • Any non-hazardous liquid may be used for the test.

    • Min. Test temp = MDMT + 30 deg. F ( 17 C )

    • Inspection temperature <= 120 deg. F.

    • The MAWP may be same as Design pr.

    • Test gauge range = 1.5 to 4 times test pr.


    UG-100 : PNEUMATIC TESTS

    • Pneumatic test is used instead of hydro when:

    • Vessels cannot be safely filled with water


    • Vessels in service in which traces of
    testing liquid cannot be tolerated

    • Test pr = 1.1 X MAWP X stress ratio.

    • Test temp shall exceed MDMT by 30 deg F.

    • Pr. Gauge range = 1.5 to 4 times test pressure


    Safety precautions for Pneumatic Test

    • All welds around openings and attachment welds


    with throat >= 6mm ( 0.25”) to be MT or PT tested

    • The pr. shall be first raised to 50% of the test pr.

    • Then the pressure shall be raised in steps of


    10% of test pr. To reach full test pressure

    • The pressure then shall be reduced to a value of


    test pressure /1.1 , to permit inspection.
    CODE STAMPING

    Each pressure vessel shall be marked with the following :

    1) The official Code U Symbol or the official UM Symbol.


    2) Name of the Manufacturer of the pressure vessel
    preceded by the words "certified by";
    3) Max. allowable working pressure ---- psi at ---- 0F.
    4) Minimum design metal temperature ---- 0F ----psi
    5) Manufacturer's serial number;
    6) Year built.
    115
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    v

    117
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    Thank You for
    your
    Time and Attention

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