Pressure Vessels Field Manual - Common Operating Problems and Practical Solutions

435 Pages·2013·9.517 MB·435\435

by  Stewart, Maurice, Lewis, Oran T.

Pressure Vessels Field Manual
Common Operating Problems
and Practical Solutions
Maurice Stewart
Oran T. Lewis
AMSTERDAM•BOSTON•HEIDELBERG•LONDON
NEWYORK•OXFORD•PARIS•SANDIEGO
SANFRANCISCO•SINGAPORE•SYDNEY•TOKYO
GulfProfessionalPublishingisanImprintofElsevier
GulfProfessionalPublishingisanimprintofElsevier
225WymanStreet,Waltham,MA02451,USA
TheBoulevard,LangfordLane,Kidlington,Oxford,OX51GB,UK
(cid:1)2013ElsevierInc.Allrightsreserved.
Nopartofthispublicationmaybereproducedortransmittedinanyformorbyanymeans,electronicor
mechanical,includingphotocopying,recording,oranyinformationstorageandretrievalsystem,without
permissioninwritingfromthepublisher.Detailsonhowtoseekpermission,furtherinformationaboutthe
Publisher'spermissionspoliciesandourarrangementswithorganizationssuchastheCopyrightClearance
CenterandtheCopyrightLicensingAgency,canbefoundatourwebsite:www.elsevier.com/permissions.
ThisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythePublisher
(otherthanasmaybenotedherein).
Notices
Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperiencebroaden
ourunderstanding,changesinresearchmethods,professionalpractices,ormedicaltreatmentmaybecome
necessary.
Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingand
usinganyinformation,methods,compounds,orexperimentsdescribedherein.Inusingsuchinformationor
methodstheyshouldbemindfuloftheirownsafetyandthesafetyofothers,includingpartiesforwhomthey
haveaprofessionalresponsibility.
Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assumeany
liabilityforanyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability,negligenceor
otherwise,orfromanyuseoroperationofanymethods,products,instructions,orideascontainedinthe
materialherein.
LibraryofCongressCataloging-in-PublicationData
Stewart,Maurice.
Pressurevesselsfieldmanual:commonoperatingproblemsandpracticalsolutions/MauriceStewartand
OranT.Lewis.
p.cm.
Includesbibliographicalreferences.
ISBN978-0-12-397015-2
1.Pressurevessels–Maintenanceandrepair–Handbooks,manuals,etc.2.Pressurevessels–Maintenance
andrepair–Standards–UnitedStates–Handbooks,manuals,etc.3.Pressurevessels–Inspection–Handbooks,
manuals,etc.4.Pressurevessels–Inspection–UnitedStates–Handbooks,manuals,etc.5.Boilers–Maintenance
andrepair–Handbooks,manuals,etc.6.Boilers–Maintenanceandrepair–Standards–UnitedStates–
Handbooks,manuals,etc.7.Boilers–Inspection–Handbooks,manuals,etc.8.Boilers–Inspection–United
States–Handbooks,manuals,etc.9.ASMEboiler&pressurevesselcode.I.Lewis,OranT.II.Title.
TS283.S742012
681'.76041–dc23
2012026721
BritishLibraryCataloguing-in-PublicationData
AcataloguerecordforthisbookisavailablefromtheBritishLibrary.
ForinformationonallGulfProfessionalPublishingpublications
visitourwebsiteathttp://store.elsevier.com
0910 11 12 10987654321
PrintedintheUnitedStatesofAmerica
Contents
Chapter 1: History and Organization of Codes 1
Overview 1
Use of Pressure Vessels andEquipment 1
History of Pressure Vessel Codes in the United States 2
Organization ofthe ASME Boiler andPressure Vessel Code 4
Section I: PowerBoilers 4
Section II: Materials 5
Section III: Rules for Construction ofNuclearPower
Plant Components 6
Section IV: Heating Boilers 6
Section V: NondestructiveExamination 7
Section VI: Recommended Rules for the Care
and OperationofHeating Boilers 7
Section VII: Recommended Guidelines for
the Careof Power Boilers 8
Section VIII 8
Section IX: Welding and Brazing Qualifications 10
Section X: Fiber-ReinforcedPlastic Pressure Vessels 10
Section XI: Rulesfor In-Service Inspection of
Nuclear Power Plant Components 11
Section XII: Rules for the Construction and
Continued Serviceof Transport Tanks 11
OrganizationofCodeCommittee 12
Updating andInterpreting the Code 12
Addenda 12
NewEdition ofthe Code 12
Code Cases 13
Code Interpretations 13
ASME Code Stamps 13
“U”Stamp 14
v
vi CONTENTS
“UM” Stamp 15
NationalBoard ofBoilerand Pressure Vessel Inspectors 15
Organization of the ANSI/ASMEB31Code for
Pressure Piping 15
B31.1: PowerPiping 16
B31.3: Process Piping 16
B31.4: PipelineTransportation Systems for
LiquidHydrocarbonsand Other Liquids 17
B31.5: Refrigeration Piping and Heat Transfer
Components 18
B31.8: Gas Transmission and Distribution
Piping Systems 18
B31.9: BuildingServices Piping 18
B31.11:SlurryTransportationPiping Systems 19
B31.12:Hydrogen Piping and Pipelines 20
ANSI/ASME B31 Piping Code Committee 20
Some Other Pressure VesselCodes andStandards
in the United States 20
Worldwide Pressure VesselCodes 21
Australia 21
Belgium 22
China 22
France 22
Germany 22
Italy 22
Japan 22
Netherlands 23
Sweden 23
United Kingdom 23
ASMECode, Section VIII, Division 1 versus Division 2 23
Division1 23
Division2 24
Design Criteria, ASME Code,Section VIII, Division 1 24
Scope 24
Structure 25
Contents vii
Allowable Stresses 26
MaterialSpecifications 27
Inspection Openings 32
Pressure Relief Devices 33
Cryogenic and Low-Temperature Vessels 33
Testing, Inspection,and Stamping 34
Design Criteria,ASMECode,Section VIII,Division 2 38
Structure 39
Allowable Stresses 39
Materials and Tests 41
Responsibilities 43
ASME Code, Section IX:Welding 44
ASME Code Requirements 44
Welding Procedure Specifications (WPS)
and Procedure Qualification Records (PQR) 44
Post-Weld Heat Treatment (PWHT) 45
ASME Code, Section I, Power Boilers 45
Scope and Limitations 45
Allowable Stresses 46
Fabrication, Inspection, and Tests 47
Additional Requirements Employed byUsers in
Critical Service 48
AdditionalRequirements 48
Chapter 2: Materials of Construction 49
Overview 49
Material Selection 49
GeneralConsiderations 49
Corrosion 50
Strength 50
Example 1 53
MaterialCost 57
Nonferrous Alloys 58
GeneralConsiderations 58
AluminumAlloys 58
viii CONTENTS
Copper and CopperAlloys 61
Nickel and High-NickelAlloys 61
Titaniumand Zirconium Alloys 62
Ferrous Alloys 65
GeneralConsiderations 65
ASME Code, Section VIII, Division1 Categories 65
Heat Treatment of Steels 67
GeneralConsiderations 67
VariousHeat Treatments of Carbon Steel 69
Brittle Factors 70
GeneralConsiderations 70
Charpy V-Notch Test (C ) 70
v
Drop-Weight Test (DWT) 73
Fracture-AnalysisDiagram(FAD) 74
Example 2 77
Example 3 78
TheoryofBrittle Fracture 78
FractureTheory 83
Hydrostatic Testing 83
FactorsInfluencingBrittle Fracture 84
Example 4 85
ASME Code, Section VIII, Division1 Criteria 86
HydrogenEmbrittlement 90
Hydrogen Decarburization 90
Hydrogen Attack 92
Chapter 3: Materials Selection for Pressure
Vessels 95
Overview 95
Selection of Materials for Service Conditions 95
GeneralConsiderations 95
Design Factors 95
Typical Selections 99
ApplicationCriteria for Common Pressure Vessel
Materials 102
Contents ix
Summary of Temperature Limitations 111
Selection of Materials for Brittle Fracture Prevention 112
GeneralConsiderations 112
More Considerations 113
Design to Prevent BrittleFracture 114
Selecting Steels for NewConstruction of
Pressure Vessels 121
GuidelinesforPreventing Brittle Fracture in
Existing Equipment 129
GeneralConsiderations 129
Determining MPTs 129
Chapter 4: Mechanical Design of Pressure
Vessels 133
Overview 133
General Considerations 133
Owner’s,User’s,and Manufacturer’s Responsibilities 134
ASME Code, Section VIII 134
ASME Code, Section VIII, Division 1 134
ASME Code, Section VIII, Division 2 137
Determining Design Conditions 139
GeneralConsiderations 139
Design Pressure:Overview 140
Design Pressure:ASME Code, Section VIII,Division1 140
Design Pressure:ASME Code, Section VIII,Division2 145
ExternalPressure 146
Design Temperature:ASME Code,Section VIII,
Division 1 146
Design Temperature:ASME Code,Section VIII,
Division 2 151
Wind and Earthquake Design 152
CorrosionAllowance 153
Externaland Internal Loads 153
MechanicalDesign 157
Overview 157
x CONTENTS
Design Summary 165
Design for InternalPressure 167
Example 168
Design for ExternalPressure 170
Example 173
Example 177
Example 177
Example 178
Example of Internal/External Pressure Design 179
Openingsand Nozzle Reinforcement 184
Example 1 Reinforcement Calculations 194
Example 2 Reinforcement Calculations 198
Example 3 Reinforcement Calculations 200
Reinforcementof Openingsfor External Pressure 202
Bolted Flanged Connections 202
Minimum Wall Thickness and Nominal PlateSizes 210
Design ofWelded Joints 211
Chapter 5: Fabrication, Welding, and
In-Shop Inspection 217
Overview 217
Plate Materials 218
Overview 218
ASME Code Requirements 219
Fabricator Considerations 219
Forming of Shell and Head Components 220
GeneralConsiderations 220
Cylindrical Shell Ring Courses 220
Heads 223
Nozzles 225
Integrally Reinforced Nozzles 225
Built-Up Nozzles 226
Fabrication Welds 228
Longitudinal Welds 228
NozzleWelds 231
Contents xi
Girth Welds 233
Skirt AttachmentWeld 235
Post-Weld Heat Treatment (PWHT) 236
Welding Processes andProcedures 237
Welding Processes 237
Consumables 247
Preheat and Interpass Temperature Control 252
Post-Weld Heat Treatment (PWHT) 257
Welding Procedure Qualification 264
Welding Procedure Review 275
Welder PerformanceQualification 283
In-Shop Inspection 290
GeneralConsiderations 290
Degree of Inspection 291
Guidelines for Choosing the Appropriate Degree
ofInspection for Pressure Vessels 294
Inspection Tasks 297
Case Study 1: Construction and Inspection of
Replacement FlareKnockout DrumdMost
Appropriate Inspection Level:Degree 5 298
Case Study 2: Construction and Inspection
ofReplacement Flue Gas CoolerdMost
Appropriate Inspection Level:Degree 9 328
Chapter 6: In-Service Inspection by
Nondestructive Examination (NDE) 347
Overview 347
General Considerations 347
Materials for Construction 348
Inspection Program 348
Nondestructive Examination(NDE) Techniques 348
Design for Inspection 349
Code and Jurisdiction Requirements 349
ASME Code, Section VIII Requirements 349
Jurisdiction Requirements 350
xii CONTENTS
API 510: Pressure VesselInspection Code 350
NationalBoard Inspection Code (NB Code) 352
AuthorizedInspector versus ASNT-Certified NDE
Technician 352
Forms of Deterioration 353
GeneralConsiderations 353
InternalCorrosion 353
ExternalCorrosion 355
Thermal Aging 356
GeneralConsiderations 356
Fatigue 359
Stress-Corrosion(Environmental)Cracking 360
InternalErosion 361
Hydrogen Attack 362
Hydrogen Blistering 362
Creep and Stress-RuptureCracks 363
Analysis ofIn-Service Inspection Data 364
GeneralConsiderations 364
InternalCorrosion 364
ExternalCorrosion 368
Thermal Aging 368
Fatigue 368
Stress-Corrosion(Environmental)Cracking 369
InternalErosion 370
Hydrogen Attack 370
Hydrogen Blisters 371
Creep and StressRupture 371
Fitness-for-Service Analysis 372
Introduction 372
Background 373
Information Required for Fitness-for-Service Analysis 376
Procedures for Fitness-for-ServiceAnalysis 377
Outline ofthe Procedure 377
Required Inspection at theNextScheduled Shutdown 385
NondestructiveExamination (NDE) Techniques 385