PRESSURE VESSEL:

Perancangan, Fabrikasi
dan Inspeksi
Ir. Tri Prakosa, M.Eng.
LAPI-ITB (22-25 Oktober
2009)
1

PRE-TEST
1.
2.
3.
4.
5.
6.
7.
8.

Sebutkan 2 jenis bentuk pressure vessel

Sebutkan 2 jenis proses fabrikasi pressure vessel
Apakah yang disebut dengan fracture toughness?
Apakah yang disebut sebagai yield strength suatu
material?
Apakah yang disebut dengan hydrogen attack?
Beban luar apa saja yang dialami oleh pressure vessel?
Apakah yang disebut dengan pressure testing
(hydrostatic testing)?
Sebutkan 3 contoh non-destructive testing (NDE) pada
pressure vessel
2

4. INSPECTION AND
TESTING

Inspection and Testing

Inspection includes examination of:
Base material specification and quality
Welds
Dimensional requirements
Equipment documentation
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Pengujian Daya Lekat Coating

Beberapa Jenis Kelainan

Cacat/Cacat Permukaan Bejana

Hydrotest

Uji Pneumatis
dengan gas N2 atau He

Pemantauan Hot Spot

secara On-stream

Pemantauan Hot Spot

secara On-stream
dengan Kamera Infra Merah

10

Tangential Radiography

11

Pemantauan Dini melalui

Radiographic Sensing

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INDIKATOR PELUMAS,
PRESSUSRE GAGE, DLL

13

Pengecekan Kebocoran
pada Packing Gland

14

Common Weld Defects

Gambar 7.1
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Weld Defects
Presence of defects:
Reduces weld strength below that required
Reduces overall strength of fabrication
Increases risk of failure
16

Types of NDE

Gambar 7.2
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Typical RT Setup

Gambar
7.3
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Pulse Echo UT System

Gambar 7.4
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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)

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Pressure Testing, contd

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
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Summary
Overview of pressure vessel mechanical
design
ASME Section VIII, Division 1
Covered
Materials
Design
Fabrication
Inspection
Testing
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5. Naval Materials
Definition
- normal load, shear load
- tension, compression
- stress, strain
Stress and Strain Diagram
Material Characteristics
- ductility
- brittleness
- toughness
- transition temperature
- endurance limit
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5.1 Classifying Load

Normal Load (Axial load) : Load is perpendicular to the
supporting material.
- Tension Load : As the ends of material are pulled apart
to make the material longer, the load is called a tension
load.
- Compression Load : As the ends of material are pushed in
to make the material smaller, the load is called
a compression load.
Tension
Compression
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5.1 Classifying Load (cont)

Shear Load : Tangential load
pulling apart

Cargo
Pressure

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5.2 Stress and Strain

In order to compare materials, we must have measures.

Stress : load per unit Area

A
F : load applied in pounds
A : cross sectional area in in
: stress in psi
A
F

F
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5.2 Stress and Strain (cont)

Strain :
- Ratio of elongation of a material to the original length
- unit deformation
Lo
e
e

Lo
L
e : elongation (ft)
Lo : unloaded(original) length of a material (ft)
: strain (ft/ft) or (in/in)
Elongation
e L Lo

L : loaded length of a material (ft)

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Baldwin Hydraulic Machine for Tension & Compression test

28

5.3 Stress-Strain Diagram

A plot of Strain vs. Stress.
The diagram gives us the behavior of the material and
material properties.
Each material produces a different stress-strain
diagram.

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5.3 Stress-Strain Diagram

ultimate
tensile
strength

3
Slope=
E

UTS

yield
strength

Strain
Hardening

Stress (F/A)

Plastic
Region
Elastic
Region

1
E

necking

y
2 1

Fracture
5

Elastic region
slope=Youngs(elastic) modulus
yield strength
Plastic region
ultimate tensile strength
strain hardening
fracture

Strain ( ) (e/Lo)

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A36 Steel

Stress and Strain Diagram

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5.3 Stress-Strain Diagram (cont)

Elastic Region (Point 1 2)
- The material will return to its original shape
after the material is unloaded( like a rubber band).
- The stress is linearly proportional to the strain in
this region.

or

: Stress(psi)

E : Elastic modulus (Youngs Modulus) (psi)

: Strain (in/in)
- Point 2 : Yield Strength : a point at which permanent

deformation occurs. ( If it is passed, the material will

no longer return to its original length.)
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5.3 Stress-Strain Diagram (cont)

Plastic Region (Point 2 3)
- If the material is loaded beyond the yield strength,
the material will not return to its original shape
after unloading.
- It will have some permanent deformation.
- If the material is unloaded at Point 3, the curve will
proceed from Point 3 to Point 4. The slope will be
the as the slope between Point 1 and 2.
- The distance between Point 1 and 4 indicates the
amount of permanent deformation.

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5.3 Stress-Strain Diagram (cont)

Strain Hardening
- If the material is loaded again from Point 4, the
curve will follow back to Point 3 with the same
Elastic Modulus(slope).
- The material now has a higher yield strength of
Point 4.
- Raising the yield strength by permanently straining
the material is called Strain Hardening.

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5.3 Stress-Strain Diagram (cont)

Tensile Strength (Point 3)
- The largest value of stress on the diagram is called
Tensile Strength(TS) or Ultimate Tensile Strength
(UTS)
- It is the maximum stress which the material can
support without breaking.
Fracture (Point 5)
- If the material is stretched beyond Point 3, the stress
decreases as necking and non-uniform deformation
occur.
- Fracture will finally occur at Point 5.
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Example 1.
Mooring line length =100 ft
diameter=1.0 in
Axial loading applied=25,000 lb
Elongation due to loading=1.0 in
1) Find the normal stress.

F 25,000 lb

31,800 psi
2
A 0.785 in
A r 2 (0.5in) 2 0.785 in 2

mooring line

loading

2) Strain?

e
1in

0.00083 ( in / in)
Lo 100 ft 12in
1 ft
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Example 2.
- Salvage crane is lifting an object of 20,000 lb.
- Characteristics of the cable
diameter=1.0 in, length prior to lifting =50 ft
y 60,000 psi

UT 70,000 psi
E 35 106 psi
1) Normal stress in the cable?

F 20,000 lb

25,478 psi
2
A 0.785 in
(A r 2 (0.5 in ) 2 0.785 in 2 )
2) Strain?

25,478 psi

0.000728 (in / in )
6
E 35 10 psi

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3) Determine the cable stretch in inches.

Lo
12in
e Lo (0.000728 in / in ) (50 ft
) 0.44 in
1 ft

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5.4 Material Properties

Characteristics of Material are described as
Strength
Hardness
Ductility
Brittleness
Toughness

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5.4 Material Properties

1) Strength
- Measure of the material property to resist deformation

and to maintain its shape

- It is quantified in terms of yield stress or ultimate tensile
strength.
- High carbon steels and metal alloys have higher strength
than pure metals.
- Ceramic also exhibit high strength characteristics.
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5.4 Material Properties

2) Hardness
- Measure of the material property to resist indentation,

abrasion and wear.

- It is quantified by hardness scale such as Rockwell and
Brinell hardness scale.
- Hardness and Strength correlate well because both
properties are related to in-molecular bonding.

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5.4 Material Properties

3) Ductility
- Measure of the material property to deform before failure.

- It is quantified by reading the value of strain at the

fracture point on the stress strain curve.
- Example of ductile material :
low carbon steel
aluminum
bubble gum
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5.4 Material Properties

4) Brittleness
- Measure of the materials inability to deform before failure.

- The opposite of ductility.

- Example of brittle material : glass, high carbon steel,
ceramics

Stress

Brittle

Ductile

Strain

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5.4 Material Properties

5) Toughness
- Measure of the material ability to absorb energy.
- It is measured by two methods.
a) Integration of stress strain curve
- Slow absorption of energy
- Absorbed energy per unit volume
unit : (lb/in) *(in/in) =lbin/in
b) Charpy test
- Impact toughness can be measured.
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5.4 Material Properties

- Charpy V-Notch Test

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5.4 Material Properties

Charpy V-Notch Test (continued)

- The potential energy of the pendulum before and after

impact can be calculated form the initial and final location
of the pendulum.
- The potential energy difference is the energy it took to
break the material. absorbed during the impact.
- Charpy test is an impact toughness measurement test
because the energy is absorbed by the specimen very
rapidly.
- Purpose : to evaluate the impact toughness as a function of
temperature

46

5.4 Material Properties

Charpy Toughness(lbin)

Charpy V-Notch Test (continued)

Ductile
Behavior
Brittle
Behavior

Transition
Temperature

Temperature (F)
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5.4 Material Properties

Charpy V-Notch Test (continued)
- At low temperature, where the material is brittle and

not strong, little energy is required to fracture the material.

- At high temperature, where the material is more ductile
and stronger, greater energy is required to fracture the
material
-The transition temperature is the boundary between brittle
and ductile behavior.
The transition temperature is an extremely important
parameter in selection of construction material.
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Charpy Test
High Carbon Steel

Stainless Steel

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5.4 Material Properties

6) Fatigue

Stress (psi)

The repeated application of stress typically produced by

an oscillating load such as vibration.
Sources of ship vibration are engine, propeller and waves.

Steel

Endurance Limit : A certain threshold

stress which will not cause the fatigue
failure for the number of cycles.

Aluminum

Aluminum has no endurance limit

Cycles N at Fatigue Failure

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Stress (x10) psi

Evaluation of fatigue curve

80
60

40

20
0

103 104 105 106 107

Number of cycles
- Endurance limit of each material :
- Case 1) stress level= 30x103 psi, max cycles=104 :
- Case 2) stress level= 30x103 psi, max cycles=106 :
- Case 3) stress level= 30x103 psi, max cycles=106 :
- Case 4) stress level= 50x103 psi, max cycles=106 :

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5.4 Material Properties

Factors effecting Material Properties
Temperature :
Increasing temperature will decrease
- Modulus of Elasticity
- Yield Strength
- Tensile Strength
Decreasing temperature will:
- Increase ductility
- Reduce brittleness
Environment
- Sulfites, Chlorine, Oxygen in water, Radiation
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5.5 Non-Destructive Testing (NDT)

NDT : Inspections for material defects
External Inspection Technique
- Visual Test (VT)
- Dye Penetrant Test (PT)
- Magnetic Particle Test (MT)
Internal Inspection Technique
- Radiographic Test (RT)
- Ultrasonic Test (UT)
- Eddy Current test
- Hydrostatic Test
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Visual Testing (VT)

- Can be used to examine only the surface of a material.

- Should be done during the all phases of maintenance (QAI).
- Can be performed quickly and easily and at no virtually cost.
- Often performed under some magnification to locate defects.
- Sometimes photographs are needed for a permanent record.

54

Dye Penetrant Test (PT)

- Can be used for location and identification of
only surface defects : cracks, seams, laps, laminations
or porosity
- Uses dyes to make surface flaws visible to naked eye.
- Can be used as a field inspection for glass, metal, castings,
forgings and welds.
- Simple and inexpensive

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Dye Penetrant Test (PT) (contd.)

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Magnetic Particle Test (MT)

- Method that can be used to find surface and near surface flaws
in ferromagnetic materials such as steel and iron.
- The technique uses the principle that magnetic fields (flux) will
be distorted by the presence of a flaw.

57

Radiographic Test (RT)

- The x-ray (gamma) rays are used.
- The rays pass through the material and exposes film.
- RT requires trained technicians.
- RT may have large effect on ship access and watchstanding.

The picture shows the integrity of welding

for the 2.5mm thick steel plate
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(Ultrasonic Test UT)

UT uses high frequency sound waves to detect flaws,
measure material thickness, or level in a tank or vessel.
Can be used on all metals and nonmetals.
Excellent technique for detecting deep flaws in tubing, rods,
adhesive-joined joints.
It is used on aircraft to detect cracks in structure

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 Ultrasonic Test (UT)

60

Eddy Current Test

- Involves the creation of a magnetic field in a specimen and
reading the field variations on an oscilloscope.
- Can only be used on conductive materials and is only good for
limited penetration depth.
- Used for measurement of wall thickness, cracks of tubes, wire,
or ball bearings.

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 Eddy Current Test

Elliptical Crack

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Hydrostatic Tests
System being tested is isolated and pressurized
by a pump.
System is inspected for leaks at welds, valve
bodies, valve seats, etc.
Automatic and manual pressure reliefs are used
to prevent overpressurizing system beyond
desired test pressure.

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Hydrostatic Test Pump

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FRACTURE TOUGHNESS
Plastic Zone Size

Plane stress and plane strain conditions

Monotonic plastic zone size
Cyclic plastic zone size

Fracture Toughness

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Plastic Zone Size

Materials develop plastic strains as the
yield stress is exceeded in the region near
the crack tip (see Fig. 1).
The amount of plastic deformation is
restricted by the surrounding material,
which remains elastic.
The size of this plastic zone is dependent
on the stress conditions of the body.
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Plastic Zone Size,contd

Gambar 1. Yielding near crack tip

67

Plane stress and

plane strain conditions
In a thin body, the stress through the thickness (sz)
cannot vary appreciably due to the thin section. Because
there can be no stresses normal to a free surface, sz = 0
throughout the section and a biaxial state of stress
results. This is termed a plane stress condition (see Fig.
2).
In a thick body, the material is constrained in the z
direction due to the thickness of the cross section and ez
= 0, resulting in a plane strain condition. Due to
Poisson`s effect, a stress, sz, is developed in the z
direction. Maximum constraint conditions exist in the
plane strain condition, and consequently the plastic zone
size is smaller than that developed under plane stress
conditions.
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Plane stress and

plane strain conditions,contd

Gambar 2. Plane stress and plane strain conditions

69