Dr. W Pao
Contents
Scope & Service Restrictions; General Requirements; Requirements for Fabrication by
Welding, Forging, or Brazing; Requirements Pertaining to Classes of Materials for
Carbon & Low Alloy Steel;Nonferrous Materials; High Alloy Steel; Cast Iron; Clad &
Lined Vessels; Cast Ductile Iron Vessels; Ferritic Steels with Tensile Properties
Enhanced by Heat Treatment; Layered Construction; High Stresses at Low
Temperatures.
ASME Section VIII, Division 2
Each unfired pressure vessel must have a valid Certificate of Fitness (CF) before it can
be operated. For this purpose, approval for the design of the unfired pressure vessel has
to be obtained in advance from the Department of Occupational Safety and Health
(DOSH) before it fabricated, installed or used.
Application for approval of the design may be made by the manufacturing company,
installer, supplier or owner of the unfired pressure vessel. Local manufacturers of unfired
pressure vessels must register as a manufacturer with the department.
Examples:
• Air container
• Steriliser
• LPG storage tank
• Heat exchanger
• PV at petrochemical plant
PV Categorisation
Pressure Vessel
FIRED UNFIRED
Biotech
Food
Design Parameters
THIN-WALL THEORY
Consequently, can treat surface as membrane with in-plane stresses. Hoop stress is:
P×r P×r
σθ = σθ =
t 2t
Cylinder Sphere
Note that the thin-wall model does not have out-of-plane stress.
Summary of Thin-wall model
Longitudinal stress
Pr
σ2 =
2t
Hoop stress
Pr
σ1 =
t
Thick-wall PV
THICK-WALL THEORY
B
Radial stress: σ r = A − 2
r
B
Hoop stress: σ θ = A + 2
r
Components of PV
Head Disc/end
Flange
Support Lug
Nozzle
Stress
Internal External
Selfweight/content
Attachment Load
Opening Nozzle
• Nozzle loading
• Opening with
• Other attachment load-
reinforcement
Heat Exchanger, plat
(Reinforcement pad)
form etc.
• Opening without
• Lifting Lug, tailing lug
reinforcement (Self
reinforcement type nozzle )
General Formula
Note:
Formula are valid for;
• Pressure < 3000psi
• Cylindrical shell t ≤0.5Ri or P
t≤0.385 SE
• Spherical shell and
hemispherical head t
≤0.356Ri or P t≤0.665 SE
• For thicker shell refer Ref. 3
Para1.3
Different Cap
Ro
Ro
Ro =0.9 Do
Sphere / Hemisphere
2.1 S.E Head
Ro
RoMax =Do
Torispherical
Vessel Formula
Vessel Formula
Design Consideration
Requirement
Technical Economical
Design standard
code and practice Safety Factor
Complexity Fabrication
Process
Site condition
End conditions
When we pressurize the vessel, the main body and the end caps will expand
differently due to different internal stress reaction.
Pr Pr
σ1 = σ1 =
2t 2t
Pr
σ1 =
t
Theory vs Application - cylinder
Theory ASME
Pr PR
σ1 = t=
t SE − 0 .6 P
t - thickness
Ri- internal radius of shell
P- working pressure
S- maximum allowable stress
E- joint efficiency
• Are these two different?
• Where do you think the extra terms in ASME design equation comes from?
PR PR
t theory = = ⇒ σ theory = S op E − 0.6 P
σ theory S op E − 0.6 P
1 1 σ theory t theory
∴ S op = (σ theory + 0.6 P ) = σ theory + 0.6
E E R
σ theory t theory
= 1 + 0.6
E R
Effect due to shape/geometry
If E=1, the smaller t/R, the faster the operational stress approaches theoretical
stress value. The ASME Standard safety factor is:
S op 1 t
= 1 + 0.6
σ theory E R
Joint Efficiency, E
72”ID
cont
Soln:
From Table, SA-516, Grade 70, below 650F, use ASME Section VIII, Div 1,
tensile strength S=20,000, welding efficiency E=0.85, corrosion tolerance =
.25”.
490 (32 )
For cylindrical shell: t= + 0 .25 = 1 .2"
20000 ( 0 .85 ) − 0 .6 ( 490 )
490 (32 )
For end caps: t= + 0 .25" = 0 .72"
2 ( 20 ,000 )( 0 .85 ) − 0 .2 ( 490 )
Safety Appliances
Advantages:
ƒ Portable
Disadvantages
ƒ External / surface defects only
the surface
ƒ Reverse Capillary due to equilibrium action
Advantages of MPI :
ƒSimple and fast technique
ƒAble to detect surface discontinuities that are not open to the surface, ie. contamination of
Disadvantages of MPI :
ƒCannot detect defects more than 1.5mm below the surface, ie. not able to detect internal
discontinuities
ƒApplicable only to ferromagnetic materials (steel, cast iron, ferritic stainless steel)
ƒSome applications (eg. high speed rotating parts) require the parts to be demagnetized
after inspection
NDT 2 – MPI
Advantages of UT :
ƒInternal defects can be detected and sized
ƒPortable
Disadvantages of UT :
ƒNo hardcopy of result available
– normally not suitable for surface and near surface defect detection (dead zone)
ƒNormally not suitable for wall thickness < 3mm
NDT 3 – UT
Back surface
4" of plate echo
Initial pulse
transducer
defect
0 1 2 3 4
1.5"
Advantages of RT :
ƒResults in a form of a picture
Disadvantages of RT :
ƒRadiation hazard
NDT operators
Jabatan Pembagunan Kemahiran (JPK)
Level I, II, III
Certification scheme for welding inspection personnel (CSWIP)
Level I, II, III
Personnel Certification in NDT (PCN)
Level I, II, III
The American Society for NDT (ASNT)
Level I, II, III
ASNT Central Certification Program (ACCP)
Level I, II, III
Failure Theory for Pressure Vessel
• at failure:
f (σ1,σ 2 ,σ 3 ) = σ c
• set σc = σu
Tresca Criteria
σ S = MAX (σ 1 − σ 2 , σ 2 − σ 3 , σ 3 − σ 1 )
• conservative
• set σc = σo
Von Mises Criteria
• set σc = σo
Example
2
σx + σy σ x − σ y 2
σ1,σ 2 = ± + τ xy
2 2
Example
localized: fatigue process acts over a localized area having high stresses
due to geometry, temperature, residual stresses, or imperfections.
fracture: the crack grows until the remaining ligament can no longer
sustain the applied stresses or strains
Features of Fatigue Failure
600
400 1500
200
1000
0
-200
500
-400
-600 0
TIME TIME
A C σ min
R=
1000 600 σ max
800 400
600
200
400
0
200
-200
0
-400
-200
TIME TIME
B D
Stress-based approach
traditional
analysis is based on the nominal, average stress
considers the mean stress and stress raisers
Strain-based approach
detailed analysis of local yielding that may occur at
stress raisers
Fracture Mechanics approach
predicts the rate of growth
analysis is based on K
Stress Based Fatigue Analysis
Un-notched
Stress Amplitude
Notched
σ a = C + D log N f
Semi-log plot
Fatigue limit
~ Half of yield
strength
For log-log plot
(1) σ a = AN B
or alternatively as
' b
(2) σ a = σ f (2N )
where the 2 equations are related by
A = 2 b σ 'f
B=b
'
σ ≈ true fracture strength in tension
f
Features of Fatigue Failure
Constant-Life Diagram
Goodman Normalized Amplitude-Mean Stress Diagram
σa σm σm
+ = 1 or σ a = σ ar 1 −
σ ar σ U σU
σa σ a = fatigue strength (σ m ≠ 0)
Conservative approach
σ ar = fully reversed fatigue limit (σ m = 0)
σ ar
σ m = mean stress
σ uts = tensile strength
unsafe
safe
σm
σU
Modified Goodman
σa σm σm
+ = 1 or σ a = σ e 1 −
σ e σU σU
σa Fatigue limit
σe
unsafe
safe
σm
σU
Life Estimate
σa σm σa
From Goodman + = 1 ⇒ σ ar =
σ ar σ u σm
1−
σu
B
Suppose S-N curve σ ar = AN f
(Can be other form)
Therefore:
σm
σ a = 1 − AN Bf
σu
Example 1
The AISI 4340 steel in Table 9.1 is subject to cyclic loading with a
tensile mean stress of 200 MPa.
a)What life is expected if the stress amplitude is 450 MPa?
b) Estimate the stress amplitude vs. Nf curve for this mean value
Solution
b
σ ar = σ '
f (2N )
f ; σ 'f = 1758 MPa; b = −0.0977
Ti-6Al-4V cylindrical pressure vessel with closed ends and diameter of 250mm and
wall thickness of 2.5mm.
a)What repeatedly applied pressure will cause fatigue failure in 100,000 cycles?
b)What is the safety factor against yielding?
Soln
For this case, notice that the pressure is applied from 0 to Pmax
σa = σm
Example 2
1 2 2 2
σa = (σ 1a − σ 2 a ) + (σ 2 a − σ 3a ) + (σ 3a − σ 1a ) = 21.65 P
2
Example 2
Step 5: Remember Goodman and replace it with the equivalent stress we calculated
σa σm
+ =1
σ ar σ u
Example 2
Step 5: continue…
σa σm 21.65 P 37.5P
+ =1⇒ + =1
σ ar σ u 570 1233
∴ P = 14.6 MPa
σ yield 1185
Safety Factor, X = = = 1.87
σ operational 634
Fatigue Analysis based on Linear Fracture Mechanics
Stress Intensity ∆K
Paris equation.
da n
= A(∆KI )
dN
2 <n< 5 n
Material ts (MPa) n
da
= A(∆KI )n
dN
−n
∫ [β(a)∆ σ π a ] da
−1
∴N = A
Cont..
−n
N=A −1
∫ [β (a)∆σ πa ] da Early
stage
for β ≠ f(a), n > 2
1 1
N = f −1 n−2 − n−2
ao 2 a 2
1 1
N f = f −1 n−2 − n−2
Late
ao 2 a f 2
stage
n
f = 0.5(n − 2)π Aβ (∆σ )
2 n n
and
1 n-2
a= 1 where m =
2
[ao − N f ] m
−m
Example
Soln
Step 1: Calculate Principle Stresses
Pr 5(0.0425)
σ1 = = = 106 MPa; σ 2 = 53.1 MPa; σ 3 = 0
t 0.002
Example
Step 7:
Vessel operates 100 times/hour = 100 cycles
84x103/100 = 840 hours life = 35 days.
The pressure vessel must be replaced within 1 month to avoid catastrophic
failure.
Q&A
© 2012 INSTITUTE OF TECHNOLOGY PETRONAS SDN BHD
All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic,
mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.