Overview of 2007 ASME Section VIII, Division 2, Pressure Vessel Code

BDK Engineering Industries Limited, India

Presentation Outline

Introduction. User Survey Development Objectives Organization Overview - Parts 1 through 9 Comparison - ASME Section VIII, Div 2: 2006 vs. 2007 Design-By-Rule Validation Beta Test Code Adoption and Use Summary and Applicability To Valve Design

Introduction

To remain technically competitive, and to facilitate incorporation of new technology and future updates, ASME has developed a new pressure vessel code This code replaced the old Section VIII, Division 2 Code, the first release was July, 2007 The new code was developed primarily to address design and fabrication of engineered pressure vessels and will result in significant cost savings for many vessels

User Survey

Survey of VIII-2 Code users performed, primarily from petrochemical industry, to determine desired features of the new code Sample of survey results: Provide alternative for Registered Professional Engineer (RPE) requirement Make the new code more user friendly Bolster design-by-rule methods Introduce updated rules for fatigue and elevated temperature design Separate technical and administrative requirements

Development Objectives

Structure/Organize Section VIII considering the following: Division 1 - Basic Pressure Vessels (Maintenance/Enhancements) Division 2 - Engineered Pressure Vessels (New Code) Division 3 - High-Pressure Vessels (Maintenance/Enhancements) Optimize code rules to balance technology, user- friendliness, and jurisdictional acceptance Develop a new organization and introduce a clear and consistent writing style to facilitate use Separate administrative and technical requirements Develop rules to facilitate computer implementation Incorporate PED and other international requirements Incorporate SI and US Customary units

Organization

The table of contents for the new code incorporates a modular flat structure to facilitate modifications and enhancements Part 1 - General Requirements Part 2 - Responsibilities and Duties Part 3 - Materials Requirements Part 4 - Design by Rule Requirements Part 5 - Design by Analysis Requirements Part 6 - Fabrication Requirements Part 7 - Examination and Inspection Requirements Part 8 - Pressure Testing Requirements Part 9 - Pressure Vessel Overpressure Protection

Organization

Technical information traditionally placed in Mandatory and Non-Mandatory Appendices at the back of the existing Code will be re-deployed as Annexs to Parts in the new Code with a similar topic Incorporation of both SI and U. S. Customary units, SI units are the primary units Tables - two options used SI and US customary units in one table appropriately identified with applicable units SI and US Customary units in two separate tables, SI units table identified using an M after the table number (e.g. Table 3.F.11M is SI units, Table 3.F.11 is US Customary units) Figures - SI and US Customary units in two separate figures, SI units figure identified using an M after the figure number (e.g. Figure 3.4M is SI units, Figure 3.4 is US Customary units)

Overview Part 1 - General Requirements

Introduction, Organization and Definitions Scope and Jurisdiction Pressure Vessels with High Design Pressures \ Unfired Steam Boilers Field Assembly Referenced Standards Units of Measure, SI and US Customary, mixed set of units may be used in a design

Overview Part 2 - Duties and Responsibilities

User responsibilities Manufacturers responsibilities Inspectors duties Annexes on User Design Specification (UDS) and the Manufacturers Design Report (MDR) Separation of administrative and technical requirements, most administrative requirements placed in Informative Annexes

Overview Part 2 - Duties and Responsibilities

UDS and MDR - Registered Professional Engineer (RPE) requirement RPE certification has been in the Code since the first issuance; however, codes and standards covering similar equipment do not require RPE certification (e.g. ASME VIII- 1, ASME B31.3, API, European, etc.) RPE certification is unique to USA and Canada Industry questionnaire confirmed that RPE certification of UDS and MDR is a barrier to the use of the old VIII-2 Alternative to the RPE certification developed - this alternative will require that the engineer certifying either the UDS or MDR has the requisite technical and legal stature, and jurisdictional authority to certify such a document

Overview Part 3 - Material Requirements

Material requirements mostly based on old VIII-2 Part AM and material requirements in VIII-1 Several significant enhancements relative to the old VIII-2 New allowable stress basis New material toughness requirements New material strength parameter model (master stress- strain curve) Updated physical properties Two sets of design fatigue curves are provided Smooth bar design fatigue curves based on Appendix 5 of the old VIII-2 Welded joint design fatigue curves based on Battelle JIP

Overview Part 3 - Material Requirements

New Allowable stress basis All product forms except bolting - allowable stress established as the minimum of the following
Room temperature tensile strength divided by 2.4 67% of MSYS at the design temperature (90% of the MSYS will also be provided for Stainless Steels) 67% of the average stress to cause rupture at the end of 100,000 hr 80% of the minimum stress to cause rupture at the end of 100,000 hr 100% of the average stress to produce a creep rate of 0.01%/1000 hr

Bolting - allowable stress established as the minimum of the following

Min. of room and design ultimate tensile strength divided by 5.0 67% of MSYS at the design temperature 67% of the average stress to cause rupture at the end of 100,000 hr 80% of the minimum stress to cause rupture at the end of 100,000 hr 100% of the average stress to produce a creep rate of 0.01%/1000 hr

Note: Allowable stresses in the creep range are based on allowable stress criteria of Section VIII, Division 1

Overview Part 3 - Material Requirements

New allowable stress basis will typically result in higher allowable stresses and lower wall thickness, the extent of wall thickness reduction is a function of the YS/TS ratio at the design temperature Justification for higher allowable stresses and reduced wall thickness Experience obtained from other PV construction codes More stringent material requirements Higher material toughness requirement Better design rules Increased NDE New allowable stress basis adopted aligns the new VIII- 2 with current European pressure vessel standards

Overview Part 3 - Material Requirements

Modernization of toughness rules - new rules will require higher toughness, typically CVN=27 J, 20 ft-lbs minimum New toughness rules based on a rigorous fracture mechanics approach Required material toughness developed in terms of a crack driving force based on API 579-1/ASME FFS-1, Part 9 - FAD approach, considers Reference flaw Primary stress Residual stress Required material resistance developed in terms of a required CVN, CVN will be a function of Material (generic type, heat treatment, yield strength) Temperature Thickness

Overview Part 4 - Design By Rule Requirements

Design-by-rule procedures significantly bolstered, many vessels may be designed using Part 4 without the need for design-by- analysis (Part 5) A screening criterion shall be applied to all vessel parts to determine if a fatigue analysis is required If the allowable stress at the design temperature is governed by time-independent properties and the results of this screening indicate that a fatigue analysis is required, then the analysis shall be performed in accordance with Part 5 If the allowable stress at the design temperature is governed by time-dependent properties, then a fatigue screening analysis based on experience with comparable equipment shall be satisfied

Overview Part 4 - Design By Rule Requirements

Part 4 design procedures may be used with allowable stresses governed by timeindependent or time- dependent (creep) properties unless otherwise noted Basic wall thickness equations in Part 4 need not be satisfied if a thinner thickness can be determined using DBA methods in Part 5

Overview Part 4 - Design By Rule Requirements

Consolidation of design requirements for welds Acceptable weld joint details are provided for the most common configurations Alternative details may be used if they can be qualified by a design procedure using Part 5 Rules for sizing welds are also provided Typical weld joint details are provided in Tables 4.2.4 through 4.2.14 These tables essentially contain all weld joint details that would typically be dispersed throughout the codebook In addition each detail will be self contained; this means that all applicable Code requirements related to the use of the details will be contained within the Figure, thereby eliminating the need to locate and read additional Code requirements within the body of the Code

Overview Part 4 - Design By Rule Requirements

New design methods Cylindrical, conical and spherical shell thickness equations Elliptical and torispherical heads (WRC 501) Combined loadings (pressure and net-section axial forces, shear forces, bending moments, and torsion) Junctions at conical transitions including junctions with a stiffening ring and/or knuckle Shells subject to external pressure (ASME CC 2286) Evaluation of compressive stresses from combined loadings (ASME CC 2286) New nozzle reinforcement design rules for internal/external pressure Lug-type, saddle, and skirt supports (e.g. Zicks analysis for saddle supports)

Overview Part 4 - Design By Rule Requirements

Inclusion of existing design methods, from VIII-1 and industry accepted methods Flat heads Spherically dished bolted covers (including Soehrens method) Quick acting closures Braced and stayed surfaces (welded only) Ligaments Jacketed vessels Non-circular vessels (completely re-written for clarity) Layered construction Rules to evaluate vessels that are outside of tolerances based on API 579-1/ASME FFS-1 2007, Fitness-For-Service Flanges (some new modifications) Expansion joints Tubesheets

Overview Part 4 - Design By Rule Requirements

Weld joint efficiency option introduced; the weld joint efficiency will appear explicitly in the design equations as SE, similar to Div 1 Weld joint efficiencies - significant differences exist between the new Div 2 Code and existing ASME Codes Div 2, 2007 Edition - weld joint efficiencies are a function of material testing group, NDE method and extent of examination, wall thickness, welding process, and service temperature Div 2, 2006 Edition - 100% examination Div 1, 2006 Edition - weld joint efficiencies are a function of extent of examination and weld type; mixed extent of examination is permitted (RT1, RT2, RT3, and RT4)

Overview Part 5 - Design By Analysis Requirements

Complete re-organization of Design-By-Analysis (DBA) methods based on prevention of failure modes Plastic Collapse Local Failure (strain limit) Collapse From Buckling Fatigue Modernization of DBA methods to accommodate advances in numerical analysis methods (i.e., FEA) Explicit load case combinations (in addition to those cited in the UDS) now provided

Overview Part 5 - Design By Analysis Requirements

Part 5 analysis methods can be used for design of all components that are not operating in the creep range; exception is that some elastic stress methods may be used if fatigue screening by experience satisfied (ASME CC 1489) DBA methods fully harmonized with FFS assessment procedures (typically Level 3) in API 579-1/ASME FFS-1, unification of analysis methods for new and in-service components facilitates whole-life management of equipment

Overview Part 5 - Design By Analysis Requirements

Normative annexes covering the following are provided Recommendations for linearization of stress results from FEA used in stress classification Histogram development and cycle counting Alternative plasticity adjustment factors (Ke factor) Stress indices (based on old VIII-2) Design of perforated plates based on elastic stress analysis Rules for experimental stress analysis are provided

Overview Part 6 - Fabrication Requirements

Based on a consolidation of fabrication requirements from the old VIII-2 Part AM and Part AF, as well as some fabrication rules from VIII-1 New fabrication tolerances; if tolerances are exceeded an evaluation may be performed using API 579-1/ASME FFS- 1 Fitness-For-Service PWHT requirements similar to old VIII-2 and VIII-1; however, development of new time-temperature- thickness criterion for PWHT is under development by PVRC

Overview Part 7 - Examination Requirements

Rules for examination of welded joints have been completely rewritten in Part 7 The concept of defining Examination Groups for pressure vessels to define NDE requirements, based on the practice used in several European standards has been utilized Examination requirements are provided in Tables 7.1 and 7.2

Overview Part 7 - Examination Requirements

With the introduction of weld joint efficiencies in the new VIII-2, the option for partial radiography is now available However, unlike the spot RT rules of VIII-1 where 1% of a weld joint is examined, when permitted in Part 7, the partial radiography rules will require between 10 and 25% of the weld to be examined Ultrasonic NDE may be substituted for radiographic NDE for weld examination (incorporation of CC2235)

Overview Part 8 - Pressure Testing Requirements

New hydrostatic test pressure P = MAWP, 1.25 MAWP Max 1.43

ST

)]

New pneumatic test pressure P = 1.15 MAWP T

ST S

The ratio in the ST / S above equations is the lowest ratio for the pressure-boundary materials, excluding bolting materials, of which the vessel is constructed

Overview Part 8 - Pressure Testing Requirements

The pneumatic pressure test option is retained; however, when used, the vessel must be monitored by acoustic emission examination per Article 12 of Section V during the test The Manufacturer must maintain complete records of the final pressure test

Overview Part 9 - Overpressure Protection

Basic rules for overpressure protection will be virtually identical to that currently published in VIII-1 For this reason, most rules for overpressure protection in the new VIII-2 will reference VIII-1 Rules not covered in VIII-1, such as Overpressure Protection by Design (Code Case 2211) are presented in Part 9 An annex covering best practices for the installation and operation of pressure relief devices, which is based on the latest revision to Appendix M of VIII-1, is also provided

Comparison ASME Section VIII, Div 2: 2006 vs. 2007

New allowable stress basis will typically result in higher allowable stresses and lower wall thickness; extent of wall thickness reduction is a function of the YS/TS ratio at the design temperature Increase in allowable stress and resulting Wall Thickness Reduction (WTR) may be significant for many materials, indicator is the MYS/MTS ratio Consider the following comparison: Design pressure: 6.89 MPa (1000 psig ) Inside diameter: 1524 mm (60 inches) Weld joint efficiency: 1.0

Comparison - SI Units ASME Section VIII, Div 2: 2006 vs. 2007

Material
MTS (MPa) MYS (MPa) Temp (C)
38 149 38 149 SA537 CL2, <= 63 mm 552 414 38 149 38 149 SA737 GR. C 552 414 38 149 38 454 38 454 38 SA832 GR. 22V 586 414 454

S-2006 (MPa)
161 154 161 151 184 179 161 161 184 184 138 118 172 151 195 169

tcyl-2006 (mm)
33.43 34.80 33.43 35.61 29.08 29.87 33.43 33.43 29.08 29.08 39.07 45.90 31.09 35.61 27.41 31.75

S-2007 (MPa)
174 154 201 200 230 230 201 190 230 228 138 118 207 151 244 199

tcyl-2007 (mm)
30.73 34.80 26.54 26.75 23.24 23.24 26.54 28.12 23.24 23.37 39.07 45.90 25.83 35.61 21.84 26.82

WRT (%)
8 0 21 25 20 22 21 16 20 20 0 0 17 0 20 16

SA516 Gr. 70

483

262

SA537 CL1, <= 63 mm

483

345

SA737 GR. B

483

345

SA387 GR. 22 CL1

414

207

SA387 GR. 22 CL2

517

310

Comparison - US Customary Units ASME Section VIII, Div 2: 2006 vs. 2007
Material
MTS (ksi) MYS (ksi) Temp (F)
100 300 100 300 100 300 100 300 100 300 100 SA387 GR. 22 CL1 60 30 850 100 850 100 850

S-2006 (ksi)
23.3 22.4 23.3 21.9 26.7 26 23.3 23.3 26.7 26.7 20 17.1 25 21.9 28.3 24.5

tcyl-2006 (in)
1.316 1.370 1.316 1.402 1.145 1.176 1.316 1.316 1.145 1.145 1.538 1.807 1.224 1.402 1.079 1.250

S-2007 (ksi)
25.3 22.4 29.2 29 33.3 33.3 29.2 27.6 33.3 33.1 20 17.1 30 21.9 35.4 28.9

tcyl-2007 (in)
1.210 1.370 1.045 1.053 0.915 0.915 1.045 1.107 0.915 0.920 1.538 1.807 1.017 1.402 0.860 1.056

WRT (%)
8 0 21 25 20 22 21 16 20 20 0 0 17 0 20 16

SA516 Gr. 70

70

38

SA537 CL1, <= 2.5"

70

50

SA537 CL2, <= 2.5"

80

60

SA737 GR. B

70

50

SA737 GR. C

80

60

SA387 GR. 22 CL2

75

45

SA832 GR. 22V

85

60

Design-By-Rule Validation

The new VIII-2 contains numerous design equations and polynomial expressions for curve fits When design rules were taken from VIII-1, old VIII-2, or other technical references, in most cases they were re- written to facilitate computerization In order to quality check each equation, figure, and polynomial expression used in the re-write, an independent organization experienced in writing pressure vessel design software was contracted to QA check all design rules in the new VIII-2 Work performed by programming all of the design rules in MathCadR and running numerous example problems . Wherever possible, existing example problems from the old VIII-2 and VIII-1 were used for the validation work

Design-By-Rule Validation

In all, over a thousand pages of calculations were performed, and the process did identify some errors, mostly in the curve fit factors This validation work will also serve as the starting point for an examples manual to be developed for a future publication This validation work also substantiated that the new writing style and presentation of the design rules using the step-by-step presentation style was highly successful as the independent organization performing the validation was able to complete the task without difficulty

Beta Test Objective

The Div. 2 project team set forth a number of goals with the undertaking of this project, and everyone involved were interested in receiving feedback from users of Section VIII, Division 2 Normally this feedback would be received once the standard was published and used for production vessels; however, a test run or beta test prior to publication was required To accomplish this, ASME authorized a project to beta test the standard during the last stages of approval Invitations to participate in a beta test of the new standard were sent to several existing Division 2 Certificate Holders. These Manufacturers were asked to select a recently completed Division 2 vessel, and re-execute the project on paper using the new standard. A number of companies responded to the invitation with a description of a vessel to be used in the evaluation

Beta Test Part Overall Results

Overall the beta test of this new standard was a resounding success and provided validation of many of the goals set forth when this project was initiated. In general All of the beta testers reported the standard easy to use, and that the design rules were clear and concise Several beta testers reported that they prefer the new format of the document whereby the nomenclature, figures and tables are all placed at the end of each part, and that all of the weld joint figures are assembled in one place; single column format The beta test generated numerous questions on the standard, but no significant errors in the standard were identified during the test As expected, significant cost savings were reported due to the increase in allowable stress for many carbon and low alloy steels. Of equal importance, most of the testers also reported a reduced amount of reinforcement required for openings resulting in a reduction in forged nozzle thickness

Beta Test Table Summary

Table 1 - Summary of Beta Test Results: Steam Superheater
Item Material Design Temperature (C) Allowable Stress - Old (MPa) Allowable Stress - New (MPa) Required Thickness - Old (mm) Required Thickness - New (mm) Change in vessel weight as a % Reduction in production time as a % Reduction in overall vessel cost as a % Shell SA-387 Gr11 Cl 2 410 151.38 151.38 34.38 34.59 -2 N/A -2.5 Heads SA-387 Gr11 Cl 2 410 151.38 151.38 38.43 33

Comments: 1.The new code provides a systematic approach to design with easy access to information. 2.The use of tables and figures instead of graphs leads to better and precise results. 3.The new format adopted is user friendly as it takes less time to find reference pages. 4.The design method for opening and reinforcements provides a substantial decrease in hub thickness 5.New code includes and accepts techniques such as TOFD, Phased Array which is a welcome change and will lead to definite improvements in quality and testing.

Beta Test Table Summary

Table 2 - Summary of Beta Test Results: 53 ft Diameter Sphere
Item Material Design Temperature (C) Allowable Stress - Old (MPa) Allowable Stress - New (MPa) Required Thickness - Old (mm) Required Thickness - New (mm) Change in vessel weight (kg) Reduction in production time as a % Reduction in overall vessel cost as a % Shell SA-738 Gr B 120 195 244 42.74 33 -51,000 -8 -12.2 Forging SA-387 Gr11 Cl 2 120 148.9 148.9 N/A N/A

Comments: 1.Overall the new Section VIII, Div. 2 code was found to be well organized and logical in its layout. The equations are located near the text where they are referenced and this reduces times spent looking for the applicable equation. 2.Having the NDE requirements summarized in a table is very helpful as are the diagrams and sketches of the welds. 3.The opening reinforcement design method is logical and intuitive.

Beta Test Table Summary

Table 3 - Summary of Beta Test Results: Hydroprocessing Reactor
Item Material Design Temperature (C) Allowable Stress - Old (MPa) Allowable Stress - New (MPa) Required Thickness - Old (mm) Required Thickness - New (mm) Change in vessel weight as a % Reduction in production time Reduction in overall vessel cost as a % Shell SA-336 F22V 454 169 199 290 244 -13.8 2 weeks -12 Heads SA-542 Tp D Cl 4a 454 169 199 145 125

Comments: 1.The Beta Test has confirmed the quality of the new code. 2.The revised safety factors and related allowable stresses results, for some materials will result in significant savings in both time and cost.

Beta Test Table Summary

Table 4 - Summary of Beta Test Results: Hydrotreating Reactor
Item Material Design Temperature (C) Allowable Stress - Old (MPa) Allowable Stress - New (MPa) Required Thickness - Old (mm) Required Thickness - New (mm) Change in vessel weight as a % Reduction in production time as a % Reduction in overall vessel cost as a % Shell SA-542 Type D Cl 4a 454 168 199.8 167 141 -14 -4 -8 Heads SA-542 Type D Cl 4a 454 168 199.8 95 81

Comments: 1.New VIII-2 Code shows the requirements in detail for each item; therefore confusion with Code interpretations will be reduced. 2.Examination requirements for the material are more severe. Cost and delivery impact for the material will be increased when purchasing the materials.

Code Adoption and Use

The B&PV Standards Committee Approval - Completed February 2, 2007 BPTCS Procedural Review - Completed March 9, 2007 ANSI Public Review/Comment Period - Completed April 2007 First Publication of the new Section VIII, Division 2 - Completed July, 2007 VIII-2 certificate holders will have the option to construct to either the old or new VIII-2 for an 18 month transition period - Code Case 2575 Approved March 2007 Old VIII-2 frozen at 2004 Edition, 2006 Addenda

Summary

To remain technically competitive and to facilitate incorporation of new technology and future updates, ASME has developed a new pressure Vessel Code, this code replaced the old VIII-2 Code The new code was developed primarily to address design and fabrication of engineered pressure vessels (as typically used in the refining and petrochemical industry); will result in significant cost savings

Summary

ASME Section VIII, Division 2, 2007 has been rewritten to incorporate the latest technology for pressure vessel design A new writing style has been used to facilitate use Alternative to RPE certification of UDS and MDR is provided A new allowable stress basis and new material toughness requirements have been incorporated Design-by-rule methods significantly updated to handle most of the common design requirements Design-by-analysis procedures have been rewritten and modernized to take advantage of the latest technologies in numerical analysis

Summary

Examination requirements have been updated to support the new allowable stress basis; UT in lieu of RRT new permitted New test pressures have been adopted Requirements for pressure relief design have been updated Validation of Design-By-Rule performed Beta Test performed Overall a resounding success .The new code will result in a significant wall thickness reduction when compared to earlier editions of Section VIII, Division 2 New layout and format preferred

Applicability To Valve Design

Valve Design using VIII-2 is optional unless required by Users Design Specification or the jurisdiction If used, must meet all of the VIII-2 requirements Certification of Users Design Specification and Manufacturers Data Reports Inspection of valve castings Rules for certain components such as flanges, non-circular sections provided

Applicability To Valve Design

Primary usage will be for specialty valves not manufactured in accordance with a listed standard in ASME B31.3, or valves subject to cyclic loading, thermal gradients, etc. Subsea valves in oil and gas production Valves in LNG service Valves in high temperature service with thermal linings (e.g. FCC Slide Valves, Flue Gas Slide Valves) Coker Valves (e.g. 3-way switch, vapor valves, bottom head valves) Pipeline valves or similar fabricated valves

Applicability To Valve Design

Design by analysis procedures in VIII-2 may result in more cost effective designs Permits similar stress categorization as old VIII-2 but with new allowable stress B31.3 requires B31.3 allowable stress for VIII-2 Part 5 assessment in-lieu of VIII-2 allowable stress Adds limit load and elastic-plastic design methods Other failure criteria types considered Fatigue Buckling

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