Common Operating Problems

Transcription

1 SYDNEY Pressure Vessels Field Manual Common Operating Problems and Practical Solutions Maurice Stewart Oran T. Lewis AMSTERDAM BOSTON HEIDELBERG LONDON NEW YORK OXFORD PARIS SAN DIEGO SAN FRANCISCO SINGAPORE TOKYO G Gulf Professional Publishing is an Imprint of Elsevier P P IK

2 Contents Chapter 1: History and Organization of Codes 1 Overview 1 Use of Pressure Vessels and Equipment 7 History of Pressure Vessel Codes in the United States 2 Organization of the ASME Boiler and Pressure Vessel Code 4 Section I: Power Boilers 4 Section II: Materials 5 Section III: Rules for Construction of Nuclear Power Plant Components 6 Section IV: Heating Boilers 6 Section V: Nondestructive Examination 7 Section VI: Recommended Rules for the Care and Operation of Heating Boilers 7 Section VII: Recommended Guidelines for the Care of Power Boilers 8 Section VIII 8 Section IX: Welding and Brazing Qualifications 10 Section X: Fiber-Reinforced Plastic Pressure Vessels 10 Section XI: Rules for In-Service Inspection of Nuclear Power Plant Components 11 Section XII: Rules for the Construction and Continued Service of Transport Tanks 11 Organization of Code Committee 12 Updating and Interpreting the Code 12 Addenda 12 New Edition of the Code 12 Code Cases 13 Code Interpretations 13 ASME Code Stamps 13 "U" Stamp 14 V

3 vi Contents "UM" Stamp 15 National Board of Boiler and Pressure Vessel Inspectors 15 Organization of the ANSI/ASME B31 Code for Pressure Piping 15 B31.1: Power Piping 16 B31.3: Process Piping 16 B31.4: Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids 17 B31.5: Refrigeration Piping and Heat Transfer Components 18 B31.8: Gas Transmission and Distribution Piping Systems 18 B31.9: Building Services Piping 18 B31.11: Slurry Transportation Piping Systems 19 B31.12: Hydrogen Piping and Pipelines 20 ANSI/ASME B31 Piping Code Committee 20 Some Other Pressure Vessel Codes and Standards in the United States 20 Worldwide Pressure Vessel Codes 21 Australia 21 Belgium 22 China 22 France 22 Germany 22 Italy 22 Japan 22 Netherlands 23 Sweden 23 United Kingdom 23 ASME Code, Section VIII, Division 1 versus Division 2 23 Division 1 23 Division 2 24 Design Criteria, ASME Code, Section VIII, Division 1 24 Scope 24 Structure 25

4 Contents vii Allowable Stresses 26 Material Specifications 27 Inspection Openings 32 Pressure Relief Devices 33 Cryogenic and Low-Temperature Vessels 33 Testing, Inspection, and Stamping 34 Design Criteria, ASME Code, 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 by Users in Critical Service 48 Additional Requirements 48 Chapter 2: Materials of Construction 49 Overview 49 Material Selection 49 General Considerations 49 Corrosion 50 Strength 50 Example 1 53 Material Cost 57 Nonferrous Alloys 58 General Considerations 58 Aluminum Alloys 58

5 viii Contents Copper and Copper Alloys 61 Nickel and High-Nickel Alloys 61 Titanium and Zirconium Alloys 62 Ferrous Alloys 65 General Considerations 65 ASME Code, Section VIII, Division 1 Categories 65 Heat Treatment of Steels 67 General Considerations 67 Various Heat Treatments of Carbon Steel 69 Brittle Factors 70 General Considerations 70 Charpy V-Notch Test (Cv) 70 Drop-Weight Test (DWT) 73 Fracture-Analysis Diagram (FAD) 74 Example 2 77 Example 3 78 Theory of Brittle Fracture 78 Fracture Theory 83 Hydrostatic Testing 83 Factors Influencing Brittle Fracture 84 Example 4 85 ASME Code, Section VIII, Division 1 Criteria 86 Hydrogen Embrittlement 90 Hydrogen Decarburization 90 Hydrogen Attack 92 Chapter 3: Materials Selection for Pressure Vessels 95 Overview 95 Selection of Materials for Service Conditions 95 General Considerations 95 Design Factors 95 Typical Selections 99 Application Criteria for Common Pressure Vessel Materials 102

6 Contents ix Summary of Temperature Limitations 111 Selection of Materials for Brittle Fracture Prevention 112 General Considerations 112 More Considerations 113 Design to Prevent Brittle Fracture 114 Selecting Steels for New Construction of Pressure Vessels 121 Guidelines for Preventing Brittle Fracture in Existing Equipment 129 General Considerations 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 ASME Code, Section VIII, Division Determining Design Conditions 139 General Considerations 139 Design Pressure: Overview 140 Design Pressure: ASME Code, Section VIII, Division Design Pressure: ASME Code, Section VIII, Division External Pressure 146 Design Temperature: ASME Code, Section VIII, Division Design Temperature: ASME Code, Section VIII, Division Wind and Earthquake Design 152 Corrosion Allowance 153 External and Internal Loads 153 Mechanical Design 157 Overview 157

7 x Contents Design Summary 165 Design for Internal Pressure 167 Example 168 Design for External Pressure 170 Example 173 Example 177 Example 177 Example 178 Example of Internal/External Pressure Design 179 Openings and Nozzle Reinforcement 184 Example 1 Reinforcement Calculations 194 Example 2 Reinforcement Calculations 198 Example 3 Reinforcement Calculations 200 Reinforcement of Openings for External Pressure 202 Bolted Flanged Connections 202 Minimum Wall Thickness and Nominal Plate Sizes 210 Design of Welded 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 General Considerations 220 Cylindrical Shell Ring Courses 220 Heads 223 Nozzles 225 Integrally Reinforced Nozzles 225 Built-Up Nozzles 226 Fabrication Welds 228 Longitudinal Welds 228 Nozzle Welds 231

8 Contents xi Girth Welds 233 Skirt Attachment Weld 235 Post-Weld Heat Treatment (PWHT) 236 Welding Processes and Procedures 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 Performance Qualification 283 In-Shop Inspection 290 General Considerations 290 Degree of Inspection 291 Guidelines for Choosing the Appropriate Degree of Inspection for Pressure Vessels 294 Inspection Tasks 297 Case Study 1: Construction and Inspection of Replacement Flare Knockout Drum Most Appropriate Inspection Level: Degree Case Study 2: Construction and Inspection of Replacement Flue Gas Cooler Most Appropriate Inspection Level: Degree 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

9 xii Contents API 510: Pressure Vessel Inspection Code 350 National Board Inspection Code (NB Code) 352 Authorized Inspector versus ASNT-Certified NDE Technician 352 Forms of Deterioration 353 General Considerations 353 Internal Corrosion 353 External Corrosion 355 Thermal Aging 356 General Considerations 356 Fatigue 359 Stress-Corrosion (Environmental) Cracking 360 Internal Erosion 361 Hydrogen Attack 362 Hydrogen Blistering 362 Creep and Stress-Rupture Cracks 363 Analysis of In-Service Inspection Data 364 General Considerations 364 Internal Corrosion 364 External Corrosion 368 Thermal Aging 368 Fatigue 368 Stress-Corrosion (Environmental) Cracking 369 Internal Erosion 370 Hydrogen Attack 370 Hydrogen Blisters 371 Creep and Stress Rupture 371 Fitness-for-Service Analysis 372 Introduction 372 Background 373 Information Required for Fitness-for-Service Analysis 376 Procedures for Fitness-for-Service Analysis 377 Outline of the Procedure 377 Required Inspection at the Next Scheduled Shutdown 385 Nondestructive Examination (NDE) Techniques 385

10 Contents xiii General Considerations 385 Visual Examination (VT) 385 Dye-Penetrant Examination (PT) 387 Magnetic Particle Examination (MT) 391 Ultrasonic Examination (UT) 399 Crack Sizing 413 Radiographic Examination (RT) 417 Chapter 7: Repair, Alteration, and Re-rating 425 Overview 425 Code and Jurisdiction Requirements 426 ASME Code 426 Jurisdictional Requirements 427 National Board Inspection Code versus API Repairs 437 General Considerations 431 Design of the Repair 438 Planning and Approval 443 Organization Making the Repair 444 Replacement Parts 445 Repair Welding 445 Post-Weld Heat Treatment (PWHT) 446 Inspection and Hydrotest 447 Approval of Repairs, Documentation, and Nameplate 449 Alteration 450 General Considerations 450 Planning and Approval 451 Organization Making Alterations 451 Materials, Replacement Parts, Welding, PWHT, and Inspection 452 Hydrotest after Alterations 452 Approval of Alterations, Documentation, and Nameplate 453 Re-Rating 454

11 xiv Contents General Considerations 454 Organization Making Re-Rating 454 Calculations 455 Information Required 456 Approval of Re-Rating, Documentation, and Nameplate 457 Index 471