GUIDEBOOK FOR THE DESIGN OF ASME SECTION VIII PRESSURE VESSELS Fourth Edition

Transcription

1 GUIDEBOOK FOR THE DESIGN OF ASME SECTION VIII PRESSURE VESSELS Fourth Edition by James R. Farr Wadsworth, Ohio Maan H. Jawad Camas, Washington

2 2010, ASME, 3 Park Avenue, New York, NY 10016, USA ( All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher. INFORMATION CONTAINED IN THIS WORK HAS BEEN OBTAINED BY THE AMERICAN SOCIETY OF MECHANICAL EN- GINEERS FROM SOURCES BELIEVED TO BE RELIABLE. HOWEVER, NEITHER ASME NOR ITS AUTHORS OR EDITORS GUARANTEE THE ACCURACY OR COMPLETENESS OF ANY INFORMATION PUBLISHED IN THIS WORK. NEITHER ASME NOR ITS AUTHORS AND EDITORS SHALL BE RESPONSIBLE FOR ANY ERRORS, OMISSIONS, OR DAMAGES ARISING OUT OF THE USE OF THIS INFORMATION. THE WORK IS PUBLISHED WITH THE UNDERSTANDING THAT ASME AND ITS AUTHORS AND EDITORS ARE SUPPLYING INFORMATION BUT ARE NOT ATTEMPTING TO RENDER ENGINEERING OR OTHER PROFESSIONAL SERVICES. IF SUCH ENGINEERING OR PROFESSIONAL SERVICES ARE REQUIRED, THE ASSISTANCE OF AN APPROPRIATE PROFESSIONAL SHOULD BE SOUGHT. ASME shall not be responsible for statements or opinions advanced in papers or... printed in its publications (B7.1.3). Statement from the Bylaws. For authorization to photocopy material for internal or personal use under those circumstances not falling within the fair use provisions of the Copyright Act, contact the Copyright Clearance Center (CCC), 222 Rosewood Drive, Danvers, MA 01923, tel: , Requests for special permission or bulk reproduction should be addressed to the ASME Publishing Department, or submitted online at: ASME Press books are available at special quantity discounts to use as premiums or for use in corporate training programs. For more information, contact Special Sales at infocentral@asme.org Library of Congress Cataloging-in-Publication Data Farr, James R. Guidebook for the design of ASME section VIII pressure vessels / by James R. Farr, Maan H. Jawad. 4th ed. p. cm. Includes bibliographical references and index. ISBN Pressure vessels--design and construction. 2. Structural engineering. I. Jawad, Maan H. II. Title. TA660.T34F dc Cover photo courtesy of the Nooter Corporation, St. Louis, Missouri.

3 Dedicated to the Farr Family and the Jawad Family, to all of the kids and their spouses, and to all of the grandkids & great-grandkids for their love and support during the years.

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5 PREFACE TO FOURTH EDITION In a continuing quest to contain the latest, modern information for the design and construction of pressure vessels and pressure vessel components, the ASME Boiler and Pressure Vessel Code, Section VIII, is a continually changing document. The 2007 Edition of Section VIII, Division 1, added metrification in some of the figures and tables as well as a list of permissible materials of construction. It also added alternative rules for nozzle reinforcement. Other changes were made to clarify the intent of various paragraphs and to update the Code to current technology. The 2007 Edition of Section VIII, Division 2, was completely revised including a change in the paragraph numbering system. The 2007 Edition of VIII-2 was issued on July 1, 2007 and became mandatory on January 1, However, the changes were so extensive that a special Code Case was issued to provide an extra 18 months beyond this regular expiration date of the 2004 Edition when either the 2004 Edition with Addenda or the 2007 Edition was allowed. The allowable design stress basis of the 2007 Edition of VIII-2 was revised to be the lowest of the ultimate tensile strength divided by 2.4 or two-thirds specified minimum yield strength at design temperatures where creep and rupture are not controlling factors. For austenitic materials and some non-ferrous alloys, 90% yield strength is also permitted. At elevated temperatures, allowable stresses are also controlled by the same creep and rupture criteria as VIII-1. The values of the ultimate tensile strength and yield strength are based on trend curves established by Section II of the ASME Boiler and Pressure Vessel Code. Many design rules which were in VIII-1 are now also in VIII-2 with use of extensive design equations. Some of the design rules in the previous editions of VIII-2 are continued while many have been changed or deleted. Both Design by Rules and Design by Analysis continue to be included in VIII-2. Some of the important additions and revisions in the 2007 Edition of VIII-2 are: (1) addition of weld joint efficiencies where previous rules required 100% volumetric examination of main vessel and vessel component welds; (2) new design rules for ellipsoidal and torispherical heads; (3) new opening reinforcement rules based on pressure-area (similar to ASME B31.3); (4) new conical transition rules; (5) added rules for jacketed vessels, noncircular vessels, and vessel supports; (6) permits setting the minimum wall thickness by Design by Analysis instead of Design by Rules, if desired. With the major revision to VIII-2 and the deletion or change to many previous design rules, a new Appendix F has been added to this book for easy reference to some of the previous design rules which have been deleted or changed.

6 vi Preface to Fourth Edition As described in the Preface to the 3 rd Edition (December 2005) of this book, brittle fracture and heat exchanger rules were update. It is also of interest to note that the Preface to the 2 nd Edition (July 2001) describes the reduction of the design factor for the first time in 50 years for the allowable stress criteria on ultimate tensile strength in the 2001 Edition of VIII-1 from 4.0 down to 3.5. James R. Farr Wadsworth, Ohio Maan H. Jawad Camas, Washington January 2010

7 Preface to First Edition The ASME Boiler and Pressure Vessel Code, Section VIII, gives rules that pertain to the design, materials selection, fabrication, inspection, and testing of pressure vessels and their components. With few exceptions, the rules that cover the design of components tend to be complicated to implement. This book was written to demonstrate the application of the design rules to various components. Other rules, such as those pertaining to fabrication, inspection, testing, and materials are not covered here. This book is intended as a reference for designers of pressure vessels and heat exchangers. The theoretical background of the equations used here was kept to a minimum, since such background can be obtained from other references. Note also that while the design requirements of such components as shells and heads are interspersed throughout the ASME Code, design requirements pertaining to some specific components are given here in one chapter for easy reference. The emphasis in this book is on solved examples, which illustrate the application of the various equations given in the ASME Section VIII Code. Chapter 1 of this book covers background information and general topics such as allowable stresses and joint efficiencies applicable to all components. Chapter 2 is for the design of cylindrical shells under internal and external loads. Chapter 3 covers the design of dished heads and transition sections that are under internal and external loads. Chapter 4 considers flat plates, covers, and flanges. Openings are reviewed in Chapter 5, and Chapter 6 covers special components of VIII-1, such as stayed construction, jacketed components, half-pipe jackets, and noncircular vessels. Chapter 7 covers heat exchangers, and Chapter 8 covers stress categories, fatigue, and other special analysis of components. James R. Farr Wadsworth, Ohio Maan H. Jawad St. Louis, Missouri January 1998 vii

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9 ACKNOWLEDGMENTS We are continually indebted to the many people, students, and organizations for their comments, corrections, and suggestions to us to help us keep this book up-to-date with the latest Code additions and revisions. Our fellow ASME Committee Members and associates also have continually aided us with background and new development items, and we thank them for the help. In addition, we want to thank all of those persons and companies that have permitted us to use some of their code material in this book. And last, we also want to acknowledge our mentors from long ago without whom we would not be in code activities Mr. Ralph A. Ecoff of Nooter Corporation, mentor to Dr. Jawad and Mr. Paul M. Brister of Babcock & Wilcox Company, mentor to Mr. Farr. A special thanks is also given to Mary Grace Stefanchik and Tara Smith of ASME for their valuable assistance and guidance in editing and assembling the book. ix

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11 TABLE OF CONTENTS Preface to Fourth Edition... v Preface to First Edition...vii Acknowledgments... ix List of Figures... xv List of Tables... xix Chapter 1 Background Information Introduction Allowable stresses Weld Joint Examination Requirements Requirements for VIII Requirements for VIII Brittle Fracture Considerations Fatigue Requirements and Protection Against Failure From Cyclic Loading Rules for Fatigue Analysis in VIII Rules for Fatigue Analysis in VIII Pressure Testing of Vessels and Components ASME Code Requirements What Does a Hydrostatic or Pneumatic Pressure Test Do? Pressure Test Requirements for VIII Pressure Test Requirements for VIII Corrosion Allowance in Design Formulas and Calculations Consideration of Amount of Corrosion Consideration of Corrosion Allowance in Design Minimum Thickness of Pressure Retaining Components Chapter 2 Cylindrical Shells Introduction Tensile Forces, VIII Thin Cylindrical Shells Thick Cylindrical Shells Axial Compression VIII-1 Rules for Axial Compression VIII-2 Rules for Axial Compression External Pressure External Pressure for Cylinders with D o /t ³ External Pressure for Cylinders with D o /t < xi

12 xii Table of Contents Empirical Equations Stiffening Rings Attachment of Stiffening Rings Cylindrical Shell Equations, VIII Internal pressure External Pressure Miscellaneous Shells Mitered Cylinders Elliptical Shells Chapter 3 Spherical Shells, Heads, and Transition Sections Introductions Spherical Shells and Hemispherical Heads, VIII Internal Pressure in Spherical Shells and Pressure on Concave Side of Hemispherical Heads External Pressure in Spherical Shells and Pressure on Convex Side of Hemispherical Heads Spherical Shells and Hemispherical Heads, VIII Pressure on the Concave Side Pressure on the Convex Side Ellipsoidal Heads, VIII Pressure on the Concave Side Pressure on the Convex Side Torispherical Heads, VIII Pressure on the Concave Side Pressure on the Convex Side Ellipsoidal and Torispherical Heads, VIII Torispherical Heads Ellipsoidal heads Conical Sections, VIII Internal Pressure External Pressure Conical Sections, VIII Internal Pressure External Pressure Miscellaneous Transition Sections Chapter 4 Flat Plates, Covers, and Flanges Introduction Integral Flat Plates and Covers Circular Flat Plates and Covers Noncircular Flat Plates and Covers Bolted Flat Plates, Covers, and Flanges Gasket Requirements, Bolt Sizing, and Bolt Loadings Flat Plates and Covers With Bolting Blind Flanges & Circular Flat Plates and Covers Noncircular Flat Plates and Covers Openings in Flat Plates and Covers Opening Diameter Does Not Exceed half the Plate Diameter Opening Diameter Exceeds half the Plate Diameter

13 Table of Contents xiii 4.6 Bolted Flange Connections ( Joints) Standard Flanges Special Flanges Flange Rigidity Bolted Dished Covers Definitions and Terminology Two Types of Dished covers Chapter 5 Openings Introduction Code Bases For Acceptability of Opening Terms and Definitions Reinforced Openings-General Requirements Replacement Area Reinforcement Limits Comparing Methods of Problem Solving of Reinforced Openings in VIII-1 vs. VIII Reinforced Openings Rules in VIII Openings With Inherent compensation Shape and Size of Openings Area of Reinforcement Required Limits of Reinforcement Area of Reinforcement Available Openings Exceeding Size Limits of Section Alternative Design Rules for Reinfoced Openings in Cylindrical and Conical Shells Alternative Design Rules for Large Reinforced Openings in Cylindrical and Conical Shells Reinforced Opening Rules in VIII Definitions, Symbols, and Terms Shape and Size Limits of Openings Configurations of Reinforced Opening Equations Given in Design by Rules of VIII Ligament Efficiency Rules Ligament Efficiency vs. Weld Joint Efficiency Nomenclature Calculation Rules Chapter 6 Design by Rules For Some Special Components in VIII-1 and VIII Introduction and Background Braced and Stayed Construction Braced and Stayed Surfaces Stays and Staybolts Jacketed Vessels Types of Jacketed Vessels Design of Closure Member for Jacket to Vessel Design of Openings in Jacketed Vessels Half-Pipe Jackets Maximum Allowable Internal Pressure in Half-Pipe Jacket Minimum Thickness of Half-Pipe Jacket Vessels of Noncircular Cross Section Types of Vessels and Pressure Loading

14 xiv Table of Contents Basis for Allowable Stresses Openings in Vessels of Noncircular Cross Section Vessels of Rectangular Cross Section Chapter 7 Design of Heat Exchangers Introduction Design of Tubesheets in U-Tube Exchangers Nomenclature Preliminary Calculations Design Equations Fixed tubesheets Nomenclature Preliminary Calculations Design Equations Additional Rules Methods of Attaching Tubes-to-Tubesheet Push Out Tests Tube-to-Tubesheet Locking Mechanism Expansion Joints Chapter 8 Design by Analysis of Components in VIII Introduction Stress Categories Stress Concentration Combinations of Stresses Fatigue Evaluation References Appendices Appendix A Guide to VIII-1 Requirements Appendix B Material Designation Appendix C Joint Efficiency Factors For Design of VIII-1 Vessels Appendix D Flange Calculation Sheets For VIII-1 Flanges Appendix E Units of Measurement and Conversion Factors Appendix F Some Design Items Prior to the 2007 Edition of VIII Index

15 List of Figures Figure Number 1.1 Welded Joint Categories (ASME VII-1) Category C Weld... 9 El.l Some Governing Thickness Details Used for Toughness (ASME VIII-1) Impact-Test Exemption Curves (ASME VIII-1) Charpy Impact-Test Requirements for Full Size Specimens for Carbon and Low Alloy Steels With Tensile Strength of Less Than 95 ksi (ASME VIII-1) Reduction of MDMT Without Impact Testing (ASME VIII-1) E Fatigue Curves for Carbon, Low Alloy, Series 4XX, High Alloy Steels, and High Tensile Steels for Temperatures Not Exceeding 700 F (ASME 2004 VIII-2) Comparison of Equations for Hoop Stress in Cylindrical Shells Chart for Carbon and Low Alloy Steels with Yield Stress of 30 ksi and Over, and Types 405 & 410 Stainless Steels C Factor as a Function of R/T (Jawad, 2004) E Geomatic Chart for Cylindrical Vessels Under Extrenal Pressure (Jawad and Farr, 1989) Some Lines of Support of Cylindrical Shells Under External Pressure (ASME VIII-1) E Some Details for Attaching Stiffener Rings (ASME VIII-1) Mitered Bend Elliptical Cylinder E E E E Reinforcement at Cone-to-Shell Junction (ASME, VIII-2) E xv

16 xvi List of Figures Some Acceptable Types of Unstayed Flat Heads and Covers (ASME VIII-1) Multiple Openings in the Rim of a Flat Head or Cover With a Large Central Opening (ASMEVIII-1) E4.5 Ring Flange Sample Calculation Sheet E4.6 Welding Neck Flange Sample Calculation Sheet E4.7 Reverse Welding Neck Flange Sample Calculation Sheet Dished Covers with Bolting Flanges (ASME VIII-1) E4.8 Example Problem of Spherically Dished Cover, Div Some Representative Configurations Describing the Reinforcement Dimension t e And the Opening Dimension d (VIII-1) Reinforcement Limits Parallel to Shell Surface Chart For Determining Value of F For Angle q (ASME VIII-1) Determination of Special Limits For Setting t r For Use in Reinforcement Calculations E5.1 Example Problem of Nozzle Reinforcement in Ellipsoidal Head, Div E5.2 Example Problem of Nozzle Reinforcement of 12 in. 16 in. Manway Opening, Div E5.3.1 Example Problem of Hillside Nozzle Reinforcement, Div. 1 (Longitudinal Plane) E5.3.2 Example Problem of Hillside Nozzle Reinforcement, Div. 1 (Circumferential Plane) E5.4 Example Problem of Nozzle Reinforcement With Corrosion Allowance, Div (ASME VIII-1) (ASME VIII-1) Nomenclature for Reinforced Openings (ASME VIII-2) Nomenclature for Variable Thickness Openings (ASME VIII-2) Radial Nozzle In a Cylindrical Shell Hillside Nozzle In a Cylindrical Shell Nozzle In a Cylindrical Shell Oriented at an Angle From The Longitudinal Axis Radial Nozzle In a Conical Shell Nozzle In a Conical Shell Oriented Perpendicular to the Longitudinal Axis Nozzle In a Conical Shell Oriented Parallel to the Longitudinal Axis Radial Nozzle In a Formed head Hillside or Perpendicular Nozzle In a Formed Head E5.5 Example Problem of Reinforcement of Radial Nozzle in 2:1 Ellipsoidal Head, Div E5.6 Example Problem of Reinforcement of Radial Nozzle in Cylindrical Shell, Div. 2 (with Inside Corrosion Allowance) Diagram For Determining The Efficiency of Longitudinal and Diagonal Ligaments Between Openings in Cylindrical Shells Diagram For Determining Equivalent Longitudinal Efficiency of Diagonal Ligaments Between Openings in Cylindrical Shells E5.7 Example Problem of Nozzle Reinforcement of Series of Openings, Div Typical Forms of Welded Staybolts (VIII-1) Typical Welded Stay for Jacketed Vessel (VIII-1) Some Acceptable Types of Jacketed Vessels (VIII-1) Some Acceptable Types of Closure Details (VIII-1) Some Acceptable Types of Penetration Details (VIII-1) Straight and Spiral Jackets, Half-Pipe and Other Shapes Factor K for NPS 2 Pipe Jacket Factor K for NPS 3 Pipe Jacket Factor K for NPS 4 Pipe Jacket Vessels of Rectangular Cross Section Vessels of Rectangular Cross Section with Stay Plates Vessels of Obround Cross Section with and Without Stay Plates and Vessels of Circular Cross Section with a Stay Plate

17 List of Figures xvii 6.13 Plate with Constant-Diameter Openings of Same or Different Diameters Plate with Multidiameter Openings E6.8 Example Problem of Noncircular Vessels (VIII-1) Various Heat-Exchanger Configurations (TEMA, 1999) A Tubesheet Integral with Shell and Channel (ASME. VIII-1) B Tubesheet Integral with Shell and Gasketed with channel, Extended as Flange (ASME. VIII-1) C Tubesheet Integral with Shell and Gasketed with Channel, not Extended as a Flange (ASME. VIII-1) D Tubesheet Gasketed with Shell and Channel (ASME. VIII-1) E Tubesheet Gasketed with Shell and Integral with Channel, Extended as a Flange (ASME.VII-1) F Tubesheet Gasketed with Shell and Integral with channel, not Extended as a Flange (ASME. VIII-1) Tubesheet Geometry (ASME. VIII-1) Typical Untubed Lane Configurations (ASME VIII-1) Curves for the Determination of E*/E and v* (ASME. VIII-1) A Tubesheet Integral with Shell and Channel (ASME. VIII-1) B Tubesheet Integral with Shell and Gasketed with Channel, Extended as a Flange (ASME. VIII-1) C Tubesheet Integral with Shell and Gasketed with Channel, not Extended as a Flange (ASME. VIII-1) D Tubesheet Gasketed with Shell and Channel (ASME. VIII-1) X a versus Z d, Z v, Z w, and Z m (ASME VIII-1) X a versus F m with Negative Values of Q 3 (ASME VIII-1) X a versus F m with Positive Values of Q 3 (ASME VIII-1) Some Acceptable Types of Tube-to-Tubesheet Attachments (ASME VIII-1) Some Acceptable Types of Tube-to-Tubesheet Strength Welds (ASME VIII-1) Schematic Detail of a Hydraulic Tube Expander Typical Detail of Grooves in a Clad Tubesheet Some Bellows-Type Expansion Joints (ASME VIII-1) Some Flanged and Flued Expansion Joints (ASME VIII-1) E Linearizing Stress Distribution E8.4 Model of a Finite Element Layout in a Flat Head-to-Shell Junction Fatigue Curves for Carbon, Low Alloy, 4XX High Alloy, and High Strength Steels for Temperatures Not Exceeding 700 F (ASME VIII-2) Cyclic Curves A.l C.l C C C C C C C C C C C C

18 xviii List of Figures C C C C C C C.20.E D.l Ring Flange with Ring-Type Gasket D.2 Slip-On or Lap-joint Flange With Ring-Type Gasket D.3 Welding Neck Flange with Ring-Type Gasket D.4 Reverse Welding Neck Flange With Ring-Type Gasket D.5 Slip-On Flange With Full-Face Gasket D.6 Welding Neck Flange with Full-Face Gasket F.1 Nozzle Nomenclature and Dimensions F.2 Limits of Reinforcing Zone for Alternative Nozzle Design E.F.1 Example Problem of Nozzle Reinforcement in Ellipsoidal Head, Div E.F.2 Example Problem of Nozzle Reinforcement of 12 in. 16 in. Manway Opening, Div F F.4 Inherent Reinforcement for Large End of Cone-To-Cylinder Junction F.5 Value of Q for Large End of Cone-To-Cylinder Junction F.6 Inherent Reinforcement for Small End of Cone-To-Cylinder Junction F.7 Value of Q for Small End of Cone-To-Cylinder Junction

19 List of Tables Table Number Criteria for Establishing Allowable Stress Values for VIII-1 Except for UCI, UCD, and ULT Material and for Bolting (ASME II-D) Criteria For Establishing Allowable Stress Values For VIII-1 For UCI, UCD, and ULT Material (VIII-1) Criteria for Establishing Allowable Design Stress Values for VIII-2 Except for Bolting Material Stress Values for SA-516 and SA-387 Materials Allowable Stress Values For Welded Connections Maximum Allowable Joint Efficiencies for Arc and Gas welded Joints For VIII E1.1 Stress Categories Examination Groups (VIII-2) NDE Requirements (VIII-2) Assignment of Materials to Curves (ASME VIII-1) Minimum Design Metal Temperatures in High Alloy Steels Without Impact Testing Tabular Values for Fig Factor K o for an Ellipsoidal Head with Pressure on the Convex Side Values of D for Junctions at the Large Cylinder Due to Internal Pressure Values of D for Junctions at the Small Cylinder Due to Internal Pressure Values of D for Junctions at the Large Cylinder Due to External Pressure Pressure Applied to Large End Junction (ASME, VIII-2) Stresses at Large End Junction (ASME, VIII-2) Pressure Applied to Small End Junction (ASME, VIII-2) Stresses at Small End Junction (ASME, VIII-2) Example of Pressure Used for Design of Components Closure Detail Requirements for Various Types of Jacket Closures Detail Dimensional Requirements For Closures Listed in Table Jacket Opening and Penetration Detail Requirements Special Requirement Details as Listed in Table Joint Efficiencies f r for various tube-to-tubesheet attachments (ASME VIII-1) Primary Stress Category Structural Discontinuity Thermal Stress Stress Categories and Limits of Equivalent Stress (ASME VIII-2) Classification of Stresses (ASME VIII-2) Some Stress Concentration Factors Used in Fatigue xix

20 xx List of Tables E8.4 Summary of Finite Element Output B.l Carbon Steel Plate B.2 Chrome-Moly Steel Plate Specifications, SA B.3 Chrome-Moly Steel Forging Specifications, SA B.4 Chrome-Moly Steel Forging Specifications, SA B.5 Quench & Tempered Carbon and Alloy Steel Forgings, SA D.1 Flange Type Rigidity Criterion E.1 Conversion of U.S. Customary Units to SI Units