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r,. tand calculation, and the thermal restraint part is not all
n.: difficult.
.\s you recall from school, the basic idea is to calculate
nc thermal growth an unrestrained body would undergo, in
-:,-rging from one temperature to another. Next, determine the
rL:rting effect of full or partial constraint of that expansion by
.: re rigid or elastic structure. The stresses, which we visualize
i' -ing created by the imaginary process of forcing the thermal
,:rins to reverse, by the full or a selected partial amount, are
with
these
;1
.)
ir
lt
106 . Chapter 6
failure. Stress concentrations are to be avoided when a
pafi's temperature must cycle. This means the shape
No melting, no
sagging
like taffy, no
cryose:lr
fracturing.
cally or abruptly.
In all cases, our simplified equations consider the properties constant over the temperature change range, ho-
mogeneous
5.
6.
1.
density,
fiiG
:u:"
rrl
-d
Lur:l
_r!li
Jl:g
i1-llr
@ T*AT
!:'i-'
;
inl
. ,{rl
I-ieure
= thermal exp.
6-1
coefficient
(1
v)
1O7
108 . Chapter 6
Q ra/,ius J'r*
plug 6{
'radius 'AThe solid circular disk is initially at uniform equilibrium temperature = "T.
At a given instant, the shaded volumetric plug region at the center, which is the radius "a," has its
temperature raised to a new value by amount "AT ' (A sudden local electrical current flowing thru center, for
example, could create heat and the AT in the resisting disk material^ The stress at location of interest radius
"/' depends on location: INSIDE or OUTSIDE of the heated reqion "a."
OUTSIDE heated region: r ) o I op is compressive, o1 is tensile, and they are equalto each
other in absolute magnitude;
q:sEjal}a-Jzft
INSIDE heated region: I < I i on and or are both compressive, and they are equal to each
other in absolute magnitude;
qiqElAI--2
= T = thermal exp.
coefficient
tF{l,r
qtuD c
-T
L*"d
}L
O"y
X|
dl
,sl
I
*lfe{ -',-
"fir VnN
- Hea**dt'
Ylr f*R
fnsg Vtgu.l I T*l,p.**file
is initially at uniform equilibrium temperature = "T." Thenn ils entire circumference is uniformly
heated so that a higher equilibrium temperaiure distribution arisee as shown above.
"ri" anylvhere in or on the disk, with or = the radial and st = the tangential stress vectors, ihe stresses are as given
these expressions, plus sign means tensile and minus sign denotes compressive stress"
below.
In
0,6:0
@r:R,O=Or",
ii the thermal boundary conditions cause the temperature distribution to change with time, then the stress distributions will change to {it
ihe new temperature distribution. As long as the temperature distribution remains radially symmetrical, the equations lor the stress
d istribution remain accurate-
o11=(aE)((tn')
ox = {rrE}
^l
'
Jordr-(1/r11jordr)
(-o+1rn21 J orcr+11tr12}J o
radialdirection
ror}
tangential
o rr =
"l"
"r"
109
110 . Chapter 6
*y
rX
The solid straight bar of uniform cross-sectional dimensions is initially at uniform equilibrium temperature =
"T." Then the bar is heated uniformly throughout, but is prevented from lengthwise expansion by singledimensional end anchor structures which are rigid in the bar's lengthwise direction. The bar is free to
expand or contract in the other two space dimensions, including the ends contacted by the anchors.
At a given instant, the bar's temperature has risen to a new value by amount "AT." The compressive
"length-axial" direction normal stress is given below. lt should always be remembered that these thermal
expansions when heat is added to a svmmetrical body are the mirror images of thermal contraction of the
body when it is cooled. The algebraic signs of stress, AT and directions of thermal motion of course
are reversed, but the same stress equations apply.
q=-sE (AI)
o = Thermal Stress (normal and/or planar [typicalt) (lbflin.z)
r = Thermal Stress (shear) (lbf/i^n.')
E = Modulus
of Elasticity (lbflin.')
cr = T =
Figure
6-4 Thermal
Cross-Section
Stress Due to External Restraint: Single Dimension Restraint of Ends of Bar of Uniform
rh
{m,
EY
+Y
rX
,y
The solid flat plate resides in the X-Y plane. lts thickness lies in the Z direction. The plaie is of uniform
.ross-secti0n, and is initially at uniform equilibrium temperature = "T." Then the plate is heated uniformly
:hroughout, bui is prevented from expansion in the X-Y plane by rigid structure. lt is free to expand or
coniract in the Z{hickness dimension, including at the perimeter edge, fully contacted by the resiraining
$ructure.
At a given instant, the bads temperature has risen to a newvalue by amount "AT," The compressive plane
slress is given below.
Unless you specifically knoui vfor the metal, you might Wsh to use y= 0.30 per the ASME Piping and
tressure Vessel Codes oractice.
q E-sElAT}-r-1-1-:rd
[typical]] (lbilin,2]
Ir
Fleure
,imraint
6-5 Thermal Stress Due to External Restraint: Complete Two-Dimensional Circumferential Edge Reof Flat Plate of Uniform Cross-Section
Chapter 6
+Y
tr
r-Y
tlx
The solid three-dimensional body is initially at uniform equilibrium temperature = "T." Then the body is
heated uniformly throughout, but is prevented from expansion in any direction by rigid structure which
encloses and bears upon the entire outersurface ofthe body.
At a given instant, the body's temperature has risen to a newvalue by amount "AT." The compressive
stress is given below. (This would be a difficult physical arrangement to set up in practice, but is useful for
understanding what happens. )
Unless you specifically know v tor a metal, you might wish to use v= 0.30 per the ASME Piping and
Pressure Vessel Codes practice. We assume it is homogenous and isotropic.
o=crE(ATl + (1-2v)
o = Thermal Stress (normal and/or^planar [typicalt) (lbf/in.2)
r = Thermal Stress (shear) (lbf/i^n.')
of Elasticity {lbf/in.')
v
Poisson's
Ratio (use 0.3 for steel)
lt= =
cr = y = thermal exp. coefficient
E = Modulus
6-6
Thermal Stress Due to External Restraint: Complete Three-Dimensional Outer Surface Restraint of
Solid Bodies and Flat Plates of Uniform Cross-Section
Figure
-he illustrated example of this case is for one specific set of end restraint conditions. There are many other
:ossible types of restraints, and they have their own solutions. You can get them from Roarks magnificent
^andbook of stress and strain, which is given in the bibliography: (37), Young, Warren C. Roark's
=crmulasforStress and Strain, McGraw-Hill, Inc., NewYork, NY, Oth ed., 1989.
:or a bunch of other end conditions and cases, see these Tables in Roark. chapter
7:
Table 3, 6a4f
Table 4, 1r-12r
Table 7, case 7
Table 8, case 7
Table'10, 6a4f
Table 1'1,6a-6f
-he first illustration is for the unrestrained bar, which curyes into
{0,
*i
(t\r
*b".t
*,,
'xnl
k1
ftTr
({ineor
tetn7.
-
,!,'itribntiin)
=fffi
TreEr.Iry
T
(
q,
sect.
,&f
:i
q.t
bar
-q .l*
5<
q, .+
tuF-+'l *
ronst''s*
efd
*erny. h _f
,,
,,
&rgfees
@
6 uer r^' h o e r.% of bqr
,
6-7 Rectangular Bar with Linear Temperature Gradient Perpendicular to Bar's Length Axis: Curvature
d L nrestrained Bars, and Thermal Stress Due to External Restraint
Ilsure
113
114 . Chapter 6
But if the bar is restrained by a rigid couple at its ends, keeping it straight, the hot side is compressed and
the cold side is stretched as shown in the diagram.
sv
cr*
.#
Y'
14
tt
L
*s
et
..c
The couple "C" in in.ibf units which the bar imposes on the rigid restraints is:
A-=-rH(Alll-rt
The max bending stresses in lbflin.2 are:
Max. gending Stress
E = Modulus
p=
of Elasticity (lbflin.2)
cr = y =
I
i
-ls was the similar case for rectangular bars, this illusffated exarnple is also good fcr only
cf
* *y.2 "-T'l
rcdr"as
Aariler.o
L the dead weight of the,circular plate is
dre perimeter, perpendicular to the pLane of the
dren there are no therrnal shesses in the plate"
edge support reactions are theteu nf cnurse, but
rill stiil be as given above"
fu*p * nT*AT*
is
.tTrl
r7
fn6s
@
Dcs. vtEW
-TEMfi
UNIF6RM
--r-
'
-fr
ll I
<a
Hor
n6n *
c ird{{l4rr
pla*e.
b^l
Borprl
cl y.c.
Nkk
pta*e
Tar vtrw
Flgure 6-8 Flat Plate, Any Plane Shape, with Linear Temperature Gradient Between Hot and Cold Faces:
furvature of Unrestrained Circular Plate and Thermal Stress in Plate of Arbitrary Shape Due to Edges Being
Homent-Clamped All Around by External Restraint
115
16 .
Chapter 6
ff the flat planar plate, of any shape and uniform thickness, is continuously restrained by
rigid couples at around its perimeter edge keeping it flaf the hot face side is under
compressive stress and the cold face side is stretched in tension. The expression for
maximum bending stresses, which occur on the surface, is the same
6-7.That is,
The max bending stresses
ln
It
ift{l
li'
l,
lx
i{l
itu
i4
l{
as
CHAPTER
UrrurY
PrprNG SysrEMS
'-"lFne
,dl{lune
The college courses dealing with mechanics of solids mentioned piping only in passing, but certainly not in enough depth
to convey understanding or gut feeling for the subject. If stress
118 .
Chapter 7
0r.il
nc
RIGID
\IERTIC,AL
SUPPORT
,il'
lld
TERMIML CONNECTION
( AilrcHoR )
.,lill
6'
-'trrl|-r
fillulr
3'
4',
'i
[]rT"
rrg,
ml
,lirtidS
z',
il
3'
Irlifi
19
+Y
6'
ill
il
'l!l
mml
I
'ti
4',
t
fl
ii
1,tl
M,!t
ilm
,]1llll
ilur
.liill[tl1
,t
dl,i
TERMIML CONNECTION
4i
JIIII
{ ANCHOR )
NODAL COORilNATES
@illll
mrr
trfulllr
,rd
Figure
7-1:
{f
Piping Isometric
l:
.U$rMl
tor quantities.)
STATEMENT OF PROBLEM
Find the stress in the pipe wall at terminal end node #10.
illrllE
i[lMI
il04
7-l
andconvert it to
freebody diagram by
\A'i
rep.uru
tris-
forces and moments, which would be acting on the crossnormal to the pipe's longitudinal axis (which lies paralle
the X-axis at nodes #10 and #80.)
We would add the weight vectors representing the c
bined weight of pipe steel, water and insulation to the free
ry
d[
iM
m6
rn
be done.
r"*e
'
119
restraint:340
netsum=3+340=343
due to thermal
(ot, o.,
these
tll'l "
lrtsum=5+111=116
b. The
stresses
any specific given point along the pipe longitudinal axis," are on
the outer surface of the pipe. They are expressed in cylindrical
120 . Chapter 7
*t'
+3"
M
rUr,
\",
q;-"*
Pol"r* pn f;ryfa-ce ot
@ hj*cde" d* JC)
?;y*
"t+
I
4'
*X
nL-
NI
lnl
tfr
d"#.4jls
lTl
.itJ
"
ouf*
a{ yge""
tm
xI
5
P
{l
\JI
StTes $sf
;
$_3
{\{*#;*
i;F
\ r*r
:-! \Jr
ID
#ff-
ii.\ ?*" *
Js*-
]T
Srt sfybsje.s
6.e . *13* braice ll;1
ae*t tr\)e- . CLVL& 4.itg
I
5hor.r,r
ov1
A5 5uc la
l&is e[ew*mt
,t!
lh
TI
1ll:
Figure
7-2:
Freebody at Node 10
.l[
ill
Il
iiral
seam.
=
=
(n)(OD2
M = {(My'
Longitudinal Stresses: o,
-IDr/4
stress = lWZ
:,-'rursework.
121
(Tc)(6.625)
Mzzl =
Fr-Lbf
NOTE:
if
the pipe at node #10, such as water hammer forces or relief valve
thrusts, the resulting longitudinal stress components would join
also
above.
sress=(PxD)/(4t)
.'. NET LONGITUDINAL STRESS
P=80psi
D = 6.625 in.
:jll
or:
31 + 3121) psi =
under-tolerance removed
= i0.875
l}le deformation due to this load is axial tensile strain; the pipe
s stretched lengthways. The stress component algebraic sign
r,i {+) since it is tensile (tension.) Compressive stress by conven::,u is (-).
b. Longitudinal component of stress resulting from anchor
=action Fx of Figure 7-2, which comes from flexure under
:irtic weight of the pipe steel, liquid contents, insulation and
ivging, added algebraically to the axial force generated by
rermal restraint of the piping by the end anchors, which are
r- nodes #10
& #80;
*ress = F/A
["s = 116
Lbf
2. Circumferential Stresses: o.
If
122 . Chapter 7
the hoop would swell in diameter until it snapped at the weakest
714 psi
of internal
stress = (P x
D/(2t) =
ql
3. Shear Stress:
,t,
rI
tl
il
(;
1l
all the other stress vectors are therefore positive in our example,
and are shown in the correct directions by convention on Figure
7-2.
stress=(Txp/(J)
T = Mx = 758 ft-lbf
p = radius of pipe at point of interest = 3.3125 in.
; = polar moment of inertia for the pipe cross r""1ion = (n/
2)(outer radiusa
stress = (V)/(A)
!G'y'+
Fz')
#ll
Thus far, with only one exception, we have done nothing mcr,.:
than perform a typical academic stress analysis of a piece r
steel cylinder, anchored to separate rigid structure at its en8.
subject to the forces of gravity and thermal expansion restrais.
We have used the manual calculation* methods we all leamaa
in our Strength of Materials class in school.
(*As a shortcut, I pulled the thermal expansion forces aru
moments out of a computer pipe stress program, but I cotrt.
i;t
stres.
sure-containment vessel and piping work. This is a point doubt you learned in school: Without a theory of failure weil
defined, s "stresst' value is a useless number.
That is a major difference between
*frlc
strength of materials calculation of the same physical objeci
tional tools.
fo finistr up with our "non-Code" stress analysis, I offer
you Figure 7-3. It contains Mohr's Circle for the plane stresse!
we have calculated. Figure 7-4 is a "freebie" I have includec
for you, so you don't have to waste time looking up Mohr'.
F-[
NT
123
+14ffi
re
ced
erfr,
nm"
,4
red
*ssfl6
rod
d
fft
ffitg + {Sx.,{00*Pl@ile
&n&
fis@
It
alp
f
dtrts
$ldi:
!{e
ffifur
[-gs
Erc
is tr
prye
b"gP
ry
-ff
hosp
inW
lIEffi
itrEil-
rylF
)tm
xr6
&,g
)fltr
HF frE
Led"
prE$-
iill
rul
dil,
nicrl
lga
II
\!
:ir'
:.E:
/tt
}|4
__::-
st
{Il
.e
]r=E.}f '{It
r.J7<
\-. f,{t
-&
-E
r9.,3
esnft
rlEr
ruIr-
rfftr
trdgd
lhr'r
slEnr
t+
veql
)sseF
ril nsi
,n
tn
ligure 7-3: Combined Plane Stresses for Example of Figure 7-2 with Mohr's Circle
ptut
{+
psftt
,
+ffil
124 . Chapter 7
r*
, {ry 7 rry
} exist,
tttb
4c
{tv)
{ry
-J**
[{x )
{ry,-rxJ
kngr.tr.r,
q-$
z-)
'{qo}
/q.t
\e
l*#
/e
rb,
: Qqvs,
$oe the "User's Coo*Booff' for Mohr's Circle on the following Page, please'
Figure
Stress
[,|OHR'$
CIRCLE
"U$ern$ SookBock"
r,
tr, o
and ru, which are found by the usual methcds of mechanics of
materials stress calculation. These values coneaBond to S e 0" on the cube's lefierence axis. Draw lhe Mohr's
Circle o nsrmai stress and t shear stress axes as per thc diagram on previous page. Fositive directions are to
tne fjg,hJ for o and SqWJ't for r ! Thi$ is our empty framerrork fsr the Mshr's Circle plot and construction.
{8.} B*gin with th* knpwn values of
* rv }} 2,
{D.} Plot point {o* nrxy } and then drarnr radius R from center lo the point. The positive direction for shear
stresg on Mohr's Circle is downward! Note that you can plot the other known stress pair, pint {ay I - Txy }
ins{eed, and draw R to it, and we get the *ame end result a cirrle centered at the point {a*vc. ,0} of radius R.
Use connpass and construcl the circle. The principal stresses ofei sr ={qnye. + R} ; {cz = $AVc. - R}. The
rnaximurn shear
T** =
R,
{E.} Now we have a nice right trinngle to play with, see below" We use it with trig lo find lhe values of R & the
physical rstaticn angle B of the planes of principal stress and oJ maximum shear at the point of analysis in ior
on) the phyeicat object. We see that reqardless of the value qf angle 8, the planes of maximum shear are
always 90o from the princioal stress plane-s on the circte, so in the real physical object it is always at
exactly half that value, = {$a frcm th* prine ipal stregs plane;. And fsr what its wor{h, ysu ean note that the
value of absolute S + absolute F = 45o.
{We do aiJ tius becarse sornefifi?es we need fu J<now al/ fftese slless direc{rons wfi mag*fudes in vecfor ftrm far superposifon
in many goblems ra.ilfiple /oadrngs ean exist ff&e bending Bt#s tersrbn prus torsion in a p,p or on a slruf or slaf, and
:hes probtrns' are easier fo anal11,;;e singty and then vse yesfor *ddifisn fo ge{ lihe gn*nd fotaa re$srfant ,sfressesJ
rurp*s$,
vre
{ax*av}fI
*-a-trffi
?@
S = 0.5 arctan
*.rr'(sx-$y }l2l;r'
Rinccyvsense!
il
ft= rl l(trx-o")/2)t*{"*r}'-t
\l
I
I
h-'l
125
126 . Chapter 7
Circle in your Strength of Materials text if you have, by any
chance, gotten a little rusty on the subject.
To summarize the results of stress superposition found
from Mohr's Circle:
.
.
.
.
for mild
Circle radius = maximum in-plane shear stress at Node
#10 = 1,385 psi.
I'
il
q't
l*
11,
[j
>
e
q
steel.
We know from tri-axial stress theory that the maximmtwo dimensional or plane shear stress in the object is exacti'
one-half of the maximum principal plane tensile stress, wher
the tensile stresses at the point in question all have the san::
algebraic sign at all angular orientations ofthe elemental plan:
(i.e., when all points on Mohr's Circle occur on the same siat
of the vertical shear axis, hence are either all in tension or a-.
in compression as in our example problem). So to be sLre t'
avoiding stress failure we must keep the absolute maximur
shear stress below 507o of the maximum allowable tensile yie;:
strength at all times.
Now if this were your answer, I would recognize you i.
a pretty sharp fellow, and would maybe tend to treat you wit:
higher regard in the future. (Maybe. Or maybe not. My be:;
friends tell me I am old, crusty, cranlcy, and unpleasant i',,
nature, and not likely to bestow kudos whether eamed or othe"wise. Others tell me worse.)
Anyway, good for you! For you would be thinking mor:
the way the pipe code and pressure vessel code experts, u'i::
all of their experience and testing data and book-smarts, thini
You would be choosing a different value of allowable stresi
namely 507o of the yield strength, since the published yietr:
strength for the material is by definition the maximum tensir*
stress it can bear without permanent plastic deformation.
For the mild carbon steel, you would choose 0.50 x 35,0-l:
psi yield = 17,500 psi as your maximum allowable shear stres'
By that standard, our example is loaded to a factor of 20tt*
17500 x IOjVo = Ll.44Vo of the maximum allowable value. ;:
is no accident that this mirrors the II.447o we obtained abor :
when we used the maximum tensile yield stress as our criterii,l
wind loads,
had better believe them, tooo if you know what's good for
yah!
The final batch of info I have included in this chapter f :r
your perusal is the little six-page copy of the pipe stress reF\r
for our example problem. If you take the time to study it, r,ru
will see that questions like "What's the pipe stress?" and ";.
the stress in the pipe too high?" are loaded, to the extrenr:
and deserve quiet, thoughtful answers.
TOPIC #20
COMPUTER
OUTPU'f
PAGE I OF 6
28 MAY 02
PIPE
I
tlt
TOPIC 2O.T
STRESS ANA],YSIS
REPORT
ANALYST:
APPROVED:
CHECKED:
DATE:
********************************************
**
**
*
*
*
*
*
**
SYS.PARM: L2 0 A 0 0 0 0 0 0 0 3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0000000000131
11 13 0
0
0
**
********************************************
ECHO
CA=O .
10, PTPEl,ANCH
20,X=4rBR
30'Y:6, BR
Ef,I
th
60, Y=3
70, Z=3, BR
80. X=6rANCH
END
**
rI
illr
!c
2** PIPE
il|
It
PIPE
NO
PROPERTIES
OD
(IN)
THK
{IN)
TEMP E, {E6.PS])
(F)
EC
EH
EXP_R CA
IN/IOO {IN)
.99
PRESS UNI-WT
(PSI)
.095
1,8/FT
80.0
F],ANGE
CI,ASS
39.9
150
RUN 10
BEND 20A
RUN 208
BEND 30A
10
20A
208
30A
30B
.00
3.25
4.00
4. 00
4 . 00
.00
00
.75
5.25
6. 00
.
,00
00 3.25 1
.00 1.18 1
. 00
4.50 1
. 75
1. 18 7
,
130
47
180
41
.00
.'75
.00
.'75
.00
90.00
.00
90. 00
127
128 .
Chapter 7
TOPIC #20
: COMPUTEROUTPUT
RUN 308 40
4.00
RUN 40
50A
4.00
BEND 5OA 5OB
4. OO
RUN 508 60
4.00
RUN 60
?0A
4.00
BnND 70A 708
4.75
RUN 708 80
10. 00
2** SUPPORT DESCRIPTTON **
6.
5.
6.
9.
9.
9.
9.
10
40
80
ANCH
STY
ANCH
21,OAD CASE NO.
E,r
dtl
2**
L,
00 1.00
00
00
75
00
00
00
00
4.00
5.25
6.00
6.00
8.25
9. 00
9. 00
PAGE 2 OF 6
3.25
7.25
1.18
2.25
2.25
r;
.1,
1. 18
2r0
. 00
. 00
90. 00
. 00
. 00
90. 00
. 00
SPRING*CONSTANT
1N
.2818f10
.00
.2818+10
.2818+10
TRiUi
WTIPRS
I*__________
**
(LB)
FY
TYPE PT
4'7
5.25
t"
I'lil
trn
90
90
41
(LB,/IN, FT-LB/DEG)
.00
.00
.00
.15
.00
.00
.75
.00
130
FX
EZ
MY
]"D<
4l
ANCH
F'
J,ir
10
STY
40
ANCH
80
NET
-2
-68
-9
-758
110
-72
599
- 160
-1
-68
-16
*1
69
*55
L'7
*18
67
19
65
-1
-55
56
-22
23
82
-81
59
-58
55
-54
55
*54
55
-54
51
-50
39
-38
39
-3S
39
*38
*598
lL4
161
* 113
114
.00
.70
.70
.00
.00
.70
.70
-29L
-548
-226
-1065
FORCE
P'
trl
il,
Ir
4r
.A
20A
BEND
2OA
208
*A
RUN
2OB
5
_A
30A
BEND
RUN
RUN
BEND
RUN
RUN
BEND
RUN
3OA
308
-A
3OB
5
*A
40
*64
IL2
-1
- 111
242
307
-1
*18
11
-74
-r6
15
592
-5 91
240
-1
4A
50A
-256
5OA
25'7
*239
-209
2IA
-1
62
L2
-11
_A
508
5OB
60
60
*A
70A
7OA
1,
*11
_A
-1
- 100
ZJ
JU
101
* 110
-22
-24
5
*A
MAX,VALUE
2LOAD CASE
6B
-61
7OB
AT PO]NT
-6L
_t
80
-1
-l
r2a
-29
70B
*ll9
*1
17
*1
-L6
111
226
-1
* 110
25
IJ
307
592
25
1A
4A
70
40
70
NO. 1,
',iTlPRS
rs8
10
149
970
842
840
932
730
703
1869
1869
Lr49
14 93
863
66
"7
785
197
868
959
800
751
1883
2209
10
.00
.42
.42
. (10
.00
.42
.42
.00
1. 00
1. 00 1. 00
1.00 1. 00
1. 00 1. 00
1. ?0 r.42
1.70 'r.42
1. 00 1.00
1. 00 1.00
1.00 1.00
1. 00 1. 00
1.70 7,42
1.70 r.42
1. 00 1. 00
1. 00 1. 00
PAGE 3 OF 6
DX
IN)
IN)
*.01
2AB
.00
.01
30A
308
60
.01
.01
.00
.00
.00
70A
.Oil
708
.00
.00
.01
*.
5{lA
508
80
].:AX.VALUE
,]-: POINT
.00
10
:-v
Ai
,I,ICH
_____F"ORCES,
20A
20A
208
]JN
2AB
:trND
30A
30A
],UN
308
308
40
* n1 1
.003
. c13
*.
MY
FY
EZ
- 111
-465
-340
-689
338
126
340
1-23
111
MX
946
00
1455
-110
-465
-339
_6BB
111
- 110
111
466
- 465
465
-158
340
-339
689
- 433
340
434
-110
-465
-339
10 9?
159
- 413
4L4
- 413
340
-1096
10 03
111
466
4r4
-330
*110
*4 65
111
- 110
111
466
340
*1002
-465
-339
-5 09
L27
340
510
*29
-339
340
* 668
669
* 168
252
*33
331
30
*110
*L26
111
'r27
508
508
-110
-126
-339
-508
:.iJN
111
* 110
111
- 110
111
* 110
111
- 110
121
*L26
340
*339
509
257
252
L27
340
-256
-257
340
-501
-126
*339
2B
r27
340
123
-329
70A
70A
:-.UN
708
708
80
"
010
.000
n1
20
*31'l
0
0
0
0
0
0
0
-1
50A
50A
:END
004
50
-END
bU
003
001
60
40
60
.001
.001
.004
.005
.006
.000
:,UN
].JN
-. 008
-.005
-. 002
-.
-.
. 015
01
50
.000
-.004
.015
.014
.008
.000
FX
!'ORCE
:END
*.
01
70
- .0L2
THERM],
I______--*_-
.lj.icH
n1
.000
00tl
-. r101
-. 003
-.003
-.003
-. 004
* . {102
.00
.00
.00
.00
.000
*.
003
006
009
RZ (DEG}
.:JP? DATA
:YFE FT
01
-.00
*.00
30
.000
-.
*.
-.
-.01
*.01
-. 01
-. 01
-. 01
.00
.00
RY(DEG)
RX (DEG)
.00
.00
.00
n]
*.
(IN)
DZ
.00
.00
.00
4A
l;-T
2AA
10
--
DY
-L26
r2]
*126
*339
*339
*27
r69
502
330
*L22
- L454
258 7016 1. 00 1. 00
-261 7376 2.2] 1. 89
s34 2L62 2 .21 1. 89
-533 1143 1. 00 1.00
34 t669 1.00 1.00
*33 358 5 2.2'7 1.89
-48 3353 2.2] 1. B9
49
1504
1. 00 1.00
731
1. 00 1. 00
-48
49
137 1. 00 1. 00
*48
984
1. 00 1. 00
49 22A4 2 .21 1. B9
-131 1776 2 .27 1. 89
732 529
.00 1. 00
147
-381
.00 1.00
382 7 47
.00 1.00
899
-381
.00 1.00
382 1709 2.2"7 1.89
*286 132? 2.2'/ 1.89
281 641 1. 00 1. 00
378 2L46 1. 00 1. 00
129
130 .
Chapter 7
MAX.VALUE 111466
'7O
AT POINT
30
2LOAD CASE NO. 2, THERML
340
?O
PAGE 4 OF 6
1097
r454
30
80
1245
10
3586
30
DX
.00
.03
.04
.01
.00
- .02
10
20A
2OB
30A
308
4A
508
OU
4r
70A
l-
708
ft,
BO
lr
MAX.VALUE
POINT
AT
!
il!
H
)
P
Il
2**
DY
IN)
DZ
(IN)
.00
.00
-.01
*.
-.06
-.06
-.42
-.
.05
*. 06
.065
30
30
40
.00
.01
.01
.01
.00
-. 06
.00
.00
.02
.03
ANCH
STY
ANCH
NET
10
40
80
-116
0
IL6
T"ORCE
20A
BEND
RUN
BEND
RUN
RUN
RUN
2OB
- 115
116
* 115
116
30A
-115
2OA
208
-.
-.
-757
342
233
-.
Ml
936
00
L442
-L'75
-626
-342
62"7
343
758
-5'1 9
-342
-500
*432
580
343
501
433
*400
-342
104
-1040
71 6
*432
A??
401
J45
-352
-342
102 0
-345
346
5OA
*115
353
343
- 1019
-223
-342
82
32
116
* 115
116
433
?12
-81
-31
-382
-342
Jd"J
343
428
L77
-r"7 6
264
-263
_Aa1
508
*115
-335
-342
5OB
116
-1 15
116
336
?4?
-44s
-246
-342
446
325
24'7
343
- 11s
-156
-342
'LzB
L5'7
343
129
RUN
60
50
BEND
?OA
7OA
LI6
.000
036
.042
4A
30
-II--_
---MZ
ERICTION
**EORCES ,
_*-I
--
(tB)
-2003
221
246
-245
616
-615
93
-92
6
-5
6
-5
6
204L
1. 00 1. 00
2308
3344
2.2"7 1 aq
-1064
116
116
.0r2
-. 003
THL+WT
* 115
40
40
.024
**
308
3OB
.040
.039
.030
015
006
-----MOMENTS, (FT-IB)
-342
.042
.000
MOMENT
}O(
.034
n?1
3OA
50A
BEND
3,
-756
*209
-99
SZ
.02L
- .423
I---------_-
.000
-.017
-.414
*. 031
-. 036
036
.00
* n]
RZ iDEG)
.000
.014
.aL2
031
- nq't
- .02
-.01
10
3, THL+WT
.000
.065
.058
.006
.003
.005
.009
.000
- .02
RY(DEG)
RX (DEG)
-.01
-.00
.04
.05
.00
-. 03
-. 04
-.06
-.06
-. 05
50A
lI
(IN)
*324
264
-263
526
*525
-J
-80
81
-342
343
-342
343
2153
2452
4246
4206
2343
1413
2.27 1. B9
1.00 1. 00
1.00 1. 00
2
,2'7 1. 89
t49L
2.21 1".89
1.00 1. 00
1.00 1.00
1.00 .00
1. 00 .00
ZZ
{4
2.2"7
ao
2335
2.21
1.00
.89
.00
.00
1438
1645
L662
1650
1693
2598
1. 00
1. 00 1.00
1. 00 1. 00
2.21 1. 89
708
RUN l0B
B0
MAX.
VA],UE
AT POINT
*115
716
-11s
-109
110
100
115
751
'7
10
(IN)
DX
n?
208
.04
.02
508
60
(IN}
.00
- .02
*.
DZ
*355
-7442
1041
r442
30
80
(IN}
o1
* .02
- .07
- .0'7
.063
-.
40
- .02
.01
.00
.02
05
.00
.00
-.
r'sx.vALUE -.06
'70
_r-T POINT
.04
30
-.
30
- .02
l0B
.012
057
- .444
-.07
-.03
*. 00
-.00
- .429
.072
.03
.00
.00
_AA
.00{)
013
- .02
-n)
-.
-.01
RZ (DEG}
.000
.045
.053
.061
.019
.018
.019
.017
.000
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- n?
- .04
*. 05
.000
-.034
01
.03
RY(DEG)
RX (DEG)
.00
-.
.01
70A
80
356
**
DY
.00
20A
30A
30B
40
50A
-233
234
*233
THL+WT
NODAL DISP],ACEMENTS
PO]NT
PAGE 5 OF 6
COMPUTER OUTPUT
-342
343
-342
70
10
nto
015
-.040
-. 038
.040
.040
.040
. 034
^24
. a2'7
-.
-.
.029
019
010
.018
.008
.000
.030
.000
040
.040
4O
50
/304.7,8Q-3/ /302.3.5,
B0
1143
0A 6 .63 .280
2AB 6.63 .280
80
B0
1143
1143
: il'I
20B 6.63
30A 6.63
.28A
.280
80
80
::ND
30A
308
.280
,280
:lN
308 6.63
40 6.63
.280
:i]'ID
-N
6.63
6.63
40 6.63
50A 6. 63
.280
.284
.284
::].trD 50A
508
6. 63
6. 63
.284
: -.J
JUIJ
C'. bJ
60
.280
6.63
.284
60 6.63
70A 6.63
.280
-tJ
.28
(c)
INT-PRESSURE SUSTAINED
DES]GN ALLOW CAI,C ALLOW
.280
'7
14 20000
OCCASIONAL EXPANSION
CALC ALLOW CA],C ALLOW
49286
20000
20000
1143
1143
49
9]A
842
840
20000
20000
49158
49L60
0
B0
1143
1143
932
730
20000
20000
49068
49270
80
80
1143
703
LI43
1869
20000
20000
703
1869
26600
26600
1504
131
48131
80
80
1143
1869
1149
20000
20000
LB69
Lt49
266A0
731
984
48131
48851
B0
80
1143
1143
L493
863
20000
20000
T493
863
26604
2244
7'7 16
48507
80
80
1143
1143
766
785
20000
20000
66
785
2660A
26600
'7
829
47
49234
49215
B0
B0
1143
1143
197
868
2{1000
'7
9'7
868
2660A
26600
747
899
49203
49132
tL43
20000
49
970
26600
26600
26640
266AA
I3-7 6 4925I
2L62 49030
49291
4973'7
132
Chapter 7
TOPIC#2O
PIPE STRESSANALYSIS
: COMPUTEROUTPU'f
B0
80
80
80
PAGE 6 OF6
rx
(l,B)
548
592
25
40
?0
40
1fi
r"11
7Q
466
340
10 97
l-455
30
'7n
30
80
1l_6
?0
?5?
343
L04 1
1442
t-0
?0
30
80
POINT
YHERMAL.
AT
POINT
THML+WT.
AT POINT
2{2).. MAXTMUM
MA)(.VAI,UE
AT POINT
MIN.VAIUE
POINT
758
10
2209
t245
l_0
3586
2003
10
4246
AT
5
?0
WEIGHT..
AT
FY (LB)
-.
IN)
DY
(]N)
DZ i
rN)
RX IDEG)
in
.05
na
2A
30
7Q
. 06s
4A
06
70
-.42
- ,47
-. 05?
50
30
2A
RY{DEG)
RZ {DEG}
.031
.442
70
5U
bao
- .429
40
ZU
-.
l_0
30
30
CHAPTER
PnnssuRE (HvDRo-)
i.ner construction, but before initial startup of mechanical piprg systems, process vessels and storage tanks, the building
:,ustruction and industrial safety and health codes nearly al*eys require some sort of physical-integrity testing to be per: -,rmed, witnessed, and passed. The test purpose is quite simple;
i':, show that the vessel will hold the intended operational pres.ure without deforming excessively and without losing fluid
: rntainment. Any material, design, and construction flaws that
:rght cause physical breakage of the vessel under pressure, or
nlrich might permit leakage, are thus detected under controlled
::'nditions, and can be corrected and retested if necessary. This
:rocedure is commonly called "hydrotesting," but the prefix
-:r'dro-" implies "water" or "liquid," and that can be misteding. Pressure tests may not involve liquids at all, and that
'""1 is a main reason for discussing pressure testing in this book.
(The systems excepted from pressure testing regulations
;'e both small and innocuous, posing no significant health or
;.tbty hazards. That does not exempt themfrom common-sense
ttk-testing before startup, or sanitarry testing per health and
t "tmbing codes, etc., of course. So don't insulate anything
:ctbre at least doing a good leak-test on it! Thermal insulation
,, as brutally expensive the second time around as the first,
,nd can cost the culprit his job as welll)
The various pressure-test regimens are typically well-de:ed in the applicable construction codebooks, and are gov::led under the auspices of state and local regulations. These
r::ulations in turn are ultimately based upon legally adopted
wofessional codes, which have historically been compiled from
. mixture of scientific principles, engineering knowledge and
: r-perimentation, common sense and real-world experience.
It is the referenced professional code which spells out
ne actual procedures, technical details, and quantitative plus
;r:alitative results required of the testing.
Some good examples of applicable professional code relr-irements are contained in the "hydrotest" paragraphs of (1)
&
\SME Section VIII Division 1 rules for design and construcr,:,n of unfired pressure vessels, and (2) the ANSUASME Bll series of pressure piping codes. Also, (3) the API Standards
Trsrs
(primarily 500 & 600-series documents) cover bulk petrochemical storage tank design, construction and safety, and their
pressure testing procedures. In absence of other criteria, the
API Standards bear scrutiny for testing tanks not covered by
the ASME rules.
As project engineer, you really should give careful reading
the supporting material in the Code as well as the basic
to
"test" paragraphs. It will help tremendously in obtaining
conrtructry
for Inspector
03 Nondestructive
Te
sting
l
,1
1l
134
Chapter
I
344.2 Visuul Exumination
UG-l15 General
aG-I 16 Required Marking
344.2.1 Definition
344.2.2 Method
Stamps
UG-l19 Nameplates
qi
l',
345 TESTING
345.1 Required Leak Test
INSPECTION
340.1 General
340.2 Responsibility
for Leak
for Inspection
(a)
;l
341 EXAMINATION
;J
!r
341.2 Responsibility
t,
34 1.3
341.1 General
|]
Tests
for Examination
(a) Examination
for Leaks
(D Heat Treatment
Exqmination Requirements
*i:
'I
u,
341.3.1 General
2 Ac c eptanc e Criteria
3 4 1. 3,
for Examination
for
Testing
![
6l'
4rl
ntI
-:]lil
3 Examination-Sev ere
Cy
clic Conditions
41. 5
Spot Radiography
}{
'18!
for Leak
Test
for Examination
@) Welds to Be Exsmined
341.5.2 Hardness Tests
{l
rE
344.1 General
lE
'm
ul
ll
il
PRESSURE (HYDRO-)
345.5.1 Precuations
345.5.2 Pressure Relief Device
345.5.3 Test Fluid
345.5.4 Test Pressure
345.5.5 Procedure
345.6 Hydrostatic-Pneumatie Leak Test
345.7
Test
for Leaks
135
It may be that, in some cases, one must choose the pneumatic pressure method, because of sheer magnitude of the volume of the vessel and piping, or unavailability of suitable
sources or quantities of water, or problems with containment
of potential water spills, or concerns about introducing corrosion or contamination into the vessel and piping along with the
liquid test media, etc., etc.
These can be real and overriding concerns, for sure, and
sometimes you have no real choice other than using compressed
gas for the testing. Fortunately, when choices of test method
are permitted, especially in major industrial applications, the
Owner usually makes the decision, using his own established
plant standards of practice as stipulated in the corporate insurance requirements.
However, in less technically structured applications such
as public and governmental works, commercial and institutional
projects, the Owner may lack scientific and engineering sophistication, and having no set standards of his own may leave it
up to you to recommend the best test method. If the applicable
regulations allow a choice between hydraulic (compressed liquid) and pneumatic (compressed gas) hydrotesting, you face a
tough decision.
TESTS
136 . Chapter I
Water
10 psig
1 ft-lbf
100 psig
22 tt-lbt
1000 psig 1,525 ft-lbf
Liquid
Gaseous Nitrogen
ft-lbf
ft-lbf
251,675 ft-lbf
2,795
101,016
im
:[
IIITEII:
tW.
Liquid
l0
psig
psig
psig
100
1000
ttt,
fl
il
'!l
Water
9 ft-lbf
223 tt-lbf
15,250
ft-tbf
(ftlbf)
Gaseous Nitrogen
ft-tbf
ft-Ibf
2,516,750 ft-tbf
27,950
1,010,160
in safety concerns. Consider the consequences of actually discovering a flaw in construction while under hydrotest pressure:
pressure-
'iliifi.'rI
mu
f0
([n
ffir
TT
FF
PRESSURE (HYDRO,
-lillJ
.,ul
|il
,l[1,
Il.
lL
J-
..lx_ljilt
l
lnl
n:lui
TfrLtLL
lu
,NLilI
"r,t 4lf
!fl;
-fitr
tmr
"11:
.11
irc
:ii
il
lii!
.lr
l1
::
ti1
ul
r.l
TESTS
137
CONCLUSIONS
CHAPTER
and Installation of Pressure-Relieving Systems in Refineries, Part I_Design and Part Il_Installation.
7.
8.
L
).
-1.
-t.
-i.
par. l0l.2,122.6
Chemical Plant and Refinery Piping:
ASME Pressure Piping Code 831.3
par. 301.2, 322.6, F322.6
(Hydrocarbon) Transportation pipelines:
6.
par. 401.2,422.6
American Petroleum Instirute (ApI)
API 521, "Guide tbr Pressure-Relier.ing and Depressur_
izing Systems. Rect'rmmended Practice 52l'.:
API RP 520. "Re.-.rmnren-Je,l precdce for the Desisn
Combustible
Liquids."
The Codes and Standards listed are well written and largely
self-explanatory. Their authors knew better than to make them
too academic in nature or too vague or cerebral, because their
subject matter has great bearing on plant safety. These are
Codes we all want to be easy to understand and safe to apply
for most technical folks, including all mechanical and chemi-
cal engineers.
So if you encounter a project involving storage tank, pressure vessel or piping safety relief engineering, requiring your
participation, then you had better acquire, read and understand
their applicable parts. They are too voluminous to permit reprinting here, and are updated regularly anyway. Go now, posthaste, and get the latest versions for your working library.
A short discussion
139
140 .
.
.
Chapter 9
.
.
r4s-r47).
Finally, an approach to satisfying ASME Boiler & Pressure Vessels Code, Section VIII Division 1, "Rules for
Construction of Pressure Vessels" UG-127(3Xb)(4). This
may help if you have to design a series installation of
Rupture Disk + Relief Valve (Figure 9-6, p. 148).
-t
&
.l
s
lts
.
,nm
contained fluidsl
I
!
I
t
in the mixture.
We need to know the pressures and temperatures in::r
the vessel at the emergency upset condition, so that we:;r:
figure out the phases of each constituent.
We need a good cross sectional elevation view drarrfuq
to apply.
In other words, we need to select vapor-relief safety valr:
(*pop action) operating at2l%o above MAWP inlet overpressu::
when the fluid at the vessel top-mounted safety valve inlet
a fire-generated vapor such as steam.
But when the fluid is a cool liquid such as water, needr..l
relief when a feed pump control valve runs wild, then we ne-':
to select a vessel bottom-mounted liquid relief valve (*prop'.,:"
r
if
when
i*
piping ar *q*ipx*nl
shsuld b* inve*tigated. l{ is espeeialfy imp*rta*t
whcn lh* vslvx is discharging io atms$phsre thraugh
an un$usgst"tad ttack.
A sir*pie Frscedur* ud*g the curves in lhis calalog,
rerrfiit$ g{ct}r&lg del*rr*rination ol discharge reac*
:ionx tfrr SSNS*|-i*ATEb $aiety H*lief Va{vex ss
sh*** i* thi* caia*cg. Th $1gS i* t*e prcc*d*re
lhrust, slressss developed
ar:
rgl-
labl* *n Fxge
-1 Lrsing *hsr1
F" x F* x F',
is
'13,*SS
Chsrt A
r.,,
Fn {rc*'r"l $tep 3 Sy F,, lrorn Step 4 :s ti*d
lh .e*cti*n *f a gnx fil SS*F. T* c*rrect tlris
t*&efirrn tar a teftlpeN'st*r* clher ]h*r* &**F., rrs*
Ch*rl S- Lgeat* tlrs Fehr*nheil t.emperelufe on
f'{uiiip,y
IGURE 9-1: Safety Relief Valve Thrust Reaction Forces Due to Discharge of Gases and Vapors. Force direction
:posite to relief flow vector (Consolidated Valve Company)
141
142 . Chapter 9
Chart
F*
fhart S Chsrl
f1]r
Wejght
11,.f
',1
g',
*..
F i-.
g
i::
; t::
giii
*i:
FIGURE
9-2:
Company)
Reaction Forces Charts for Temperature Correction and Outlet Correction (Consolidated Valve
tft*
143
IIGURE
9-3:
Reaction Forces Due to Valve Discharge (Steam Service) (Consolidated Valve Company)
144
Chapter 9
4.6805f
Given: 3x41912KValve
Sel Pressure 896 psig Saturatd Starn
10olo Accumulation"
u.
sc;
: 1.3910
h"r
1192.9
4.5028 ft3/lb
Inlet Conditions
1489 ftlsec
V,
Since the exit velocity (1487) dces not exceed the
h"r = .1 186.0
as: : 4.6982
0r*r
4'6805
V'
v.: /144sk% u;
g : 32'174 ftlsec'
k - 1.13 {ASMF Steam Tables, Fig. 'l'l}
Pz : 94 Psia
r," - 4.508 it3llb
*
=
3600 V" A
sr:
Outlet area,
Ar =
103,783 lbs/hr
lsentropic quality,
X'
1."'***:j3*
1"39'10
0.4684
y.yo
80.98%
This is a good comparison with the valve rated capacily and the calculations should b'e cansidered
correct.
1.1393
fnthalpy at exit, h, :
hrn
{X" x h'u3}
V.:
* 148? fty'sec
=
h-r+ah'-hF'
f\
\I ^u*,
flr"t
223.8
'{4415 t:n
:
*
*
Dynamic Force, Fn
Fa
*
-
MV
P: x Ar
{94
14.7i (12.57}
997;P
t0!,149 x t:A!.
32.174 x 3600
1337$
cn=tc2-
FIGURE
9-4:
F"
Fa
RF:997+1337=2334+
145
KgtIEF VAL1rS
gasket diameter,Inches
6r
l$1
t/
P
l//
iv
PRESSURE VESSEL
.""'
.LI F I
T}e s&net{ loait at t}& mome&t t'he ra^lzte psp$ rrps, is the maxit*ruwr loll,rt on the syste*. ,$.ltlr.lo*glr i:t iteesr*
quicklg t* tke $e*ily etate blasrdoton l*ad, it stiil tnust be r{.'itlr.stoed by the {laxge bolt*, {If th* flal'v;ge bol*s
sfie*clr, altnwing pipe ta m*ve *Iightiy, the *rust blo,ck lrr's to absarb tbe ntirs laard, w# *ti* cam be
acaa**crdoteil itt t:he sttucttrral design of thc thrxstblack. Tkis is a consenlqtiu* ryproach")
stat* l*ad appl,ie* *fter t*e pipe has filleit with liquid and is discharging against a:tmasphertt
brrck?l*ssure (i*to either tfte reeeiver vsssel or tke a|r:r'r.splwr* itself") T&{r is tke achml load *n the blad*
?ke stearJy
SIGURE
9-5:
Itl
146 . Chapter 9
W:Theworst-caseshockforcesforthrustblockdesignare:
Fu =
k"ho.k x
(FH)
{Fv perpendicularto
{
g. =
F11,
Vertical- upward.
32.174 Lbm-Ft/Lbf-Secz
Fn
= (Pr )(n
Fv
S.l
EXAMPLE: for a nominal -inch dia. safety aakte outlet, set to open at 200 psig and required to deliaer 350
gpm of rnater in the relief condition.
P""t = 200 psig as given. This is a plant vessel safety data item.
6.19 inches ( the outside diameter of the raised face; see chapter on pipe flanges.)
=
Mdot = acfual flowrate for this valve, obtained with the valve inlet pressure = 200 psig with zero
-:
::
:lr
*1.
.tti
?,{
Us-e Dc
$"'Tr
22O
psig
Now we can solve for the two sets of forces we want the shock loads and the steady blowdown
forces. HERE ASSUME ACTUAL FLOWRATE = THE REQD. FLOW = 350 gpm.
Shock Loads:
c:
.Ji;
'i{
n(
l{l
nl
147
Fn
Discussion: The shock load is more than twice the steady state. The impact load factor of course is a
doubling effect on the static force, but in addition it is an unbalanced transient acting on the entire
rvetted flange area, which we saw was about 30 square inches versus the pipe cross section which is
only 12.73.
:ontinued from p.
1401
lt
is.
airplane
148 . Chapter 9
ltilIlL.
llllllirrr|{
mrq;
llllilfilllrx'lli
{till:L'l
fffi*,
t(
$$.rff#
1,
?&,&-?t*s" cpsd,I*
f.Strr
{ rr?c$ ru i-rec*
\r* gtr
',*
J
-s
T
ql
iLl
{r
{*f.}
Xb
Y}
tf,
&qll
,r
t$
P*E
g
f
:b
"Sr
rir{Artt?XrA,
a*
a{
.f,-**e*r
,," I
9-6:
l-}iv
j.
il& * l#.Tgrlay*)
FIGURE
,illllli
lllill :
lllillJl
|||lll'
,turff"
Tilllir' .
'ifl]rr:
'1,' t
lillit
a. a(
*rn
|tdafif,q
??ttdf;rd Tc
.Ffrfi- L6
ilqlf,
S-S
,trf6. * .sd$*mdJ"rc"
$*gt
il|fff "
rur '[
Ir
*3
fiffp remE
rlgssgc-
flllltl-rft,
b {,t
ilil]l,
*
vl
VIII Div.
l..1tii
'li!
r^zss
Focess, you would calculate the chemicul constituency, prespre, temper&ture, specific gravity and other pertinent thermophysical values (k, R, m and state points of the relief fluids),
vhich must be identijied to size the relief devices properly.
An example of two simultaneous failures which WOULD
:,ave to be considered RELATED and ADDITIVE is: A vessel's
arrogen pad regulator valve and its steam feed regulator valve
rre both electric-motor actuated and electronically controlled,
r! the same programmable logic-type multichannel setpoint
149
!'taybe some control-room yahoo spills his coffee onto its moth-
rboard while its cover is off. Or maybe a rat gets into it and
sraws through a circuit board. Whatever. The PLC fails to
nork, and both valves go wide open simultaneously.
Granted, it would take some ultra-lousy E&I engineering
csign to set the stage for this scenario, but the world is no
lsilnger to lousy engineering and such a thing could come to
lrl-ss. If it does, the vessel's relief device will have to handle
lhe concomitant sum of both flows, wild nitrogen feed plus
nriled-offheat generated vapor. It would be yourjob to calcu.!rle the flow details (good luck, Doctor Einstein!) (Actually,
tle thing to do is earmark this vessel for a system safety upgrade,
n:"separate the controls for the two regulators so that one device
i*rlure cannot force both valves to go wide open. Good luck,
Wr. Project Engineer.)
To aid you in constructing your decision matrix and making
ne host of calculations required to get to the relief device sizing
n:,int, I have stuck a bunch of blank, self-instructive checklist:':rm data calc sheets which will help you in this task. They
u: located on pp. 151-165.
Wow! Now we have reached the stage of deciding the
ryF(s), size(s), desired feature details and the pertinent vessel
ur-rzzle location(s) for the devices you will select for your safety
r:rief system. Congratulations! All you have to do now is write
lhe whole thing up in a recoverable fashion for your file, and run
,te computer programs of your favorite Safety Relief Device
'.:ndor
to select and size the devices.
By the way, get Mr. Vendor to run the selection programs
m'Jependently, and provide his results to compare with your
i'; n. A good competent technical check of the myriad thermor.emical and thermophysical calculations you had to make
':ould also be obtained and verified. (Most plant safety review
t.'"rrds will insist on these or similar steps, and probably more.)
llis
:-.
sheets.
il
l|
ul
u!
iii
u'l
{1tt
150 . Chapter 9
+ 14.J = 135.7 PSIA. My old steam table says that at saturation
pressure of about 135.7 PSIA, steam temperature is about
350.5'F, and the latent heat of evaporation h1, is about 870.3
BTU/Lbm.
of
135.7
psia, 350.5"F.
We wish to know:
a. How much relief steam, Lbm./hr.
b. Required Safety Valve size: Body size and orifice size.
ment. I used it on some jobs once. It may not work in r,urapplication. Use it at your own peril. (Of course that goes .-v
any author-generated designs shown in any chapter of:*u:,
book. Only an idiot copies blindly the work of another b,:r,t
idiot !!)
in the physitu
system?
::n'
:
!
151
d
FROCESS VES$EL
MT
CONDITION CHECKLIST
!u!f
M[
:fi;
[r
fi'n"
il@{
U[''
ior
!r3
JO8#-
BY:-
CLIEXT:
EAU|PIiGHTT{AI'E
rlut}#f
EqUtPNTt{TCSDE
NOF'il
REFERENCE PFD
FLU|Dia0ror.Ec.wr.)
REFERE}ICE P&ID
rsRt ritN(
TYPCFSAn\fiCE
Fluro |3 (iloLEC.fVT.)
rtoRil.oP.pfis$.
(Psrs)-...---*-
{rm-c.!YT.}
LgtltR_Gpil
'IiAK
ltFRrr,
DATE:
SCFH
LA*rR_SPX
"SCFH
)
l|$(
SCFH
GPTJ|
tufr
xqM.oP.TErrrP.
tic-
(DFC.F)--*_--*
FLTJTO
E!il]
trD*
I
il
r[
llil:
fr'
c'
L8/FIR_GFtl
ttcRll t ltAx
FLU|O
GFII
*7 (i,OLEC-WT.)
O
O
GPU
*--
scFtt
SCFH
r.5 gtocxEoclEAlrqjTDRAlil
1.6 OPNVALVEBY?ASS
1.7 TTIANTJALVALI,ERROR
1,$ oTlgrn
2.t ccolf{G
o
o
o
o
o
o
WATER
O 2.2 ELECTRICP$I'ER
O 2,3 9TEAi"EOILERFEUffATR
2.5 COilPRE$SOAR
3.0 LOCALEAUP''ENTFAILURE
o
o
O
O
O
O
O
O
O
3.3
3,3
3.4
3.5
3.6
3,7
3.8
ArR
COGfDCOti6fl{$R/HX
PIAT'FRAI'HE*TEXCHANSER
REBOITEX
REFLUX
FAl.t/8L{XflrER/VACWil puitP
EJECTOR
PUMP
3.9 FLASfI TANK
3.'O OTHFR
REUEF0VICE(S)REAURO?
--
1.3 SLOCKEDf*ffiMALYENT
1.T BLCCXFOFURGE\GilT
sl![
cP$
_-LslttR
LA*'R
) l{oRlr r t{A)( .-_.-.
)NORltrt{$(
O .'.0 OPERATOREIROR
O 1,1 BLOCXEDIiLFT
o 1.? glocKosJrlgr
O
O
rp\
SCFH
THI$ EQUIP}||ENT {tdAY BF SUSJECT TO TI{T FOLLONN}.IA UFST , TAILURE CONDMAN$ { CI{CK WXERS APPLICABLE.}
|iIIilI
{t{Ol-C.${T.}
HORUtilN(
Frul0i6 (MoLEc.wT.)
SCFH
S 5.1 EXTERilALRREE'PO6I.'RE
o 5: $ITERf{ALE(pLS|ST
o S.3 TttERl$AL EXPAtlSfiot{
o 5"4 V${JISISELEF
o 5.$ $Lg"rr$Ltn Lo{r(Eo,Rui{ W*YFED}
o $.6 qrrLETFl&{n{ALCCXD,RUil $'AYO$CXARC}
o 5.7 twr.\,rt$rFA[rrRE
o 5.8 PtRGEtNTF*tLulg
o 5.3 CHEUTALnEACfl{}il{EXOTHERiT}
o 5.10 Rr.&{AntAY ggqg(LNoRSPARGE}
0 5"1r Rtf*AritAYl{fTRoGf{pAs
o 5.r2 TuSFRUPTT,RErGAM)
I 5-13 1L8RUPruRE(COA[.A0{T}
O 5.I{ REg$II.ERFAILURE
C, 5.15 LOSSOFCS0-AI{|T
o 5.t6 PUR6/iaAlNT. DRAllil FAIIURE
O 5.'7 PRSSUR TRAI{SII{TS I,'YATER HAT'ilgR
o 5.r3 o?HR
J
O(Yt$)
o(Ns)
{?}
{}Iiii|ERATOR'THER'!|ALSXI0|ZER} O (\,ENTTOLSiIIRPRESS{'nSYSTSI*}
(Sa3\'R} O
{CHU.TREATTTilT)
il
Ip
rl
p{
]|
lll
iil
iill
llrli
152 . Chapter 9
IE
BY:
CLIENT:
JO#
BATE:
CHECKTYP OFVE$SEL
('
SEE ATTACHED DN'Eil$IO}IECI \'ESSEL SKETCH WITH IHSTALLEO LVATNN. MATER}ALS & THICI$IE$SES,
NOTES:
STTLL ATTACHED
{YES}
O ($O}
MAITUFACTURER
T0 VESSEL?
PRE$1.**---------{?SIG)
D$GN
rEilF._.'.-.."..-**-(OG.F)
CCfif{"*tt-Ot1t
ficHgs}
JI
MAWP
(F$IG):TIYOROTESIPRESSURF
*.".** ,., {P
G}IEGKOATASO{,J}iGE: o NAHEPT-ATE OOSFttpwe. O RERATC.ALCS{PROGRA}i-}
OtYgS)
O(t{O}
ARET||ESESATAr0SUSEDFORS|Z|ilCSASETYREUFovlCtSF
tF NO. WlrY r.r0T?
PRS,S"
{P$lG}:OPER.'fElilP.
MEASURO MlNlfdl.ilrt sHsLL rHlcxilss------jINCHES] & ELw
OpERAltltG
MEA$URED
(OEG.F}:
rsxnT
SOTTOtI OF STEEL)
MEASUREDMTI$i,IUSOTTc|'HEf,DT|||CXNSS
PSEUOSi,AWP
tPS!3)
..{Sac}ts}
O{pEnffinAT$SGPfiOCRST}
otlA}lDcAtc-cHEcK)
RECOi,fIiENDED HYOROTST
PRESS *-
pROCEDURE
{PSIG} &
PROCESS \trSSEL
REF. UPSET CONDITIOI'I
&
EAUIPMETTT SAFETY
'
8Y:_JOg#_DATF:
CLIENT:
EQUIPITffiNT |\[ATiE
THIS RECORS DOCUTIIENTS THE $AFETYAELEF CATCUTANONS APPLICAELE TO THE FOLLOWING
CONDMONS UARI(ED OIII THE REFERENCED CHECXTIST {CHECK ONE OR iiIORE} AI{CI AS NOTTO
TJPSET
o 1.1
o 1.2
o 1.3
o 1.4
o 1.5
o 1.6
o 1.7
o 1.8
o 2.'t
o 2.7
o 2.3
o 2.4
o 2.5
o 2"6
o 2.7
o 2.9
o 2.s
o
o
o
o
o
o
o
o
o
o
o 4.1
o 4.2
o 4.3
o 4.4
o 4.5
o 4.6
o 4.7
o 4.8
3.1
3.2
3.3
3.4
3"5
3.6
3_7
3.8
o 51
o 5.2
o 5.3
o 5.4
o 5.5
o 5.6
o 5.r
o 5.8
o 5"9
o 5.10
o 5.11
o 5.12
o 5.13
0 5.14
o 5.15
o 5.16
o 5.17
0 5.18
3.9
3,10
O (LlOUlO)
{VAP0FUCTAS}
FLUID }.IAME:
RELIEF FLOWRATE :
{2-p}rAsE}
triOLEC. WT.
LgtHR
GPM
PRE$$URE_{PSIG}
if.C
_
GAS / VAPOR V!$CO$|TY
GAS / VAPOR DENSITY
RELlEVll.lGTEltP.
:
Vl$C
(DG.
{cP}: SATURATI0}.|
{8TU/IB): SPEC.HEAT @ F
r}
TE}F @ F.C.
{OEG. F)
--
{sTUn-8-F}
DEHSffY
using Z=
(cP) : GA$ / VTFOR RAIIO GgCv
: COI,PR. FACTOR Z
{LBlCu.Ft. @ f .C. using Z= '1.0}:
SIZE & TYPE OF $AFETY RELIEF DEVICE REQ'CI. FOR THIS CASE : {f$ in)
153
154 . Chapter 9
CaAS
iEj
NG
BY:_JOH_OATE:_
CLIENT;
g."Elr.
0HEG|(tF||ttl{AFPUCAALDAT*Fm*LLVrrErTDVSSELffiirNFgpOSED?ORAneB{UFTOSA
O 9OT. FIEAI}
DIA__
sEcT.DtA
O COltllC.SFGT. Me
O lsT
SHELL
ff{.} : XFOSEE
$R"
LG.
FIGJ
.{SCLFT.} :
L.
{Fl.}:ETFOSD
FljI,ES
Si,--.]FQ.FT.}:
LCin pf.
{SA.FT.)
.--.
PAn GAAfti
m'3
{g,Ttrr}lR}
llOLEC.Ylr?.00
poRATs{ATRg.EFle',Vrcgrq..gronoirslcco|rlDfTpiltl}_
t8n$"s
el$:}
vAFORSElEntnOnRAIE,SCFl{A{RgAslt}{!0F,tt1.7F$A}.7ll.iFQ,
tltil*O5}l;lSDFAfrr0.O?HltDAHl
RELIEF FLOIAI =
(scrH)
lllltfERE l/lfr
C.tincilurofrpccfrshcdrdc,|f{|e'Cpt!)loehCfiornAFP.it;A:n|lfdafur*&!qescr{uts$,n,havc*pnmc@;
K * rolcf drslcr &rrlp ro{ldu* {lnlqm*. bauc x grgtx&r} ; p : (l .10 x ret pn*.} + 1d.7 pd. &ts rt potrntiila.}
CALC.14fo:
Vlty =
"{
AB\r"cRAFq__{Fr}
trXlhpOFF,IiIAf,IE
tifi!
r8\r.CRAtl--{Fr}
-.
LATEf{trfiAtoFEtr
GRAD_*---__(FD
l-$tE Aglt
{A}
Q:
FLUID
A6Oi/EGnlDe}
*A
{L3.ACT.FLUII}THR.}
-i
ri
. RUNAWAY
FEED
'
EQUIPMNT NAME
REF, SATETY'RELICF EI|}GII'IERS{G RECORO IDEXT.}IO.
IDEHTIFICATIOhI NUiNBER OF THIS STIEET
BY:
cLtNt
$tZF''._tin.)
VALVE IDENT,
tilLET
tpsK) : vAL\,f
slEAhl P(E$S{JRF
vAtvE DELTAf
tfitEr
o'rTLsr)-
TYPE..
JOB#
.. -
DATE:
{ESTJACT.}
Cs:,"
& C1=
SSIPONI } P*$SURF
DELTSP ${llrtu}
tP$e}
ilsFrR)
HOW DOES TH|S STEAI| RAIE CAUEE VE$$EL PRcS$URE RISF FIRT ? TCHECK OllE UPSET CQilDITIONi
(A)
n*ffi
a {s} r*CKASEil0RilTALBOLSFFnA.IE 0
soe#FLtQmDCCfifTEins-AS{ffi[aAL
*ffi
lr*f trllti*t*fi
***i.
tl*f*ffi
*t***i*}r#tf
**i*ffi
-******ffit*t**tr**
{C} LlvE$EAXEXpAt{SlS{
llTEr{r
>
>
HEAT sF EVAP.
{11}
(8-run:Bl, _ , _,
CICAPr)
(LE.VApORfttR)
ESIIMA1ED HORitA! tCfr C*prCrr OF VESSEL FOR Tllls VApOR O RzuEF OElltGE SEr PRESS.
(N$TE: ll{cLuOE Xm}ilALCOilO}lSERTl#SlAlCAPAC|Wlt{THEASOVE. IFAF&AABLE; ATllCtl CATCS'}
*
Xeef r{ELASE l CSIOEN. s.|EA$ t0s) * Wrtn r I Eil*$LFry sd.vepsr O b*r* !ru6s. - E]rmLPY sd*q. @ ** procs- ]
> COI{TNTS
*l
o (sECOllD
{ffi.l
{Qs I L1} -
\/cAPi'
e2)
SIOTE: II{CLIJOE
coltTEt{Ts
>
fi
ltffiSlAL C${Oi{SERTtEnnALeApAClTY
'}{S
(V6&} r fits
/ LE} - \tOAp?
F{
pr!&qi,
g.VAFOFJ!|R)
{VCnP2}
- tt
C'ALCS.}
(LBr|lR)
.,.- -.-
Fnfi-B}
0rcAP) -
\rlit C*P^dTY
=Qa>
Frun*n)
(LSTHR!
RELIEF FLUID
NORMVENT
(LB.STsArirHR) SATTJRAIED @
SE
PRE$S. OF
.-
{PSIG)
=
{P$lG}
155
156 . Chapter 9
30
RE
fi
BY:_JO*_
CLIENT:
DATE:
r||
>> CHECK
(GPfr)
(L8r!tR;
>)
o INLEIFEcDFIUHP{$)
O GRAVT?Y-rEELTA!|K O
OrrERFLeVCUpEmArs\$SL
O I,ESSELVACT.|JiI
>>|FPutlFED'$|ilGLrPur,FNoR},"cF}|@TI}H:-{GP[|}e-tFT.}r2CI}{rT.ua.}(Ps|}
>> lF PUIiPED,
ltfORM,CIPER.
o srircrlrc*Xmfi;sAlpt
i*p
o ouAlcifixr. nFARALLEL o
o vACUUfi{
O VALT'ECOilTROI.LSRFAILTIRETOT'TffiOPS}I
O FEOTAf{I{
O IhXI,'AIVAL\G
LFTOPI{
O RUf{AI'IAYPIJIFSEEOCO$TROT
p)
O OT}IER
o NoirstEpl"*il{l
>)
p,o. Funp
r(
(DEG.F} : OENSITY
{pse}
{LS|CU.FT.)
S.S._
(Hl0-l)
PRESSURE
vlsCO9lY-*{cP}
L&HR)
tcplll)
>:
157
VESSEL
FLOW}
EOUIPfiENT }.|Afiffi
REF, SAFETY'RFLEF EI'IGI}IERIT{G RCORD IDENT.XO.
8Y:-JO8#-D*TE:-
CLIENT:
NAME OF OI.ITLETLIQUIO;
NORMAT'
iI$(|llAJ$
>> CHECK
LIQUIO OUTFLOW
(GFu)
(LBTHR)
DrscHARcE
FrjirPts) o
CRAVTTY O $rHER
ll
i
>> CHECK
O AUTOilATEDCOT{TROLVAL\|E O
FLOU,RATE COilTROL:
ITIANIJALVAL}IE
O OIS}1. FUTaPSFEEDCOff|RON- O
L*ElR
O VACuUtil
uI
tf
O rnmIALVAt\G Ctffi]R
O SPEED CONTROU:R FAILURE
O LOSSOTDUAL PUITIP$
o vAL\rE cot{TRor.tER FsLunE o YrrEllt BLocl(ABE
o LosswstrrtcL P{JMP
O plPf &OCI(*GE
l[l
lr
l[.
rt
oTlrgR
>> CHFCK
rt
lI
o gtlR
th
rul
i{
f
Li
]|EAD tPDPTJTTPDtADneADORRESTCDFLSffl
}tAO tCEt$R|F\GALFT.FDrDfAAffiiElArCEXlFLOTU
O OT}IER
o r{saEG)(P|.*${
>> RELIEF FLUID I{AME:
>> RELIfF LIOUID CO}"IDIT|O}IS AT RELEF T}EIACE INLT $ET PRES$IJRE :
REUEF DE1/IC ST
PRES$ME
TEilPRAIUffi-{Ds-F}
{P$rc}
:
(L8rCu.Fr.) : S.G.
Ua$O DENSITY
RrLlrF
FLOIIVRATE @
Srr
PRE$$URE
_ - (ll&t):lXltJlDVlliCOElW-:(cP)
(LSHR)
(GPM)
158 . Chapter 9
ga
REF. SAFETY'RELIEF
f,E
NE
3Y;-JOL_DATE:_
CLIEHT:
NATyIE
OF OUTLET LIQUID:
NORMAL
MN(MUM OUTFLOT'V:
{crul
{18'}rR}
r
t>
>>|FPulJ|PED's|NcLeP$pl'pRrn.GP[@T0H:-{GPM}@-iFT.}|20}(FT'LKl.){PsD
>> lF PUltlPED, NORIi.OFER.
>> CHECK NORTIAT
srrrct-E cEr{TRFrJcAr-
pln
e anl
cEr{TRf. t{
vAwEcCIHTRoltERFIrltURTOLtllOOpN o itAlq.l*tvAl\rE
O LEVELCO}ITROLSFALUNE O EXCS$$
>> CI{ECK GOVER}IIXG CAU$E OF
LEFTSN
Rlrl{AwAYPUtlPspeDcOf{TRq.
VACULA' GEilTNATCI{
o NoNE(EXprAtr{}
TEI'PERATURE
-*-*-TDS.FI
tPS)
: OEilTTTY
PRE$$UR
LS}IR)
{GPM)
>:
BY:-JOLDATE:-
cLtEt'lT:
(GPM)
tL6rHR)
>>
O AUTOT'ATEDCONTROLVALVE O
I'A}ITJALVALVE
O FETOPTS|PSPSOCOITTROL
g $frlR
o vAcuux
OF LOS$ OF FEEDSTRATiI:
O PIFE &CCI(AGE
s FEgo Tt!0t Loss oF lE'lrEL
O }'AI{IIALVALVF CLOSURE
o Lo$$ OFSINSLE PUtrlP
O SPED COfiTROU"ER FAILUR
o LossoFDUAt PuMPl,
C VALV COIIITROILR FAILURE O WE|R ELOCI(AGE
LosT vAcuuil
Not{E
TYP:
VACUUftI O NONE
O 2.PHA$E
CIAS/VAPOR ONLY
TEMPsRATuRE-tsEc'F}:LtoU0DEilsrry-(Lscu.FT.}:L|QU|DVlSCo$rrr_-...-.*(cP}
{IB/CU.FT.) : VAFOR CpCv
VAPOR DENSITY
>>
$Ef
VAPOR
: VAPOR
MSC"-
(r_s,HR)
PRESSURE
t0p)
{$crn AR
BAS|S}
159
160 . Chapter 9
BY:_JOB{__DATE:
CLEilT
NANF OF IT'.LET VAFOR:
NORMAT /
(13't{R}
ftAfft
8oiril$reAil
{ilOTE:
o REAcTIofi o
co$toEltsER ooJllf{srREAx
oTltR
frcRf l}lAtl
O AUTOCIA1D|f{LETCOi{IROL\riL\G
'
il
il
ll
fr
O OT}FR
>> CHECK
o iloilE(${PLAlN)
TYPE:
O GASwAPOR
0 3-PllASE
OltlLY
O LnU*t
TEMPERATURE-(DG.n:LQU|DDEHsfrY-tLgrcU.FT.):L|QUlDV|SCoS|TY'(cP)
VAPOR DElil$lTY
VAFOR
VAFOR
Vl$C.-
$rr
PRE$$URE
tcP}
{LBTHR)
(scFlr
ArR 8A$rs)
161
FLOyY}
EQUIPITIENT NAilIE
REF. gAf ETYIRELEF fNGNEERlltlG RCORD lOl{T.N0.
IDET.ITIFICATA}{
HtNffiR
OF THI$ $}IEET
BY:-J03#-SATE:
CLIENT:
iIAXiI{'II
NORMAT
VAPOR OUTFLOW:
tL"g'HR}
'
THERIiAL
o vAc[Jr.st
rifl
FLOVTI:
;$
i'AY APPLY.}
tEOtLrEr/ApJO{$nU$lOSr} O VACln
owrilstREAil
if sPARAllOf{
lr
{l
O oOilI}ef{SER Dg$ril$'rffiAnl
lri;
REActpN o oT]R
rlt
rI
th
rft
o AUTOT*AIEDU,TTLETCOifIK"VAL\,E O
o O(nfiflttlffilll
VAC{ff,Si|
th
{
il
O OTI{ER
il
I
li
LcxtsoFlm,xoFEFo
OT}TER
xof{E{F)(pr.A|H}
>>
CHECK RELIEF
FIUD TVPf :
O GASVAFTOR
Ot'lLY
O ?+lltSE
_
vApCIR OE}l$lTY _
TEMPERATURE
{DG"F)
: LQUfI) DEXSTTY
{L$CU.FT.} : LlQUlf}
VAFOR
(!
S'r PRESSURE
WSCOSITY-________;(cP1
VAFO*
Vl$C"_
(cP)
(LBllrR)
{SCFH AIR BASI$)
162 . Chapter I
lileRT
CIAS PAD
EQUlPll'NT NAI|E
REF. SAFEW'RELIEF EXSINEERING RECORD IDNT.HO.
8t_J08*_DATF:_
CLIEXT:
}TAME OF IHLE'T FLUID:
o PUilP(S)
Of
PRSS._{Pstc)
tl
o ston*cETA!{x
AUToiTATEOCO|TaTRCILVALTTE
OTHER
o NofrE(E)(FlllN)
vAct t rti
TYPE:
LIQUID
O GASwAPOR
: IIOLEC.IIVT
TEIPERATURE
VAPOR DENSTTY
NOIIE
DEHSffY-{L$CU.FT.}:
: ViFOR Z-:
(LBICU.FT.) : VAFOR ClCv
{DG.F) : LKIUIB
TE @ SET PRFSSURE
Ssr PRESSURE
Vl$COSfi
VAPOR \/lSC.-
LKIUID
(cP}
(Cp)
(LB'HR)
'
BY:-JO8#-
CLIENT:
DATF:
Of TUBESII}E FLUID
{LB'}|R}
ENTERlNGTuBE$|pEPREss.(P1}-tP$G}:AVG'$HELLsilXPREs$.
(DG"F) : AVG. SHEtLSIffi TEIF.
ruBE
RUPTUREO
nfgEs
{DEG.F)
{pstG}
I.D.
RUPTURF TLOWARA
{FStG}
{$0.lN.}
tsa,N.)
= 0.63} TO FIND
FLOWRATE")
O GA$I/APOR Ol,lLY
LIQUIS ONLY
z-PHAST
IEMPFRArURE-{DEG.F}:L|QUloDENs|TY-(Lecu.FT.}:L|QU|DV|$co$|TY-_-:(cP)
VAPOR
DENSITY
{LBTCU.FT.} : VAPOR
Cplev
VAPOR
Z--:
VAPOR
Vl$C..----.-
tcP}
{LB1HR)
(|FGAsruAPoR:}REL|EFij[AssFLowRATE@SETPREssURE-tscFHAlRBAs|s}
163
164 .
Chapter 9
E'
EOUIPMENT HAii|E
IE
BY:_JOS{_DAT:
CLIENT;
(LBTHR)
NOTES:
PRESSURE
TrMp.
(PS|G) AND
{DEG.F)
>)
O ?.PHASE
O VAPOR ONLY
_
VAPOR DENEITY
TEMPERATURE
{DEG.F}
LIQUID
DENSTTY
-TPSIG}
tlst$t
:
>:
:
.FT.} : LIQUID
VAPQR
VISCOSITY-(cP'
: VAFOR
Vl$C.-
-*
@ SET PRSSURE
tLBfi-lR)
{cP)
tr;
>)
.i!E
l SETPRESSURE
(scFH
ArR BAS|S)
))
I9 THIS CONDENSER $AFEW RELIEF PROVIDEO BY RELIEF OEVICE ON VESSEL FEEDING IT?
OYES
IF
YES.
ONO
I$.AM THE
FEEDVES$L
'
165
TO HEAT GAIN
HANNE
IDNTIFICATIOH Nl.ilffiER OT
TH$ $HEET:
3Y:-JOg*-D*TE:-
CLIET'IT:
IS IT POSSIELE FORTHI$\'ESSEL'EQI.'IP.TOgEIIECI{ANICALLYBLOCXIO{N?
'.:..I*.]ff s,j*.s.msl,*K::.:53ffi
rF
NO
VAwE
:!SXin}:g.gHnffiT3t'
RELIEF
YE$
{P$lG}
{oEs.R : OE|{$TY
SOUFISOF T{EAT:
**-
$"BiCil.Fr.}
$..*
&l2Q*l}
of
T1 1'E8SL
VISC.
{c?}
SC.HEAT
FOR
TtULBf}
O?ln LIAUDS. }
o A$$eilTsQuRlAT
>> (ATTACII
GPlil * { B x H )
TS t
SDS ARSA,
{sru/lrn}
{ SO x $.G. x $FEC.HfAT }
{rBrHR)
(GPU}
166 . Chapter I
magazine CHEMICAL ENGINEERING in the October 28, 1985 issue. Mr. R.A. Crozier
*as its author; at the time he was a project engineer with
DuPont in Wilmington, Delaware. I love the useful way in
*hich this article is written.
It is based on sound principles and referred to current codes
167
168
Chapter 9
SIZING RELIEF
\,{LVE$ FOR FIRE
EMERGENCIES
A pressure*relief volve for
venting a vessel thot mcy
be exposed to fire can
be sized differenlly because of inconsistencies
R.rq.
bnt de
Her.e,
Q:
Q: qA
heat flux,
ir)
Strr(hXftl;
and
4:
heat transfer
area, ft:.
Considemble expoimental d*ta for vessels exposed to frc have been colleeted.
The tests ll'ere conducted under contrslled conditians fhat included ninimizing
wind di*tortion of the 11ame, suppiying &esh fuel to sustain the fire, and diking an
alea ofsuffcienl size to allcw flames lo toially envelope the container. Unfo*unately, iotal flame envelopmenl ofthe container lvas not xhieved, and the heatlrancfer af,ea had to be estimated by observation in older to calculate the heat
flux.
Fig"
Heller-llEwkinson moditisqtlon
Yia nonlinear regression analysis, !l J. Heller and
oped the following equation &om the data:
Q
P.
: 29,3e3.4e
Here, ;{s = exposed wetted-sur{ace area impinged by liarnes (i.e., the heattransfer area)^
flame size or impingement area tlepends on ihe type and quantity of fuei,
deglee of combustion, flame distortion, and m:rny otherfactors. The same data as
those for Fig. I were evaluated on the basis of totai wetted area (i.e., the
contairer sur{aee in contact r+ith liquid, w'hich, ii should be noted, does nol
depend ou flame conditions)" Fig. 2 graphieally rrepr*sents the data based on the
total rvetted area definition. Helier and Hawkinson cune-fitted the data and
obtaincd lhe following equati*n:
Her,
d,' :
21,&7
Aw
(3)
wetted al'e*.
A*A
q: qFEA
t ttlilil
tt
r^
-o
10.0
19
P.
,#j
.l,9
.d
7*c
l"d
6"s"
,5
!'
.9
';
(4)
r.0
e : @e/A)
100
1.000
Figure
46,
10,000
ft2
1
Comparison of data lrom experimenls canducled
under controlled conditions llotted on total exDosed wettod-area basis
l-
Code souace
NFPA.'30
osHA 1310.10S
As
APr
F'
Tank
dralnage
5e0
20&ll
Chlorina lnstitute
Compressed Gas Assn.
o.st
o.si
N0*
0.5
ND
ND
Insulatlon
Insulatlon
and
wa{er spray
Water
spray
0.3
0.3
0,30tt
0.30
0.07s.0.3$ 1.0{
o.075-0.3$s 1.0{
NO
0,3
0.15t*
0.15
ND
ND
ND
$lnsulatloneonduclancsal1300f:alF=0"3,,(*[4.0Btu/th]{ft1lfFIn.}iatF-0,15,X:!.0:
F: 0.075. K ; 1.0.
$SThickne* of iffiulatton: l'in. at F
;0
cHEIlcALElicrN[gBlNc]oc1r]BER18.1985
API Subcom-
No
(5)
Here, A6 : total exposed area enveloped in flame, ft!; and A = total surface area of the vessel, ft?.
a:
(uA)0.ts
: d-.0.18
i6)
can be combined:
i?)
Q = g!$0'8?
In a series of committee meetings,
the individuals and agencies responsible for develgping a relief-valve-sizing
formul* for fire exi$sure agreed on the
following definitions of heat flux: g =
21,000 Btd(hxft'), with A being the
q:
34,500
169
Ghapter 9
W = CKAaP{M|ZT)% (s)
Here, W = flow through valve, lb&; K
coefflcient of discharge; C
florv
coefficient, deterrnined by the ratio of
the speeific heats, &, ofthe gas or vapor
= As = 3s71.a, af vessl in
contact with liquid contents
at slandard condidons*i.e.. C =
520 lk tzl(k + l)jtA + tr& - tII'h; AR
=,effective dischal.ge area ofthe valve,
in"; P
upstl'eam pressure, lblins absoiute (this is the set, pressure mult!
plied by 1.21 for fire exposure, plus the
ai,mospherie plssure, Ib/inz; .4{ = molecular weight of gas or vapor, lbr'lbmol; Z = compressibility faetor for the
deviation ofthe actual gas from a perfeet gas, a natio evaluated at inlet conditions; and ? = absolute tempetature
of the inlet vayrr, 'F + 460.
For a rclief valve tested with dry air
at 60"F and 1 atm:
Wo
= CaKAaP(Ma/Z&T)k
lfo :
Here,
28.9 lb/lb-mol;
ffiffi
936.4004s"a38j
?#
NFPA-3o, OSHA 1910.106
(9)
"r-"r-r-**
Io :
520"R; Zo
1.0; and Co
356 (i.e.,
& = 1.a).
After the physical properties ofair at
Iable ll
10,000
Figure 2
Experimental data presentd in Fig. 1 on total
exposed $retted area basis is rtow ptoted on,,@i$ryS$*$*$$qq$i::::
{sa,)
Table lll
Wettd area vs. ft3/h free air at 14.7 psia and 6O.F
ftz tt3/h
ttr
ttslh
ti8
tttth
20 21,000 200 " 211,000 " '1,200
1,000 524,ooo
30 31,6@ 250 239,000
557,000
40 42,1@ 300 . 265,0@ 1,400 587.000
50 52,700,,. 350 288,000 t,600 614.000
.400 312,000 1,800 639,000
...:!60, 1,, .63,20O,
7A 73,7W 500 354,000 2,000 662.000
r: 80 ,: 84,2tA.,. , 600': 392,000 ' 2,400 704,000
90 94,800 700 428,000 2,800 742,000
100 105,000 800 462,000 2,800
]?9
129,qCq eoo 4e3,0o0 and 242,000.
1.t0., 147,00C 1,000 524:000 ' ovsr
"'
i, 160 .168.000 '
, .. .
:'
180 t90,000
2oo 211.000
*f
than,
:
$ere, Q
1y : QtL
(10)
I -
p*,
lf
and
ths qesxre is
oreat*
air flow for vapor generatirrn frcm heat input, lbh, can be
calculatedl
WCI
(Q/0.0119/C)Qr/Wk
(cfin)"
ofair in ft3lmin
* {18.UQlIi)g'YM)v'
cllE}rrcAL El{ct}iEtnl}-crocToBER
{11)
is:
a9,
(1S)
l9r5
51
lati,w
P ^,
lvoluotlng e qnd
recomrnendgllons
^ tlte vatious leconr"nendations lor
By means of Eq. (12),
deternriiing heat l1u, Q, and the col'resporrding defiritions
of heat-transfer area, A! can be evaluated. After Q and d
0.2
60
4A
20
Volume of liquid
{96
80
have been desned, the implied assumptions can Lle ascertained, and this knowledge ean be applied to speeifying
under g'hieh applicatians a couelation is valid.
100
of tank volume}
(13)
Here, I, :
/F--:- --:-,:--:---
*-
8z
t Ott*"l"t
{__*_
CCA S.1.3:
{cfnt')o
Here, Gu.
Heat-transter area,
tl'r
Rellet-valve
oriffce
designation
BCAB
ltz
A
"1,22A 915 610 1,220 4.73 4.03
1,470 r,100 795 1,470 4.99 4.71
1,7?O 1,290 8S0 1,7n 5.27 5.36
.' 1,970 1,,180 985 1,970 5.52 5.98
Codlngr A : OSHA; B : API 520; C : Chlorin lnstitut
c ,. - A I C
't1.?1 K J M
13.65 K J N
rs"52 K K N
17.35 , KX N
Assumptions: normal level 50% full, and.rninsulaid vssef with approved drainaga'
Orificedesignationand size:J = 1.?87 in2', K = 1.ff18in2; M :3.60in2: N = 434 in2.
fulief-valvedesignation: J-2in. v 3in.;K-3in. x 4in.:M-4in- x 6in.: N-4in
'tuea definitions: OSHA
)2
in Sectiun M.
S11
;{0'32
(11,1
I ue
the
ciln;urcAltrNctNtERlNoiocroBEk:r,rrn)
Q _ 34.500
A11.8? (15)
The heat-flux value of 3'{,500
Btu,{hxft1 is based an the total o,r!
i.e-, the rvetted
poserl wetted area
equations;
ou,oo"
area,
lnstit{.d
34'500 F'd0.8?
Fioure 3
9, 4 aild b
anrl
'
171
172 . Chapter 9
= A* = gui-;6.. of ve$el in
contact with l;quid contents
For 20>.4<2([,
o=
8:20,000A 06a)
For 200>d<1.ffi0.
g: 199,300A0.566 (l6b)
199.300/0.568
For 1,000>A<2,800,
e=
986,400
40.438
(16c)
API 2,000
For 4>2,800
.
:
"'
1ry, ft?
Figura 4
I -
III
tf it
f :
,,,''
{18)
ltclh)u .; .7,pi41$i$&,#4',,
is aiSo aSsu*ia ttrat the pxxess liquid is hexane,
I' M'a *
1,33?,
it eontains an
implied protection factor of 0.5 for good drainage. I{eat flur,
g, is defined in API 520 as:
{ : 21,000
lII
{scflt'}"
sefi'{I'93'l/L
Mq
(19)
(21)
21,000 A0.82
cunMrcAt 0NcltiEltRlNC/o0?oBrR, a.
1985
(.J
5Si
F, values.
?he OSHA area criterion of 90?o liquid-full is ree$onable
for storage tanks but ean be conservative for process lanks.
Although the API 520 area criterion is niore realislic for
process equipment, one must consider upset conditions or
ftiture process ehanges ihat might inerease the liquid level
for example,
and eause the relief valve tc be undersized,
the initial caleulation rvere based on a holding lank being 307o
liquid full, and a process change requires it to be 60% liquid
full, the relief valve wculd have to be vesized. Because a
maximum liquid level is assumed in the OSHA criterion, one
does not have to be conoerned rvith liquid-level changes and
the efibct on relief-vslve size.
API 520 and O$HA 1910.106 diff*r in the protection factor
for water spray. The fu'st says "to supply the volume of
water required to ab'sorb most of the radiani heat hecotnes
impracfieal." Henee, a factnr for water spray is ttot provided
in API 520, but 0.3 is alloned in 0SHA 1910.106.
Il
equipment'
J,
References
I.
2.
3,
laNions in relation to
,1.
5.
54
*la*ey,9d.ihr
6.
78.
9.
the outhor
R. A- Crozier, Jr., is a project engin*r sirh Du hnt
(Enginering Deut., l*uviero BldE., Wilmindon. DE
198f8). reso6nsidle for petrchemiials lrrnc* delirn.
He is a member of AIChE's Ercrsi Crrnseruailon
Commil.tee and cf Du
dards Committee,
lbnt'i llet
Exehanger Stan.
ruW m$;ii$&1{r,nriffiii;*i;;#',ffi
rlieles nublished in Chetnieal Ensilieerin,.. the lmt beinc "Eouiralocc mcthod solscs imompresihle.0uid
ffors problcns," which appeai*l in
the Nov. . 1983 issue.
several
173
i
I
174 .
Chapter 9
PROCESS VESSEL
&
AAA- 0I
...Ix+AeJllankx f.o, By: ALC ros-!-el
loENrlFrcAnoNNUMBERoFrHtssHEEr,
f,"ll
*ou,"ur*r,**, ?;ffin&n-Ecf*.,
cL'ENr,
.Ye.
fBfI - I
ASME
PFD {
eurpuErrcoor
REFEREN.E
REFEREHCE PITID
rypeoFsRvrcg
NoRm"op-pRess"
DEslGr.r
"*ess.
"CHgM. TgT
(p$rel**fi-O--
tpsro)----JOO
- D,rrE .X/y/e
WAT-R. =- ,1{:
iloRun Ax
FLUID
scFt-l
|? {riOLEg
WT.)
L3/hR
LB&tR--cplr_scFH
L8/HR
FLU|O *7 {MOLEC.WT.)
f{ORlr t lylAx
O 1.0 OPRATORERROR
O
SLOCKEDII{LET
O 1.?
'.1 SLOCKEDOUTLE"T
LE/tfR
***
_
GPM _
GPM
SCF|I
SCFH
o
o
42 VALVE
ELOCKSDNORft4AL\,Ei{T
O 1.4 FLOCKEOPURGEI/EHT
O 1,5 BLOCXEDCLEA}IOUTORA'N
o
c
opENv L\BY?ASS
trtAtluALVAL\m ERROR
1.8 oTltER
1.6
O t.7
4.6 pLC
r.7 LossoFsGNAtcOitDugToR
unLfYFAttuRE tcENERAtTpARnAL)
2.r coouNowA?ER
2"0
o
o
o
L8/tlR_
_
) f'lORtt / l{$( _
FLUID;6 {MOLEC.WT.}
9CFH
FLurD,* firorc.'ryr.)
'
$CFH
.{enr / rrAx
NORII I*A.X
epu
RrJrD*r{rmLEc.ffr.)
(DEG.R*--U3--HoRrrl r.AX
orsr.rdrEirp.(ogc.n 7n
-- FLUlori0fi!rc.'rvr.)
O'.3
rBlnR \
NoRrr.op.TEMp.
rHls
--
O
O
O
O
2.6 I{.TSTRUilSNTAIR
2.7 PtAttlTVACUUtl
2.8 PLAt{T DM,f.l
2.5
coilpRssoAtR
O 5.7 il*fi,\EI{TFAILtJR
O 5.6 FURGE\GXTFAILT,IRS
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(SHEM. TREATIT,E!{T}
175
176 . Chapter 9
T- 1
EQUIPMENT NAME
Y f.
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BY:
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o Nol.r-coDE
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178 . Chapter I
&t'*a*-4
AREA
======_========
CALCUIJATION SIIEE?
1. Customer MectrMentor
3. Inguiry g y.I.C. Uxample
5.
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42
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none
2. Sheet 1
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4. Rev 0
5. Date 08-28-03
7. By
m.m.
T-7
9. Service
8- Tag No.
Sizing Code
t2. Fluid State
15. Fluid
10.
ASME SEC
Sat"
VIII
chem.
Steam
Fire-vapor 6en.
NO
PSIG
PSIG
Constant
LB/r{R
F
-ill
IN2
I
A-
*-
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Cold Dif f Set press t-00.000
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150#
48- out1et Class
49. Manufacturer
Inlet, size
90. Note ].
FOR EXAMPIJE PROBTJEM,
"oP]c
CoefficienLs are:
kd = 0"9530 kv - 1.0000 kb = t.0000 ksh
EQUATTON USEP IN CALCUI,A?ION:
PSIG
?
#9.
1-.0000
cf = 9.0000 kn =
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A:
Ws
Kn
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capaciCy
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'
179
CHAPTER
10
JacTETED PrprNG Issuns
General Info
The term "jacketed piping" refers to a pair of pressure pipes.
consisting of a smaller diameter pipe nested coaxially inside a
larger diameter pipe. The larger, outer pipe is called the
ttcorett
"jackettt and the smaller, inner pipe is called the
(see
Figure 10-1).
The "core fluid" is the hot material being transported in
the particular process. An example would be molten plastic or
polymer being pumped to extrusion dies to make fibers or
bulk chips.
The "jacket fluid" serves as thermal insulation, and typically is supplied to the jacket as saturated vapor of one of the
commercially produced heat transfer oils, such as one of the
DowTherms. A typical hot oil vapor jacket fluid temperature
Heat transfer oil is not the only jacket fluid you may
elrounter. Sometimes moderate pressure steam may be used
b pipe (and heated mixing vessel) jackefs. The normal steam
r*stem rules must be followed, including startup blowdown
means, supervisory controls, and especially liquid condensate
m-ip system collection and return system design. Because of
fu
?HT'SICAL DESCRIPTION
Mnh pipes maintain the same axial centerline. They are held
lr rrsition by rigid steel spacers, located periodically on centers
ilr
lt'
_T
182 . Chapter 10
TOPrc# 25
4,puT[
o
F
()
o
5
J
IL
{}
tu
()
a
(f)
n
o
o
u
(J
tr
IIJ
tr
(,
il
$PlDtR $PACIR
IL
sEcTroN
ll
TI.||RU SpIDER
I
I
[rJ
&
uJ
u
o
(J
CORT
flPI
JACKET NPT
3OffiAN$I $LIP.O}'IFMI\|GE
FIGURE
10-1 Typical
,lli
Finally, after the jacket sections are all welded into place
around the core, the actual pipe supports are installed and
hydrotesting is accomplished per Code (ASME 831.3). It is
not unusual to see a lot of variable spring hangers among the
supports, and directional guides are critical for displacement
and sffess control.
It is important to note that the pipe supports that attach to
plant structure actually support the jacket directly, but the core
only indirectly. The actual core pipe support is provided by
the jacket pipe via direct contact through the spiders. This
is crucial to recognize for Code pipe stress purposes. If you,
as the piping engineer, do not demand that the specific quantity,
configuration and exact locations of each and every one ofthe
spiders be documented as-built, for the pipe stress analyst to
use in his modeling, then the pipe stress analysis will be at
best a guess, and as such will be essentially worthless.
Stress-wise, jacketed piping is somewhat crude, and presents a considerably more complex design problem for the mechanical piping engineer than single pipes.
.
.
.
183
Of course, single pipes can be exposed to abnormal conditions. They can be surrounded externally by matter at higher
than atmospheric pressure. Buried soil pipe, underwater oceanic
piping and pipe coils inside pressure vessels are examples of
externally pressurized piping. The external pressure creates
compressive stresses which tend to crush the pipe wall. So in
pipes such as these, you need to calculate the minimum wall
thickness required to withstand the maximum possible differential pressure, inside-out as well as outside-in. The thicker ofthe
two calculated wall schedules is then selected for construction.
Core pipes in jacketed pipe systems thus fall under this
"abnormal" condition.
lill
rit
A-l =
15.28 ksi.
184 . Chapter 10
allowable working stress @ 422"F per ASME 831.3 Code
Table A-1 = 19.76 ksi.
xxJacket fluid: 300 psig saturated steam.
xxJacket corrosion allowance: 0.06 in.
**Max jacket internal pressure: 315 psia.
**@ max jacket fluid working temp: 422oF.
so D +
t=
12.15/0.50 = 25.5
t.=[PD(2XSE+PY)]+c
before making allowance for mill undertolerance of wall
thickness, or
t
P
=[PD(1.75XS8+PY)]+c
if
(-
= 24.1 psi
D = 12.75 in.
B" = 6.900.
for all runs of pipe which are longer than (L/Do) >
I0.0. {Note: the calculated max allowable external pressurt
will thus be conservative for shorter runs of un-reinforcedpipe.
So Po = (4X6900) + (3X25) = 368 psig.
pressure
Step #5; Compare this result to the design requirement "Marimum design value ofjacket pipe internal (differential) pressure
= 315 psig @ max jacket fluid working temp = 422'F.
Since the calculated value of 368 psig for the ASME Code
max allowable external pressure is > 315 psig design re'
quirement for the external differential pressure acting on
the Core in our example problem, we conclude that Schedule 80S is acceptable for the Core pipe wall thickness.
Code Requirements.
831.3 Paragraph 304.1.3 tells us how to calculate for external
pressure. It refers us to two other ASME Codes, from which
we must dig out the appropriate data and equations: these are
Discussion of Results
In this example, the core pipe wall thickness must be selecterj
on the external pressure crushing criteria. Schedule 80S is the
proper selection. I will leave it as a practice exercise for you
to check my calculations in stating:
*xlf the core pipe wall thickness had been selected using
185
50.0
d0.0
35.0
30.0
200
18.0
16.0
14.0
\'
l1n
lt
r0.0
s
o
9.0
8.0
rt
o
6.0
O
.i.
5.0
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J.3
?.0
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l-o
1.4
3 { 56r8S
5 fi /89
5 6189
5 6 ? 89
.00t
I
|'
FACiOR A
!
|"
FIGURE
10-2 Figure
would be 245 psig steam, too much less than the required 300
psig saturated steam pressure.
::llr
du
fill.
The reason
uil
r
mlr
sl
xlli
II Part
to crushing is the core pipe cylinder under external fluid pressure. Cylinder crushing is a stability phenomenon, just as is
buckling of a slender column. A threshold of elastic response
is passed in both cases, and drastic catastrophic plastic failure is
the result in both cases. (.1 strongly recommend to the interested
reader all of Chapter 8, "Buckling of Vessels Under External
Pressure," in Prof. John E. Harvey's terrific reference text,
Theory and Design of Pressure Vessels, Van Nostrand-Reinhold, Second Edition, 1991, New York. h is immensely valuable
to the design engineer.)
186 . Chapter 10
'0t
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FIGURE
Ir'
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31?L) I$lote
1.,]
tlil
in
'
187
length, because
the
flange weldments.
This means that the pipe with the greater thermal coefficient will end up being compressed axially, while the other
pipe will be axially stretched. In other words' each pipe will
have a physical strain relative to the free length the pipe would
have attained if its thermal growth had not been restrained.
These strains are acco
@omtt.
188 . Chapter 10
In general, the nearer the elastic stress to the tensile yield
point, the fewer cycles it takes to cause this failure. If the yield
stress is exceeded, what happens on any given cycle is that the
points of strain corresponding to tensile or compressive stress
above the material's yield strength will relnx locally, due to
plastic deformation at the maximum stress points after the
maximum temperature has been reached. When this occurs,
fatigue failure will occur rather quickly; only a relative few
thermal cycles will be needed to crack the pipe wall.
Remember, ASME B31.3 prohibits stressing pipe to the
But a crack in the core pipe weld will cause the 300 psig
steam to blow into the core pipe, and the leak at first will
be physically undetected. The condition will persist until
something in the core system blows up, necessitating emergency shutdown of the system, and hopefully not involving
death or personal idury. Once this has happened, if you
had a hand in it, you will no longer enjoy being an engineer.
So do your best to avoid letting one of these bastard systems
get built in the first place. Get your boss to read this chapter
before approving the project.
If you can't do that, then be very careful in your participation and make absolutely no technical errors.
And if you can't do that, then either beg off the project, or
go find anotherjob where they are not bent on self-destruction.
Illustrate Cot" Pip" Wull Cr*king bar"d on the condiof the ASME 831.3 Code to make these catculations:
J*I*L{J,sTR.ATH.
Fi-xr'ls:q.
Shrxrr
&:
{c.s}
f$s e {s"5t
&c""r * t***$
f*.
:h,
tr
g.
-E
J*
e(g_s-*
ffi
7l*
in
Fuu*"L*.
*1i
.rt3.
o-l
/in-'' F
&
='{
rd
qr.' f*I
C'l
.$
\J3 a.J
* rt$
F-"
.a
Iiqt
*r
"(}(
.f,
trt"/in.* 6F
x f.E**
f**{*
lrA
{u
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n"*
*rJ
+.J
t*
tr
A,t
l FI
*f( &r
w
t:
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FIGURE
f0-4
.Ii&c
lI** tl'3O
Ls
*.1
fi*
{ F*s*rsff
trpe.
$ \Jltcke{e&
$
I( bFdpiue_ @
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7'rn,e.
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{ERT FIP.
Lr
r\l
d3F
189
Chapter 10
"H'
Lr(ATli
Lg =
Lr + a. LI{AT}"
Lr = free length of jacket and core when both are at room temperature (70"F.) and unstressed.
ci = thermal expansion coefficient of the carbon steel jacket, at the mean value between 70'F. &
final jacket temperature.
crc : thermal expansion coefficient of the stainless steel core, at the mean value between 70"F. &
final core temperafure.
*{AT}i = final jacket temp. 70oF.
*(AT)" : final core temp. 70"F. *(note that these deltas can be different)
-
abspr)>abs{Lz);
L: are the free lengths which jacket and core would grow to, if not end-restrained
by the "infinitely'' stiff flanges. But since the flange connections force the two to end up at the
same hot length, the jacket is stretched by amount " 6 " beyondLz, and the core is compressed to
amount " $ " shorter than Ls. In algebraic terms,
Lz and
Lz
+ 5-
Ls
g.
Assume elastic axial shess and strain in both pipes, the core and the jacket:
iacketskess o;=E;e;
; c0restress 6.=E."
{stresso_psi}=ElasticMod.
Note that in this particular example the jacket pipe stress oi is tensile and core pipe stress o" is
cawryessiae because crc ) cri . Otherwisg if a" < cr.; .the reverse would be true. And if the
expansion coefficients are equal, ck = a; , and both pipes reach the same final hot temperature,
(ATh = {AT}., then the stresses o7 and 6c ole zero.
The jacket shetch "6" relates to the strain e; by { ei = 6/Lz} ,
and the core compression " $ " relates to the core strain e" by {e.=
e; L2
e. Ls.
We can now substitute the expressions for Lz and L:from the deflection equations into these little
strain relationships, and we get
6= t; I Lr + crj LI{AT);]
ILr+a;Lr{AT};] * n = [Lr+a"Lr{AT)"]-$,whichwasobtainedpreviously,andget:
Lr+[a';LI(AT]j] + [etl[Lr+ct;Lr{AT};l =Lr+[cr.Lr(AT)"]-[".][Lr+u"Lr(AT]"1
When we divide each term of this mess by
Lt,Lt
Obtain the necessary secr:nd equatinn from a STATICS analysis of the pipes-to-flange connection.
The figure belaw is a {reebatty diagram oJ the flange, ign*ring its weight and assr'rming perfect
*ytooritry. It is a raised $ace slip*on ANSI flange, which is typical for iacketed pipes ccnskuction'
p;F
i,ackef
ot'
brce
xF=
evi*[
*-c*ing
f/a na/"
yv
E,
f
frxrs t4
or
nFi7u
"* aA #angz.
"acfing
lpct
191
Chapter 10
"d"
The force u Fc'n is compressive, caused by axial compressive skess o'" acting on core pipe crosssectional area " Ac" . Likewise, "Fi" is tensile shess o; acting on jacket pipe cross-sectional area
" Aj " ,At equilibrium, the sum of forces
zeto, and we can write directly:
Fx = 0 = (Ft - Fc) =
o'j
Ai
t}1
Ej
oc = oiAi /Ac
Note: This analysis is valid within the linear-elastic range of the specific piping materials. ff the
1'teld stress is exceeded, it shows that your piping design is overskessed for proper ASME 831
Code purposes. Also, it assumes that the flanges are of sufficient weight/pressure class to remain
rigid under maximum loading. Thin flanges can deform and spring leaks under these loading
conditions, especially when the pipe flanged end is subfected to significant compound loadings
of which bending stresses play the major role.
193
Ej
:
prpE
E"Ac= 26;36 x106x 14.58= 3.8433xL08
1 + cc;
COMI'O$ITE:
(ATli = 1.,ffi2499
COMPOSITE:
2e35 / 14.58 = 1,.67
Ai/&-=
oi :
{1,.06152x1016X0.003339
0.002499}
= SAllLbtl inz
(6.7255 x 108)(1.003339)
6c
= oiA;fAc =
8,411
x1.67
= 14,M6Lbflin3
we have found the carbon steel jacket in tensile stress, sketched to B411 psi.
The stainless steel core is compressedto 14,A46 psi. The rigid weldments of both pipes to the
massive flange transfer the loads, pipe-to-pipe. If, instead of heavy ANSI steel flanges we tried to
connect these pipes rigidly through a thin plate membrane like a tubesheet, the thin plate would
be warped cut of shape and prcbablv lose confinement of the jacket pipe fluid.
So
194 . Chapter 10
"f'
(1.f) Evaluate the effect of these stresses per the intent of the ASME Process Piping Code 831".3.
831.3 Paragraph 302.3.5{d} applies to cyclic fatigue stress due to thermal restrainf as is
thoroughlv discussed in Chapter 1of this Volume. Our conservative "first look" is via Equation
(1a) of Para. 302.3.5(d), since we have developed no information at this stage of our pipe stress
analysis regarding any longifudinal stresses which may accrue to sustained external loads on the
piping system which probably do exist.
Therefore, we apply 302.3.5(dx1a) to find Sg" the allowable thermal stress range:
Se = f {1.25 5c + 0.25 SH} , in which "t' is a stress range reduction factor s 1.00, sn6l "gs// 6nd
"SH" are the cold and hot allowable material stresses tabulated in Table A.1 of the 831.3 Code.
We look up the allowable stresses for the core pipe by finding the austenitic stainlesses in Table
A.1 of the 831.3 Codg and see that their cold and hot allowable stress values are:
@ room temp 70 oF, Sc z 16,7A0 psi, and @ hot working condition 420oF, Sn= 15,700 psi.
Soby B373 3A2.3.5(d)(7a),9-4 = t (1.25 Sc + 0.25 SH) = 1.0(L.25 x167A0 + 0.25 x 1.5700) = ?4.800
p,qi.
We must compare this with the local stress in the stainless steel core pipe caused by the thermal
reskaint of the flange which we found to be cr'. = 1.4,A46 psi. Bat not quite yet! The 831 Codes
incorporate statistically determined stress intensification factors (SIF's, see Chap. 1) which for the
local core pipe slip*on flange weld, which is specified in Appendix D of 831.3, = ii= 1.20. So the
Expansion Stress range we must use - Sr = (ii)(<r"1 = {1.2 xM,846 psi) = 16.855, psi.
Discuss results:
On the surface, it appears that we probably would be OK since the calculated expansion stress
range $r, 16,855 F$i, ( Code-Allowable Appendix A.1 shess for thermal expansion Se, which
for the temperature is 24,800 psi. The expansion shess range is less than the code allowable
maximum skess by some 32%, which would be a safe-enough operating margin if the axial
restraint-inducecl thermal expansion stress were all we had to be concernecl with.
However, the restrained expansion of the piping system itself, in reacfing with its internal spider
guides and its jacket-external anchors, guides and pipe supports will also create lonqitudinal
bending stresses in the core pipe and in the iacket pipe which are in the same plane as the
axial flange restraint skesses we just calculated. These adclitional bending stresses must be
calculabd, as required by the Code, as best we can (which would normally be done by one of the
Code-Compliance-capable computer pipe stress programs or by some other approved means,
such as by a validated finite element analysis OEA). These additional bending stresses ra,ould be
subject to the same 1.20 SIF in their computation, and would be superimposed by vector
"g"
The expansion stresses are cyclical, going back and forth over a range of min to max to mio and
thus cause tiny fatigue crack failures at stress-raiser points to gradually develop over time, as the
thermal cycles pile up. On the other hand, the sustained weight stresses (if large enough) cause
immediate plastic-range gross distortion failure the first time the piping is installed. They arise
from inadequate support. The two types of stresses are computed separatell', in different wavs,
and evaluated separatelSr by the ASME Codes, using different sets of evaluation acceptance
criteria. THE UPSHOT OF THIS tS: ALL THE VARIOUS THERMAL EXPANSION STRESSES
MUST BE ADDED TOGETHE& AS VECTOR QUANTITIES, FOR THE CODE EXPANSION
ANALYSIS REQUIREMENT. DO NOT ADD THE WEIGHT STRESSES DIRECTLY TO THE
THERMAL EXPANSION STRESSES FOR THIS PURPOSE. (Chapter l and Case #2 explains all
this in greater detail.)
In conclusion for SAMPLE SOLUTIONS CASE #1, the contribution of the stress <i'" from the
flange restraint of dissimilar metal expansions core-vs.-;'acket, 16,855 psi, may or may not be fatal,
trut it is &&d!g[y large enough that it would have to be addecl to the thermal expansion stresses
caused by external support guide and anchor restraints, and thus be incorporated into the formal
expansion stress analysis per ASME Code 831.3 para. 302.3.5(dx1.b), in which the various
lcngitudinal stresses INCLUDING VVEIGHT STRESSES are taken into account. On the next page,
we will look at a second sample solution, which is a worse case where the core and jacket pipes
do not reach the same equilibrium temperature. We rn'ill take a look at ASME Code 831.3
paragraph 302.3.5{dx1.b) there, and demonstrate how it is applied.
196 . Chapter 10
"h"
steam condensate retutu systew, which did ttot alluo the jacket pipe steam traps to rernoue the condensate from tlrc
jacket prpe, and so the jacket pipe "ran clld", ex&cerbating the dffirential expansion stress problew already tlrcre
because of dffirent core t jacket pipe ruaterials. It contributed to q wassir:te plant upset and piping failure.)
In this case, the "hot-end" flange will have the core pipe temperafure Tc = 420oF due to process
heat in the core fluid, as in Case #1. But the jacket fluid heating fails, so the jacket pipe will be
much colder, receiving only radiant heat from the core pipe. We will start by assigning an
approximate intermediate value of iacket pipe temperature Ti = (42A + 70)/2: 245oF. It could be
even lower, quite easily, and most probably would be. For illustration purposes, we will assume
a nonconservative value T; = 220oF (nonconservative here meaning the shesses we calculate may
not be the maximum and could go higher because the value of T; might in fact be lower than
assumed.)
REVISED ]ACKET DATA:
]acket pipe 16-in. diameter Schedule 40 carbon steel at 2?09F steady operation.
Core pipe 12-in. diameter Schedule 40S austenitic stainless remaining at {?89I.
FIND STRESS IN CORE AND }ACKET DUE TO THERMAL RESTRAINT.
COMPARE TO ASME 831.3 ALLOWABLE STRESS FOR THERMAL STRESSES.
r
r
(2.a) Data for Carbon $teel Tacket {revised from Case #1}:
16-in. dia. NPS Sch.40: Outside Dia. = 16.00 in.. Wall Thickness = $.500 in.
Cross*sectional Area A; :24.35 in.z
Thermal Expansion Coefficient @ 22AOF = crj = 6.4 x 10-6oF -1
PIPE
COMPOSITE:
COMPOSITE:
4/A.-=
24.35114.58 = 1.67
197
"i"
(2.d) Calculate iacket pipe stress from Wingate's {not the Code's} Eq. #1-a:
oj *
u1
{AT};l
oj=
24,165Lbfl inz
(was 8,4.11 in Case #1)
(2.e) Calculate core pipe stress from Wingate's (not the Code's) Eq. #2-a:
oc =
c';A1
0c:
/As
24,165 x1,.67
40,356 tb#in z
(was L4,046 in Case #1)
(2.f) Calculate core pipe stress Sn from 831.3 Code's para.302.3(dXEq. 1a):
SN
=#,*H*psL
The allowable core stress Sertot considering otha' sotffces af lottgitudinsl exp*nsion stresses
thsn the single soilrce, intenml flange-induced restrain{, remains a4g0!-p$i as before, since it
depends only on the hot and cold allowables from Code Appendix A.1.
Since SE >> S,q, (48,+:27 is much greater than 24,800) we definitely must include the dissimilar
metal shess in Code Equation 302.3.5(dx1.b) which reduces the amount of stress allowance by a
part of the SUSTAINED longitudinal (WEIGHT) stress Sr . Let us write that Code equation now
and see what it says:
831.3.302.3.s(dx1.b) Sa
= ( f )l 1.25(Sc + Sn) - Sr ]
The 831.3 Codebookverbiage reads to the effect that when the hot allowable stress for the
material at operating temperature, which is called Ss, is larger than the calculated sustained
longitudinal stress (w-eight stress) which is called Sr, then we can take adun:ntnge of the fact by
letting the allowable displacement stress range Se be Inrger than it is lohefi culcttlsted by Eqtt{}fion
198 . Chapter 10
"
8313342.3.5{ilft.s1, which we used previously on Case #1 Core Fatigue Sheet "f ", and then
calculated 24+8ffi psi as a result for Se. Equation 831.3.302.3.5(d){1.a) tacitly assumes that Sr
Euals, but does not exceed. Slr. Therefore it assumes that Sr not only exists, but exists and is as
large as can be safely allowed (namely the hot allowable stress for the material.) Therefore, if we
can prove that the longitudinal (bending) stresses in either Case #1 or Case #2 due to sustained
(weight) loading are lower than the material's hot allowable shess, which is 15,700 psi, then our
allowable expansion stress range can be higher than the 24,800 psi which applies otherwise.
I know it is tedious and difficult to keep ttris Code stuff skaight, but bear with me. It is the only
safe way to design piping systems and still get the maximum usage out of each pound of pipe
material used.
Now the question arises: how much higher can the allowable stress range for thermal expansion
(displacement) be? And does it help us out any, is itworth considering?
Well, if there were zero weight shess in the actual piping system, which of course is pretty much
impossible, then by (L.b), using 1,.0 for the stress range reduction factor "f ," we get:
- 44375 psi.
_.{
-rt
"4
.,|
But since there will be some suskined weight stress, we can only say at this point of knowledge
of the piping system that:
-{
2$o/o!!!
We conclude that this operation with cold jacket and hot core will cause eventual fatigue cracking
in the pipe-to-flange filletweld joints and ihus is in violation of the 831.3 Code. Once S,. is
factored in, the number of cycles to failure can be calculated.
end
!1
SprpcrnD RpTERENcEs
ANSI Forged Steel Flanges, Tayior Forge Bulletin 691-881, GW
Taylor Forge Canada Ltd., Hamilton, Ontario, Canada L8N
3H8,
1981.
FebruMechani-
York.
Dek-
Heat-
York, 1989.
ASME Boiler and Pressure Vessel Code Section VIII-Div. 1. Rules
for Construction of Pressure Vessels-l998 Edition. American
Society of Mechanical Engineers Int'|., New York.
a.
b.
tems. 1966:
c.
d.
e.
ASMECodeforPressurePiping83l.l-PowerPiping-1998Edition.
Carlson, G.F., Central. Plant Chilled Water SystenlsPumping and Flow BalaLrce, ASHRAE Journal Reprint, February 1972;
1991.
Grinnell Pipe Hangers, Catalog PH-90, Grinnell Corp., ITT GrinSIMFLEX.S, Program Manual V3.0, Pipe Stress Analysis, Peng Enginell Pipe Hanger Division, Exeter, New Hampshire.
neering, Liang-Chuan Peng, P.O. Box 801 167, Houston, Texas
j j280-1167 .
Haupt, R.W.; Flenner, P.D.l Nance, L.D. ASME 83l.l Power Piping
Seminar, Course Notes, ASME Professional Development, April
Steam, Its Generation and {Jse,40th ed., Babcock & Wilcox Power
8-12,2002, Charleston, South Carolina. American Society of
Generation Group, Barberton, Ohio, 1992.
Mechanical Engineers Int'l,, New York.
Steam Conseruation Guidelines for Condensate Druinage,Armstrong
Haupt, R.W. ASME 831.3 Process Piping Semfuar, Course Notes
Machine Works-Steam Specialty Products, Three Rivers,
Vol. II; Woods,G.;ASME83I.3 Process Piping Seminar,Course
Michigan, 1976.
199
200
References
l99l.
Thomas, L.C. Heat Transfer-Professional Versioz, 1st ed., PrenticeHall, Englewood Cliffs, New Jersey, 1993.
INDEX
d
140
Accidents, l40
Act of God,
C,2
147
Convolute.9.
11
Cyclic expansions, 2
Cyclic fatigue stress analysis, 4
Cylinder crushing, 185
816.5,2, 67,72,'73
Backpressure, 150
Bastard systems, 188
Bellows, 9, 11, 13
Bellows joints, 9, 11
B
831.1 Power Piping, I
831.3 Appendix A (Table A.1),
831.3 Process Piping Codes, 1
Depressurization, 136
Design fatigue life, 9
Diameter of the gasket load reaction cucle,70
Discharging gases, vapors or steam, 140
Displacement stress range, SE, 2
Displacement stress range,3
Dissimilar metal thermal fatigue stress problem, 187
Dissimilar pipe materials, 187
Documented as-built, 183
Dowtherms, 181
Drastic catastrophic plastic failure, 185
Ductile or malleable iron,67
201
2O2
E, 1,2
Earthquake, 5, 12, 19, 22, 68, l2l, 126
Earthquake loads,22
Effective section modulns 7", 4
Elastic constants of metals, 65
Elastic spring constant, 61
Elastic structure. 105
Equivalent pressure due to pipe loading, 70
Examination requirements, I 34
Excessive elastic deformation, 73
J
Jacket, 6, 71,181,183, 184, 185, 187, 188
Jacket fluid. 181. 184
Jacket steam hammer problem, 185
Jacketed piping, 134, 140, 181, 183, 187
L
Lateral bending,9, I2l
Lateral flexibility, 11
F,3
Failsafe devices. 140
Failure mode of the piping system, 5
Failure theory,6, 126
Fatigue crack,2,5, 6, 105, 189 fig.
Fatigue life analysis, 105
F-factor,149
Finite element. 105. 106
Fire-sizing heat flux, 149
Integral flanges, 67
Internal fluid design pressure, 2
joints,
145
134
Longitudinal stresses, I 2l
Lousy engineering, 149
134
M,,3
M'0,4
Mri,4
M'o,4
M",3
Mou 5
Moi,5
Moo, 5
Gasket, 67,71,73, 74
Glynn Woods, 6
Grey cast iron. 136, 137
M"3
trA'.5
Magnetic particle examination, 134
Mass flow balance, 140
Maximum allowable tensile yield strength, 126
Maximum allowable working pressure {MAWP), 133, l4O
Gross failure. 4. 21
H
HAZOPS, vii, 149
l2l,122,
Mill undertolerance,4,
183, 184
118, 184
I
Ii'
N,3,5
Nu' 3
N',3
.
Nitrogen pad regulator, 14'1,149
Nodal point, 3,4,5,
Non-corrosive internal components, 150
Nozzle pipe, 70, 71
Number of distinct load case i's, 3
Number of partial-displacement loading cycles, 3
RFWN,70,72
P,2
P*,2
D')
P&ID,
,i!
Occasional, 19
Occasional excursions, 6
Occasional load stresses, 4
Occupational Safety & Health Administration (OSHA), 139
osHA, 139, r40,149
Outlet reaction correction for molecular weight, 142
Out-of-plane bending moments, 3,4, 5
zlXl
19
Rigidity, 22,61,183
Rigidly anchored, 118
S,
140
Peq,70,71
Phase engineer,68, 140
Phases, 68
So' 3
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
flange, 67
gradient for drainage, 150
reactions on supports & end connections, 19
stress,117
stress analysis repofi,24
supports, 17, 61, 183
Piping & Instrumentation Diagram, 140
Piping spool piece, 150
Pitfalls ofjacketed piping design, 183
Plane stress element, 124
Pneumatic Leak Test, 135
Pneumatic Test, 133, 134
Poisson's ratio, 62, 105
Pressure balanced elbows, 14
Pressure relief device, 135
Pressure tests, 133
Pressure thrust,9, 11, 13
Pressure-compensating expansion
Pressure temperature cycles, 6
joint,
Prestressing,6T
Primary failure: gross deformation, 5
Primary failure mode,4
Primary stress, 4
Process & instrumentation diagram, 140
Prof. John E. Harvey's text (pressure vessels), 185
Professional codes, 133
Proof tests, 133
Propagate,
5,136, I87
S,, 2
SA, 2, 6
s", 3, 71
s., 3, 71
sE, 3, 5, 6
sf,71,72,'73
56
sh,2,3,6,7,71
sL, 3, 4, 6
s,,
s", 7l
SoL,4, 5
Su3
Safety device sizing. l-10
Safety relief valve thrust reaction forces due to ,iru:mlqc ld .guro,
and vapors, 141
Safety/relief valve. 139. 140, 150, 174
Sample calculation of reaction force, 144
Seal-water makeup valve, 150
Secondary failure: fluid leaking, 5
Section modulus, 4, 121
Self-limiting, 5, 6
Self-limiting stress, 4
Sensitive Leak Test, 135
Shear stress, 121, 122,126
Shock forces for thrust block design, 146
Shock load, 147
Shrapnel,137
Side sway force,22
Simple vertical support, 19, 2l
Simultaneous unrelated failures, 147
Single failure modes, 147
Slip-on flange, 188
Spacers, 181
Spiders,181,183
Spot radiography, 134
2O4 .
THL+WT,68, 119
Threshold of elastic response, 185
Stop nuts, 11
Sftess concentrations, 106
Stress intensification factors. 3. 4
Stress Isometric, 68
Stress raiser, 5
Stress range reduction factor, 3
Support displacements, 2
Support types, 61
Sustained, 2,3, 4, 5, 6, 19,21,22, 135
Sustained bending, 4
T_,2,184
Table A-1, 2
Table A-1B. 2
Table 304.1.1,2, 184
Temperature correction curve, 142
Temporary closure, 136
Temporary supports, 134
Terminal equipment, 20
Test fluid expansion, 134
Theory and design of pressure vessels, 185
Theory of fallwe, 122
Thermal expansion coefficient, 105
Thermal restraint. 119. l2l
THERML, 19,68,II9
Thin-walled toroidal convolutes. 9
Tie rods,
11
U
Ultrasonic examination, 134
Unbalanced pressure thrust forces, l1
Uncompensated-bellows, 1 1
U-stamped, 149
User's cookbook,125
v
Vapor cloud explosion, 68
Variable spring, 19, 21,183
Vessel overpressure protection and safety 139
w
Welding neck flange, 7l
Welds to be examined, 134
Wind (aerodynamic drag) forces,4
WT/PRS, 19,68, 119
Y,2
Yield point, 5,6,62, 187, 188
2,4
188
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