PART C : Inspection of UPV

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Philosophy of UPV inspection

The basic reasons for inspection are;

To determine the physical condition of the vessel

To determine the type, rate, and causes of deterioration To determine if vessel can still perform its intended function

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Philosophy of UPV inspection

The BIG questions for you.

How do you inspect your vessels?

When do you inspect them?

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Philosophy of UPV inspection

PETRONAS corporate policy statement on HSE

PETRONAS shall ensure that the facilities it designs, builds, and operates, the product it manufactures, and the services it provides, are in accordance with appropriate legal requirements, industry standards, and best practices

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Philosophy of UPV inspection

Local regulations vs. industry best practices

In one aspect, pressure vessels inspection is governed by local regulations

On the other hand, in order to be competitive, we need to follow the guidelines outlined by industry best practices otherwise, we would be left behind

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Philosophy of UPV inspection Local regulations with respect to pressure vessel inspection Local authority Department of Occupational Safety & Health (DOSH) DOSH outlined inspection requirements of pressure vessels & boilers

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Philosophy of UPV inspection

Local regulations with respect to pressure vessel inspection Generally, every vessel will undergo 5 types of statutory inspection; 1. Initial inspection 2. Regular inspection every 15 months 3. Supplementary inspection 4. Special inspection

5. Further inspection

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Philosophy of UPV inspection

Industry best practices

Reflects whats the best out there

American Petroleum Institute produced documents relating to vessel inspection, among them: API 510 Maintenance, Inspection, Repair, Rerating, and Alteration of Pressure Vessels API 572 Inspection of pressure vessels (Towers, Drums, Reactors, Heat Exchangers, Condensers)

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Philosophy of UPV inspection

Industry best practices

API 510 Section 4: Risk Based Inspection

Contains provision that allows an operating plant to extend the inspection interval of its pressure vessel, provided it has performed risk based analyses

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Perhaps the most well known & widely used pressure vessel design code in the world today

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

History
In early 1900, a number of factory explosions in USA had killed many workers and civilians In 1911, the American Society of Mechanical Engineers set up a committee to formulate standard rules for the construction of steam boilers and other pressure vessels, that will perform in a safe and reliable manner

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

History..continued
The scope includes; Made of nonferrous materials, cast iron, high alloy and carbon steel Made by welding and forging Applying a variety of construction methods and details

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

History..continued
The prime concern of ASME Code is to construct a vessel that will operate safely It is not concerned about non-safety issues e.g. whether the vessel should be painted or not

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Common materials of construction

Carbon steel is most common e.g. rolled plates SA 516 Grade 70 For special purposes, alloys of chromium, molybdenum, nickel, vanadium, etc. are used

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Common materials of construction

Materials that will most economically resist the type of corrosion expected in service, are selected Cladding plain carbon steel with stainless steel is an economical way of saving cost of alloy steel

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Common materials of construction

Metallic liners are installed using various methods weld overlay (small sections), rolled, or explosion bonded Nonmetallic liners are also used to resist erosion and corrosion, or to insulate vessel shell e.g. rubber lining, refractory material

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Common materials of construction

However if the operating pressure and temperature are too high, solid alloy steels may be the only choice Lists of ferrous and nonferrous materials allowed by ASME are found in ASME Section II

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Loadings on vessels
Vessel materials usually degrade in two manners; 1. Corrosion

2. Metallurgy
The Code only handles metallurgy failures: Creep Brittle fracture Fatigue Etc.
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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Loadings on vessels
Loadings exert stresses on vessel components Types of loadings include:

Internal or external pressure

Weight of vessel and content Static reactions from attachments piping, ladders, supports, etc. Wind pressure Temperature gradients Abnormal pressure during plant upset
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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Loadings on vessels
Operating pressure due to normal process operation Design pressure used in design of vessel typically 30 psi or 10% higher than operating pressure Maximum allowable working pressure MAWP. The highest pressure allowed at the top of the vessel Hydrostatic test pressure at least 1.3 times the MAWP

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Brief overview of pressure vessel design

ASME Boiler & Pressure Vessel Code Section VIII

Pressure & load retaining components

The common components of pressure vessels are: Shell cylindrical, spherical, spheroidal, boxed

Heads flat, hemispherical, ellipsoidal, conical, toriconical, torispherical

Supports steel columns, cylindrical plate skirts, plate lugs

Nozzles
Jacketed vessel built with casing or outer shell

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Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components The common components of pressure vessels

Figure 2.1: Various shapes of vessel heads

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Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components The common components of pressure vessels

Figure 2.2: Various vessel shapes

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Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components

Lets do calculations..
P = 120 psi design pressure S = 20,000 psi allowable stress value for SA 515 Grade 70 @ 500oF E = 1.00 joint efficiency R = 60 inches radius D = 120 inches diameter = 30o one half of apex angle L = 120 inches dish radius t = required wall thickness, which we want to PMTSB 2006 calculate

Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components

Formula
For cylindrical shell
t PR SE 0.4 P

For spherical shell or hemispherical head

t PR 2SE 0.8P

For 2:1 ellipsoidal head

t PD 2SE 1.8P

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Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components

Formula
For conical section
t PD 2 cos ( SE 0.4 P)

For torispherical head with small knuckle section

t 0.885PL SE 0.8P

For flat head

td 0.33 P SE

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Brief overview of pressure vessel design ASME Boiler & Pressure Vessel Code Section VIII Pressure & load retaining components

Calculation results
Shape Hemispherical Cylindrical Thickness required (inch) Ratio 1

2:1 ellipsoidal
Conical Torispherical Flat

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Brief overview of pressure vessel design

Pressure & load retaining components Questions What is the best shape to resist pressure?

What is the worst shape to resist pressure?

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Brief overview of pressure vessel design

Pressure & load retaining components Other learning points.. For vessel under static pressure, which welds are most critical?

Figure welds on PV

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Brief overview of pressure vessel design

Pressure & load retaining components Other learning points.. For vessel under cyclic pressure, which welds are most critical?

Figure welds on PV

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Brief overview of pressure vessel design

Internals

Figure 2.3: Examples of vessel internals

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Brief overview of pressure vessel design

Essential fittings for pressure vessels One or more pressure relieving device A pressure gauge The manufacturers nameplate

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