30th April -4th May,2018

Short Term Training

on
Design of Pressure vessel
as per
ASME Sec VIII, Div 1 & 2

Dr. D. C. Patel 1
1. Design Philosophy
and
Introduction to ASME

Dr. D. C. Patel 2
 Overview of pressure vessels
• Vessels, tanks, and pipelines that carry, store, or receive fluids are called pressure vessels. A pressure vessel is
defined as a container with a pressure differential between inside and outside. The inside pressure is usually higher
than the outside, except for some isolated situations.
• Generally speaking, pressurized equipment is required for a wide range of industrial plant for storage and
manufacturing purposes.
• In general, pressure vessels designed in accordance with the ASME Code, Section VIII, Division 1, are designed by
rules and do not require a detailed evaluation of all stresses. It is recognized that high localized and secondary
bending stresses may exist but are allowed for by use of a higher safety factor and design rules for details. It is
required, however, that all loadings (the forces applied to a vessel or its structural attachments) must be
considered. (See Reference 1, Para. UG-22.)
• The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section VIII, Division 1,
specifies a range of internal pressures from 0.1 MPa to 30 MPa. Pressure equipment, such as the American
Petroleum Institute (API) storage tanks are designed to restrict internal pressure to no more than that
generated by the static head of the fluid contained in the tank.

FROM : BOOK PRESSURE VESSEL DESIGN MANUAL

DENNIS MOSS (P.No 3-11)

Dr. D. C. Patel 3
It is general practice when doing more detailed stress analysis is to apply higher allowable stresses. In effect, the
detailed evaluation of stresses permits substituting knowledge of localized stresses and the use of higher allowable
in place of the larger factor of safety used by the Code. This higher safety factor really reflected lack of knowledge
about actual stresses.

Stress analysis is the determination of the relationship between external forces applied to a vessel and the
corresponding stress. The starting place for stress analysis is to determine all the design conditions for a given
problem and then determine all the related external forces. We must then relate these external forces to the vessel
parts which must resist them to find the corresponding stresses. By isolating the causes (loadings), the effects
(stress) can be more accurately determined.

Membrane stress : Pressure vessels commonly have the form of spheres, cylinders, cones, ellipsoids, tori, or
composites of these. When the thickness is small in comparison with other & mentions (R/t > 10), vessels are
referred to as membranes and the associated stresses resulting from the contained pressure are called membrane
stresses. These membrane stresses are average tension or compression stresses. They are assumed to be uniform
across the vessel wall and act tangentially to its surface. The membrane or wall is assumed to offer no resistance to
bending. When the wall offers resistance to bending, bending stresses occur in addition to membrane stresses.

In a vessel of complicated shape subjected to internal pressure, the simple membrane-stress concepts do not suffice
to give an adequate idea of the true stress situation. The types of heads closing the vessel, effects of supports,
variations in thickness and cross section, nozzles, external attachments, and overall bending due to weight, wind,
and seismic activity all cause varying stress distributions in the vessel. Deviations from a true membrane shape set up
bending in the vessel wall and cause the direct loading to vary from point to point. The direct loading is diverted from
the more flexible to the more rigid portions of the vessel. This effect is called “stress redistribution.”
Dr. D. C. Patel 4
In any pressure vessel subjected to internal or external pressure, stresses are set up in the shell wall. The state of
stress is triaxial and the three principal stresses are:

1ongitudinal stress
circumferential/ hoop stress
radial stress

Since ASME Code, Section VIII, Division 1, is basically for design by rules, a higher factor of safety is used to allow
for the “unknown” stresses in the vessel. This higher safety factor, which allows for these unknown stresses, can
impose a penalty on design but requires much less analysis.

In conclusion, “membrane stress analysis’’ is not completely accurate but allows certain simplify assumptions to
be made while maintaining a fair degree of accuracy. The main simplifying assumptions are that the stress is
biaxial and that the stresses are uniform across the shell wall. For thin-walled vessels these assumptions have
proven themselves to be reliable. No vessel meets the criteria of being a true membrane, but we can use this
tool with a reasonable degree of accuracy.

1. MAXIMUM PRINCIPAL STRESS THEORY

2. MAXIMUM SHEAR STRESS THEORY

Dr. D. C. Patel 5
Comparison of the Two Theories
Both theories are in agreement for uniaxial stress or when one of the principal stresses is large in comparison to the
others. The discrepancy between the theories is greatest when both principal stresses are numerically equal.
For simple analysis upon which the thickness formulas for ASME Code, Section I or Section VIII, Division 1, are based,
it makes little difference whether the maximum stress theory or maximum shear stress theory is used. For example,
according to the maximum stress theory, the controlling stress governing the thickness of a cylinder is circumferential
stress, since it is the largest of the three principal stresses. According to the maximum shear stress theory, the controlling stress
would be one-half the algebraic difference between the maximum and minimum stress:
The maximum stress is the circumferential stress,
= PR/t
The minimum stress is the radial stress,
r= -P
Therefore, the maximum shear stress is: ( - r)/2
ASME Code, Section VIII, Division 2, and Section III use the term “stress intensity,” which is defined as twice the maximum shear
stress. Since the shear stress is compared to one-half the yield stress only, “stress intensity” is used for comparison to allowable
stresses or ultimate stresses. To define it another way, yielding begins when the “stress intensity” exceeds the yield strength of
the material.
In the preceding example, the “stress intensity” would be equal to : ( - r) And For a cylinder where P = 300 psi, R = 30 in.,
and t = .5 in., the two theories would compare as follows:
Maximum stress theory
=  = PR/t = 300(30)/.5 = 18,000 psi
Maximum shear stress theory
 = PR/t + P = 300(30)/.5 + 300 = 18,300 psi
Two points are obvious from the foregoing: 1. For thin-walled pressure vessels, both theories yield approximately the same
results. 2. For thin-walled pressure vessels the radial stress is so small in comparison to the other principal stresses that
it can be ignored and a state of biaxial stress is assumed to exist.
Dr. D. C. Patel 6
Categories of Failures
1. Material-Improper selection of material; defects in material.
2. Design-Incorrect design data; inaccurate or incorrect design methods; inadequate shop testing.
3. Fabrication-Poor quality control; improper or insufficient
fabrication procedures including welding; heat treatment or forming methods.
4. Service-Change of service condition by the user; inexperienced operations or maintenance personnel;
upset conditions. Some types of service which require special attention both for selection of material, design
details, and fabrication methods are as follows:
a. Lethal
b. Fatigue (cyclic)
c. Brittle (low temperature)
d. High temperature
e. High shock or vibration
f. Vessel contents
Hydrogen ( HIGH TEMP HYDROGEN ATTACK )
Ammonia
Compressed air
Caustic
Chlorides

Dr. D. C. Patel 7
Types of Failures

1. Elastic deformation-Elastic instability or elastic buckling, vessel geometry, and stiffness as well as properties
of materials are protection against buckling.
2. Brittle fracture-Can occur at low or intermediate temperatures.
Brittle fractures have occurred in vessels made of low carbon steel in the 40’50°F range during hydro test where
minor flaws exist.
3. Excessive plastic deformation-The primary and secondary stress limits as outlined in ASME Section
VIII, Division 2, are intended to prevent excessive plastic deformation and incremental collapse.
4. Stress rupture-Creep deformation as a result of fatigue or cyclic loading, i.e., progressive fracture.
Creep is a time-dependent phenomenon, whereas fatigue is a cycle-dependent phenomenon.
5. Plastic instability-Incremental collapse; incremental collapse is cyclic strain accumulation or cumulative
cyclic deformation. Cumulative damage leads to instability of vessel by plastic deformation.
6. High strain-Low cycle fatigue is strain-governed and occurs mainly in lower-strength high-ductile materials.
7. Stress corrosion-It is well known that chlorides cause stress corrosion cracking in stainless steels; likewise
caustic service can cause stress corrosion cracking in carbon steels. Material selection is critical in these
services.
8. Corrosion fatigue-Occurs when corrosive and fatigue effects occur simultaneously. Corrosion can reduce fatigue
life by pitting the surface and propagating cracks. Material selection and fatigue properties are the major
considerations.

Dr. D. C. Patel 8
Dr. D. C. Patel 9
 LOADINGS (UG-22)
Loadings or forces are the “causes” of stresses in pressure vessels. These forces and moments must be isolated
both to determine where they apply to the vessel and when they apply to a vessel. Categories of loadings
define where these forces are applied. Loadings may be applied over a large portion (general area) of the vessel or over a
local area of the vessel. Remember both general and local loads can produce membrane and bending
stresses. These stresses are additive and define the overall state of stress in the vessel or component. Stresses from local
loads must be added to stresses from general loadings. These combined stresses are then compared to an allowable stress.
Loadings can be outlined as follows:

1. General loads-Applied more or less continuously across a vessel section.

a. Pressure loads-Internal or external pressure (design, operating, hydrotest. and hydrostatic head of liquid).
b. Moment loads-Due to wind, seismic, erection, transportation.
c. Compressive/tensile loads-Due to dead weight, installed equipment, ladders, platforms, piping, and vessel contents.
attachment.
d. Thermal loads-Hot box design of skirt head

2. Local loads-Due to reactions from supports,

internals, attached piping, attached equipment, Le., platforms, mixers, etc.
a. Radial load-Inward or outward.
b. Shear load-Longitudinal or circumferential.
c. Torsional load.
d. Tangential load.
e. Moment load-Longitudinal or circumferential.
f. Thermal load. Dr. D. C. Patel 10
B. Types of loadings
1. Steady load-Long-term duration, continuous.
a. Internal/ external pressure.
b Dead weight.
c. Vessel contents.
d. Loadings due to attached piping and equipment.
e. Loadings to and from vessel supports.
f. Thermal loads.
g. Wind loads.

2. Nonsteady loads-Short-term duration; variable

a. Shop and field hydro tests.
b. Earthquake.
c. Erection.
d. Transportation.
e. Upset, emergency.
f. Thermal loads.
g. Start up, shut down.
Dr. D. C. Patel 11
Vessel Loading Requirements ASME Section VIII, Div.1 (UG-22)

Dr. D. C. Patel 12
Dr. D. C. Patel 13
 Design philosophy of ASME code

ASME Code, Section VIII, Division 1 does not explicitly consider the effects of combined
stress. Neither does it give detailed methods on how stresses are combined. ASME
Code, Section VIII, Division 2, on the other hand, provides specific guidelines for
stresses, how they are combined, and allowable stresses for categories of combined
stresses. Division 2 is design by analysis whereas Division 1 is design by rules.

Dr. D. C. Patel 14
Overview

• What is ASME?
• What is a standard?
• Why do we have standards?
• How are standards developed?
• How are standards used by an engineer?

FROM :ASME Training Module (P.No.12-)

Dr. D. C. Patel 15
What is the American Society of Mechanical
Engineers?

Dr. D. C. Patel 16
 ASME Mission Statement:
To serve diverse global communities by advancing, disseminating and applying
engineering knowledge for improving the quality of life; and communicating the
excitement of engineering.

Sectors:
• Technical Events and Content
• Public Affairs and Outreach
• Group Pathways and Support
• Student and Early Career Development
• Standards and Certification

Dr. D. C. Patel 17
The American Society of Mechanical Engineers

• Organization started in 1880 by a small group of leading industrialists

• Has over 140,000 members in the society

• One of the worlds largest technical publishing operations

Dr. D. C. Patel 18
What is a Standard?

Dr. D. C. Patel 19
 What is a Standard?

A set of technical definitions, instructions, rules, guidelines, or

characteristics set forth to provide consistent and comparable results,
including:
- Items manufactured uniformly, providing for interchangeability
- Tests and analyses conducted reliably, minimizing the uncertainty of the results
- Facilities designed and constructed for safe operation

Dr. D. C. Patel 20
Why do we have Standards?

Dr. D. C. Patel 21
Why do we have Standards?
• Safety
• Uniformity/Consistency
• Efficiency
• Commerce and Trade

Dr. D. C. Patel 22
Safety
• Sultana

Dr. D. C. Patel 23
Safety
• Grover Shoe Factory Disaster

Dr. D. C. Patel 24
Safety

• After the Grover Shoe Factory, Massachusetts took the monumental step
and established a 5 man Board of Boiler Rules.

• ASME formed the Boiler Code Committee in 1911.

• Published the first edition of the Boiler and Pressure Vessel Code (BPVC) in
1915

• Today, BPVC is incorporated into laws in most states, US territories, and

Canadian providences.

Dr. D. C. Patel 25
 HISTORY

Timeline of Early ASME Standardization Milestones

1884 1914 1916 1921

Issues first standard, 1905 First edition of the Safety Code for
Safety Code for
1880 Code for the Conduct Standard for Boiler and Pressure Cranes Elevators
ASME founded to of Trials of Steam Proportions of Vessel Code
Boilers Machine Screw Sizes 1918
address issues with
industrialization and Founding member of
mechanization American Engineering
Standards Committee
(later known as ANSI)

Dr. D. C. Patel 26
 Uniformity/Consistency
• Standards ensure that various goods and systems are the same
everywhere
• Bolt and Screw Sizes, threading
• Rail gauge
• Material composition
• Plumbing fittings
• Computer Fonts/Typesetting

Dr. D. C. Patel 27
Efficiency
• Use of standards reduces the time in developing proven technology
• Standards provide a common language for all stakeholders

Dr. D. C. Patel 28
Commerce and Trade
• Standards play a large role in trade
• Examples of Organization Developing Standards for Worldwide
market include:
• ASME
• ASTM
• ISO Standards
• IEEE
• (Ideally) one universal standard, one universal test

Dr. D. C. Patel 29
How are Standards Developed?

Dr. D. C. Patel 30
Who Creates Standards?
• The American National Standards Institute (ANSI)
• Central clearing house and coordinating body for Standards Development
Organizations (SDO)
• Professional Societies - such as ASME, ASCE and SAE
• Trade associations - such as API and AGA
• Testing and certifying organizations - such as UL
• Organizations whose main business is standards development - such as ASTM, NFPA, and ISO

Dr. D. C. Patel 31
Different Types of Standards
• Voluntary - Not compulsory by choice.
• Defacto - A de facto standard is a custom or convention that has achieved a
dominant position by public acceptance or market forces. Eg. Qwerty
keypad,pdf,html etc.
• Consensus standards- are standards developed through the cooperation of all
parties who have an interest in participating in the development and/or use
of the standards. Consensus requires that all views and objections be
considered, and that an effort be made toward their resolution. Consensus
implies more than the concept of a simple majority but not necessarily
unanimity.
• Regulatory – by law.
• Other
Dr. D. C. Patel 32
How are Standards Developed in ASME?

Dr. D. C. Patel 33
 How are Standards Developed?

• Standards are a “living document” that are constantly being developed and revised

• Developed using a series of checks and balances

• Written by volunteers

• Approved by a consensus process

• Follow procedures set by the American National Standards Institute (ANSI)

Dr. D. C. Patel 34
Voluntary Consensus Process
ASME standards actions are approved by consensus

This means:

• There is substantial agreement by affected interest categories on the proposed action

• All views have been considered and attempts have been made to resolve any objections from the
consensus body or any other source

• Unanimity is not required. For example, ASME’s accredited procedures require a 2/3 affirmative
vote of the committee membership

Dr. D. C. Patel 35
Key Principles of Consensus Process
• Openness
• Balance of Interest
• Due Process

Dr. D. C. Patel 36
From Concept to Publication
• Starts with engineering problem or new idea
• Research
• Formation of new committee if none in place
• Development
• Approval
• Publication

Dr. D. C. Patel 37
HISTORY ASME Standards Today
…by the numbers
• 500+ published standards (more recently, over 50
technical related non-standards publications)
• 5,000+ volunteer subject matter experts from over 50
countries
• 700 boards, standards developing committees and
supporting subgroups
• 7,000+ certified companies (>50% non-U.S.) in 75
countries

Dr. D. C. Patel 38
Pressure Technology
Requirements for
pressure equipment
including:
• Boilers
• Pressure Vessels
• Piping systems
• Piping components

Dr. D. C. Patel 39
Safety
Safety requirements for:
• Elevators
• Escalators
• Moving walkways
• Cranes
• Man lifts
• Conveyors
• And others

Dr. D. C. Patel 40
Nuclear
Requirements for nuclear
components including:
• Containment
• Reactors
• Piping
• Pumps
• Heat exchangers
• Turbines

Dr. D. C. Patel 41
Standardization and Testing
Requirements for many
different things including
• Hand tools, fasteners,
machine tools
• Dimensioning and
tolerancing
• Performance test codes

Dr. D. C. Patel 42
Emerging Technologies
• Concentrated Solar Power
• Thermal Energy Storage Systems
• Fuel Cell Performance Testing
• Overall Plant Performance with Carbon Capture
• Nanotechnology
• Super Critical Pressure Technology

Dr. D. C. Patel 43
How do Standards Affect an Engineer?

Dr. D. C. Patel 44
How does the ASME Standard Affect an Engineer?

• Material Selection
• Design Requirements
• Fabrication Requirements
• Examination and Testing Requirements
• Quality Assurance

Dr. D. C. Patel 45
Material Selection
• Standards provide a list of allowable materials
• Provide maximum allowable stresses
• Users have choice

Dr. D. C. Patel 46
Design Requirements
• Standards provide minimum design requirements
• Ex. Section VIII-1 has a design margin on 3.5

Dr. D. C. Patel 47
Design Requirements
• Standards provide pertinent equations
• Examples: Design Pressure, Thickness, Bearing Loads, Moments

• Does not replace engineering judgement

Dr. D. C. Patel 48
Fabrication Requirements

• Material requirements
• i.e. cutting, grinding
• Tolerances
• i.e. Bolt spacing
• Attachment
• Welding
• Bolting

Dr. D. C. Patel 49
Examination and Testing Requirements
• Nondestructive examination
• Radiography, Ultrasound, Visual
• Destructive Testing
• Nondestructive Testing
• Leak Testing
• Hydrostatic
• Pneumatic

Dr. D. C. Patel 50
Quality Assurance
• Some standards require filling out a data report
• Most Standards allow the product have a specific marking to show
conformance

Dr. D. C. Patel 51
ASME Conformity Assessment
• Process by which a product is shown to be in full compliance with a standard
• ASME accredits manufacturers who produce products compliant with their
codes and standards
• There are over 9,000 ASME accreditation account holders worldwide
• ASME offers product certification for the following programs
• Boiler
• Nuclear
• NQA (Nuclear Quality Assurance)
• QSC (Quality System Certificate for nuclear material suppliers)
• BPE (Bioprocessing Equipment)
• AIA (Authorized Inspection Agency)

Dr. D. C. Patel 52
 Summary
• Engineering Standards were developed to improve public safety, allow for
uniform consistency of products, and help ensure fair and free commerce and
trade
• ASME develops standards using an ANSI accredited voluntary consensus
approach
• Standards help engineers by providing requirements for design, fabrication,
materials, testing, and other areas

Dr. D. C. Patel 53
Thank YOU
Dr. D. C. Patel 54