SERVICE USING ASME SECTION VIII, DIVISION 2 AND DIVISION 3 PRESSURE VESSEL CODES 2 nd ASME/USCG Workshop on Marine Technology and Standards July 29-30, 2010 Washington DC, USA Louis E. Hayden, PE President, Louis Hayden Associates Bethlehem, PA, USA J Robert Sims Becht Engineering Co., Inc. Liberty Corner, NJ , USA INTRODUCTION Pressure vessels on board ships can account for significant volume and weight and thus affect the overall performance of the vessel. Classically, shipboard pressure vessels have been designed to ASME Section VIII, Div. 1. This code requires pressure vessels that are designed using a basic design by rule approach with a 3.5 to 1 design margin on specified minimum tensile strength. In recent years the ASME Standards Committee responsible for Section VIII developed two design codes, Section VIII, Div. 2 Alternative Rules for Construction of Pressure Vessels and Section VIII, Div. 3 Alternative Rules for Construction of High Pressure Vessels. 3 INTRODUCTION These pressure vessel design codes offer lower design margins, an improved design by rule approach for Division 2, and allow or require design by analysis based on the vessel operating conditions and environment such as cyclic service. Use of these codes can improve shipboard vessel design by lowering the weight of vessels while providing a safe reliable pressure vessel. 4 CODE HISTORY The initial edition of the Unfired Pressure Vessel Code, Division 1, was distributed in 1925, and Section VIII, Division 2 was issued in 1968. These codes have been actively maintained and updated by a dedicated group of volunteers. In 1981, the ASME Boiler and Pressure Vessel Standards Committee authorized the development of a new code to cover high pressure vessels. High pressure was generally considered to include vessels with design pressures of 70 MPa (10,000 psi) or higher. Section VIII, Division 3 was first issued in 1997. 5 CODE HISTORY In 1998, the ASME Boiler and Pressure Vessel Standards Committee authorized a project to rewrite the Section VIII, Division 2 pressure vessel code to introduce new technologies and to produce more competitive designs. The new standard was modernized with regard to the latest technical advances in pressure vessel construction, and was structured in a way to make it more user-friendly to both code users and the committees that maintain it. The new Section VIII, Division 2 was first published in J uly, 2007. 6 DEVELOPMENT OF THE REWRITE OF SECTION VIII, DIVISION 2 Some of the new technologies incorporated into the new Section VIII, Division 2 Code rewrite include: Adoption of a design margin on the specified minimum ultimate tensile strength of 2.4 Toughness requirements based on the fracture mechanics approach provided in API 579-1/ASME FFS-1 Design-by-rule for the creep range Conical transition reinforcement requirements Opening reinforcement rules Load case combinations for elastic, limit load, and elastic-plastic analysis Local strain criteria for design-by-analysis using elastic-plastic analysis 7 DEVELOPMENT OF THE REWRITE OF SECTION VIII, DIVISION 2 New Technologies (Continued) Limit load and plastic collapse analysis, Ultrasonic examination in lieu of radiographic examination. Fatigue design for welded joints based on the Master S/N Curve and the Structural Stress Method, and Ultrasonic examination in lieu of radiographic examination. 8 DEVELOPMENT OF THE REWRITE OF SECTION VIII, DIVISION 2 Some enhancements included in the new Division 2: Alternatives to U.S. and Canadian Registered Professional Engineer (RPE) certification of the User Design Specification (UDS) and Manufacturers Design Report (MDR) provided to accommodate Manufacturers outside of North America, Introduction of a weld joint efficiency factor and the use of partial radiographic and ultrasonic examination, Significant upgrade to design-by-rule and design-by-analysis procedures, User-friendliness; extensive use of equations, tables, and figures to define rules and procedures, and ISO-like format; logical paragraph numbering system and single column format. 9 SECTION VIII, DIVISION 2 This Code is made up of nine parts: Part 1 General Requirements Part 2 Responsibilities and Duties Part 3 Material Requirements Part 4 Design-by-Rule Requirements Part 5 Design-by-Analysis Requirements Part 6 Fabrication Requirements Part 7 Inspection and Examination Requirements Part 8 Pressure Testing Requirements Part 9 - Pressure Vessel Overpressure Protection 10 DESIGN BY RULE REQUIREMENTS Numerous enhancements were made to the design-by-rule procedures in Part 4: Introduction of explicit design rules for combined loadings (i.e. pressure, weight, wind and earthquake), as well as adoption of the ASCE/SEI 7-05 [4] load combination methodology for allowable stress design and strength design. Weld joint efficiencies are introduced in the Section VIII Division 2 rewrite permitting for the first time less than 100% volumetric examination for main vessel welds. Introduction of new design rules for cylindrical shells, spherical shells and heads, ellipsoidal heads, torispherical heads, and spherically dished bolted covers. 11 DESIGN BY RULE REQUIREMENTS Introduction of new opening reinforcement rules based on pressure-area stress calculations. Introduction of new rules for conical transitions subject to internal/external pressure. Inclusion of design rules for stayed construction, jacketed vessels, noncircular vessels, vessel supports, and clamped connections. Inclusion of bellows and tubesheet design rules based on Part UHX from ASME Section VIII, Division 1. Use of API 579-1/ASME FFS-1 to evaluate vessels outside of tolerance. 12 VESSEL DESIGN COMPARISON OLD Div. 2 vs. NEW DIV. 2 . Table 2 Section VIII, Division 2 Wall Thickness Comparison SA 382 Grade 22V, SMYS=413 MPa, SMTS=586 MPa, SMYS/SMTS=0.71 Temperature (C) 2004 Edition, 2006 Addenda 2007 Edition Reduction in Wall Thickness (%) Allowable Stress (MPa) Wall Thickness (mm) Allowable Stress (MPa) Wall Thickness (mm) 38 195 2.74 244 2.18 20.3 66 195 2.74 244 2.18 20.3 93 195 2.74 244 2.18 20.3 121 195 2.74 244 2.18 20.3 149 195 2.74 244 2.18 20.3 177 195 2.74 244 2.18 20.3 204 195 2.74 244 2.18 20.3 232 195 2.74 244 2.18 20.3 260 195 2.74 244 2.18 20.3 288 193 2.77 244 2.18 21.2 316 190 2.81 244 2.18 22.4 343 187 2.87 244 2.18 23.8 371 183 2.93 241 2.21 24.4 399 179 3.00 236 2.26 24.6 427 174 3.09 230 2.32 24.9 454 169 3.18 199 2.68 15.5 482 163 3.30 164 3.27 0.9
Design Parameter Division 1 Division 2 Material SA-537 Cl.1 2009 SA-537 Cl.1 2009 Design Conditions 500 psig @ 300F 500 psig @ 300F Inside Diameter 90.0 in 90.0 in Corrosion Allowance 0.125 in 0.125 in Allowable Stress @ Design Condition Section II Table 1A- 19,700 psi Section II Table 5A- 29,000 psi Weld J oint Efficiency 1.0 1.0 Corroded Diameter D=90.0 +2(o.125) =90.25 in D=90.0 +2(o.125) =90.25 in Cylindrical Shell Thickness Per UG-27(c)(1) t =1.163 in t =1.163 +0.125 =1.288 in Use t =1.375 in Per 4.3.3 t =0.785 in t =0.785 +0.125 =0.910 in Use t =1.00 in 14 DESIGN COMPARISON DIV.1 vs. DIV. 2 NOZZLE IN A CLYNDRICAL SHELL . Design Parameter Division 1 Division 2 Nozzle Material SA-105, 2009 SA-105, 2009 Inside Diameter 18.0 in 18.0 in Thickness 1.50 in 1.50 in Allowable Stress @ Design Condition 20,000 psi 21,200 psi External Nozzle Projection 15.0 in 15.0 in Corrosion Allowance 0.125 in 0.125 in Weld J oint Efficiency 1.0 1.0 Nozzle Type Inset With no Internal Projection Inset With no Internal Projection Reinforcing Pad Outside Diameter 31.0 in 31.0 in Reinforcing Pad Inside Diameter 21.0 in 21.0 in Reinforcing Pad Thickness 1.25 in 0.875 in
15 DESIGN COMPARISON DIV.1 vs. DIV. 2 SPHERICAL SHELL . Design Parameter Division 1 Division 2 Material SA- 537Cl. 1, 2009 SA 537Cl. 1, 2009 Design Condition 500 psig @ 300F 500 psig @ 300F Inside Diameter 180.0 in 180.0 in Corrosion Allowance 0.125 in 0.125 in Allowable Stress @ Design Condition 19,700.00 psi 29,000 psi Weld Efficiency 1.0 1.0 Shell Thickness UG- 27(d)(1) t =1.147 in t =1.147 +0.125 =1.272 in Use t =1.375 in Paragraph 4.3.5 t =0.780 in t =0.780 =0.125 =0.905 in Use t=1.00 in
16 SECTION VIII, DIVISION 3 17 BACKGROUND OF DIV. 3 Published in 1997 after ~15 years of development. Developed for design pressures > 70 MPa (10 ksi). Initial applications for pressures up to 620 Mpa (90 ksi). Since rules can be applied at any pressure, some recent applications have been for pressures well below 70 MPa (10 ksi). Much of the technology was developed for large naval gun barrels. 18 SOME CURRENT APPLICATIONS OF DIV. 3 High pressure polyethylene manufacturing (since early 1940s). 20,000 to 60,000 psi (140 to 415 MPa) Hot and cold isostatic pressing (since early 1950s). 15,000 to 60,000 psi (100 to 415 MPa) Food sterilization (last 10 to 20 years). 60,000 to 90,000 psi (415 to 620 MPa) Composite fiber wrapped vessels for compressed natural gas. 3,000 to 4,000 psi (21 to 28 MPa) Composite fiber wrapped vessels for compressed hydrogen. 8,000 to 15,000 psi (55 to 105 MPa) 19 TYPES OF VESSEL SHELL CONSTRUCTION IN DIV. 3 Conventional rolled and welded Forged monoblock cylinders Shrink fit cylindrical shells, Multilayer welded vessels, Profile strip wound vessels, Wire wound vessels Composite fiber wrapped vessels. 20 COMPOSITE WRAPPED PRESSURE VESSELS Glass and carbon fibers can be used to wrap the outside of a cylindrical vessel to provide reinforcement in the hoop direction. Div. 3 Code Cases for this type of construction have existed for several years, but these have been incorporated into the Code in the 2010 Edition. There are also applications for fully wrapped vessels that are covered in ASME Section X, Fiber-Reinforced Plastic Pressure Vessels. 21 ADVANTAGES OF COMPOSITE WRAPPED PRESSURE VESSELS Good fatigue life because the composite wrap can produce high residual compressive stresses in the shell after autofrettage. Light weight Fabrication processes readily adapted for mass production 22 OTHER CONSIDERATIONS FOR HOOP WRAPPED COMPOSITE VESSELS Nozzles are not permitted in the hoop wrapped cylindrical shell portion. In-service examination is typically done using acoustic emission, since access to the metallic core for conventional UT is limited by the overwrap. The overwrap is treated in much the same way as a weld in the construction process, rather than as a material. A Laminate Procedure Specification is prepared and qualified by an extensive series of tests. Over 12 essential variables are defined. 23 LAMINATE PROCEDURE QUALIFICATION TESTS Cyclic pressure qualification test using Div. 3 Article KD- 12. Static pressure qualification test of fatigue cycled vessel at 2 times the design pressure or 2.5 times the service or working pressure, whichever is greater. Subsequent burst test to determine failure mode. Procedure must be re-qualified every year or after every 1,000 vessels produced. 24 HYDROGEN SERVICE Transport and storage of hydrogen at pressures up to 15,000 psi (103 MPa) is of interest for the hydrogen economy. Div. 3 includes Article KD-10 on Special Requirements For Vessels In High Pressure Gaseous Hydrogen Transport And Storage Service. The following hydrogen partial pressures are included: Nonwelded vessels greater than 41 MPa (6,000 psi) with actual measured tensile strength less than or equal to 945 MPa (137 ksi). Nonwelded vessels greater than 5.2 MPa (750 psi) with actual measured tensile strength greater than 945 MPa (137 ksi). Welded vessels greater than 17 MPa (2,500 psi) with actual measured tensile strength less than or equal to 620 MPa (90 ksi). Welded vessels greater than 5.2 MPa (750 psi) with actual measured tensile strength greater than 620 MPa (90 ksi). 25 REQUIREMENTS FOR HYDROGEN SERVICE Three heats of material must be tested in the hydrogen environment and at the hydrogen pressure to be used in service. Base metal, weld metal and HAZ must be tested as applicable. The threshold for subcritical crack growth from the test replaces the critical crack tip stress intensity for determination of critical crack size. The maximum crack growth rate from the tests is used rather than the values in air in Div. 3 and in most literature references. Crack growth rate is affected by: Cycle frequency Maximum to minimum stress intensity ratio (R ratio) 26 SUMMARY Vessels for use on ships that are constructed to Div. 2 or Div. 3 make more efficient use of materials and have equivalent integrity to vessels constructed to Div. 1. 27