Overview of ASME codes for

design , fabrication & testing

(as per ASME Sec. VIII Div. 1)

Vishal Tailor & Dhaval

Trivedi
ENCS – LEI
23.09.2016
 Structure of ASME Section VIII Div-1(Code)

ASME SEC –VIII DIV- 1 Consists of:

Introduction -U
Subsection A -General Requirements
(Part UG)
Subsection B -Specific Requirements -
Methods
(Parts UW, UF, UB)
Subsection C -Specific Requirements -
Materials
(Parts UCS, UNF, UHA, UCI,
UCL,
UCD, UHT, ULW, ULT,
UHX)
Mandatory Appendices
-Appendix 1 to 44
Non Mandatory Appendices
-Appendix A, C, … FF, NN

Cover page of Code, Edition -2015

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 Structure of ASME Section VIII Div-1(Code)

Part UG : General Requirements for all Methods of Construction and all Materials
Materials UG-4 to UG-15
Design UG-16 to UG-35
Openings and Reinforcement UG-36 to UG-46
Fabrication UG-75 to UG-85
Inspection and Tests UG-90 to UG-103
Markings and Reports UG-115 to UG-120

Part UW : Requirements for Pressure vessels fabricated by Welding

General UW-1 to UW-3
Materials UW-5
Design UW-8 to UW-21
Fabrication UW-26 to UW-42
Inspection and Tests UW-46 to UW-53

Specific Requirements - Materials

Carbon and Low Alloy steel: UCS – 23 ( Material) , 56 ( PWHT) , 57 ( Radio graphic
examination-RT), 66 (MDMT) ,
79 ( Forming requirement)
High Alloy steel UHA - 8 (Material), 32 ( PWHT ) , 33 (RT) , 44 ( Forming
Requirement) ,
51 ( Impact test)
Cladding & Overlay UCL – 11 ( Material) , 34 ( PWHT) , 35 ( RT) , 51 ( Tightness testing)

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 Structure of ASME Section VIII Div-1(Code)

Mandatory Appendix
Definition Appendix – 3
Flanged and Flued expansion joint Appendix – 5
Bellow Expansion Joints Appendix – 26
Electric Immersion Heater support plate Appendix – 41
Establishing Governing code Appendix – 43
Cold stretching Appendix – 44

Non - Mandatory Appendix

Load for Tube # Tube sheet joint Appendix – A
Rules for Joint Efficiency Appendix – L
Flat Face flange with metal contact Appendix – Y
Half pipe Jackets Appendix – EE
Unit conversion Appendix – GG
Graphical representation of Ft of (UHX) Appendix – LL

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 Discussion on UG

— U-2(g)
— This Division of Section VIII does not contain rules to cover all details of design and
construction. Where complete details are not given, it is intended that the Manufacturer,
subject to the acceptance of the Inspector, shall provide details of design and
construction which will be as safe as those provided by the rules of this Division.

Example :
— Large opening offset nozzle,
— Cone with half apex angle greater than 30 degree, ( Code case – 2150 )
— lateral buckling of stiffening ring, ( Design requirement given in ASME VIII – Div-2)
— When axial load at cone # shell junction are in compression and exceed PR/2 ( Normally
FEA required)
— Etc.

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 Discussion on UG

— UG- 15 (d) Pipe Under tolerance

Screen shot of PVElite

Recommended to perform Calculation keeping

MINIMUM tab.
As, PVELite is not considering under tolerance in
WRC, if performed on Nominal.
For the nozzle necks specify electric-resistance-
welded (ERW) pipe or seamless pipe (SMLS).
Seamless pipe cost is considerably higher and will
increase the vessel’s cost.

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 Discussion on UG

— UG- 20 Design Temperature

Maximum
— The maximum design temperature shall not be less than the mean metal
temperature expected under operating conditions
Minimum
— The minimum metal temperature used in design shall be the lowest expected in
service.

Material selection based of design temperature are given below ( as per LS 129 - 07
Temperatu -254 °C to -81 -80 °C up to -48 °C up to 50 °C 50°C up to 344 °C up to
re
Part-01)
°C -49 °C 343°C 454 °C
SA-240 Type SA-203 Gr. D / SA-516; SA-537 Cl. 1 SA-516; SA- SA-204 Gr. A /
Plate -
304 / 316 / 321 Gr. E SA-537 Cl. 2 537 Cl. 1 Gr. B
Material
SA-537 Cl. 2
SA-182 Gr. SA-350 Gr. LF3; SA-350 Gr. LF2; SA- SA-105; SA- SA-182 Gr. F1;
F304 / F316 / SA-765 Gr. III 765 Gr. II(-48°C to 266 Gr. 2 / SA-336 Gr. F1
F321 1 -30°C) Gr. 4; SA-181 SA-765 Gr. IV
Forging – 6 Bolts Cl. 60 / Cl.
Material SA-965 Gr. SA-350 Gr. LF1; SA- 70
F304 / F316 / 105; SA-266 Gr. 2 / Gr.
F321 4(-29°C to 49°C)

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 UG- 21 - Design pressure , MAWP & MAP

Design Pressure ( @ top of vessel)

—The pressure value used in the design of the vessel component together with the coincident
design metal temperature to determine the minimum permissible thickness or physical
characteristics of the different zones of the vessel
—Static head shall be added when applicable

Maximum Allowable Working Pressure (MAWP):

— The MAWP is the maximum pressure allowable in the “hot and corroded” condition.
— This pressure is based on calculations for every element of the vessel using nominal
thicknesses exclusive of corrosion allowance.
— The designpressure may be substituted if the MAWP is not calculated.

Maximum Allowable Pressure (MAP):

— The term MAP is no longer used by the Code but is used here as a matter of
convenience. It refers to the maximum permissible pressure based on the weakest
part in the new (uncorroded) and cold condition, and all other loadings are not taken
into consideration.
— MAP is normally used to calculate highest Hydrotest pressure for vessel @ shop.

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 Corrosion Allowance

— All calculation shall be performed in corroded condition.

— In many cases un-corroded calculation are also required.

— Tube sheet design,
— Expansion bellow calculation

— Further, many a time un-corroded ( Nominal ) thickness shall be consider

— To determine PWHT, Time of PWHT
— To calculate forming strain and to determine PFHT
— To determine MDMT and Impact test requirement
— Radiographic Examination

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 UG-22 Loading

- For long vessel, Rigging load may

govern design.
- Long vessel, Horizontal Hydrotest @
shop may govern design.
- Vessel with pump. Pump vendor shall
provide load and vessel vendor to
design nozzle with these load.
(Additional gusset plate are normally
provided)
- For jacketed vessel, Manufacture to
consider combine load

- For large vessel, Trunion may also

required higher shell thickness.
-
Deflagration : combustion which propagates
through a gas of an explosive at subsonic
speeds(thru shock waves)
Non – Mandatory appendix – H : Guideline for
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 UG-23 MAXIMUM ALLOWABLE STRESS
VALUES

Tensile stress
Longitudinal compressive
stress

Minimum of following :
(1)the maximum allowable tensile stress
value permitted in ;
(2) the value of the factor B determined
by as per external pressure calculation.
[ See UG-23(b)]

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 UG-23 MAXIMUM ALLOWABLE STRESS
VALUES

UG-23 (c)
UG-23 (d)

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 UG-23 MAXIMUM ALLOWABLE STRESS
VALUES

UG-23 (e)

PVElite does not consider 2Y.

Hence, it is possible that nozzle failing
due to 3S may pass with 2Y.
This is particularly helpful when load chang
during later stage of project where geometr
changing is difficult.

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 Design formulas for difference component

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 Recommended Design practice

— Design of Shell under external pressure

— Stiffening ring shall be spaced approx. at 2D for vessel ID
— Stiffening ring should way for circumferential weld seams, Nozzle opening .
— Height of stiffening ring shall be minimum then platform, ladder clip
— Some of acceptable method of welding stiffening ring. Fillet size shall be varied with
calculation

— For horizontal vessel with large diameter (above ID 3000) and length 10000 mm. Stiffening
ring may be required at saddle location.

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 Recommended Design practice :

— Design of cone under the external pressure :

For all cone to shell junction, reinforcement required shall as per Appendix 1-5 & 1-8 to be
checked & provided.
Reinforcement by means of stiffening rings shall be within √RT (R = radius of small end or
large end & t = thickness accordingly @ respective ends.)
Reinforcement may be provided by means of toricon. If, any specific requirements shall be
clarified during the bid evaluation.
Toriconical may be used when the angle, α ≤ 30o & are mandatory for conical head designs
when the angle α exceeds 30o.

— UG-33 Formed heads , pressure on convex side (external pressure)

– Determines minimum required thickness after forming of ellipsoidal, tori spherical,
hemispherical, conical & toriconical heads under the external pressure.
– Dished head with bolting flange to be designed as per Appendix 1-6. Such as head of
floating tube sheet cover.

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 Recommended Design practice

— Design of Dished Head in Internal pressure

– Straight Face ( SF) shall be provided as per Fig 13.1

Normally,
S.F = 38 mm or 50 mm are
considered. It is mainly
depend of head
manufacturer

– Straight face ( SF ) and mean – matching requirement for hemispherical head

This configuration normally

applicable for
Hemispherical head.

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 Design of nozzle opening

UG-36 Openings in pressure vessels

— Shape of Opening
— Openings in cylindrical or conical portions
of vessels, or in formed heads, shall preferably
be circular, elliptical, or obround
— long dimension of an elliptical or obround
opening not to exceeds twice the short dimensions
( Hence, Tangential, Off-set opening not qualify this
requirement need FE Analysis)
RF PAD – Reinforcement Area
— Design of reinforcement
— Openings in cylindrical and conical shells
subjected to internal pressure may be designed
satisfy the requirements in Mandatory
Appendix 1, 1-9 in lieu of the internal pressure
requirements in UG-37.
— It is advisable but not mandatory for reinforcing
pad material to be the same as the vessel material and thickness
— While no minimum is stated, it is recommended that
re-pads be at least 2 in. wide.
Self Reinforcing Nozzle –
Reinforcement Area
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 Design of nozzle opening

— UG-42 Reinforcement of multiple opening

— openings closer than 2 times the average diameters and where limits of reinforcement
overlap
— Must have a combined area equal to the sum of the two areas.
— No portion of the cross-section shall apply to more than one opening.
— Any overlap area shall be proportioned between the two openings by the ratio of the diameters.
— If the area between the openings is less than 50% of that required for the two openings, the
supplemental rules of Appendix 1-7(a) and (c) shall apply.

— When more than two openings are to be provided with combined reinforcement
— The minimum distance between the centers is 1⅓ the average diameters.
— The area of reinforcement between the two nozzles shall be at least 50% of the area required for the
two openings.

— For openings less than 1⅓ times the average diameters

— No credit may be taken for the area between the openings.

— Multiple openings may be reinforced as an opening equal in diameter to that of a circle

circumscribing the multiple openings.

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 Design of nozzle opening

UG-39 Openings in Flat head

— Reinforcement is only required for operating conditions not bolt up.

— Options in lieu of calculating reinforcement: No additional reinforcement is
required if flange thickness is greater than 1.414 to. ( to = Required flange
thickness in Operating )
— No additional reinforcement is required if to is calculated substituting 0.6 for 0.3
in the equation for to (doubling of c value, C value mention in Fig UG-34).

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 Various Clauses

— UG-99 Standard hydrostatic test

— A hydrostatic test shall be conducted on all vessels after
— All fabrication has been completed
— all examinations have been performed, except those required after the test
— Vessels designed for internal pressure shall be subjected to a hydrostatic test
pressure that at every point in the vessel is at least equal to 1.3 times the
maximum allowable working pressure multiplied by the lowest stress ratio (LSR)
for the materials of which the vessel is constructed
— No hydro test allowable stress limit in code. However, 90 % Yield stress of shell /
Dished end are normally used in practice.
— UG-100 Pneumatic test
— A pneumatic test may be used in lieu of the standard hydrostatic test prescribed in
UG-99 for vessels
— That are so designed and/or supported that they cannot safely be filled with water
— Not readily dried
— Pneumatic test pressure at every point in the vessel shall be at least equal to 1.1
times the maximum allowable working pressure multiplied by the lowest stress
ratio (LSR)

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 Part UW - Pressure vessels fabricated by
welding

— UW-2 Lethal Service restrictions

— When vessels are to contain lethal substances, either liquid or gaseous, all butt
welded joints shall be fully radiographed
— ERW pipe or tube is not permitted to be used as a shell or nozzle in lethal service
applications
— When fabricated of carbon or low alloy steel, such vessels shall be post weld heat
treated

— UW-3 Welded joint category

— The term “Category” as used herein defines the location of a joint in a vessel, but not
the type of joint
— The joints included in each category are designated as joints of Categories A, B, C,
and D

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 UW-3 Illustration of welded joint locations
typical of categories A, B, C, AND D

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 Radiographic Examination

— UW-11 Radiographic and ultrasonic

examination

— Full Radiography
— Spot Radiography
— No Radiography

Full Radiography requirement based on

thickness is give in UCS-57.

— ultrasonic examination may be

substituted for radiography for the
final closure seam if the construction
of the vessel does not permit
interpretable radiographs

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 Post Weld Heat Treatment (PWHT)

— UCS-56 Requirements for post weld heat treatment

— What is PWHT?
— Post weld heat treatment (PWHT), defined as any heat treatment after welding, is
often used to improve the properties of a weldment
— Stress Relieving
— Stress relief heat treatment is used to reduce the stresses that generated in a
structure as a consequence of manufacturing processes

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 UCS-79 : Post Forming Heat Treatment

— For formed vessel heads, the fiber elongation in the knuckle will always govern.
However the Fiber Elongation (FE) should be calculated for the crown radius as well.
— (Equation for FE calculation : UG-79)

— For pipe bends, the inside of the pipe bend gets thicker, while the outside of the
bend tends to stretch the material and thinning occurs. The maximum FE is at the
far outside of the bend, also known as the extrados

— Requirements for heat treatment;

— All material with a FE > 5% should be heat treated except for exception given P No.
1 & G 1 & 2(see UCS-79 for detail).
— Normalizing is only required when called out by customer or material specifications.
— If the section is hot formed above the normalizing temperature, and allowed to air
cool, no further heat treatment is required.

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 Brittle fracture phenomena

— In general, four main factors, in combination, can cause brittle fracture of steel vessels
— factors that contribute to the brittle fracture of carbon or low-alloy steel pressure vessels
are reviewed briefly here
— Low temperature
— A metal depending on its toughness property has a transition temperature range
within which it is in a semi-brittle condition (ductile to brittle transition)
— Within this range, a notch or crack may cause brittle fracture (notch brittleness)
— Above the transition range (warmer), brittle fracture will not happen even if a
notch exists
— Below the transition range (colder), brittle fracture can happen even though no
notches or cracks may exist
— Loading
— Dynamic loading associated with cyclic mechanical/thermal or impact loading is a
brittle-fracture contributing factor

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 Minimum Design Metal Temperature
( MDMT)

— Based on the stress levels applied, component material, effective thickness and
minimum metal temperature, ASME Section VIII, Divisions 1 and 2 present criteria for
vessel-component material-impact test requirements and/or exemptions

— Some of steps to eliminate the need for impact testing

— Upgrade the material to a higher group.
— Increase the thickness of the component to reduce the stress in the part.
— Decrease the pressure at MDMT. This is a process change and may or may not be
possible. Sometimes a vessel does not operate at full design pressure at the low
temperature condition but has alternate conditions, such as shutdown or
depressurization. These alternate low temperature conditions can also be stamped
on the nameplate.

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 Ductile to Brittle Transition

— At low temperatures some metals that

would be ductile at room temperature
become brittle
— This is known as a ductile to brittle
transition
— The ductile to brittle transition
temperature is strongly dependant on the
composition of the metal

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 UCS-66 Low temperature operation

— The minimum design metal temperature

(MDMT) of a vessel is the minimum metal
temperature in which the vessel can sustain
its full design pressure without having to be
impact tested
— Unless exempted by the rules of UG-20(f) or
other rules of this Division, Fig. UCS-66 shall
be used to establish impact testing
exemptions for steels listed in Part UCS.
When Fig. UCS-66 is used, impact testing is
required for a combination of minimum
design metal temperature and thickness
which is below the curve assigned to the
subject material
— If a minimum design metal temperature and
thickness combination is on or above the
curve, impact testing is not required by the
rules of this Division
Selection of curve is depend of material heat
treatment condition. Hence, vendor should
considered actual heat treatment condition in
design calculation to determine MDMT & impact
test requirement
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 FIG. UCS-66.1M Reduction in minimum
design metal temperature without impact
testing

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 Reference chart for ASME SEC VIII Div-1

(From Book : The ASME CODE Simplified , 8th Edition )

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Thanks for your attention
and inform the topic to cover onward…….