Engineers’ Guide to Pressure Equipment The Pocket Reference

Chapter 1 Websites: Quick Reference 1
1.1 Organizations and associations 1
1.2 General technical information 4
1.3 Directives and legislation 6
1.4 The KKS power plant classification system 7

Chapter 2 Pressure Equipment Types and Components 11
2.1 What is pressure equipment? 11
2.2 Pressure equipment categories 11
2.3 Pressure equipment symbols 13

Chapter 3 Basic Design 21
3.1 Introduction – the influence of codes and standards 21
3.2 Vessel design – basic points 21
3.2.1 Design basis 21
3.2.2 Safety first – corrosion allowance and welded joint efficiency 23
3.2.3 Pressure vessel cylinders 24
3.2.4 Vessel classes 25
3.2.5 Heads 25
3.2.6 Openings and compensation 29
3.2.7 Inspection openings 32
3.2.8 Pipes and flanges 33
3.2.9 Pads 33
3.2.10 Vessel supports 34
3.3 Simple pressure vessels (SPVs) – basic design 35
3.3.1 Material selection 35
3.3.2 Welds 37
3.3.3 Stress calculations 37
3.4 Gas cylinders – basic design 39
3.5 Heat exchangers – basic design 47
3.5.1 Contact-type exchangers 47
3.5.2 Surface-type exchangers 47
3.5.3 Thermal design 47
3.5.4 Special applications 53
3.6 Design by Analysis (DBA) – pr EN 13445 53
3.6.1 What does DBA offer? 53
3.6.2 How does DBA fit into pr EN 13445? 55
3.6.3 DBA – the technical basis 55

Chapter 4 Applications of Pressure Vessel Codes 59
4.1 Principles 59
4.2 Code compliance and intent 59
4.3 Inspection and test plans (ITPs) 60
4.4 Important code content 63
4.5 PD 5500 64
4.5.1 PD 5500 and the PED ESRs 70
4.6 The ASME vessel codes 76
4.6.1 Summary 76
4.6.2 Allowable stresses 81
4.6.3 Cylindrical vessel shells 81
4.6.4 Flat plates, covers, and flanges 85
4.6.5 Vessel openings – general 90
4.6.6 Heat exchangers 91
4.6.7 Special analyses 91
4.6.8 ASME ‘intent’ 95
4.7 TRD 96
4.8 Air receivers 98
4.9 Shell boilers: BS 2790 and EN 12953 101
4.10 Canadian standards association B51-97, part 1 boiler,pressure vessel, and piping code – 1997 106
4.11 CODAP – unfired pressure vessels 107
4.12 Water tube boilers: BS 1113/pr EN 12952 107
4.13 Materials and referenced standards – quick reference 109
4.14 Pressure vessel codes – some referenced standards 111

Chapter 5 Manufacture, QA, Inspection, and Testing 113
5.1 Manufacturing methods and processes 113
5.2 Vessel visual and dimensional examinations 114
5.2.1 The vessel visual examination 114
5.2.2 The vessel dimensional check 116
5.2.3 Vessel markings 118
5.3 Misalignment and distortion 118
5.3.1 What causes misalignment and distortion? 118
5.3.2 Toleranced features 119
5.4 Pressure and leak testing 122
5.4.1 The point of a pressure test 122
5.4.2 The standard hydrostatic test 123
5.4.3 Pneumatic testing 124
5.4.4 Vacuum leak testing 125
5.5 ASME certification 126
5.5.1 The role of the AI (Authorized Inspector) 126
5.5.2 Manufacturers’ data report forms 127
5.5.3 The code symbol stamps 129
5.5.4 ASME and the European Pressure EquipmentDirective (PED) 131
5.6 European inspection terms and bodies: EN 45004: 1995 132
5.7 The role of ISO 9000 133
5.7.1 The objectives of the changes 133
5.7.2 What will the new standards be? 134
5.7.3 What are the implications? 134
5.7.4 The ‘new format’ ISO 9001: 2000 134

Chapter 6 Flanges, Nozzles, Valves, and Fittings 137
6.1 Flanges 137
6.2 Valves 141
6.2.1 Types of valves 141
6.2.2 Valve technical standards 141
6.3 Safety devices 151
6.3.1 Safety relief valves – principles of operation 152
6.3.2 Terminology – safety valves 153
6.4 Nozzles 155
6.5 Power piping – ASME/ANSI B31.1 code 158
6.6 Fittings 161
6.6.1 Pressure equipment fittings 161
6.6.2 Pipework classification 161

Chapter 7 Boilers and HRSGs 167
7.1 Fundamentals of heat transfer 167
7.1.1 Specific heat, c 167
7.1.2 Enthalpy, h 167
7.1.3 Latent heat 168
7.1.4 Steam characteristics 168
7.1.5 Gas characteristics 173
7.2 Heat recovery steam generators (HRSGs) 173
7.2.1 General description 173
7.2.2 HRSG operation 176
7.2.3 HRSG terms and definitions 180
7.2.4 HRSG materials 183

Chapter 8 Materials of Construction 185
8.1 Plain carbon steels — basic data 185
8.2 Alloy steels 185
8.3 Stainless steels – basic data 186
8.4 Non-ferrous alloys – basic data 189
8.5 Material traceability 190
8.6 Materials standards – references 192

Chapter 9 Welding and NDT 195
9.1 Weld types and symbols 195
9.2 Weld processes 195
9.3 Welding standards and procedures 203
9.4 Destructive testing of welds 205
9.4.1 Test plates 205
9.4.2 The tests 205
9.5 Non-destructive testing (NDT) techniques 209
9.5.1 Visual examination 209
9.5.2 Dye penetrant (DP) testing 209
9.5.3 Magnetic particle (MP) testing 212
9.5.4 Ultrasonic testing (UT) 213
9.5.5 Radiographic testing (RT) 219
9.6 NDT acronyms 223
9.7 NDT: vessel code applications 225
9.8 NDT standards and references 227

Chapter 10 Failure 229
10.1 How pressure equipment materials fail 229
10.1.1 LEFM method 230
10.1.2 Multi-axis stresses states 231
10.2 Fatigue 232
10.2.1 Typical pressure equipment material fatigue limits 233
10.2.2 Fatigue strength – rules of thumb 234
10.3 Creep 235
10.4 Corrosion 238
10.4.1 Types of corrosion 238
10.4.2 Useful references 241
10.5 Boiler failure modes 241
10.6 Failure-related terminology 244

Chapter 11 Pressure Equipment: Directives and Legislation 249
11.1 Introduction: what’s this all about? 249
11.1.1 The driving forces 249
11.1.2 The EU ‘new approaches’ 250
11.2 The role of technical standards 250
11.2.1 Harmonized standards 250
11.2.2 National standards 251
11.2.3 The situation for pressure equipment 251
11.3 Vessel ‘statutory’ certification 253
11.3.1 Why was certification needed? 253
11.3.2 What was certification? 253
11.3.3 Who could certificate vessels? 254
11.4 The CE mark – what is it? 255
11.5 Simple pressure vessels 255
11.6 The simple pressure vessels directive and regulations 256
11.6.1 SPVs – summary 256
11.6.2 Categories of SPVs 257
11.6.3 SPV harmonized standards 264
11.7 Transportable pressure receptacles: legislation and regulations 265
11.7.1 TPRs legislation 265
11.8 The pressure equipment directive (PED) 97/23/EC 271
11.8.1 PED summary 271
11.8.2 PED – its purpose 273
11.8.3 PED – its scope 273
11.8.4 PED – its structure 274
11.8.5 PED – conformity assessment procedures 275
11.8.6 Essential safety requirements (ESRs) 294
11.8.7 Declaration of conformity 311
11.8.8 Pressure equipment marking 312
11.9 Pressure Equipment Regulations 1999 312
11.9.1 The Pressure Equipment regulations – structure 312
11.10 Notified Bodies 314
11.10.1 What are they? 314
11.10.2 UK Notified Bodies 314
11.11 Sources of information 317
11.11.1 Pressure system safety – general 317
11.11.2 Transportable pressure receptacles (gas cylinders) 318
11.11.3 The simple pressure vessel directive/regulations 318
11.11.4 The pressure equipment directive 318
11.11.5 The pressure equipment regulations 319
11.11.6 PSSRs and written schemes 319

Chapter 12 In-service Inspection 321
12.1 A bit of history 321
12.2 The Pressure Systems Safety Regulations (PSSRs) 2000 322

Chapter 13 References and Information Sources 325
13.1 European Pressure Equipment Research Council (EPERC) 325
13.2 European and American associations and organizations relevant to pressure equipment activities 327
13.3 Pressure vessel technology references 335
Appendix 1 Steam Properties Data 337
Appendix 2 Some European Notified Bodies (PED) 343
Notified Bodies (PED Article 12) 343
Recognized Third-Party Organizations (PED Article 13) 348
Appendix 3 Standards and Directives Current Status 351
Index 383




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