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transcript
Presented by: David M. Allore
Field Services Manager
September 12, 2012
HSB Global Standards
ASME Code Changes and Discussions
Copyright © 2012 The Hartford Steam Boiler Inspection and Insurance
Company of Connecticut. All Rights Reserved.
AGENDA
• Guidelines for AI Review of Design Calculations
• Frequent Mistakes on ASME Design Files
• Overview of COMPRESS, APV and PV Elite Output Files
• What’s New at ASME
• ASME B&PV Code Updates: 2011 Addenda
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations
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Section VIII The Inspector has the duty of verifying that the
applicable calculations have been made and are on file
at the Manufacturer’s plant at the time the Data Report is
signed. Any questions concerning the calculations
raised by the inspector must be resolved
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations (Cont.)
Interpretation: VIII-79-45
Subject: Section VIII, Division 1, U-2(e) and UG-90(c)(1)
Date Issued: July 26, 1979
File: BC-79-105
Question (1): Is it the intent of U-2(e) of Section VIII, Division 1, that the Authorized Inspector
shall check and accept (by signing the U-1 Form) the accuracy of the design calculations with
respect to the proper choice of applicable design formulas, stress values for materials used, and
mathematics?
Reply (1): U-2(e) requires the Inspector to verify that the applicable calculations have been made
and requires that any questions raised by the Inspector be resolved. The Inspector is not required
to check the calculations.
Question (2): Is the intent of U-2(e) in any way modified when Section VIII, Division 1 does not
provide rules covering all the design details as per U-2(g)?
Reply (2): No.
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations (Cont.)
Interpretation: I-81-03
Subject: Sections I, IV, and VIII, Duties of Authorized Inspectors
Date Issued: January 27, 1981
File: BC-80-691
Question (1): As related to Section I, Section IV, and Section VIII - Division 1 of the ASME Boiler and Pressure Vessel Code, is the Authorized Inspector responsible for the accuracy of the calculations submitted for the finished Code component or part?
Reply (1): No. It is the duty of the Authorized Inspector to determine to his own satisfaction that the necessary calculations were done in accordance with the Code. The responsibility for accuracy of the calculations lies with the Manufacturer.
Question (2): What is the extent of Authorized Inspector responsibility in reviewing design calculations that are made available by the Manufacturer [UG-90(c)(1)(b)]?
Reply (2): The Authorized Inspector must verify that all required design calculations applicable to the construction have been made in accordance with the Code, and that any questions raised by the Inspector are resolved. The Inspector is not required to check for accuracy of the calculations. The responsibility for accuracy of the calculations lies with the Manufacturer.
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations (Cont.)
• “necessary calculations” or “required design calculations”
– Phrases interpreted to mean that all pressure retaining
components covered by the Code Stamp must be supported by
code calculations
– AI must have a clear understanding of what constitutes the Code
Stamped Vessel when reviewing assembly drawing
– Complications include:
• Multiple chamber vessels, where one chamber may not be stamped
• Communicating chamber
• Mfg. includes additional piping under Code stamping
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations (Cont.)
• Phrase more difficult to interpret
– “… done in accordance with the Code “
• Two possible interpretations
– 1) Verify that each pressure retaining component is supported by a
Code calculation using the correct Code equation, when one is
published, or U-2(g) or equivalent.
– 2) Verify that each pressure retaining component is supported by a
Code calculation using the correct Code equation, when one is
published, or U-2(g) or equivalent. Additionally verify that all of the
variables (dimensions, allowable stress, joint efficiency, etc.)
substituted into the equation are correct. The AI is not responsible
to perform the math.
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Company of Connecticut. All Rights Reserved.
Guidelines for AI Review of
Design Calculations (Cont.)
• Interpretation 2 Can Present Some Challenges
– Variables substituted into the equation may not be readily
available; for example
• Component dimensions
• Mixed use of units
• Allowable stress; need access to II-D; interpolation may be
necessary depending on design temperature
• Joint efficiency; requires working knowledge of joint efficiency rules
• Complex calculations; e.g. Part UHX tubesheet calculations, App. 5
& 26 bellows, App. 13 noncircular vessels, App. 2 flanges
• Verification of correct test pressure (hydrostatic or pneumatic)
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Company of Connecticut. All Rights Reserved.
Frequent Mistakes on ASME Design Files
• Common Design Mistakes Identified During Design
Reviews
– Codes & Standards design review process not only verifies that
pressure/temperature (P/T) rating for vessel described on
drawing is correct, but that the P/T rating for all vessel
components are fully supported by the calculations
– Most common mistake
• Discrepancies between drawings and calculations
– Multiple revisions to drawings not always reflected in calculations
• Difference in dimensions
• Difference in material specification or grade
• RT marking versus joint efficiency, E, used in calculations
• Design pressures
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Company of Connecticut. All Rights Reserved.
Frequent Mistakes on ASME
Design Files (Cont.)
• Drawings lack details needed to verify calculations
– Vessel support dimensional information
– Material information; calculations often require detailed
information about material ( e.g. spec/grade/class, normalized or
Q&T, impact tested (Yes or No)
– Weld sizes ( e.g. nozzle, supports)
– UG-22 – Manufacturers should indicate on either drawings or
calculations that UG-22 loads have been considered
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Frequent Mistakes on ASME
Design Files (Cont.)
• Openings
– Reinforcement –
Taking credit for
material that
does not exist
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Company of Connecticut. All Rights Reserved.
Frequent Mistakes on ASME
Design Files (Cont.)
• Openings – Overlapping limits of reinforcement
– Some commercial and Mfg. in-house software do not look at the
location of opening in relation to other openings
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Frequent Mistakes on ASME
Design Files (Cont.)
• Small opening weld size
– Small openings that are exempt from reinforcement per
UG-36(c)(3) and weld strength per UW-15, still require their
attachment welds to satisfy UW-16
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Company of Connecticut. All Rights Reserved.
Frequent Mistakes on ASME
Design Files (Cont.)
• Finite Element Analysis (FEA)
– Not enough information provided
• Finite element calculations often only include stress result plots
• Critical information missing
– Type of analysis performed; e.g. elastic, limit load, elastic-plastic
– Description of finite element model; e.g. 3-D, axisymmetric
– Description of model elements used
– Description of boundary conditions applied
– Description of applied loads
– List of assumptions, including some technical justification for the assumption
– Reference back to drawings
– Summary with code allowable stress comparisons; stress classification per VIII-2
• Wrong stress theory comparison – Sections VIII-1 based on Maximum Principle Stress Theory; incorrect to use von Mises stresses
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Company of Connecticut. All Rights Reserved.
Overview of COMPRESS, APV and
PV Elite Output Files
• Most common commercial software used for VIII-1
calculations
• COMPRESS by Codeware
• APV (Advanced Pressure Vessel) by Computer
Engineering
• PV Elite or CodeCalc by Coade (or Intergraph)
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COMPRESS
• Summary Tables – usually in the front of the package
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Company of Connecticut. All Rights Reserved.
COMPRESS
• Summary Tables - continued
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Company of Connecticut. All Rights Reserved.
COMPRESS
• Most of the programs also have listing of UG-22 loads
and whether they were considered.
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Company of Connecticut. All Rights Reserved.
COMPRESS
• The Weight
Summary is also a
good place to see
if they accounted
for items such as
insulation and
other attached
equipment. These
would add weight
to the vessel
support structure.
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Company of Connecticut. All Rights Reserved.
COMPRESS
• Also important to review is the hydrostatic/pneumatic test
summary.
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Company of Connecticut. All Rights Reserved.
COMPRESS
• Drawbacks of the summary tables:
– Location of nozzles
– Nozzle (UW-16) or SO flange weld sizes (UW-21)
– Sizes of supports
• Should check these against the drawing
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Company of Connecticut. All Rights Reserved.
APV
• APV does not have a summary section.
• Need to review each page to determine if the correct
materials, diameters, thicknesses, efficiencies, etc. have
been used.
• Be careful – The cover page is just that - a cover page.
It could have different pressures, temperatures, RT
indication and MDMT than the actual calculation
package uses.
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Company of Connecticut. All Rights Reserved.
APV
• Each page/section will have the inputs (materials, sizes,
thicknesses, efficiencies) that need to be compared to
the information on the drawing.
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Copyright © 2012 The Hartford Steam Boiler Inspection and Insurance
Company of Connecticut. All Rights Reserved.
APV
• Some issues to be aware of when looking at APV
calculations:
– Does not look at location of nozzle in relation to anything else
– Joint efficiency is a manual input regardless of what “RT” or type
of joint is chosen.
– Joint efficiency for the longitudinal and circumferential stress
equations can be different and is a manual input not dependent
on type of joint (i.e. designer needs to know the Code well)
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Company of Connecticut. All Rights Reserved.
PV Elite
• PV Elite and CodeCalc both produced by Coade.
• Similar in structure but PV Elite has more for the overall
pressure vessel designer.
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Company of Connecticut. All Rights Reserved.
PV Elite
• Summary tables like COMPRESS but they tend to be at
the back of the reports.
• Summarizes not only nozzle size and thicknesses but
also locations, actual weld sizes for the attachment of
nozzles and SO flanges.
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Company of Connecticut. All Rights Reserved.
PV Elite
• Does list the inputs (materials, sizes, pressures, etc.) at
the front of the report but does it from a point (node) to
point (node) basis. Difficult to interpret sometimes and
to check that they have all components in the report.
27
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Company of Connecticut. All Rights Reserved.
PV Elite
• It appears that the designer selects the RT marking in
the inputs and the program then selects the efficiencies.
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Company of Connecticut. All Rights Reserved.
PV Elite
• Hydrostatic Test pressure determined for each
component.
• Nozzle flanges P-T ratings summarized in the report
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Company of Connecticut. All Rights Reserved.
PV Elite
• Some advantages to PV Elite is that is contains
Appendix 13 rules as well as some of the more popular
International wind and seismic Codes.
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Company of Connecticut. All Rights Reserved.
Miscellaneous
• We have not seen any programs that evaluate the weld joint
(fillet and groove sizes) of UW-13 for the attachment of flat
heads or tubesheets.
• APV does not have a Division 2 option where COMPRESS
and PV Elite do.
• Although they all have their pros/cons, drawbacks and
idiosyncrasies, if the correct inputs are used, the Code
calculation part of the process is correct.
31
Copyright © 2012 The Hartford Steam Boiler Inspection and Insurance
Company of Connecticut. All Rights Reserved.
What’s New at ASME?
• 2011 Publication
– ASME published complete reprints (white pages) for all B&PV Code books
– Some books were published with their old software and some with new
software (xml)
– Even though it is a complete reprint, it is considered an Addenda
• On Data Reports, “2010 Edition” and “2011 Addenda” would be listed, not like when
the 1998 Edition came out
• Next publication will be the 2013 Edition
– No Addenda in 2012
– Code Cases will still be published quarterly
– Errata will be published on ASME website as soon as approved
– “Special Safety Notices” may be published on website
– Can subscribe to notifications on website
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Copyright © 2012 The Hartford Steam Boiler Inspection and Insurance
Company of Connecticut. All Rights Reserved.
What’s New at ASME?
• Code Symbol Stamp
– phased out separate stamps (such as the U) for each Code
– Moved to a single mark for all codes
– new term: "Certification Designator “or “Designator“ defines
the area in which the Certificate Holder is certified by ASME
– For example, for VIII-1, "U" , "UV" or "UD“ marked on the
nameplate directly under the Certification Mark
– Non-nuclear Code Case for 18 month transition
• 2710 (I, IV, X, XII), 2714 (VIII)
• See Code Services Discussion database postings for further
details
– Numerous errata in 2011 Addenda
– ASME posted FAQ’s regarding use of the new Mark.
U
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Company of Connecticut. All Rights Reserved.
What’s New at ASME?
• Code Construction at Location Other than that Listed on Certificate
– Certificate Holder may request ASME to authorize code construction at another
location
• Intended for situations where Cert. Holder needs additional production space to
handle overflow work, or perhaps access to a larger crane
– Certificate Holder would apply to ASME requesting permission to fabricate at
additional location (temporary shop)
– ASME would request AIA to audit Temporary Shop and verify that it is suitable
for intended construction activity
– Following receipt of the AIA’s audit report, ASME may issue a Letter authorizing
temporary use of a new shop location for a period of not longer than one year
or to the time the Certificate Holder’s Certificate will expire
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Company of Connecticut. All Rights Reserved.
What’s New at ASME?
• Adding Additional Shop Location to Current Certificate
– New Policy - Issued April 2012
– Permits adding one or more locations to existing certificate w/o
audit by ASME
– Intended for shop locations near ( approx. 6 miles ) address on
certificate
– Requires AIA audit to verify all necessary controls in place to
ensure Code compliance at both locations
– Requires same AI to service all locations
– According to Bob Wielgoszinski, there may be some future
restrictions placed on this new policy in near future
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SIGNIFICANT REVISIONS
FROM 2011 ADDENDA
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Company of Connecticut. All Rights Reserved.
Significant Revision 2011 Addenda
Section VIII, Division 1
• UG-11 – Prefabricated or Preformed Pressure Parts
– Complete rewrite of paragraph
– Combination of restructuring existing requirements, significant clarifications and additional rules
– NET RESULT - clearer rules may be viewed as “new rules”
• Major changes include:
– Emphasis that all UG-11 parts must comply with applicable rules, including design
– Each part must be supported by documentation to demonstrate Code compliance relative to materials, basis for P/T rating, welding complies with Section IX
– Cert. Holder can subcontract welded part fabrication to a non-certificate holder
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Company of Connecticut. All Rights Reserved.
Significant Revisions in 2011 Addenda
Section VIII, Division 1
• UG-90(c)(1)(n) – “acceptance by the Inspector”
– Statement added that by the Inspector’s acceptance, an Inspector
does not assume any responsibilities that belong to the
Manufacturer
• UG-93 and App 3 – Material documentation
– UG-93(a)(1): expanded documentation requirements for plate
material
– App 3: revised definition of “certificate of compliance”, “material”,
“material supplier” and “Material Test Report”
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Significant Revisions in 2011 Addenda
Section VIII, Division 1
• UW-11(a) – Requirements for full radiography
– Rewrite of UW-11(a)(1) through (a)(4) [See Interpretation VIII-1-07-14]
– Revisions prompted by inquiry
– Changes involve:
• UW-11(a)(2) – changed “vessels” to “shell and heads of vessels” to be consistent with
UW-11(a)(1); also relocated small nozzle and communicating chamber exemption to
UW-11(a)(4)
• UW-11(a)(3) – Added coverage for unfired steam boilers with design pressure < 50
psi (350 kPa)
• Separate full radiography requirements for nozzles and communicating chambers
from vessels [UW-11(a)(2)] and place the requirements in UW-11(a)(4)
– Net Result Unfired steam boiler with P < 50 psi and thickness at welded joint
exceeding thickness limits defined in UW-11(a)(2) will require Full RT
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Company of Connecticut. All Rights Reserved.
Significant Revisions in 2011 Addenda
Section VIII, Division 1
• UW-21 – use of B16.5 Flanges
– Code change and Intent Interpretation – rules apply to B16.5 socket
and slip-on flange welds, no matter where they are installed on the
vessel
• Question: Is it the intent that the socket and slip-on flange attachment
details given in Fig. UW-21 for ASME B16.5 flanges apply only to
attachments to nozzle necks?
Reply: No; These attachment details shall be used wherever an ASME
B16.5 slip on flange is used on a Section VIII, Division 1 vessel.
– Note: The revision to Fig. UW-21shows that the dimensional
requirement of the ID fillet weld is only for sizing the weld.
• The artwork was corrected by Errata. It now shows that the fillet
weld is not necessarily flush with the face of the flange.
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Company of Connecticut. All Rights Reserved.
Significant Revisions in 2011 Addenda
Section VIII, Division 1
• UW-50 – pneumatic test NDE
– clarify that the required NDE is to take place prior to pneumatic
testing
• UW-51(a)(4) – incorporation of CC 2235 (UT)
– Refers to VIII-2 paragraph 7.5.5 for UT procedure, flaw evaluation
and acceptance criteria
– UT may be used for t > ½ in. (13mm)
– VIII-1 Cert. Holder will need to purchase VIII-2 for UT rules
• UB-30 – subcontracted brazers
– Made consistent with UW-26(d)
– permit subcontracted brazers only at the location(s) at which ASME
has authorized the Manufacture to do work
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Significant Revisions in 2011 Addenda
Sections VIII-1 & VIII-2
COMMON RULES
• UCS-67 and 3.11 – toughness rules
– completely rewritten for production testing
– Some technical changes
– Paragraphs deleted and reformatted for better clarity
• UW-3 and 4.2.2 – weld joint Categories
– Clarified that not all weld joints are assigned to a Category
– For example, jacket closure-to-shell and bellows expansion joint
fillet welds
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Significant Revisions in 2011 Addenda
Sections VIII-1, VIII-2 & VIII-3
• Tolerances
– Insert the contents regarding tolerances in the Forewords
– New paragraphs: VIII-1 = U-5, VIII-2 =1.5, VIII-3 = KG-160
– Foreword not part of the Code
• Updated referenced standards
– VIII-1 = Table U-3, VIII-2 = Table 1.1, VIII-3 = Table KG-141
– If the Table references “Latest Edition” for the “Year”, this would be
the latest edition publicly available by the standard developing
organization (e.g., ASME or ASTM) as of the contract date (similar to
setting the Edition/Addenda)
• Other editions may be accepted on a case-by-case basis subject to
concurrence by the AI (and SCS and/or Home Office, if necessary)
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Significant Revisions in 2011 Addenda
Section IX
• Diffusion Welding
– Added as a new welding process
– QW-185 paragraphs added
– QW-266 – new table of variables
– QW-4XX – new variables added
– QW-386 – new welding operator requirements
– QW/QB-492 – new definition added
• QW-161.1 – specimens
– allow multiple specimens to be taken across the weld
– the entire weld and heat affected zones are tested
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Significant Revisions in 2011 Addenda
Section IX
• QW-264 – Laser Beam Welding (LBW)
– Deleted and added references to existing variables and added new
variables
– Made less restrictive
– Will require evaluation of WPS’s and PQR’s
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