1

ENGINEERED PRESSURE VESSELS FOR MARINE

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.
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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.
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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.
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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.
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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
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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.
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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.
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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
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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.
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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.
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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

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DESIGN COMPARISON
DIV. 1 vs. DIV. 2 CLYNDRICAL SHELL
.

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
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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

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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

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SECTION VIII, DIVISION 3
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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.
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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)
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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.
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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.
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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
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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.
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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.
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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).
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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)
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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.
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