Pressure Vessel Design and

NDT Requirements
 Objective

•To provide the general review about of pressure vessel

design

•General review of NDT test requirements for PV

•Malaysia regulation on registration of PV by DOSH

 PV Design Process

Client requirements

Design ASME VIII/API501/BS / JIS

Design Approval (PE/DOSH)`

Fabrication (Material data/qualified welder/DOSH)

Inspection (Pressure Test, 3rd Party Inspector)

Installation (Fitness Test, API)

Regulated Inspection (DOSH)

 Art line of presentation
Part 1 - Pressure Vessel (PV) Design
• Definition
• Classification of PV
• Type of PV
• Used of PV
• Unfired PV
• General design of PV
• Design Standard of PV – ASME VIII and API 501

•Part 2 - NDT Requirement for PV

• VT Visual Examination,
• PT Liquid Penetrant Test,
• MT Magnetic Particle Test,
• RT Gamma and X-ray Radiography, and
• UT Ultrasonic Test
 Pressure Vessels Definition
•A pressure vessel is a closed container designed to
hold gases or liquids at a pressure substantially
different from the ambient pressure.

•Pressure vessels are used to store and transmit liquids,

vapors, and gases under pressure in general.

•Because of the internal loading, stresses are including

on certain sections of the cylinder (pressure vessel)
wall.
 Two Category of PV
An "Unfired Pressure Vessel" (UPV) means any enclosed
vessel under pressure greater than atmospheric pressure by
any gas or mixture or combination of gases and includes any
vessel under pressure of steam external to steam boiler and any
vessel which is under pressure of a liquid or gas or both, and
any vessel subject to internally to a pressure less than
atmospheric pressure. Example of UPV include air receivers,
autoclave, sterilizers, petrochemical treatment, LPG storage
tank and water treatment vessels.

Fired" pressure vessels are a separate category of vessels that

include power boilers and other vessels that are designed to
accept heat.

Standard design of pressure vessel

• American Society of Mechanical Engineers (ASME)
• American Petroleum Inspection (API)
ASME Section VIII –Division 1 (Power Boilers) is for fired
pressure vessels.
ASME Section VIII –Division 2 is for the unfired PV
Division 1
Basic Coverage
• This Division of Section VIII provides requirements applicable to the design,
fabrication, inspection, testing, and certification of pressure vessels operating at
either internal or external pressures exceeding 15 psig.
• Such pressure vessels may be fired or unfired. Specific requirements apply to several
classes of material used in pressure vessel construction, and also to fabrication
methods such as welding, forging and brazing.
• It contains mandatory and nonmandatory appendices detailing supplementary
design criteria, nondestructive examination and inspection acceptance standards.
Rules pertaining to the use of the U, UM and UV Code symbol stamps are also
included.
Contents
Scope & Service Restrictions; General Requirements; Requirements for Fabrication by
Welding, Forging, or Brazing; Requirements Pertaining to Classes of Materials for
Carbon & Low Alloy Steel;Nonferrous Materials; High Alloy Steel; Cast Iron; Clad &
Lined Vessels; Cast Ductile Iron Vessels; Ferritic Steels with Tensile Properties Enhanced
by Heat Treatment; Layered Construction; High Stresses at Low Temperatures.
Division 2 Alternative Rules
Basic Coverage
• This Division of Section VIII provides requirements applicable to the design,
fabrication, inspection, testing, and certification of pressure vessels operating at
either internal or external pressures exceeding 15 psig. Such vessels may be fired or
unfired.
• This pressure may be obtained from an external source or by the application of heat
from a direct or indirect source, or any combination thereof.
• These rules provide an alternative to the minimum requirements for pressure vessels
under Division 1 rules. In comparison the Division 1, Division 2 requirements on
materials, design, and nondestructive examination are more rigorous; however,
higher design stress intensity values are permitted.
• Division 2 rules cover only vessels to be installed in a fixed location for a specific
service where operation and maintenance control is retained during the useful life of
the vessel by the user who prepares or causes to be prepared the design
specifications.
• These rules may also apply to human occupancy pressure vessels typically in the
diving industry. Rules pertaining to the use of the U2 and UV Code symbol stamps
are also included.
Contents
General Requirements; Material Requirements; Design Requirements; Fabrication
Requirements; Pressure Relief Devices; Inspection in Radiography; Testing; Marking;
Stamping; Reports & Records.
Division 3 High Pressure P. Vessels
Basic Coverage
• This Division of Section VIII provides requirements applicable to the design,
fabrication, inspection, testing, and certification of pressure vessels operating at
either internal or external pressures generally above 10,000 psi.
• Such vessels may be fired or unfired. This pressure may be obtained from an external
source, a process reaction, by the application of heat from a direct or indirect source,
or any combination thereof.
• Division 3 rules cover vessels intended for a specific service and installed in a fixed
location or relocated from work site to work site between pressurizations.
• The operation and maintenance control is retained during the useful life of the vessel
by the user who prepares or causes to be prepared the design specifications.
• Division 3 does not establish maximum pressure limits for either Section VIII,
Divisions 1 or 2, nor minimum pressure limits for this Division. Rules pertaining to
the use of the UV3 Code symbol stamps are also included.
Contents
General Requirements; Material Requirements; Design Requirements; Fabrication
Requirements; Pressure Relief Devices; Examination Requirements; Testing; Marking;
Stamping; Reports & Records.
 Design of Unfired Pressure Vessels

Introduction To Unfired Pressure Vessels

Under the Factories and Machinery Act 1967, each unfired pressure vessel must have a valid certificate
of fitness (CF) before it can be operated. For this purpose, approval for the design of the unfired
pressure vessel has to be obtained in advance from the Department of Occupational Safety and Health
(DOSH) before it fabricated, installed or used.
Application for approval of the design may be made by the manufacturing company, installer, supplier
or owner of the unfired pressure vessel. Local manufacturers of unfired pressure vessels must register
as a manufacturer with the department.
The following are several examples of unfired pressure vessels that require design approval:
» Air container
» Steriliser
» LPG storage tank
» Heat Exchanger
» Pressure vessels at the petrochemical plants etc
Information to be submitted for approval of the design of unfired pressure vessels:
Application for Unfired Pressure Vessel Design Approval (Local Manufacturer recognized by
Department)
Application for Unfired Pressure Vessel Design Approval (Import, IDxDP more than 3000psig-in)
Application for Unfired Pressure Vessel Design Approval (Import, IDxDP equal or less than
3000psig-in)
Application for Unfired Pressure Vessel Design Approval (Used)
 Type I
Boiler Pressure vessels of all metal
construction, typically steel
or aluminum.

PV
Fired

Type II
Classification of pressure

Hoop Wrapped Pressure Vessels,

unidirectional composite plies
overwrapped in the cylindrical
section only

Type III Fully wrapped Pressure Vessels

Unfired PV

with Metal Liner, overwrapped

entirely with composite plies

Type V
vessel

Type IV

All-composite pressure vessels

Fully wrapped Pressure Vessels that do not use a metallic or
with Polymeric Liner polymeric liner
 Onshore oil/fuel Industry
Chemical Energy Processing
industry
Applications of Pressure Vessels type I

Cosmetics processing Food and beverage industry

Pharmaceutical and
plastic processing Biotechnology Industry
 Uses of pressure vessels
The pressure vessels are used fluid to store such as liquid vapours and
gases under pressure. Major uses of pressure vessels are as follows.
•Pressure vessels are used in steam boilers
•Pressure vessels are also used in storage of chemical in chemical plants
•Use in storage of petroleum products (petrol, diesel etc)

•Pressure vessels are used in a variety of applications in both industry and

the private sector. They appear in these sectors as industrial compressed
air receivers and domestic hot water storage tanks.

•Other examples of pressure vessels are diving cylinders, recompression

chambers, distillation towers,autoclaves, and many other vessels
in mining operations, oil refineriesandpetrochemicalplants,nuclear reactor
vessels,submarineandspaceshiphabitats, pneumatic reservoirs, hydraulic r
eservoirs under pressure, rail vehicle airbrake reservoirs, road vehicle
airbrake reservoirs, and storage vessels for liquified gases such
as ammonia, chlorine, propane, butane, and LPG.
 Important parameters of UPV
Important parameters to consider when specifying pressure vessels include
the capacity, the maximum pressure and the temperature range.

• The capacity is the volume of the pressure vessel.

• The maximum pressure is the pressure range that the vessel can
withstand.
• The temperature ranges indicates the temperature of the material that the
container can withstand.

Types of Pressure Vessels

There are mainly two types of pressure vessels:

i. Spherical Pressure Vessel

• These pressure vessels are thin walled vessels.
• This forms the most typical application of plane stress.
• Plane of stress is a class of common engineering problems involving stress in a thin
plate.

ii. Cylindrical Pressure Vessel

This a vessel with a fixed radius and thickness subjected to an internal gage pressure.
The vessel has an axial symmetry.
Spherical Pressure Vessel

Cylindrical Pressure Vessel

Basic component of pressure vessel

Head Disc/end

Flange

Support Lug

Nozzle

Bottom Disc / end

 Process of Design Pressure Vessel

• Study and apply the

• Study Technical
concept of the stress of
requirement and
PV
specification
• Perform the manual
• Study Relevant
calculation using
standard
standard formulae and
graph

• Perform design
calculation using the
CAD Customized
Software;
• PVElite, PVE5 and
Others.
• Analyze the design
data
ULTRASONIC TESTING
• Ultrasonic inspection is a
nondestructive method in which beams
of high-frequency sound waves are
introduced into materials for the
detection of subsurface flaws in the
material.
• The sound waves travel through the
material with some attendant loss of
energy (attenuation) and are reflected
at interfaces (cracks or flaws).
• The reflected beam is displayed and
then analyzed to define the presence
and location of flaws or discontinuities.
• The most commonly used ultrasonic
testing technique is pulse echo,
wherein sound is introduced into a test
object and reflections (echoes) are
returned to a receiver from internal
imperfections or from the part's
geometrical surfaces.
• Applications include inspections for
voids, cracks, and laminations,
 Magnetic particle inspection (MPI)
• Magnetic particle inspection (MPI) is used for the
detection of surface and near-surface flaws in
ferromagnetic materials.
• A magnetic field is applied to the specimen, either
locally or overall, using a permanent magnet,
electromagnet, flexible cables or hand-held prods.
• If the material is sound, most of the magnetic flux is
concentrated below the material's surface.
• However, if a flaw is present, such that it interacts
with the magnetic field, the flux is distorted locally
and 'leaks' from the surface of the specimen in the
region of the flaw.
• Fine magnetic particles, applied to the surface of the
specimen, are attracted to the area of flux leakage,
creating a visible indication of the flaw

• The materials commonly used for this purpose are

black iron particles and red or yellow iron oxides.
• In some cases, the iron particles are coated with a
fluorescent material enabling them to be viewed
under a UV lamp in darkened conditions.
 Gamma Ray (X-Ray)
• This technique involves the use of penetrating gamma
or X-radiation to examine parts and products for
imperfections.
• An X-ray machine or radioactive isotope is used as a
source of radiation.
• Radiation is directed through a part and onto film or
other media.
• The resulting shadowgraph shows the internal
soundness of the part.
• Possible imperfections are indicated as density changes
in the film in the same manner as an X-ray shows
broken bones.
• Radiographic applications fall into two distinct
categories evaluation of material properties and
evaluation of manufacturing and assembly properties.
• Material property evaluation includes the
determination of composition, density, uniformity, and
cell or particle size.
• Manufacturing and assembly property evaluation is
normally concerned with dimensions, flaws (voids,
inclusions, and cracks), bond integrity (welds, brazes,
 Dye Penetration Test
• Apart from visual inspection this is probably the oldest and
most widely used of all the NDT methods.
• It can be used on any non-porous material. Its use is confined
to the detection of surface breaking defects.

Liquid penetration inspection is used to reveal surface

breaking flaws by bleed out of a colored or fluorescent dye
from the flaw. Test objects are coated with visible or
fluorescent dye solution. Excess dye is then removed from the
surface, and a developer is applied.
• The developer acts as blotter, drawing trapped penetrant out
of imperfections open to the surface.
• With visible dyes, vivid color contrasts between the penetrant
and developer make "bleed out" easy to see.
• With fluorescent dyes, ultraviolet light is used to make the
bleed out fluoresce brightly, thus allowing imperfections to be
readily seen.
• Penetrant inspection can be used on any material and is most
often used on materials clad in stainless steel, and stainless
welded items which cannot be inspected by other methods.
 Eddy Current Testing
• Eddy current is the most widely applied electromagnetic NDT technique.
• Eddy current testing uses an electromagnet to induce an eddy current in a conductive sample.
• The response of the material to the induced current is sensed. Since the probe does not have to
contact the work surface, eddy current testing is useful on rough surfaces or surfaces with wet
films or coatings.
• In standard eddy current testing, a circular coil carrying an AC current is placed in close
proximity to an electrically conductive specimen.
• The alternating current in the coil generates a changing magnetic field, which interacts with the
test object and induces eddy currents. Variations in the phase and magnitude of these eddy
currents can be monitored using a second 'search' coil, or by measuring changes to the current
flowing in the primary 'excitation' coil.
• Variations in the electrical conductivity or magnetic permeability of the test object, or the
presence of any flaws, will cause a change in eddy current flow and a corresponding change in
the phase and amplitude of the measured current.
 Acoustic Emission Testing
GCS Receiver
Remote Signal
Processor

Sensor Sensor
X
D
•Sound travels through water at a X1 = [V (T1-T2) + D] / 2
known and constant speed of
approximately 4,850 feet per second. Where:
•The time it takes for a sound to X1 = Distance of acoustic event from Hydrophone
arrive at a sensor is directly related #1
to the distance it travels. V = Velocity of sound in water
•The physical location of a wire T1 = Time of arrival of acoustic signal at
break can be determined by Hydrophone #1
comparing the arrival
T2 = Time of arrival of acoustic signal at
times of that event at both sensors
Hydrophone #2
Nondestructive testing method categories
Basic Categories
Mechanical and optical
Penetrating radiation
Electromagnetic and electronic
Sonic and ultrasonic
Thermal and infrared
Chemical and analytical
Auxiliary Categories
Image generation
Signal image analysis
Objectives
color, cracks, dimensions, film thickness, gaging, reflectivity, strain distribution and
magnitude, surface finish, surface flaws, through-cracks
cracks, density and chemistry variations, elemental distribution, foreign objects,
inclusions, microporosity, misalignment, missing parts, segregation, service
degradation, shrinkage, thickness, voids
alloy content, anisotropy, cavities, cold work, local strain, hardness, composition,
contamination, corrosion, cracks, crack depth, crystal structure, electrical and
thermal conductivities, flakes, heat treatment, hot tears, inclusions, ion
concentrations, laps, lattice strain, layer thickness, moisture content, polarization,
seams, segregation, shrinkage, state of cure, tensile strength, thickness, disbonds
crack initiation and propagation, cracks, voids, damping factor, degree of cure,
degree of impregnation, degree of sintering, delaminations, density, dimensions,
elastic moduli, grain size, inclusions, mechanical degradation, misalignment,
porosity, radiation degradation, structure of composites, surface stress, tensile,
shear and compressive strength, disbonds, wear
bonding, composition, emissivity, heat contours, plating thickness, porosity,
reflectivity, stress, thermal conductivity, thickness, voids
alloy identification, composition, cracks, elemental analysis and distribution, grain
size, inclusions, macrostructure, porosity, segregation, surface anomalies
Objectives
dimensional variations, dynamic performance, anomaly characterization and
definition, anomaly distribution, anomaly propagation, magnetic field configurations
data selection, processing and display, anomaly mapping, correlation and
identification, image enhancement, separation of multiple variables, signature
analysis
 GUIDELINE FOR UNFIRED PRESSURE VESSEL (UPV) DESIGN APPROVAL
(APPROVED LOCAL FABRICATOR)
1. Application letter must come from approved manufacturer or owner.

2. UPV Attachment should be completed and attached together with application.

3. 3 sets of design drawing must be as large as practicable (preferable A1) with 1/2'' border line and properly
scaled. The drawings must be furnished with the following :

a) Main dimensions
b) Welding details
c) Service of nozzles & orientation of nozzles
d) Details of material specifications
e) Design data such as design pressure, design temperature, working pressure, working
temperature, test pressure, design code, working media, volume, corrosion allowance, welding
factor, flange rating and etc.
f) Detail drawings of any components and welding including reference or configuration must be
noted on the drawing.
g) Location of main safety features such as pressure gauge and safety valve.
h) Other useful information, if needed
4. Design calculation must be calculated in accordance with one of the latest version of the recognized codes.

5. Documents submitted must be in Malay or English language.

6. For further information, please refer to Factories and Machinery (Steam Boiler and Unfired Pressure
Vessel) Regulations, 1970 and Factories and Machinery Act, 1967.

Notes:
 GUIDELINE FOR UNFIRED PRESSURE VESSEL (UPV) DESIGN APPROVAL.
(IMPORTED)
1. Application letter must come from supplier, importer, consultant or owner.

2. UPV Attachment should be completed and attached together with application.

3. 3 sets of design drawing must be as large as practicable (preferable A1) with 1/2'' border line and properly scaled. The drawings
must be furnished with the following :

a) Main dimensions.
b) Welding details.
c) Service of nozzles & orientation of nozzles.
d) Details of material specifications.
e) Design data such as design pressure, design temperature, working pressure, working temperature, test pressure,
design code, working media, volume, corrosion allowance, welding factor, flange rating and etc.
f) Detail drawings of any components and welding including reference or configuration must be noted on the
drawing.
g) Location of main safety features such as pressure gauge and safety valve.
h) Other useful information, if needed.
4. Design calculation must be calculated in accordance with one of the latest version of the recognized codes.

5. Manufacturer Data Report (MDR) (including size and dimensions of pressure containing components, design pressure, design
code, material certificates, procedure and welding report, in - plant check list, non destructive / destructive test (if any), PWHT
chart (if any), hydrostatic test, maker's or manufacturer's serial numbers and other useful information) approved by manufacturer
or Authorized Inspecting Authorities recognized by department . This MDR must be produced to the DOSH Inspector during
hydrostatic test.

6. Documents submitted must be in Malay or English language.

7. Items (3), (4) and (5) above must be checked and approved by the Inspecting Authorities recognized by DOSH if design pressure
(psi) x inside diameter (inch) exceeds 3000 pounds per square inch (psi. in).

8. For further information, please refer to Factories and Machinery (Steam Boiler and Unfired Pressure Vessel) Regulations, 1970
and Factories and Machinery Act, 1967.
 GUIDELINE FOR UNFIRED PRESSURE VESSEL (UPV) DESIGN APPROVAL.
(USED VESSEL)
1. Application letter must come from supplier, importer, consultant or owner.

(Note: Prior to the application of design approval for used vessel, discussion between Head of Design Section and
applicant must be made with reference the history of the unfired pressure vessel including custom declaration
form, maintenance records and tests done by the previous owner. These information’s is needed for assessment
purpose by department before any application submitte)
2. UPV Attachment should be completed and attached together with application.

3. 3 sets of design drawing must be as large as practicable (preferable A1) with 1/2'' border line and properly
scaled. The drawings must be furnished with the following :

a) Main dimensions.
b) Welding details.
c) Service of nozzles & orientation of nozzles.
d) Details of material specifications.
e) Design data such as design pressure, design temperature, working pressure, working temperature, test
pressure, design code, working media, volume, corrosion allowance, welding factor, flange rating and etc.
f) Detail drawings of any components and welding including reference or configuration must be noted on
the drawing.
g) Location of main safety features such as pressure gauge and safety valve.
h) Other useful information, if needed.
4. Confirmation of design calculation must be based on current thickness in accordance with original version of
design code. A comprehensive report by the Authorized Inspecting Authorities must be provided to prove the
vessel is fit for service at identified design pressure. The report must cover all items, and not limited to:
a) Internal and external visual inspection of the pressure vessel.
b) Non-destructive test at all welding joint.
c) Thickness measurement.
d) Hardness test on material
Pressure Testing (HT)
•acceptable medium for pressure testing PV is HT

•normally part of a periodic pressure vessel inspection.

•necessary after certain repairs and alterations .

•Any repairs to a PV will require restamping.

•Pressure test should not exceed 1.5 times the MAWP .

•The metal temperature during a pressure test should not be less than 60
deg F

•The metal temperature is not to be more than 120 deg F unless the owner
specifies the requirement for a higher test temperature.

• conducted at 1.5 X MAWP and temperature higher than 120 deg F

•The test pressure shall be held for a period of 15 minutes.

•pressure drop exceeds more than 10 percent, leaks should be repaired and
the test repeated.

• If the pressure drop is less than 10 percent and an inspection does not
reveal leaks in the pressurized parts, it may be assumed that the leaks
are through the isolation valves, manholes, and handholes.