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Fabrication of Metallic Pressure Vessels
A comprehensive guide to processes and topics in pressure vessel fabrication
Fabrication of Metallic Pressure Vessels delivers comprehensive coverage of the various processes used in the fabrication of process equipment. The authors, both accomplished engineers, offer readers a broad understanding of the steps and processes required to fabricate pressure vessels, including cutting, forming, welding, machining, and testing, as well as suggestions on controlling costs.
Each chapter provides a complete description of a specific fabrication process and details its characteristics and requirements. Alongside the accessible and practical text, you’ll find equations, charts, copious illustrations, and other study aids designed to assist the reader in the real-world implementation of the concepts discussed within the book.
You’ll find numerous appendices that include weld symbols, volume and area equations, pipe and tube dimensions, weld deposition rates, lifting shackle data, and more.
In addition to detailed discussions of cutting, machining, welding, and post-weld heat treatments, readers will also benefit from the inclusion of:
Perfect for new and established engineers, designers, and procurement personnel working with process equipment or in the fabrication field, Fabrication of Metallic Pressure Vessels will also earn a place in the libraries of students in engineering programs seeking a one-stop resource for the fabrication of pressure vessels.
Owen R. Greulich is active on the High Pressure Task Group of the American Society of Mechanical Engineers’ Process Piping Code Committee and the American Institute of Aeronautics and Astronautics (AIAA) Aerospace Pressure Vessel Committee. He previously served as Pressure and Energetic Systems Safety Manager in the Office of Safety and Mission Assurance at NASA Headquarters, responsible for the safety of pressure and vacuum systems.
Maan H. Jawad is President of Global Engineering & Technology in the United States. He was previously on the Board of Directors and Director of Engineering of the Nooter Corporation. He is active on various ASME Codes and Standards committees and the author of numerous books and publications related to pressure vessels.
Preface
Acknowledgements
1. Introduction
1.1 Introduction
1.2. Fabrication Sequence
1.3 Cost Considerations
1.3.1 Types of costs
1.3.2 Design choices
1.3.3 Shipping
1.3.4 General approach to cost control
1.4 Fabrication of Non-nuclear Versus Nuclear Pressure Vessels
1.5 Units and Abbreviations
1.6 Summary
2. Materials of Construction
2.1 Introduction
2.2 Ferrous Alloys
2.2.1 Carbon steels (Mild steels)
2.2.2 Low alloy steels (Cr-Mo steels)
2.2.3 High alloy steel (stainless steels)
2.2.4 Cost of Ferrous alloys
2.3 Nonferrous Alloys
2.3.1 Aluminum alloys
2.3.2 Copper alloys
2.3.3 Nickel alloys
2.3.4 Titanium alloys
2.3.5 Zirconium alloys
2.3.6 Tantalum alloys
2.3.7 Price of nonferrous alloys
2.4 Density of Some Ferrous and Nonferrous Alloys
2.5 Nonmetallic Vessels
2.6 Forms and Documentation
2.7 Miscellaneous Materials
2.7.1 Cast iron
2.7.2 Gaskets
2.8 References
3. Layout
3.1 Introduction
3.2 Applications
3.3 Tools and Their Use
3.4 Layout Basics
3.4.1 Projection
3.4.2 Triangulation
3.5 Material Thickness and Bending Allowance
3.6 Angles and Channels
3.7 Marking Conventions
3.8 Future of Plate Layout
3.9 References:
4. Material Forming
4.1 Introduction
4.1.1 Bending versus three-dimensional forming
4.1.2 Other issues
4.1.3 Plastic Theory
4.1.4 Forming limits
4.1.5 Grain direction
4.1.6 Cold versus hot forming
4.1.7 Spring back
4.2 Brake Forming (Angles, Bump-Forming)
4.2.1 Types of dies
4.2.2 Brake work forming limits
4.2.3 Crimping
4.2.4 Bending of pipes and tubes
4.2.5 Brake forming loads
4.3 Roll Forming (Shells, Reinforcing Pads, Pipe/Tube)
4.3.1 Pyramid rolls
4.3.2 Pinch rolls
4.3.3 Two roll systems
4.3.4 Rolling radius variability compensation
4.3.5 Heads and caps
4.3.6 Hot forming
4.4 Tolerances
4.4.1 Brake forming tolerances
4.4.2 Roll forming tolerances
4.4.3 Press forming tolerances
4.4.4 Flanging tolerances
5. Fabrication
5.1 Introduction
5.2 Layout
5.3 Weld Preparation
5.3.1 Hand and automatic grinders
5.3.2 Nibblers
5.3.3 Flame cutting
5.3.4 Boring Mills
5.3.5 Lathes
5.3.6 Routers
5.3.7 Other cutter arrangements
5.4 Forming
5.5 Vessel Fit up and Assembly
5.5.1 The fitter
5.5.2 Fit up tools
5.5.3 Persuasion and other fit up techniques
5.5.4 Fixturing
5.5.5 Welding fit up
5.5.6 Weld shrinkage
5.5.7 Order of assembly
5.6 Welding
5.6.1 Welding position
5.6.2 Welding residual stresses
5.6.3 Welding positioners, turning rolls, column and boom weld manipulators
5.7 Correction of Distortion
5.8 Heat Treatment
5.8.1 Welding preheat
5.8.2 Interpass temperature
5.8.3 Post weld heat treatment
5.9 Post-fabrication Machining
5.10 Field Fabrication – Special Issues
5.10.1 Exposure to the elements
5.10.2 Staging area
5.10.3 Tool and equipment availability
5.10.4 Staffing
5.10.5 Material handling
5.10.6 Energy sources
5.10.7 PWHT
5.10.8 Layout
5.10.9 Fit up
5.10.10 Welding
5.11 Machining
5.12 Cold Springing
6. Cutting and Machining
6.1 Introduction
6.2 Common Cutting Operations for Pressure Vessels
6.3 Cutting Processes
6.3.1 Plate cutting
6.3.2 Pipe, bar, and structural shape cutting
6.4 Common Machining Functions and Processes
6.5 Common Machining Functions for Pressure Vessels
6.5.1 Weld preparation
6.5.2 Machining of flanges
6.5.3 Tubesheets
6.5.4 Heat exchanger channels
6.5.5 Heat exchanger baffles
6.6 Set Up Issues
6.7 Material Removal Rates
6.7.1 Feed
6.7.2 Speed
6.7.3 Depth of cut
6.8 Milling
6.9 Turning and Boring
6.10 Machining Centers
6.11 Drilling
6.12 Tapping
6.13 Water Jet Cutting
6.14 Laser Machining
6.15 Reaming
6.16 Electrical Discharge Machining, Plunge and Wire
6.17 Electrochemical Machining
6.18 Electron Beam Machining
6.19 Photochemical Machining
6.20 Ultrasonic Machining
6.21 Planing and Shaping
6.22 Broaching
6.23 3D Printing
6.24 Summary
6.25 References
7. Welding
7.1 Introduction
7.2 Weld Details and Symbols
7.2.1 Single fillet weld
7.2.2 Double fillet welds
7.2.3 Intermittent fillet welds
7.2.4 Single bevel butt welds
7.2.5 Double bevel butt welds
7.2.6 J-groove or double J-groove welds
7.2.7 Backing strips
7.2.8 Consumables
7.2.9 Tube to tubesheet welds
7.2.10 Weld symbols
7.3 Weld Processes
7.3.1 Diffusion welding
7.3.2 Electron beam welding
7.3.3 Electrogas welding
7.3.4 Electroslag welding
7.3.5 Flux-cored arc welding
7.3.6 Flash welding
7.3.7 Friction stir welding
7.3.8 Gas metal-arc welding
7.3.9 Gas tungsten-arc welding
7.3.10 Laser beam welding
7.3.11 Orbital welding
7.3.12 Oxyfuel gas welding
7.3.13 Plasma-arc welding
7.3.14 Resistance spot welding
7.3.15 Resistance seam welding
7.3.16 Submerged-arc welding
7.3.17 Shielded metal-arc welding
7.3.18 Stud welding
7.4 Weld Pre-heat and Interpass Temperature
7.5 Post Weld Heat Treating
7.6 Welding Procedures
7.7 Control of Residual Stress and Distortion
7.8 Material Handling to Facilitate Welding
7.9 Weld Repair
7.10 Brazing
7.10.1 Applications
7.10.2 Filler metal
7.10.3 Heating
7.10.4 Flux
7.10.5 Brazing Procedures
7.11 References
8. Welding Procedures and Post Weld Heat Treatment
8.1 Introduction
8.2 Weld Symbols and Details
8.3 Common Weld Joint Configurations
8.4 Welding Procedures
8.5 Weld Preparation Special Requirements
8.6 Weld Joint Design and Process to Reduce Stress and Distortion
8.6.1 Reduced heat input
8.6.2 Lower temperature differential
8.6.3 Choice of weld process
8.6.4 Weld configuration and sequencing
8.7 Weld Pre-Heat and Interpass Temperature
8.8 Welder Versus Welding Operator
8.8.1 Welders
8.8.2 Welding operators
8.8.3 Differences in qualifications
8.9 Weld Repair
8.9.1 Slag inclusion during welding
8.9.2 Surface indications after cooling of welds
8.9.3 Delayed hydrogen cracking after welding
8.9.4 Cracks occurring subsequent to PWHT
8.10 Post Weld Heat Treating
8.10.1 PWHT of carbon steels
8.10.2 PWHT of low alloy carbon steels
8.10.3 Some general PWHT requirements for carbon steels and low alloy steels
8.10.4 PWHT of stainless Steel
8.10.5 PWHT of Nonferrous alloys
8.11 Cladding, Overlay, and Loose Liners
8.11.1 Cladding
8.11.2 Weld overlay
8.11.3 Loose liners
8.12 Brazing
8.12.1 Applications
8.12.2 Filler metal
8.12.3 Heating
8.12.4 Flux
8.12.5 Brazing procedures
8.13 References
9. Fabrication of Pressure Equipment Having Unique Characteristics
9.1 Introduction
9.2 Heat Exchangers
9.2.1 U-tube heat exchangers
9.2.2 Fixed heat exchangers
9.2.3 Floating head heat exchangers
9.2.4 Attachment of tubes-to-tubesheets and tubes-to-headers
9.2.5 Expansion joints
9.2.6 Assembly of heat exchangers
9.3 Dimpled Jackets
9.4 Layered Vessels
9.4.1 Introduction
9.4.2 Fabrication of layered shells
9.5 Rectangular vessels
9.6 Vessels with Refractory and Insulation
9.7 Vessel Supports
9.8 Summary
9.9 References
10. Surface Finishes
10.1 Introduction
10.2 Types of Surface Finishes
10.2.1 Surface characteristics, unfinished
10.2.2 Passivation
10.2.3 Applied coatings
10.3 References
11. Handling and Transportation
11.1 Introduction
11.2 Handling of Vessels and Vessel Components within the Fabrication Plant
11.3 Transportation of Standard Loads
11.4 Transportation of Heavy Vessels
11.4.1 Handling heavy vessels using specialty cranes
11.4.2 Shipping by truck
11.4.3 Shipping by rail
11.4.4 Shipping by barge or ship
11.4.5 Shipping by air
11.5 Summary
12. ASME Code Compliance and Quality Control System
12.1 Need for ASME Code Compliance
12.2 What the ASME Code Provides
12.3 Fabrication in Accordance with the ASME Code
12.4 ASME Code Stamping
12.4.1 Design calculations
12.4.2 Fabrication drawings
12.4.3 Material mill test reports
12.4.4 WPS for the vessel welds
12.4.5 Records of Nondestructive Examination
12.4.6 Record of PWHT
12.4.7 Record of hydrotesting
12.4.8 Manufacturer’s Data Report, U-1 Form
12.4.9 Manufacturer’s Partial Data Report, U-2 form
12.4.10 Name plate
12.5 Authorized Inspector and Authorized Inspection Agency
12.6 Quality Control System for Fabrication
12.6.1 Organizational chart
12.6.2 Authority and responsibility
12.6.3 Quality control system
12.6.4 Design and drawing control
12.6.5 Material control
12.6.6 Production control
12.6.7 Inspection
12.6.8 Hydrostatic and pneumatic testing
12.6.9 Code stamping
12.6.10 Discrepancies and nonconformances
12.6.11 Welding
12.6.12 Nondestructive examination
12.6.13 Heat treatment control
12.6.14 Calibration of measuring and test equipment
12.6.15 Records retention
12.6.16 Handling, storage, and shipping
12.7 Additional Stamps Required for Pressure Vessels
12.7.1 National Board Stamping, NB
12.7.2 Jurisdictional stamping
12.7.3 User stamping
12.7.4 Canadian Registration numbers
12.8 Non Code Jurisdictions
12.9 Temporary Shop Locations
13. Repair of Existing Equipment
13.1 Introduction
13.2 National Board Inspection Code, NBIC, NB-23
13.2.1 Repairs
13.2.2 Alterations
13.2.3 Reratings
13.2.4 Post weld heat treating of repaired components
13.2.5 Hydrostatic or pneumatic testing of repaired vessels
13.3 ASME Post Construction Code, PCC-2
13.3.1 External weld buildup to repair internal thinning
13.3.2. Full encirclement steel reinforcing sleeves for pipes in corroded areas
13.3.3 Welded hot taps
13.4 API Pressure Vessel Inspection Code, API-510
13.5 API 579/ASME FFS-1 Fitness-For-Service Code.
13.6 Miscellaneous Repairs
13.6.1 Removal of seized nuts
13.6.2 Structural supports and foundation
13.7 References
Appendix A Units and Conversion Factors
A.1 Some Customary Units
A.2 Conversion Factors
A.3 Length Conversions
A.4 Miscellaneous Unit Conversions
Appendix B Welding Symbols
Appendix C Weld Process Characteristics
C.1. Weld Process Advantages and Disadvantages
C.2. Weld Process Applications
Appendix D Weld Deposition
Appendix E Shape Properties
E.1. Properties of Cross Sections
E.2. Properties of Solids
E.3. Properties of Hemispheres and Spherical Segments
E.4 Properties of Commonly Used Ellipsoidal Heads
E.5 Ellipsoidal Head Formulas
Appendix F Pipe and Tube Dimensions and Weights
F.1 Pipe Properties
F.2 Tube Properties
Appendix G Bending and Expanding of Pipes and Tubes
G.1 TEMA Requirements for U-Tube Thinning
G.2 ASME B31 Code Requirements for Tube Thickness at U-Bends
G.3 Expansion of Tubes into Tubesheet Holes
Appendix H Dimensions of Some Commonly Used Bolts and Their Required Minimum Spacing
Appendix I Shackles
I.1 Sample Loads and Dimensions for Chain Shackles
I.2 Sample Loads and Dimensions for Anchor Shackles
I.3 Load Reduction Factors for Side Loaded Shackles with Size up to 3 Inches
I.4 Load Reduction Factors for Side Loaded Shackles with Size Larger than 3 Inches
I.5 References
Appendix J Shears, Moments, and Deflections of Beams
Appendix K Commonly Used Terminology
K.1. Glossary
K.2. Acronyms and Other Letter Designations
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