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    Pressure Vessel and Stacks Field Repair Manual
    Pressure Vessel and Stacks Field Repair Manual
    Pressure Vessel and Stacks Field Repair Manual
    Ebook357 pages2 hours

    Pressure Vessel and Stacks Field Repair Manual

    By Keith Escoe

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    About this ebook

    Written from the practitioner's perspective, this book is designed as a companion for engineers who are working in the field and faced with various problems related to pressure vessels and stacks, such as: modification, retrofitting existing pressure vessels or stacks to either enhance process capability, lift, move or replace damaged equipment. This makes the book a valuable guide for new engineers who need to develop a feel for these types of operations or more experienced engineers who wish to acquire more useful tips, this handy manual provides the readers with rules of thumbs and tips to mitigate or remediate problems which can occur on a daily bases.

    Because of their size, complexity, or hazardous contents, pressure vessels and stacks require the highest level of expertise in determining their fitness for service after these operations. Care must be taken in installation / removal of the vessel to avoid damage to the shell. Damage to the shell can result in catastrophic failure and possible injury to personnel. The book will cover topics such as: lifting and tailing devices; an overview of rigging equipment; safety consideration; inspection and repair tips; methods to avoid dynamic resonance in pressure vessels and stacks; wind loads and how to apply them for various applications and assessment guidelines for column internals, tables and pressure vessel calculations, and code formulas.

    The examples in the book are actual field applications based on 40+ years of experience from various parts of the world and are written from a view to enhance field operations. In many parts of the world, often in remote locations, these methods were applied to repair pressure vessels and stacks. These problems will still continue to happen, so there is a need to know how to address them. This book is to present assessments and techniques and methods for the repair of pressure vessels and stacks for field applications. Also the book is to be a repair manual for easy use for mechanical engineers, civil-structural engineers, plant operators, maintenance engineers, plant engineers and inspectors, materials specialists, consultants, and academicians.

    • Lifting and tailing devices
    • An overview of rigging equipment
    • Inspection and repair tips
    • Guidelines for column internals
    • Tables and pressure vessel calculations, and code formulas
    LanguageEnglish
    PublisherElsevier Science
    Release dateApr 8, 2011
    ISBN9780080559186
    Pressure Vessel and Stacks Field Repair Manual
    Author

    Keith Escoe

    A. Keith Escoe, P.E., has worked in the chemical process, oil refining, and pipeline industries for thirty two years all over the world. His experience includes South America, the North America, and the Middle East. He is retired from Saudi Aramco in the Kingdom of Saudi Arabia where he was an engineering specialist. He is currently an international consultant. The author of many technical papers and books, Mr. Escoe has a B.S. in Mechanical engineering from the University of Texas at Arlington, an MBA from the University of Arkansas and is a licensed professional engineer in Texas.

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    Book preview

    Pressure Vessel and Stacks Field Repair Manual - Keith Escoe

    Pressure Vessel and Stacks Field Repair Manual

    A. Keith Escoe

    Copyright

    Copyright © 2008, Elsevier Inc. All rights reserved.

    30 Corporate Drive, Suite 400, Burlington, MA 01803, USA

    Linacre House, Jordan Hill, Oxford OX2 8DP, UK

    No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.

    Permissions may be sought directly from Elsevier's Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail: permissions@elsevier.co.uk. You may also complete your request on-line via the Elsevier homepage (http://www.elsevier.com) by selecting Support & Contact then Copyright and Permission and then Obtaining Permissions.

    Library of Congress Cataloging-in-Publication Data

    Application submitted.

    British Library Cataloguing-in-Publication Data

    A catalogue record for this book is available from the British Library.

    ISBN: 978-0-7506-8766-9

    For information on all Butterworth-Heinemann publications, visit our Web site at: http://www.books.elsevier.com

    Typeset by Charon Tec Ltd., A Macmillan Company (www.macmillansolutions.com).

    Printed in the United States of America.

    08 09 10 11 12 13 9 8 7 6 5 4 3 2 1

    Brief Table of Contents

    Copyright

    Brief Table of Contents

    Table of Contents

    List of Figures

    List of Tables

    Dedication

    About the Author

    Preface

    Chapter 1. Systems of Units

    Chapter 2. Handy Pressure Vessel Formulas

    Chapter 3. Dynamic Response of Pressure Vessels and Stacks

    Chapter 4. Wind Loadings on Pressure Vessels and Stacks

    Chapter 5. Pressure Vessel Internal Assessment

    Chapter 6. Safety Considerations for Lifting and Rigging

    Chapter 7. Lifting and Tailing Devices

    Chapter 8. Assessing Weld Attachments

    Chapter 9. Rigging Devices

    Index

    Table of Contents

    Copyright

    Brief Table of Contents

    Table of Contents

    List of Figures

    List of Tables

    Dedication

    About the Author

    Preface

    Chapter 1. Systems of Units

    Getting Familiar with Metric SI Units

    Other Important Metric SI Units Used in Mechanics

    Density

    Bending Moments and Torque

    Units for Stress and Pressure

    A Warning About Combining Metric SI Units

    Units for Energy

    Thermal Conductivity Units

    Coefficient of Thermal Expansion

    The Unit of Toughness

    Chapter 2. Handy Pressure Vessel Formulas

    Cylindrical shells

    Circumferential Stress in a Cylindrical Shell (Longitudinal Joints)

    Longitudinal Stress (Circumferential Joints)

    Final or Resulting Values

    Spherical shell or hemispherical head

    Elliptical head

    Torispherical head

    Geometrical Equations for a Torispherical Head

    Conical sections

    Circumferential Stress (Longitudinal Joints)

    Longitudinal Stress (Circumferential Joints)

    Final Values

    Knuckle Section

    Final Values

    Conical Transitions

    Conical Transition Knuckle Section

    Conical Transition Flare Section

    Equations Based on a Pressure-Area Force Balance Procedure

    Final Values

    Computation of the Half-Apex Angle of a Conical Transition

    Handy formulas for computing head weights

    2.1 ellipsoidal head weights

    Asme F&D head weights

    Hemispherical head weights

    Partial volumes and pressure vessel calculations

    Partial Volume of Cylinder in Horizontal Position

    Partial Volume of a Hemispherical Head

    Partial Volumes of Spherically Dished Heads

    Spherically Dished Head in Horizontal Position

    Spherically Dished Head in Vertical Position

    Partial Volumes of Elliptical Heads

    Elliptical Head in Horizontal Position

    Elliptical Head in Vertical Position

    Partial Volumes of Torispherical Heads

    Torispherical Head in the Vertical Position

    Torispherical Head in the Horizontal Position

    Chapter 3. Dynamic Response of Pressure Vessels and Stacks

    Flow-induced vibration-impeding devices

    Helical Strakes

    Damping Pads

    Ovaling Rings

    Guy cables, remediation devices, and support of flare stacks

    The Basic Methodology

    Chapter 4. Wind Loadings on Pressure Vessels and Stacks

    The velocity pressure distribution, qz

    Wind directionality factor, Kd

    Velocity pressure coefficient, Kz

    Topographic factor, kzt

    Basic wind speed, V

    Importance factor, I

    Gust-effect factor, G

    Solving for the Gust-Effect Factor, G

    The projected area normal to the wind, af

    Chapter 5. Pressure Vessel Internal Assessment

    Forces on internal components

    Lined plates and internal components

    Helpful structural formulations

    Tray Support Ring

    Support Clip Welded on Two Sides with Fillet Welds with Force on Short End

    Support Clip with Applied Tensile Force

    Support Clip with Out-of-Plane Bending Moment

    Support Clip with an In-Plane Bending Moment

    Support Clip with Continuous Fillet Weld with an Out-of-Plane Bending Moment, Myy

    Support Clip with Continuous Fillet Weld with an In-Plane Bending Moment, Mzz

    Internal expansion joints

    Chapter 6. Safety Considerations for Lifting and Rigging

    The concept of a ton weighs heavy when lifting

    Maximum capacity of slings

    Bridles and center of gravity (CG)

    Lift categories

    Preparing for the lift

    American National Standard Institute (ANSI) safety codes

    Helpful references for rigging

    Chapter 7. Lifting and Tailing Devices

    Impact factor

    Tension at net section

    Hoop tension—splitting failure beyond hole

    Double plane shear failure

    Out-of-plane instability (dishing) failure

    Bearing failure

    Validation Tests for Bearing Failure

    Pin hole doubler plates

    Multiple loads on lifting and tail lugs

    Trunnions

    Chapter 8. Assessing Weld Attachments

    A few words about reinforcing pads and lifting lugs

    Chapter 9. Rigging Devices

    Blocks

    Selection of a block

    Lifting and erecting pressure vessels and stacks

    Shackles

    Index

    List of Figures

    Chapter 1. Systems of Units

    Figure 1.1. Schematic diagram showing impact hammer of M dropping from height L1, impacting sample S, and rising to a height L2. The energy absorbed by the sample, related to the difference of heights L1−L2, is recorded on gauge G.

    Chapter 2. Handy Pressure Vessel Formulas

    Figure 2.1. Right circular cylinder.

    Figure 2.2. Right circular cylinder showing circumferential and longitudinal axes.

    Figure 2.3. Hemispherical head or sphere.

    Figure 2.4. Ellipsoidal head.

    Figure 2.5. Torispherical head (Note: Cr=L below).

    Figure 2.6. Torispherical head geometry (where Ri=Cr=L).

    Figure 2.7. Conical section.

    Figure 2.8. Conical transition section (Courtesy of the American Petroleum Institute).

    Figure 2.9. Toriconical head geometry (Courtesy of the American Petroleum Institute).

    Figure 2.10. Conical transition geometry (courtesy of the American Petroleum Institute).

    Figure 2.11. Conical transition geometry—Unsupported length for conical transitions (courtesy of the American Petroleum Institute).

    Figure 2.12. Forming a formed head in the mill.

    Figure 2.13. Sketch for calculating partial volume of a cylinder.

    Figure 2.14. (a) Partial volume of a hemispherical head in the vertical position. (b) Partial volume of a hemispherical head in the horizontal position.

    Figure 2.16. Spherically dished head in the horizontal position showing the liquid level at 10.0 inches below the centerline.

    Figure 2.15. Partial volume of a spherically dished head in the horizontal position.

    Figure 2.17. Volume of a spherically dished head in the vertical position.

    Figure 2.19. Ellipsoidal head in horizontal position example.

    Figure 2.18. Partial volume of an ellipsoidal head in the horizontal position showing the elevation and front views.

    Figure 2.20. Partial volume of an elliptical head in the vertical position.

    Figure 2.21. Partial volume of torispherical heads: (a) vertical position, (b) horizontal position, (c) knuckle region in vertical position, (d) knuckle region in horizontal position.

    Figure 2.22. Partial volume of torispherical head in vertical position showing the dish and knuckle volumes.

    Figure 2.23. Sketch for the example of the partial volume in a torispherical head in the horizontal position.

    Figure 2.24. Example of torispherical head in the horizontal position.

    Chapter 3. Dynamic Response of Pressure Vessels and Stacks

    Figure 3.1. Probabilistic plot of the stack's natural frequency f versus Δ, the ratio of the maximum dynamic amplitude (in) to the total height (in) for various values of structuralt damping (ξ). UB=the upper bound value for Δ for a given frequency value; LB=the lower bound frequency value for Δ.

    Figure 3.2. Schematic showing the process column that experienced unacceptable dynamic amplitudes.

    Figure 3.3. (a) Equation sheet for solution for natural frequency. (b) Variable sheet showing results and answers for solution of natural frequency.

    Figure 3.4. Cylindrical strake helix geometry.

    Figure 3.5. Strake fabrication detail.

    Figure 3.6. Clamping each strip on 45° offsets and hot-forming with a torch to obtain the desired geometry.

    Figure 3.7. Fabricating helical strakes from a flat plate.

    Figure 3.8. Helical strakes fabricated using the method described in Example 3.2.

    Figure 3.9. Damping pad details.

    Figure 3.10. Flare stack guy wire thermal movements. Points A, A9, and A0 are at the cable connection on the upper portion of the flare stack; Point C is at the base of the stack; and Point B is where the cable ties into the ground with a dead man… The term dead man refers to an anchor in the ground that has sufficient rigidity to restrain the forces in the cables. Typically they are concrete masses embedded in the ground.

    Figure 3.11. Flare stack guy cable details.

    Figure 3.12. Beam subjected to a uniform load with axial tensile load.

    Chapter 4. Wind Loadings on Pressure Vessels and Stacks

    Figure 4.1. The effective wind diameter can vary with height [3].

    Figure 4.2. Wind area for conical sections [3]

    Chapter 5. Pressure Vessel Internal Assessment

    Figure 5.1. The collapse of internals of an MTBR Regenerator air distributor.

    Figure 5.2. Air distributor piping.

    Figure 5.3. Gusset plate attachment.

    Figure 5.4. Bent and warped channel sections.

    Figure 5.5. Warped reinforcing members.

    Figure 5.6. Forged fitting designed for cyclic service was an integral part of the rebuild and withstood the pulsation pressure forces (courtesy of WFI International, Inc.).

    Figure 5.7. Comparison of spatially uniform compression to propagative compression.

    Figure 5.8. Tray support ring.

    Figure 5.9. Support clip welded on two sides with fillet welds; see Giachino et al. [3].

    Figure 5.10. Support clip with applied tensile force; see Giachino et al. [3].

    Figure 5.11. Support clip with an out-of-plane bending moment, Myy; see Giachino et al. [3].

    Figure 5.12. Support clip with an in-plane bending moment, Mzz; see Giachino et al. [3].

    Figure 5.13. Support clip with continuous fillet weld with an out-of-plane bending moment, Myy; see Giachino et al. [3].

    Figure 5.14. Support clip with continuous fillet weld with an in-plane bending moment, Mzz; see Giachino et al. [3].

    Chapter 6. Safety Considerations for Lifting and Rigging

    Figure 6.1. Load vectors and sling angles. The force vectors are shown in the upper right. The two slings form is known as a two-leg bridle.

    Chapter 7. Lifting and Tailing Devices

    Figure 7.1. The lifting lug configuration.

    Figure 7.2. (a) The modes of failure of a lifting lug (dishing is shown in Figure 7.2(b))

    Figure 7.2. (b) Four of the five modes of failure of

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