SIST-TP CEN/TR 13445-101:2015
(Main)Unfired pressure vessels - Example of application
Unfired pressure vessels - Example of application
This Technical Report presents an application of EN 13445 through an example of design and fabrication of an
unfired pressure vessel. Every step is described as far as possible:
— Material choice;
— Design and calculation;
— Fabrication;
— Inspection and testing;
using the following part of EN 13445:
— EN 13445-1:2009;
— EN 13445-2:2009;
— EN 13445-3:2009;
— EN 13445-4:2009;
— EN 13445-5:2009 .
As applicable, some choices for design or fabrication are made according to “the state of art” practice.
Some parts of EN 13445 are reproduced in order to show which requirements are relevant to the design and
fabrication of the target vessel.
Unbefeuerte Druckbehälter - Teil 101: Anwendungsbeispiel
Récipients sous pression non soumis à la flamme - Partie 101 : Exemple d'application
Neogrevane tlačne posode - Primer uporabe
General Information
Standards Content (Sample)
SLOVENSKI STANDARD
SIST-TP CEN/TR 13445-101:2015
01-julij-2015
1HRJUHYDQHWODþQHSRVRGH3ULPHUXSRUDEH
Unfired pressure vessels - Example of application
Unbefeuerte Druckbehälter - Teil 101: Anwendungsbeispiel
Récipients sous pression non soumis à la flamme - Partie 101 : Exemple d'application
Ta slovenski standard je istoveten z: CEN/TR 13445-101:2015
ICS:
23.020.30 7ODþQHSRVRGHSOLQVNH Pressure vessels, gas
MHNOHQNH cylinders
SIST-TP CEN/TR 13445-101:2015 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST-TP CEN/TR 13445-101:2015
TECHNICAL REPORT
CEN/TR 13445-101
RAPPORT TECHNIQUE
TECHNISCHER BERICHT
April 2015
ICS 23.020.30
English Version
Unfired pressure vessels - Example of application
Récipients sous pression non soumis à la flamme - Partie Unbefeuerte Druckbehälter - Teil 101: Anwendungsbeispiel
101 : Exemple d'application
This Technical Report was approved by CEN on 10 February 2015. It has been drawn up by the Technical Committee CEN/TC 54.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United
Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2015 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 13445-101:2015 E
worldwide for CEN national Members.
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Contents Page
Foreword . 3
1 Scope . 4
2 Normative references . 4
3 Presentation of example . 5
3.1 General . 5
3.2 Pressure vessel data . 5
3.3 PED 97/23/CE Category . 7
3.4 Extracts from EN 13445-1 to EN 13445-5:2009 and from others standards . 7
4 Materials . 7
4.1 General . 7
4.2 Minimum requirements for materials . 7
4.3 Mechanical properties of the chosen materials . 9
4.4 Type of material certificate . 12
4.5 Prevention of brittle fracture . 13
4.6 Particular Material Appraisal (PMA) . 25
5 Calculations and design . 26
5.1 General . 26
5.2 Definitions related to pressure . 26
5.3 Thickness definitions and joint coefficient . 27
5.4 Prevention of brittle fracture . 28
5.5 Maximum allowed values of the nominal design stress . 28
5.6 Calculations and design . 30
6 Fabrication . 68
6.1 General . 68
6.2 Minimum requirements for fabrication . 69
6.3 Production tests. 72
6.4 Forming of shell . 76
6.5 Post weld heat-treatment (PWHT) . 82
6.6 Others requirements . 84
7 Inspection and testing . 84
7.1 General . 84
7.2 Performance of inspection and testing . 85
7.3 Technical documentation . 85
7.4 Inspection and testing during fabrication . 85
7.5 Others requirements . 91
7.6 Final assessment . 91
7.7 Marking and declaration of compliance with the standard . 94
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Foreword
This document (CEN/TR 13445-101:2015) has been prepared by Technical Committee CEN/TC 54 “Unfired
pressure vessels”, the secretariat of which is held by BSI.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights.
CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
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1 Scope
This Technical Report presents an application of EN 13445 through an example of design and fabrication of an
unfired pressure vessel. Every step is described as far as possible:
— Material choice;
— Design and calculation;
— Fabrication;
— Inspection and testing;
using the following part of EN 13445:
— EN 13445-1:2009;
— EN 13445-2:2009;
— EN 13445-3:2009;
— EN 13445-4:2009;
— EN 13445-5:2009 .
As applicable, some choices for design or fabrication are made according to “the state of art” practice.
Some parts of EN 13445 are reproduced in order to show which requirements are relevant to the design and
fabrication of the target vessel.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are indispensable
for its application. For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments) applies.
EN 287-1:2004+A2:2006, Approval testing of welders — Fusion welding — Part 1: Steels
EN 473:2008, Non-destructive testing — Qualification and certification of NDT personnel — General principles
EN 764-5:2002, Pressure Equipment — Part 5: Compliance and Inspection Documentation of Materials
EN 1092-1:2007, Flanges and their joints — Circular flanges for pipes, valves, fittings and accessories, PN
designated
EN 1418:1997, Welding personnel — Approval testing of welding operators for fusion welding and resistance weld
setters for fully mechanized and automatic welding of metallic materials
EN 1515-3:2005, Flanges and their joints — Bolting — Part 3: Classification of bolt materials for steel flanges, class
designated
EN 1515-4:2009, Flanges and their joints — Bolting — Part 4: Selection of bolting for equipment subject to the
Pressure Equipment Directive 97/23/EC
EN 1759-1:2004, Flanges and their joint — Circular flanges for pipes, valves, fittings and accessories, Class
designated — Part 1: Steel flanges, NPS 1/2 to 24
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EN 10025-2:2004, Hot rolled products of structural steels — Part 2: Technical delivery conditions for non-alloy
structural steels
EN 10028-1:2007, Flat products made of steels for pressure purposes — Part 1: General requirements
EN 10028-2:2003, Flat products made of steels for pressure purposes — Part 2: Non-alloy and alloy steels with
specified elevated temperature properties.
EN 10029:2010, Hot-rolled steel plates 3 mm thick or above —Tolerances on dimensions and shape
EN 10204:2004, Metallic products — Types of inspection documents.
EN 10216-3:2002, Seamless steel tubes for pressure purposes — Technical delivery conditions — Part 3: Alloy
fine grain steel tubes
EN 10222-4:1998, Steel forgings for pressure purposes — Part 4: Weldable fine grain steels with high proof
strength.
EN 10269:1999+A1:2006, Steels and nickel alloys for fasteners with specified elevated and/or low temperature
properties
EN 12560-4:2001, Flanges and their joints — Gaskets for Class-designated flantes — Part 4: Corrugated, flat or
grooved metallic and filled metallic gaskets for use with steel flanges
CR ISO 15608:2000, Welding — Guidelines for a metallic material grouping system (ISO/TR 15608:2000)
EN ISO 15614-1:2004, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys (ISO 15614-
1:2004)
3 Presentation of example
3.1 General
The target vessel consists of several components:
— a cylindrical shell,
— two elliptical ends,
— a welding neck flange,
— a nozzle,
— two saddle supports arranged symmetrically
3.2 Pressure vessel data
The data specified for the present example are the following:
— Vessel data:
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Key
D = 3 468 mm
i
L = 20 000 mm (cylindrical shell length)
Figure 1 — Pressure vessel data
Material: steel
— Service data:
Normal service conditions:
— Internal pressure: 44 bar
— Maximum temperature: 50 °C
— Minimum metal temperature: -20 °C
— Liquid group 1, density: 0,54
— Pressure loading predominantly of non-cyclic nature
There are not exceptional service conditions.
PED 97/23/CE regulation applies.
The calculation of all components is performed by formulas (DBF: Design By Formula). According to the specified
operating conditions, the pressure vessel is neither subjected to fatigue nor to creep.
It is supposed that there is only a risk of atmospheric corrosion during operation of the vessel. Thus, a corrosion
allowance of 3 mm is added.
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3.3 PED 97/23/CE Category
The maximum allowable pressure PS used as a first approach is 44 bar and the fluid is a liquid of group 1.
The category which applied for the target vessel is category II as defined in Clause 3 paragraph 1.1(b) of the PED
which indicates the use of Table 3 of Annex II of PED to set the category.
3.4 Extracts from EN 13445-1 to EN 13445-5:2009 and from others standards
The extracts from the EN 13445 Standard clauses which are the most relevant at each step of the example are
reproduced in black frames. When necessary, the adequate requirements in these extracts are framed in red.
Other extracts of standards referenced in EN 13445 are reproduced, also in black frames, and the standard from
which they are extracted is mentioned. When necessary, the adequate requirements in these extracts are framed
in red.
4 Materials
4.1 General
EN 13445-2:2009 gives the minimum requirements to be fulfilled for steel entering the manufacturing of pressure
vessel. The informative Annex E of this standard references European materials usable for pressure vessel
manufacturing. The corresponding steel grades come from harmonized European standards. The Grouping
according to CEN ISO/TR 15608:2000 is also given for each grade.
The minimum requirements concern elongation, impact test and chemical composition. These requirements for
steel should ensure toughness and good behaviour of materials during manufacturing (weldability and forming).
Table 4.1-1 of this report summarizes some properties of the materials which have been chosen for fabrication of
the target vessel. This table shows how the requirements of EN 13445-2:2009 are fulfilled.
4.2 Minimum requirements for materials
4.2.1 General
The following clauses of EN 13445-2:2009 shall be fulfilled:
4.2.2 Minimum elongation
The requirements for minimum elongation are fulfilled by the chosen materials, see Table 4.1-1.
Figure 2 — Abstract from EN 13445-2:2009
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4.2.3 Impact test for ferritic steel
The requirements for impact test are fulfilled by the chosen materials, see Table 4.1-1. Requirements of Annex B of
EN 13445-2:2009 shall also apply; see 4.5 of this report.
Figure 3 — Abstract from EN 13445-2:2009
4.2.4 Chemical composition of selected grade
The requirements for chemical composition are fulfilled by the chosen materials, see Table 4.1-1, except for the
bolting grade 42CrMo4 (1.7225), but this product is not intended for welding or forming as stated in 4.1.7 of
EN 13445-2:2009. Indeed, following EN 10269:1999, EN 10269:1999+A1:2006, the specified chemical composition
for this grade of bolting is:
— %C: 0,38 to 0,45;
— % P: 0,035 max;
— % S: 0,035 max.
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Figure 4 — Abstract from EN 13445-2:2009
4.3 Mechanical properties of the chosen materials
The selected grades and their appropriate properties are summarized in Table 4.1-1.
All the mechanical properties presented in this table are minimum values from transversal specimen and are
specified in the relevant technical specification. Transversal specimens are defined as specimen taken in a
direction perpendicular to the direction of principal deformation of the product (e.g. for flat products the transversal
direction is perpendicular to the rolling direction).
Since the minimum yield strength and tensile strength values are specified in the material technical specification as
a function of the product thickness the values to be used for the design of each specific component are not known
at first. They can be set only once the design calculations performed according to the relevant EN 13445-3:2009
rules have shown that the thickness assumed for calculation is acceptable. In some cases an iteration on the
thickness and the corresponding mechanical properties is necessary to get the correct values (see Clause 5 of this
report).
For determination of the material characteristics above 20 °C, the interpolation rules which apply are those defined
in 4.2.2 of EN 13445-2:2009:
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Figure 5 — Abstract from EN 13445-2:2009
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Table 4.1-1
Specified
Specified Specified
minimum Impact
minimum Specified minimum minimum
yield energy Classification
Grades yield strength tensile strength elongation Heat
strength KCV according to
at room at room temperature after fracture treatment
Component Standard(s)
(Steel
at 50 °C
(EN 13445- CR
temperature A%
Number) Rm condition
2:2009, ISO 15608:2000
Rp0,2 (MPa) (EN 13445-
Rp0,2/t 4.1.6)
(MPa) 2:2009, 4.1.4)
(MPa)
P295GH 27 J @
Cylindrical EN 10028-
285 276 460 21 +N 1.2
shell 2:2003
(1.0481) -20 °C
P295GH 27 J @
EN 10028-
Elliptical end 285 276 460 21 +N 1.2
2:2003
(1.0481) -20 °C
P275NL2 47 J @
EN 10216- EN 13445-
Nozzle 275 390 22 +N 1.1
3:2002 2:2009, 4.2.2
(1.1104) -20 °C
EN 1759-
1:2004 P285QH 27 J @
EN 13445-
Flange 255 390 23 +QT 1.2
2:2009, 4.2.2
EN 10222- (1.0478) -20 °C
4:1998
42CrMo4 40 J @
EN 10269:199
Bolting 730 720 860 14 +QT 3.2
9
(1.7225) -40 °C
P295GH 27 J @
Reinforcing EN 10028-
285 276 460 21 +N 1.2
plate 2:2003
(1.0481) -20 °C
S275J2 27 J @
EN 10025-2:
Saddle support 275 No value 430 21 +N 1.1
2004
(1.0145) -20 °C
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4.4 Type of material certificate
4.4.1 PED requirements
Annex I paragraph 4.3 of the PED states that for the Category II main pressure-bearing parts of pressure
equipment, the material certificate shall be a certificate of specific control. In accordance with EN 10204:2004, this
certificate shall be, as a minimum, of type 3.1.
4.4.2 Type of certificate for pressure vessel components
Material certificate may be selected in accordance with EN 764-5:2002 which specifies the type of material
certificate to obtain from the material producer following the considered part (main pressure-bearing parts, pressure
parts other than main pressure-bearing parts or non pressure-bearing parts).
Figure 6 — Abstract from EN 764-5:2002
Figure 1 of EN 764-5:2002 below is useful to determine the type of certificate:
NOTE Edition of EN 10204:1991 is used for application of EN 764-5:2002 and edition of EN 10204:2004 is
used for application of EN 13445-2:2009. Type 3.1B of EN 10204:1991 is replaced by 3.1 of EN 10204:2004.
Types 3.1A and 3.1C is replaced by 3.2 of EN 10204:2004.
Figure 7 — Abstract from EN 764-5:2002
Table 4.4.2-1 below summarizes the type of material certificate according to EN 764-5:2002:
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Table 4.4.2-1
Minimum type of certificate according
Components Type of components
to EN 10204:2004
Cylindrical shell Main pressure-bearing parts 3.1 (3.1B as defined in EN 10204:1991)
Elliptical end Main pressure-bearing parts 3.1 (3.1B as defined in EN 10204:1991)
Pressure part other than main pressure-
Nozzle 2.2
bearing parts
Pressure part other than main pressure-
Flange 2.2
bearing parts
Pressure part other than main pressure-
Bolting 2.2
bearing parts
Reinforcing plate (for
Non-pressure-bearing parts 2.2
saddle support)
Saddle support Non-pressure-bearing parts 2.2
NOTE The type of certificate for the saddle support reinforcing plate could be of type 3.1 because the
material grade is chosen for being the same as for the cylindrical shell. To manufacture the reinforcing plate, the
vessel manufacturer could use a plate from the lot used to manufacture the cylindrical shell.
4.5 Prevention of brittle fracture
4.5.1 General
Annex B of EN 13445-2:2009 proposes three methods to prevent the risk of brittle fracture. The two first methods
are applied to the target vessel. The last one, Method 3, is not used because it would need to perform a complete
fracture mechanics analysis.
4.5.2 Method 1 (B.2.2 of EN 13445-2:2009)
4.5.2.1 General
As stated in B.2.2.1 of EN 13445-2:2009, Method 1 permits to select steels taken from harmonized European
standards. The assumptions are that T = T = T and the required toughness values shall be obtained after
R 27J KV
manufacturing.
4.5.2.2 Determination of test temperature T
KV
The Tables in B.2.2 give reference temperature T as a function of grade, reference thickness (depending on
R
whether PWHT is performed or not). Corresponding table for each product shall apply for each type of products.
Results corresponding to PWHT shall be taken into account (see 6.5.2 of this report):
— Plates and strip
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Figure 8 — Abstract from EN 13445-2:2009
— Tubes
Figure 9 — Abstract from EN 13445-2:2009
— Forgings
Figure 10 — Abstract from EN 13445-2:2009
— Nuts and bolts
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Figure 11 — Abstract from EN 13445-2:2009
4.5.3 Method 2 (Clause B.2.3 of EN 13445-2:2009)
4.5.3.1 General
Method 2 may be used to derive a reference temperature T that is lower than the one derived from Method 1.
R
4.5.3.2 Definitions
The following definitions are given by EN 13445-2:2009 and apply:
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Figure 12 — Abstract from EN 13445-2:2009
4.5.3.3 Impact energy requirements
Table B.2-13 gives also the required impact energy KV on a 10 mm x 10 mm test piece, KV = 27 J. The parent
material, heat affected zone and welds shall meet this impact energy at the impact test temperature T derived
KV
from Method 2.
Figure 13 — Abstract from EN 13445-2:2009
4.5.3.4 Determination of the test temperature T
KV
4.5.3.4.1 Components and welded joints
A PWHT is applied for some welded joints as described in 6.5.2.1 of this report.
The reference temperature is defined as being T = T = -20 °C.
R M
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Diagrams permit the determination of the impact test temperature T . The relevant ones shall be selected from
KV
Table B.2-13 of EN 13445-2: 2009 here-above.
The reference thickness e is determined from Table B.4-1 of EN 13445-2:2009. The way to obtain T from the
B KV
values of T and e in the relevant diagram is illustrated for each construction detail of the target vessel in
R B
Table 4.5.3.4.1-1 to Table 4.5.3.4.1-4 of this report.
There is no construction detail applying to longitudinal seam welds and to circumferential seam welds in the
cylindrical shell. In other words, the construction detail No.1 does not apply because it makes reference to butt
welded components of unequal thickness.
Therefore, for these welded joints, the reference thickness e is equal to the nominal thickness of the component,
B
i.e. 45 mm.
Then, Figure B.2-3 of EN 13445-2:2009 applies to derive T (see Table 4.5.3.4.1-1 below).
KV
Table 4.5.3.4.1-1 — Longitudinal and circumferential seam welds in cylindrical shell
Figure 14 — Abstract from EN 13445-2:2009
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Table 4.5.3.4.1-2 — Base material of cylindrical shell and elliptical end –
Circumferential joint between cylindrical shell and elliptical end
Figure 15 — Abstract from EN 13445-2:2009
The reference thickness e is determined as follows:
B
— For the cylindrical shell, e is defined by Part A and is referenced as e (T is equal to 0 °C, see
B 1 KV
Table 4.5.3.4.1-1 of this report).
— For the elliptical end, e is defined by Part B and is referenced as e . The diagram used is the one of Figure
B 3
B.2-3 (T is equal to -6 °C, see Table 4.5.3.4.1-2 above).
KV
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— For the weld, e is referenced as e and is taken as equal to 50 mm to be conservative. The diagram used is
B 2
the one of Figure B.2-3 (see Table 4.5.3.4.1-2 above).
Table 4.5.3.4.1-3 — Construction detail for the branch
Figure 16 — Abstract from EN 13445-2:2009
The reference thickness e is determined as follows:
B
— For the cylindrical shell, e is defined by Part A and is referenced as e ; the diagram used to determine the
B 2
impact test temperature T for the cylindrical is that of Figure B.2-3 of EN 13445-2:2009 (R ≤ 355 MPa, see
KV e
Table 4.5.3.4.1-1 of this report).
— For the nozzle, e is defined by Part B and is referenced as e , Figure B.2-1 (see Table 4.5.3.4.1-3 of this
B 1
report) of EN 13445-2:2009 shall be used.
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— For the weld, e is referenced as e or e (the thickness of the cylindrical shell and of the reinforcing plate is
B 2 3
the same) and the diagram used to determine the impact test temperature T for the weld is that of Figure
KV
B.2-3 of EN 13445-2:2009 (R ≤ 355 MPa, see Table 4.5.3.4.1-1 of this report).
e
For the nozzle (Part B), e is less than 20 mm, B.2.3.2 of EN 13445-2:2009 shall apply:
B
Figure 17 — Abstract from EN 13445-2:2009
It is not possible to determine T from T because the intersection point with the curve for 20 mm falls outside the
KV R
diagram.
If one assumes an impact test temperature T = 20 °C, the permitted T is -53,1 °C which is below the reference
KV R
temperature of the target vessel (-20 °C). Thus, the considered T value is confirmed and is equal to 20 °C.
KV
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Table 4.5.3.4.1-4 — Construction detail for the welding neck flange and the nozzle
Figure 18 — Abstract from EN 13445-2:2009
The reference thickness e is determined as follows:
B
— For the flange, e is defined by Part A and shall be the one determined from the requirement given by the Note
B
a of the Table B.4-1 of EN 13445-2:2009:
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Figure 19 — Abstract from EN 13445-2:2009
Therefore, e (12,5 mm) is applied to Figure B.2-2 for as-welded condition and e/4 (63,5 / 4 = 15,875 mm) is
2 f
applied to Figure B.2-1 for non-welded condition (see Table 4.5.3.4.1-4 above).
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Table 4.5.3.4.1-4 — Construction detail for the welding neck flange and the nozzle (continued)
Figure 20 — Abstract from EN 13445-2:2009
— For the nozzle (Part B) e is referenced as e , the diagram used to determine the impact test temperature T
B 1 KV
for the nozzle is the one of Figure B.2-1 (Re ≤ 275 MPa, see Table 4.5.3.4.1-3 of this report).
— For the weld, e is referenced as e , the diagram used to determine the impact test temperature T is the one
B 2 KV
of Figure B.2-2 (Re ≤ 265 MPa, see Table 4.5.3.4.1-4 of this report).
In that case, all the reference thicknesses e are less than 20 mm, and B.2.3.2 of EN 13445-2:2009 shall apply:
B
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Figure 21 — Abstract from EN 13445-2:2009
It is not possible to determine T from T because the intersection with the curve for 20 mm falls outside the
KV R
diagrams.
If one assumes an impact test temperature T = 20 °C, the permitted T for each part is the following:
KV R
— For the flange (Part A), two verifications shall be performed:
— the one by using Figure B.2-2: T = -25 °C,
R
— the other by using Figure B.2-1: T = -53,1 °C
R
— For the nozzle (Part B), by using Figure B.2-1: T = -53,1 °C
R
— For the weld, by using Figure B.2-2: T = -25 °C
R
Therefore, the reference temperature to retain is the greatest: T = -25 °C. This temperature is lower th
...
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