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Preface Thirty years ago, after completing my degree inmechanical engineering, I began my career in a pressure vesselfabrication company.Because Iwas a newcomer to the industry, I sought areliable reference explaining fabrication and the corresponding proceduresof quality assurance and control IQAC). T came acrossbooks such as Pressure Vessel Design Manual,by Dennis R.Moss, and Pressure Vessel Handbook,by Eugene F. Megyesy,but these were confined to aspects of design. The ASME code and the other national codes were theonly documents available for reference. TheASME code provided all the expected specifications butfailed to suggest the means of achieving compliance with suchspecifications-perhaps because it was intended for engineers with an insight intothe underlying logic of the code. Thus, my efforts tounderstand the code led only to further confusion. Thisbook summarizes myefforts, over 30 years, to bridge the gap between code specifications and the proceduresnecessary to comply with them. Itcan be considered a guide to and clarification of the ASME code-encompassing fabrication,inspection, testing, anddocumentation. Because the book offers wide coverage of fabrication(from organization setup to final testing anddocumentation), it also promotes uniformity in manufacturing,inspection, testing, and documentation. Chapters 1 through 10,which are based on my experience in QAC and heavy fabrication, are dedicated to practical aspects of fabrication, beginning with organizationalrequirements and leading up to thefinal documentation of the vessel. Chapters 11 to 16 describeprocedures that are essential for conducting variousinspections and tests. Chapter 17 addresses welding procedure specifications, the procedurequalification record, and welderqualification tests. Chapters 18 and 19 detail a typicalquality plan and an inspectionand test plan, which is alsoincluded in QAC documentation. Chapter 20 provides recommendedtolerances for vessels; suchtolerances, which vary only slightlybetween most consultants, are usually not given in thecode. Chapter 21 consists of excerpts from ASME Section VIII Div(1) (2013 edition), which isfrequently referred to during manufacture.Because the code is continually updated toincorporate the latestavailable data, users of this book areencouraged to refer to these sections from the latest editionsof the code as they becomeavailable. The book is written basedon the requirements of ASME Section VIII Div(1). Other sections of the ASME code, such as V and IX, arealso referred to for the full coverage. Even though the book is basedonly on ASME codes, it could beextended to other codes forpressure vessels, because the relationship between fabrication and nondestructive testing (NDT) is the same regardless of the code used. I would like to acknowledge the assistance and cooperation I havereceived from the learned surveyors ofLloyd's Register, ABS Industrial Verification,Det Norske Veritas, and HartfordSteam Boiler. The continued interaction I have had with these third-party inspection agencies hasbeen a tremendous helpin giving this book its present shape. Similarly, the technical and moral supportextended to me by my colleagues at FACT Engineering and Design Organization (FEDO) has played a vita1 role in my completion of thiswork. Ming E Chen Part 1 Introduction 1 GENERAL Pressure vessels are manufactured all over the worldunder various international standards. These standards dospecify the requirements to be metduring the manufacture of pressure vessels; however, themeans used to meet these requirements are not specified in any of these standards. In the following chapters, a detailed methodology to check each essential parameterspecified in the relevant standardsis established. Even though the attempt ismade based on ASME Section Ⅷ Div (1), the same methodologycould also be extended to pressure vesselsmanufactured under different standards. The only difference would be in the acceptability norms that obviously could begathered from the applicable standard. 2 PRESSUREVESSEL A vessel used forthe containment of pressure (either internal or external) is a pressure vessel.Pressure vessels can be of any shape. However, the most complicated one, asenvisaged in ASME Section Ⅷ Div (1), is shown in Figure 1.1. 3 STANDARDS The most commonlyused standard in the manufacture of pressure vessels in India is ASME Section Ⅷ Div (1) eventhough there is another Indian standard for unfired pressure vessels. Thestandards that are commonly used in India for the manufacture of pressure vesselsare the following. 1. ASME Section Ⅷ Div (1): Rules for Construction of Unfired PressureVessels 2. ASME Section Ⅷ Div (2): Alternative Rules for Construction of Unfired Pressure Vessels 3. ASME Section Ⅷ Div (3): AlternativeRules for Construction of High Pressure Vessels 4. IS 2825: IndianStandard code for Unfired Pressure Vessels 5. BS 5500: Specificationfor Unfired Fusion Welded Pressure Vessels 6. Chapter J ofRules and Regulations for the Construction and Classification of Steel Ships by Lloyds Register of Shipping 7. AD MerkblaterTechnical Rules for Pressure Vessels 4 METHODOLOGY The basicinformation for designing pressure vessels, being a part of the process plant,should be formulated by the process engineering group and contain such criteriaas shown in Figure 1.2. This is known as the design data sheet (DDS).
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