Fabrication of Metallic 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.

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:
* A thorough introduction to construction materials, including both ferrous and nonferrous alloys
* An exploration of layout, including projection and triangulation, material thickness and bending allowance, angles and channels, and marking conventions
* A treatment of material forming, including bending versus three-dimensional forming, plastic theory, forming limits, brake forming, roll forming, and tolerances
* Practical discussions of fabrication, including weld preparation, forming, vessel fit up and assembly, correction of distortion, and transportation of vessels
 
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.

Preface xvii
 
Acknowledgments xix
 
1 Introduction 1
 
1.1 Introduction 1
 
1.2 Fabrication Sequence 1
 
1.3 Cost Considerations 5
 
1.3.1 Types of costs 5
 
1.3.2 Design choices 6
 
1.3.3 Shipping 11
 
1.3.4 General approach to cost control 12
 
1.4 Fabrication of Nonnuclear Versus Nuclear Pressure Vessels 12
 
1.5 Units and Abbreviations 13
 
1.6 Summary 14
 
2 Materials of Construction 15
 
2.1 Introduction 15
 
2.2 Ferrous Alloys 16
 
2.2.1 Carbon steels (Mild steels) 16
 
2.2.2 Low alloy steels (Cr-Mo steels) 18
 
2.2.3 High alloy steels (stainless steels) 19
 
2.2.4 Cost of ferrous alloys 20
 
2.3 Nonferrous Alloys 20
 
2.3.1 Aluminum alloys 20
 
2.3.2 Copper alloys 22
 
2.3.3 Nickel alloys 30
 
2.3.4 Titanium alloys 30
 
2.3.5 Zirconium alloys 30
 
2.3.6 Tantalum alloys 32
 
2.3.7 Price of nonferrous alloys 33
 
2.4 Density of Some Ferrous and Nonferrous Alloys 34
 
2.5 Nonmetallic Vessels 35
 
2.6 Forms and Documentation 35
 
2.7 Miscellaneous Materials 38
 
2.7.1 Cast iron 38
 
2.7.2 Gaskets 38
 
References 43
 
3 Layout 44
 
3.1 Introduction 44
 
3.2 Applications 44
 
3.3 Tools and Their Use 45
 
3.4 Layout Basics 45
 
3.4.1 Projection 46
 
3.4.2 Triangulation 46
 
3.5 Material Thickness and Bending Allowance 49
 
3.6 Angles and Channels 50
 
3.7 Marking Conventions 52
 
3.8 Future of Plate Layout 54
 
Reference 54
 
4 Material Forming 55
 
4.1 Introduction 55
 
4.1.1 Bending versus three-dimensional forming 55
 
4.1.2 Other issues 55
 
4.1.3 Plastic Theory 56
 
4.1.4 Forming limits 62
 
4.1.5 Grain direction 64
 
4.1.6 Cold versus hot forming 64
 
4.1.7 Spring back 64
 
4.2 Brake Forming (Angles, Bump-Forming) 65
 
4.2.1 Types of dies 67
 
4.2.2 Brake work forming limits 68
 
4.2.3 Crimping 68
 
4.2.4 Bending of pipes and tubes 69
 
4.2.5 Brake forming loads 70
 
4.3 Roll Forming (Shells, Reinforcing Pads, Pipe/Tube) 70
 
4.3.1 Pyramid rolls 70
 
4.3.2 Pinch rolls 71
 
4.3.3 Two-roll systems 71
 
4.3.4 Rolling radius variability compensation 72
 
4.3.5 Heads and caps 72
 
4.3.6 Hot forming 74
 
4.4 Tolerances 74
 
4.4.1 Brake forming tolerances 75
 
4.4.2 Roll forming tolerances 76
 
4.4.3 Press forming tolerances 76
 
4.4.4 Flanging tolerances 76
 
Reference 76
 
5 Fabrication 77
 
5.1 Introduction 77
 
5.2 Layout 77
 
5.3 Weld Preparation 78
 
5.3.1 Hand and automatic grinders 78
 
5.3.2 Nibblers 78
 
5.3.3 Flame cutting 79
 
5.3.4 Boring mills 79
 
5.3.5 Lathes 80
 
5.3.6 Routers 80
 
5.3.7 Other cutter arrangements 82
 
5.4 Forming 82
 
5.5 Vessel Fit Up and Assembly 83
 
5.5.1 The fitter 84
 
5.5.2 Fit up tools 84
 
5.5.3 Persuasion and other fit up techniques 84
 
5.5.4 Fixturing 85
 
5.5.5 Welding fit up 86
 
5.5.6 Weld shrinkage 88
 
5.5.7 Order of assembly 89
 
5.6 Welding 90
 
5.6.1 Welding position 90
 
5.6.2 Welding residual stresses 90
 
5.6.3 Welding positioners, turning rolls, column and boom weld manipulators 91
 
5.7 Correction of