Pressure Vessel Engineer: Pressure Vessel Design &
Inspection

OBJECTIVES:

At the end of this program, participants will be able to:

• Explore the fundamentals of pressure vessel design, components, and materials.
• Perform design calculations and stress analyses for pressure vessels.
• Apply ASME PCC-2 standards for planning and executing pressure vessel repairs.
• Develop effective maintenance strategies to prevent failures and ensure long-term pressure
  vessel integrity.
• Conduct inspections, document repairs, and develop maintenance plans for vessel integrity.

WHO SHOULD ATTEND?

• Engineers involved in pressure vessel design, modification, and repair.
• Plant operators and maintenance personnel responsible for pressure vessel integrity.
• Inspectors and surveyors verifying pressure vessel compliance with standards.
• Quality assurance and quality control professionals overseeing pressure vessel projects.
• Employees seeking comprehensive knowledge of pressure vessel design and repair.

COURSE OUTLINE

Day 1:

Pressure Vessel Design Fundamentals:

• Basic Pressure Vessel Components and Terminology: Shell, heads, nozzles, closures, supports.
• Design Loads and Stresses: Internal pressure, dead weight, wind, earthquake, thermal expansion.
• Pressure Vessel Materials and Selection: Steel, alloys, polymers, composites, corrosion considerations.
• Code Requirements and Standards: ASME BPVC sections, design formulas, material specifications.
• Pressure Vessel Fabrication Processes: Forming, welding, machining, heat treatment, testing.

Day 2:

Pressure Vessel Analysis and Design Calculations:

• Theoretical Basis of Pressure Vessel Design: Thin-walled cylinder theory, stress-strain relationships.
• Design Calculations for Cylindrical Shells and Heads: Hoop stress, membrane stress, bending stress.
• Discontinuity Stress Analysis: Nozzle attachments, openings, supports, fatigue considerations.
• Finite Element Analysis (FEA) Introduction: Basic principles and applications in pressure vessel design.
• Pressure Relief Devices and Safety Systems: Safety valves, rupture discs, overpressure protection.

Day 3:

ASME PCC-2 Repair Principles and Requirements:

• Introduction to ASME PCC-2 Standard: Scope, limitations, benefits, and applications.
• Repair Planning and Procedures: Damage assessment, material selection, weld qualification, testing.
• Types of Pressure Vessel Repairs: Welding repairs, mechanical repairs, composite repairs, bolted connections.
• Welding Repair Techniques: Procedures, filler metals, preheating, post-weld heat treatment.
• Non-Welding Repair Techniques: Mechanical clamps, adhesives, composites, bolted sleeves.

Day 4:

Advanced Pressure Vessel Maintenance and Failure Prevention:

• Techniques for Preventive and Predictive Maintenance: Scheduling, monitoring, and inspection practices.
• Common Causes of Pressure Vessel Failures: Corrosion, fatigue, cracking, and material degradation.
• Failure Prevention Strategies: Protective coatings, cathodic protection, and proper material selection.
• Monitoring Systems for Vessel Health: Sensors, data logging, and remote monitoring technologies.
• Developing Maintenance Plans: Crafting effective long-term strategies to ensure vessel integrity.

Day 5:

Pressure Vessel Inspection and Documentation:

• Pre- and Post-Repair Inspection Procedures: Visual inspection, non-destructive testing methods.
• Repair Documentation and Quality Assurance: Reporting forms, procedures, certifications.
• Maintaining Pressure Vessel Integrity: Long-term inspection and maintenance plan development.
• Future Trends and Advancements in Pressure Vessel Design and Repair.