Course Outcomes

Emphasis
Course Outcomes Total
Very high High Medium Low
Design pressure vessels using ASME

Lecture-06 CLO1 standards and emphasis on safety and

resource sustainability.
66.0 66.0

Use readily available software (e.g.

Welding Methods,
CLO2 Excel) to carryout design calculations and 18.0 18.0
material selections

Practice leadership, cooperation, and 6.0

CLO3 6.0

Part-1:
accountability in a teamwork setting.

Produce a standard technical report for a 10.0

CLO4 10.0
chemical equipment design.
0.0

Pressure Vessels
Total 66.0 18.0 10 6 100.0

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CONTENT Learning Outcomes

1. Introduction
At the end of this lecture, you should be able to
➢ Summary of Lecture-05
– Explain the working principle of various arc welding methods
➢ Why welding?
– Describe the factors considered in welding method selection
2. Welding Methods

3. Types of Welded Joints – Discuss the types of welds and welded joints

4. Welding Standards – Explain the requirement for pressure vessels fabricated by welding

5. Welding Design – List the codes relevant to Welding

6. Welding Symbol and Technical Drawings

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 Summary of Lecture-05
➢ Definition of pressure vessel: according to ASME BPVC,
pressure vessel refers to "A container designed to withstand
internal or external pressure and intended to store or
transport fluids, gases, or vapors."

Introduction:
➢ Classification: (i) unfired pressure vessels, (ii) fired pressure
vessels, and (iii) storage tanks.

➢ Manufacturing: must comply to standards such as ASME

BPVC Sec. VIII, Div.1 to Div. 3

➢ Common processes: metal cutting, metal forming, welding,

heat-treatment, inspection, and hydraulic testing.
Can we use AI
technology to facilitate
➢ Engineering Design Process: (i) Conceptual Design, (ii)
pressure vessel
Embodiment Design, and (iii) Detail Design construction?

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Why welding? Some facts:

• Pressure vessels are almost always spherical or cylindrical, as this shape has no corners that
• There are several options for pressure vessel fabrication. However, welding is often the
could form stress points in the structure.
preferred method due to its ability to create strong, leak-proof, and durable joints, ensuring
structural integrity and reliability under high-pressure conditions.“ • To contain high-pressure products, pressure vessels are almost always built using metal 3
millimeters (about ⅛ inch) or more in thickness.
➢ Strength and integrity: welding creates strong and continuous joints.
• Welding pressure vessels is a delicate process that must be done with extreme care.
➢ Efficiency and cost-effectiveness: welding can be done more quickly than other joints.
• Any flaw in the welding process can have disastrous consequences once the vessel is in
➢ Compliance with standards: (i) pressure vessels must comply with standards such as
operation.
ASME BPVC Sec. VIII, and (ii) welding allows rigorous quality control or inspection methods.
• Choosing the right welding process, one must consider the material the vessel will store or
➢ Advanced techniques: (i) we can apply modern welding methods (e.g. TIG and MIG), (ii)
produce and the pressure the material will be under.
can maintain consistence through automation.

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 Some facts (continued):

• Welding is the most commonly used method of fabrication of pressure vessel shells.

• Structural parts (e.g. stiffening rings, lifting lugs, support clips for piping, internal trays, etc.) are
attached to the vessel by welding.

Welding
• For lethal fluids or high-temperature service, welded joints are used for piping-to-vessel
connections.

• Type of welding methods:

Methods:
➢ Forge welding: applicable for low-carbon steels

➢ Fusion welding: does not require any pressure; through heating to fusion temperature;
Example: arc welding.

➢ Pressure welding: resistance welding; utilizes heat created by an electric current passing
against high resistance through two pieces at the contact interface.

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Types of Welding Shielded Metal Arc Welding (SMAW)

• The SMAW process uses an electric circuit that supports a
• Shielded Metal Arc Welding (SMAW) welding arc to convert electric line power or fuel into heat.

• Flux-Core Arc Welding (FCAW) • The heat from the welding arc is intense and extremely
concentrated. It immediately melts a portion of the
workpiece and the end of the electrode.
• Gas Metal Arc Welding (GMAW)

• The welder maintains the arc length by holding a

• Gas Tungsten Arc Welding (GTAW)
consistent space between the electrode and the weld pool
that forms on the work piece.
• Submerged Arc Welding (SAW)

Source: Welding Pressure Vessels: How It’s Done - AdvanTec

• When the arc is removed, the liquid fuses and the melt solidifies Source: FABTECH 2023 - Chicago (fabtechexpo.com)

Global Innovations into continuous metal.

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 Flux-Core Arc Welding (FCAW)
Video of SMAW
• FCAW is a semi-automatic or automatic arc welding
process evolved from the MIG process to improve arc
action and metal transfer.
• It requires continuously fed tubular electrode containing
flux and a constant current welding power supply.
• Uses a tubular wire that is filled with a flux.
• The arc is started from the electrode to the job.

• The flux which is filled in electrode melt during the

welding process and shields the welded area from
the atmosphere.
There are basically 2 types of flux cored arc welding processes:
1. Self-shielded FCAW- without shielding gas
Source: https://adtwlearn.com/ 2. Gas shielded FCAW- with shielding gas Source: Flux Cored Arc Welding (FCAW) Process - Main
Parts, Working, Advantages and Disadvantages with
Difference is of different fluxing agents in consumables. Application - The Welding Master

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Gas Metal Arc Welding (GMAW) Difference between FCAW & GMAW
• Known as MIG welding process.
• Yields high productivity.
• Produces high quality welds

Source: Gas Metal Arc Welding - an overview | ScienceDirect

Topics Source: Academic Gain Tutorials;
https://www.youtube.com/@Acade
micGainTutorials/featured
• The source of heat is an arc formed between consumable metal electrode and the work metal.
• It is an externally supplied gaseous shield of gas either inert such as argon and /or helium.

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 Gas Tungsten Arc Welding (GTAW)/(TIG) Video of GTAW
• Uses a non-consumable tungsten electrode that must be shielded
with an inert gas.

• The arc is established between the tip of the electrode and works
to melt the metal being welded.

• Reduced the propensity for fabrication-induced hydrogen cracking

problems (Not usually a problem in the type of “small” joints)

• Results in low hydrogen pick-up during welding. Source:

https://www.sciencedirect.com/topics/engineering/gas-
• The consumable filler metal is added either tungsten-arc-welding
Source: techsurgelearning.com;
https://www.youtube.com/watch?
manually or by some mechanized process. v=P5m9-Xmqrk8

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Submerged Arc Welding (SAW) Video of SAW

• Producing an arc between electrode and the work piece within a
granular shielding flux applied around the weld.
• The arc heats and melts both the work pieces edges and the
electrode wire.

• The molten electrode material is supplied to the surfaces of the

welded pieces, fills the weld pool and joins the work pieces.
• Utilizes a bare consumable metallic electrode.

Source:
https://www.substech.com/dokuwiki/doku.php?id=submerged
• Since the electrode is submerged into the flux, the arc is invisible. _arc_welding_saw

• The flux is partially melts and forms a slag protecting the weld
Source: https://adtwlearn.com/
pool from oxidation and other atmospheric contaminations.

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 Summary The choice of a welding method to make a
• SMAW is a manual type, inexpensive and portable. However, the welder must be highly skilled to welded joint depends on:
produce high-quality results using this method.
• Circumstances of welding:
• FCAW is a semi-automatic used to weld thick metals. It’s similar to SMAW, but the operator ➢ Accessibility of the joint
doesn’t have to be nearly as skilled due to the continuous wire feed.
➢ Equipment of the manufacturer
Welded Joints Where to refer to?
• GMAW involves a continuous wire-fed electrode and inert shielding gas. It’s one of the easiest • Code Requirement:
Type Table UW-12
welding processes to perform and makes welds that are cleaner than SMAW or FCAW. ➢ the code states requirements Design Table UW-2, UW-3
based on service, material, and Examination UW-11(a)(5)
• GTAW is an all-position welding process that uses a tungsten electrode and inert shielding gas. It location of welding.
UW-2: Service Restriction
creates very clean, high-quality welds with excellent fusion and penetration. However, it’s a slow • Economy of Welding: UW-3: Welded Joint Category

process that can be difficult to master. ➢ V-edge preparation is more

economical than the use of J or U
• SAW requires the weldment to be submerged in flux to shield it from oxygen and other gases in the preparation.
atmosphere. It’s a very clean welding process with a high rate of deposition.

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• For design purposes, welds are divided into three weld types: groove, fillet, and plug.

• Welded joints (described by the position of pieces to be joined) are divided into five

Weld Types
types: butt, tee, lap, corner, and edge.

& Welded
Joints:
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 • Various forms of welds are needed to construct a pressure vessel.

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A welded joint is expected to fulfil the following basic requirements:

Welding
• provide good accessibility for welding and inspection.

• require the minimum amount of weld metal.

• provide good penetration of the weld metal, from both sides of the joint , if

Standards:
practicable.

• incorporate sufficient flexibility to avoid cracking due to differential thermal

expansion.

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 Relevant Codes and Standards: Welded Joint Categories:
• The term “Category ” as used herein defines the location of a joint in a vessel, but not the
• ASME BPV Code Sec. VIII Div.(1), Part UW: type of joint.

➢ Requirements for pressure vessels fabricated by welding.

• ASME BPV Code Sec. VIII Div.(1), Part UW-9:

Category Where to refer to?
➢ Welding plates of different thickness A Longitudinal and spiral
B Circumferential
• ASME BPV Code Sec. VIII Div.(1), Part UW-40:
Welded joints connecting
C
flanges
➢ Post-welding heat treatment.
Welded joints connecting
D
• ASME BPV Code Sec. IX: communicating chambers

➢ Welding and brazing qualifications

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2 3
1

Permissible
welds

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 Activity 6-1: Solution:
• Identify the weld categories for the joints shown in the figure.

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Table 6-1
Requirements for PVs Fabricated by Welding:
All joints of
• When vessels are to contain lethal substances, either liquid or gaseous, all butt- Category Requirement

welded joints shall be fully radiographed. • Type No. (1) of Table UW-12;

• When vessels are to operate below certain temperatures designated by Part UCS A
• Type No. (2) for Austenitic chromium-nickel stainless steel Types 304,
or impact tests of the material or weld metal are required by Part UHA, the joints of 304L, 316, 316L, and 347, which satisfy the requirement of UHA-51(f)
various categories shall be as per Table 6-1. B • Type No. (1) or No. (2)
• Unfired steam boilers with design pressures exceeding 50 psi (343 kPa) shall C • Full penetration welds extending through the entire section at the joint
satisfy all of the requirements in Table 6-2. • Full penetration welds extending through the entire thickness of the
D vessel wall or nozzle wall except that partial penetration welds may be
• Pressure vessels or parts subject to direct firing may be constructed in accordance
with all applicable rules of the Division and shall meet the requirements in Table 6-3. used b/n materials listed in Table UHA-23.

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 Table 6-2 Table 6-3

All joints of Category Requirement All welds in

Requirement
A • Type No. (1) of Table UW-12 Category**
B • Type No. (1) or No. (2) A* • Type No. (1) of Table UW-12;
B* • Type No. (1) or No. (2) if the thickness exceeds 16 mm

• All butt-welded joints shall be fully radiographed except under the provision of UW-11(a)(4)
and except for ERW* pipe weld seams.
• * No welded joints of Type No. (3) of Table UW-12 are permitted for either categories in any thickness.
• When using ERW pipe as the shell of an unfired steam boiler, its thickness shall not • ** when the thickness as welded joints exceeds 16 mm for carbon steels and for all thickness for low

exceed 13 mm, its diameter shall not exceed 24” (DN 600), and the ERW weld shall be alloy steels, postweld heat treatment is required. For all other material and in any thickness, the
requirements for postweld heat treatment shall be in conformance with the applicable Subsection of the
completed using high frequency (HFI) welding.
code.

• When fabricated of carbon or low-alloy steel, such vessels shall be post-weld heat treated.

* ERW: Electric Resistance Weld

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UW-9 Design of Welded Joints:

Feature Remarks

Welding
Permissible welding • The types of welded joints permitted for Category A, B, C, and D joints are listed in
Types: Table UW-12
Welding Grooves: • Qualification of the welding procedure, as required in UW-28, is acceptable as proof
that the welding groove is satisfactory.
Tapered Transitions: • A tapered transition having a length not less than three times the offset between the

Design:
adjacent surfaces of abutting sections
• neck nozzle that has a taper transition angle, α , less than 71.5 deg shall be located
a minimum o f 1.5 tn from the taper, where tn is the nominal thickness of the nozzle
wall at the butt weld.
Lap Joints • the surface overlap shall be not less than four times the thickness of the inner plate
Welded Joints Subject
• fillet welds s hall be added where necessary to reduce stress concentration
to Bending Stresses
Minimum Weld size: • Sizing of fillet and partial penetration welds shall take into consideration the loading
conditions in UG-22

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Post weld Heat Treatment (PWHT):

• Pressure vessels and

Welding Symbol
pressure vessel parts shall
be postweld heat treated as
prescribed in UW-40 when

& Technical
post-weld heat treatment is
required in the applicable

Drawings:
part of Subsection C.

Source:
• Ellenberger et al.,”Pressuree Vessels,” 8th Edition,
McGraw-Hill, 2004, pp. 197

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 • The weld symbol completely describes the specifications for welding a joint and a bent line with
an arrow at the end points at the joint to be welded.
• The weld symbol is made of the leader, reference line, and tail. A large amount of information can
be attached to the leader line.
• The eight basic parts to a complete weld symbol are:
➢ Reference line
Standardised
➢ Leader line and arrow by AWS and
➢ Basic weld symbol (location/depth of weld) ANSI.

➢ Finish symbol
➢ Weld symbol (type of weld)
➢ Dimensions
➢ Supplementary symbols
➢ Tail and specifications

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 Examples:

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 Review
Questions:
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MCQ’s MCQ’s
3. Metal Inert Gas (MIG) and Metal Active Gas (MAG) welding are welding variants of

1. Which one of the following welding process also known as stick welding? (a) Gas Tungsten Arc Welding (GTAW)
(b) Gas Metal Arc Welding (GMAW)
(a) Gas Tungsten Arc Welding (GTAW)
(d) Shielded Metal Arc Welding (SMAW)
(b) Flux-Core Arc Welding (FCAW)
(e) Submerged Arc Welding (SAW)
(c) Gas Metal Arc Welding (GMAW)
4. In a _____________ welding process the electrode is non-consumable.
(d) Shielded Metal Arc Welding (SMAW)
(a) Gas Tungsten Arc Welding (GTAW)
(e) Submerged Arc Welding (SAW)
(b) Gas Metal Arc Welding (GMAW)
(d) Shielded Metal Arc Welding (SMAW)
2. ________electrode is used in Flux cored arc welding(FCAW). (e) Submerged Arc Welding (SAW)
(a) Tubular electrode containing flux
5. Granular flux is fed through hopper to the weld spot in _______welding process.
(b) Flux-Core Arc Welding (FCAW)
(a) Gas Tungsten Arc Welding (GTAW)
(c) Gas Metal Arc Welding (GMAW)
(b) Submerged Arc Welding (SAW)
(d) Gas Tungsten Arc Welding (GTAW) (d) Shielded Metal Arc Welding (SMAW)
(e) Gas Metal Arc Welding (GMAW)

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 MCQ’s

Answer: 1 (d), 2(a), 3(b), 4(a), 5(b)

Thank You!

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References Service Considerations*

1. ASME, “Pressure Vessel Code, Sec. VIII, Div. 1,”

ASME, Year: 2019

2. Henry H. Bednar, “Pressure Vessel Design

Handbook,” 2nd Edition, Krieger Publishing
Compay, Year: 1991

* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 34.

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 Miscellaneous Design Considerations* Material Selection Guide*

* Dennis R. Moss, Michael M. Basic, “Pressure Vessel Design Manual,” Butterworth-Heinemann, 4th Edition, Year: 2013, pp. 35.

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