A practical procedure to assess critical defects in pressure vessels subjected to fatigue loads

PSA pressure vessels are equipments used in refining industries for cleaning the hydrogen upcoming from the reforming or hydrogen generation unities. In one regular inspection, some embedded cracks were found in the entrance nozzle-head weld. Then, instead of advance its decommissioning and waste much time until the refinery purchase a new vessel, a structural stress analysis using the finite element method was performed in order to obtain the stress field at the site of the crack, considering the real loading cycle. Despite the acting load is only the internal pressure, the nozzle-head weld is a region where a complex stress state is present (bending and axial stresses). ASME VIII Division 2, Appendix 5 addresses this issue by applying a rule for multiaxial fatigue life estimation for non-proportional loading. With ASME estimated fatigue life results, it was applied the British Standard 7910 procedure to decide if the equipment can operate safely. The calculation also assesses the crack growing by using a modified bi-linear Paris law. Finally, it was computed how long the cracks would take to get to their critical size and then retire definitively the equipment.