UCRL-MA-133867

and

ESH manual
Environment, Safety, and Health
Volume II
Part 18: Pressure/Noise/Hazardous Atmospheres

18.2
Pressure Vessel and System Design
(Formerly H&SM Supplement 32.03)

Recommended for approval by the ES&H Working Group

Approved by:

Robert W. Kuckuck
Deputy Director for Operations

New document or new requirements

Approval date:

February 1, 2000

Minor revision, no new requirements

Approved by:
Approval date:

Revision 1

The Hazards Control Department

December 19, 2001

UCRL-MA-133867

DISCLAIMER
This document was prepared as an account of work sponsored by an agency of the United States
Government. Neither the United States Government nor the University of California nor any of
their employees, makes any warranty, express or implied, or assumes any legal liability or
responsibility for the accuracy, completeness, or usefulness of any information, apparatus,
product, or process disclosed, or represents that its use would not infringe privately owned
rights. Reference herein to any specific commercial product, process, or service by trade name,
trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or the University of California.
The views and opinions of authors expressed herein do not necessarily state or reflect those of the
United States Government or the University of California, and shall not be used for advertising or
product endorsement purposes.

This work performed under the auspices of the U.S. Department of Energy by University of
California Lawrence Livermore National Laboratory under Contract W-7405-ENG-48.

Revision 1

UCRL-MA-133867

18.2
Pressure Vessel and System Design *

Contents
1.0 Introduction ....................................................................................................................
2.0 Hazards of Pressure Vessels and Systems..................................................................
3.0 Documentation for Pressure Vessels and Systems....................................................
3.1 Plant Engineering (Livermore) (PEL) Standards...............................................
3.2 Equipment Requiring an Engineering Safety Note...........................................
4.0 Design Controls for Pressure Vessels..........................................................................
4.1 Design Criteria........................................................................................................
4.2 Material Selection...................................................................................................
4.3 Design Considerations ..........................................................................................
4.4 Calculation Guide for Ductile Vessels ................................................................
4.5 Stored Energy .........................................................................................................
4.6 Testing......................................................................................................................
4.7 Retesting and Inspection.......................................................................................
4.8 Expansion and Compression of Gases................................................................
4.9 SF-3 Pressure Vessels.............................................................................................
4.9.1 Materials......................................................................................................
4.9.2 Tensile Testing............................................................................................
4.9.3 Toughness Testing .....................................................................................
4.9.4 Compatibility..............................................................................................
4.9.5 Welded Vessels...........................................................................................
4.9.6 Nondestructive Testing.............................................................................
4.9.7 Pressure Testing and Labeling.................................................................
4.10 War Reserve Vessels ..............................................................................................
4.10.1 Documentation ...........................................................................................
4.10.2 Design Criteria............................................................................................
4.10.3 Handling......................................................................................................
5.0 Design Controls Gas-Pressure Containment Vessels ...............................................
5.1 Special Shipping Requirements ...........................................................................
5.2 Design Safety Factors.............................................................................................
5.3 General Design Requirements..............................................................................
5.4 Testing and Labeling .............................................................................................
6.0 Design Controls for Pressure Systems ........................................................................
6.1 Precautions..............................................................................................................
6.2 Pipe and Tubing ....................................................................................................
6.3 Pipe and Tube Support..........................................................................................
*

1
2
2
2
3
3
3
5
6
9
12
13
14
15
15
15
17
17
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18
18
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19
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20
20
21
21
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Minor revision

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UCRL-MA-133867

6.4 Fittings .....................................................................................................................

6.4.1 National Pipe Taper Thread (NPT) Fittings...........................................
6.4.2 Straight-Thread (Face Seal) Fittings ........................................................
6.4.3 Flare Fittings ...............................................................................................
6.4.4 Flareless or Bite-Type Fittings..................................................................
6.4.5 Coned and Threaded Connections ..........................................................
6.5 Valves.......................................................................................................................
6.6 Relief Devices..........................................................................................................
6.7 Pressure Gauges .....................................................................................................
6.8 Flexible Hose...........................................................................................................
6.9 Flash Arrestors and Check Valves.......................................................................
6.10 Regulators................................................................................................................
6.11 Manifolds.................................................................................................................
6.11.1 Industrial Gas Cylinder Manifolds..........................................................
6.11.2 Safety Manifolds.........................................................................................
6.12 Temperature Considerations................................................................................
6.13 Installing Pressure Systems ..................................................................................
6.14 Pressure Testing .....................................................................................................
7.0 Work Standards..............................................................................................................
7.1 Work Smart Standards ..........................................................................................
7.2 Other Required Standards ....................................................................................
8.0 References........................................................................................................................
9.0 Resources for More Information..................................................................................
9.1 Contacts ...................................................................................................................
9.2 Lessons Learned .....................................................................................................
9.3 Other Sources..........................................................................................................

23
24
24
25
26
28
29
32
33
34
35
35
36
36
37
37
38
39
39
39
40
40
41
41
41
41

Appendices
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
Appendix F
Appendix G

Revision 1

Terms and Definitions................................................................................... 43

Example of an Engineering Safety Note ..................................................... 45
ASME Pressure Vessel Code Guide ............................................................ 64
Piping and Tubing Pressure Ratings........................................................... 65
Metric Guide ................................................................................................... 83
Joint Efficiencies ............................................................................................. 98
High-Pressure Drawing Symbols ................................................................ 100

ii

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UCRL-MA-133867

Tables
Table 1.
Table 2.

Specifications of materials and alloys for use in pressure vessel...............

Suggested pipe support spacing ....................................................................

6
23

Figures
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Figure 5.
Figure 6.
Figure 7.
Figure 8.
Figure 9.
Figure 10.
Figure 11.
Figure 12.
Figure 13.

Revision 1

LLNL documentation requirements for pressure equipment....................

Relationships between test pressures, the MAWP, and MOP....................
Some acceptable types of unstayed flat heads and covers..........................
LLNL pressure-tested label for manned area operation
(silver on black). ................................................................................................
LLNL pressure-tested label for remote operation only
(silver on red).....................................................................................................
Remote operation label (silver on red)...........................................................
Amagat chart......................................................................................................
Typical 1/16-in. high-pressure compression fitting. ...................................
Typical 1/4-in. high-pressure coned and threaded fitting
(60,000 psig)........................................................................................................
Typical high-pressure coned and threaded connection
(to 60,000 psig)...................................................................................................
Type 1 high-pressure valve. ............................................................................
High-pressure valve body patterns................................................................
Safety manifold system. ...................................................................................

iii

4
8
10
14
14
14
16
27
28
28
30
31
38

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18.2
Pressure Vessel and System Design

1.0 Introduction
This document contains requirements for all pressure vessels and systems used at
LLNL. Appendix A contains terms and definitions, and Appendices B through G
contain supporting information. Pressure designers and experimenters shall fully
understand these requirements or ask a pressure consultant or the pressure safety
manager for assistance. Document 18.1, "Pressure," in the Environment, Safety, and Health
(ES&H) Manual contains the responsibilities of individuals who work with pressure
vessels and systems. All workers and organizations shall refer to Document 2.1,
"Laboratory and ES&H Policies, General Worker Responsibilities, and Integrated Safety
Management," in the ES&H Manual for a list of general responsibilities. The
requirements in Section 3.0 of this document do not apply to the systems listed below.
Unmodified compressed gas or liquid cylinders approved by the Department
of Transportation (DOT) and the appropriate regulators.
Utility systems that

Comply with "Laboratory Gas Systems," PEL-M-13200. This standard

can be found in "LLNL Facility Design Standards." Operate at a
maximum allowable working pressure (MAWP) of no more than 2
MPa gauge (300 psig).
Are inspected at installation and subsequently maintained by the Plant
Engineering Department.

Refrigeration systems that comply with the American Society of Mechanical

Engineers (ASME) Boiler and Pressure Vessel Code1 and applicable Air
Conditioning and Refrigeration Institute (ARI) standards.
Systems that operate at an MAWP less than atmospheric pressure. (Design
guidance for these systems is given in the ASME Boiler and Pressure Vessel
Code1 and Mechanical Engineering Design Safety Standards, M-012, Section 3.3,
"Vacuum Systems." However, the requirements apply to vacuum systems
that may be pressurized (i.e., for purging or backfilling).
ASME-coded air-pressure tanks, liquefied petroleum gas tanks, anhydrousammonia tanks, and fired steam boilers that are inspected periodically in
accordance with 8 CCR 450560, "Unfired Pressure Vessel Safety Orders"
or ASME Boiler and Pressure Vessel Code.1 The responsible designer shall
notify management whenever such systems are installed.

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UCRL-MA-133867

The LLNL Pressure Safety Program is administered and monitored by the Hazards
Control Department through the pressure safety manager. Responsible Individuals
shall conduct all pressure work safely in accordance with the ES&H Manual. The
pressure safety manager oversees the work of pressure installers and pressure
inspectors and coordinates all pressure safety training. The Mechanical Engineering
Department Safety Committee and the pressure safety manager provide technical
guidance for the program. In addition, pressure consultants are available to help on
pressure safety design and to answer engineering questions.

2.0 Hazards of Pressure Vessels and Systems

The hazards presented to equipment, facilities, personnel, the public, or the
environment because of inadequately designed or improperly operated pressure vessels
and system include blast effects, shrapnel, fluid jets, release of toxic or asphyxiant
materials, contamination, equipment damage, personnel injury, and death.

3.0 Documentation for Pressure Vessels and Systems

Designers shall maintain a design file for all pressure vessels and systems in accordance
with requirements specified by their department. This file shall contain appropriate
records (e.g., Engineering Safety Note, if required) that shall be reviewed at least every
three years when vessels or systems are inspected. Revisions and addendum to the file
shall be made as appropriate.

3.1

Plant Engineering (Livermore) (PEL) Standards

Normal pressure systems designed or fabricated by Plant Engineering (PE) Livermore

personnel or by contract employees working through a PE field team shall conform to
the requirements in "Laboratory Gas Systems," PEL-M-13200. Any deviation from this
standard requires approval by an LLNL pressure consultant. Systems that are not
covered by PEL-M-13200 require an ESN or equivalent documentation (e.g., a drawing
that includes the information from the ESN and the required approval signatures).

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UCRL-MA-133867

3.2

Equipment Requiring an Engineering Safety Note

The documentation guide for ESNs is shown in Fig. 1. The following vessels and
systems require an ESN unless listed as "ESN Exempt":
All manned-area vessels at any gas pressure that contain over 75,000 ft-lb
(100 kJ) of isentropic energy. This includes ASME-coded vessels that have
been modified structurally.
All manned-area vessels and systems at gas pressures over 150 psig (1 MPa
gauge) and liquid pressures over 1500 psig (10 MPa gauge). Unmodified,
commercially manufactured hydraulic systems with a safety factor of at least
4 do not require an ESN unless their working pressure exceeds 5000 psig
(34.5 MPa).
All programmatic steam boilers operating at over 15 psig (100 kPa gauge).
Operation of these types of equipment must comply with 8 CCR 450560.
All manned-area systems that confine a hazardous material at less than the
above-specified limits when required by an OSP.
All manned-area vessels or systems used with cryogenic fluids.

4.0 Design Controls for Pressure Vessels

The criteria listed in this section apply to pressure vessels used for manned-area
operations. For remote operations, the extent to which these criteria apply depends on
the required functional reliability.

4.1

Design Criteria
Use a safety factor of 4 based on the known or calculated failure pressure of the
vessel or ultimate strength of the material when designing for normal mannedarea operation. Use a higher factor if an operation involves detrimental
conditions, such as vibration, corrosion, shock, or thermal cycling.
Never use a safety factor less than 4 when designing a vessel for manned-area
operation unless the design conforms to the ASME code or to the
requirements listed in Section 4.9 of this document and is approved by the
division leader.
Have the Deputy Associate Director for Mechanical Engineering approve any
manned-area vessel design that is based on a safety factor of less than 3.
Design any vessel or system containing hazardous materials such that the
contained fluid leak rate will not pose a hazard to personnel.

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UCRL-MA-133867

Approved
commercial
equipment

DOE-contractor-designed
or modified
commercial equipment
A

PELcovered

DSS Design Safety Standards

ES&H Manual Environment, Safety
and Health Manual
PEL Plant Engineering Standards, Livermore
ESN Engineering Safety Note
OSP Operational Safety Plan

1
Yes

Off-site
pressurized
shipment

Abbreviations

No

3
No

Yes

Remote
operation
only

ASMEcoded

1
Yes

No

No

DOTapproved

NOTE:
This document guide is intended for use
at ambient temperature. Special consideration
should be given to the strength of materials,
reactive fluids, vibration, seismic safety,
and/or operation at elevated temperatures.

1
Yes

No

Yes

Toxic,
radioactive, or
irritant

5
No

Yes

Cryogenic
liquid

Stateinspected

5
Yes

No

No

Hydraulic
<5 ksi (35 MPa)
& SF >4

Yes

Flammable
contents

Gas
>150 psig ( 1 MPa)
or liquid >1500 psig (10 MPa)
or stored energy >75 k ft-lbs
[ 100 KJ ]

1
No

Program
steam boiler
>15 psi
(100 kPa)

5
No

5
No

Yes

Yes

Yes

War
reserve (WR)
component

to
A
5

5
Yes

No

No

Yes

1.

No ESN or OSP is required (documented hazards are low). Go to "A."

2.

No ESN or OSP is required, but notify PE M&O and facility management. Go to "A."

3.

Approved DOT and/or DOE shipping containers that comply with LLNL shipping requirements.

4.

No ESN is required for the pressure equipment. Comply with Chapter 4 of the ME Design Safety Standards. An
OSP may be required (see Document 3.3, "Operational and Facility Safety Plans," in the ES&H Manual.

5.

An ESN, and/or OSP is required, or you should follow PEL-M-13200.

Figure 1.

LLNL documentation requirements for pressure equipment.

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UCRL-MA-133867

4.2

Material Selection
Select materials that remain ductile throughout the working temperature
range of the vessel. If you cannot avoid using a brittle material for the body
of a manned-area pressure vessel, your Department Head must sign the ESN.
Select materials that are compatible with the liquid or gas to be contained in
the vessel.
Beware of hydrogen embrittlement. High-pressure hydrogen gas drastically
degrades the ductility of highly stressed, high-strength pressure vessel
materials. This problem can be solved using either one, or both, of the
following methods:
1.

Use lower-strength vessel materials such as type 304, 316, 321, 347, or
21-6-9 stainless steel; 2024 or 6061 aluminum alloy; oxygen-free copper;
phosphor bronze; beryllium copper; or other materials recommended
by a recognized expert in the field or through a peer review.

2.

Include an inner liner (or bladder vessel) made of one of these

hydrogen-resistant materials. When designing such a liner, be sure that
it will withstand working and testing stresses. Consider positively
venting the liner/body interspace so that any hydrogen that penetrates
the liner cannot subject the high-strength vessel body to high-pressure
hydrogen. Provide means for periodic verification that the vent path is
open to the atmosphere.

Consider the creep characteristics of the material. This is particularly

important when the pressure is to be contained for extended periods at
elevated temperatures.
Make sure the vessel material is of acceptable fracture toughness throughout its
working temperature range. Various test methods may be employed to make
this toughness evaluation, e.g., Dynamic Tear Test (ASTM E604-77 or latest
version), Plane Strain Fracture Toughness of Metallic Materials (ASTM E399-78
or latest version), or J-Integral Test. In addition, Charpy impact tests (ASTM
E23-72, 78) should be included to check material variability. Charpy impact
values of less than 22 ft-lb (30 J) or "equivalent KIc" (via JIc Dynamic Tear Energy
or KIc tests) values of less than 100 ksi-in.1/2 are often found to be unacceptable
for manned-area operation; however, the actual required toughness values
should be determined to ensure safe operation of the vessel. The required
critical crack size should provide for "leak-before-break" with a safety factor of 4
on the flaw dimension (not on fracture toughness). For pressure vessels with
wall thicknesses greater than 2 in. (50 mm) and working pressures over 14.5
psig (100 kPa), specify impact testing of vessel specimens at the lowest vessel
working temperature or at 20F (7C), whichever value is lower.

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UCRL-MA-133867

Confirm the material's identity by verifying it to be of a particular

specification using x-ray diffraction, chemical analysis, metallography,
radiography, or sample testing, as required.
Materials listed in Table 1 of this document are normally satisfactory for pressure-vessel
fabrication. The strength values apply between 20F (30C) and 200F (95C). At
working temperatures below ambient, there is a possibility of brittle behavior; at
temperatures over 200F (95C), reduction in strength usually becomes significant. The
tabulated information is from Refs. 14.
Refer to Section 5.4 (Fracture Critical Components) of the ME Design Safety Standards5
for design and documentation requirements. Questions about the fracture integrity of
the vessel should be directed to the Mechanics of Materials Group, Nondestructive and
Materials Evaluation Section, Manufacturing and Materials Engineering Division
(MMED).

4.3

Design Considerations
Specify that all purchase-fabrication welding be done by certified ASME welders
in accordance with the approved ASME Boiler and Pressure Vessel Code.1
Avoid longitudinal welds in vessels less than 6 in. (0.15 m) in diameter. Seamless
tubing or pipe, or bar stock, is usually available in these smaller diameters.
Avoid stress concentrations. This is most critical when vessel material elongation
or fracture toughness is relatively low.
Adjust the design and the allowable stresses to compensate for environmental
conditions such as vibration, cycling, temperature fluctuation, shock, corrosion,
and extreme thermal operating conditions.
Specify inspection by appropriate nondestructive detection methods, such as
radiographic, ultrasonic, dye penetrant, and magnetic particle inspection, when
designing a high-strength, high-pressure vessel. Specify appropriate ultrasonic
inspection of all manned-area pressure vessels with wall thicknesses over 2 in.
(50 mm). Maximum permissible defects should be based on the capability of the
vessel material to resist crack growth under the specified operating conditions.
Contact the subject-matter expert for assistance with properly specifying
ultrasonic inspection.
Prepare a Fracture Control Plan for all gas-pressure vessels with wall thicknesses
over 2 in. (50 mm) that are to be operated in a manned area. These vessels should
be periodically monitored using appropriate nondestructive inspection
techniques to assure that previously undetectable, undetected, and detected
cracks are not approaching critical size. Contact the subject-matter expert for

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UCRL-MA-133867

assistance. A plan should be prepared for vessels with thinner wall thicknesses
wherever radioactive, toxic, explosive, or flammable materials are involved.
Table 1.

Specifications of materials and alloys for use in pressure vessel.

Grade or Type

Hardness
(Rockwell)

Minimum ultimate
tensile strength

Minimum yield
strength

ksi

ksi

(MPa)

30
22
30
40
24

(210)
(150)
(210)
(275)
(165)

(MPa)

Remarks

Low-Carbon Steels
ASTM SA-30
ASTM SA-129
ASTM SA-201
ASTM SA-299
ASTM SA-414

55
40
55
75
45

(380)
(275)
(380)
(500)
(310)

Low-Alloy Low-Carbon Steels

ASTM SA-202
ASTM SA-203
ASTM SA-225
ASTM SA-353
ASTM SA-357
ASTM SA-387
USS "T-I"
HY 80
HY 100
HY 180

75
65
70
90
60
60
115
105
125
200

(500)
(450)
(485)
(620)
(415)
(415)
(800)
(~725)
(~860)
(~1380)

45
37
40
60
30
35
90
90
110
180

(310)
(255)
(275)
(415)
(210)
(240)
(620)
(620)
(760)
(1240)

Alloy Steels (all tempered at 700 (370C) or higher)

4130
32
8630
4340

2530 RC
3236 RC
2530 RC
3236 RC
2530 RC
3236 RC
3943 RC
4346 RC

125145
150170
125145
150170
125145
150170
180200
200220

(8601000)
(10351170)
(8601000)
(10351170)
(8601000)
(10351170)
(12401380)
(13801515)

103
132
103
132
103
132
163
175

(710)
(910)
(710)
(910)
(710)
(910)
(1125)
(1210)

0.3 in (7.5 mm) thick

max.
0.3 in (7.5 mm) thick
max.
Beware of low
fracture toughness

(620)
(830)

RS-110C, A-110 AT
RS-128, C-120 AV

Titanium Alloys (beware of brittle welds)

TI-5 A1-2.5 Sn
TI-6 A1-4 V

115
130

(800)
(900)

90
120

Austenitic Stainless Steels (resistant to hydrogen embrittlement)

21-6-9 VIM/ESR
(ASTM A-276)
304
316
321, 347

annealed
96 RB
34 RC
7090 RC
1035 RC
7085 RC
1030 RC
7090 RC
1035 RC

95100
112
145
7090
100150
7590
100150
7590
100150

(655690)
(770)
(1000)
(485620)
(7001240)
(500620)
(7001035)
(500655)
(7001035)

45
68
130
2550
50150
3060
50125
3055
50125

(310)
(470)
(900)
(170345)
(3451035)
(210415)
(345860)
(210380)
(345860)

Enhanced properties
result from warn
high-energy rate
forging

(1) See UW-12(a) and UW-51.

(2) See UW-12(b) and UW-52.
(3) The maximum allowable joint efficiencies shown in this column are the weld joint efficiencies multiplied by 0.80 (and
rounded off to the nearest 0.05), to effect the basic reduction in allowable stress required by this Division for welded vessels
that are not spot examined. See UW-12(c).
(4) Joints attaching hemispherical heads to shells are excluded.

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UCRL-MA-133867

When specifying welding of pressure vessel components, consider the following:

Checking a weld cross section for toughness, because a weld might be

brittle and welding might embrittle the material in the heat-affected zone.

Including realistic joint efficiencies in calculations (see Ref. 1, Table UW12), because a weld might not penetrate to the full thickness of the parent
material.

Including the reduced properties of the heat-affected zone when

calculating the overall strength of the vessel, because welding normally
anneals the material in this zone.

Consulting with a welding or materials expert when planning to weld a

vessel that will contain a high-pressure hydrogen gas, because welding
reduces resistance of some materials to hydrogen embrittlement.

Percent of MAWP

Use a realistic MAWP as a basis for design calculations. Select an MAWP that
exceeds the highest anticipated MOP by 1020% (see Fig. 2). This permits
proper relief protection against overpressure without degrading the
dependable leak-tight function of the vessel at its operating pressure.
150

Test pressure for:

Pressure vessels
Reactive pressure systems
(flammable, toxic, oxygen, radioactive)

125
120

Test pressure for inert systems

Test pressure for remote operation vessels and systems

100

Maximum allowable working pressure, MAWP

Maximum relief device setting
Retest pressure for all vessels and systems

90
Maximum operating pressure, MOP*
80
* Recommended range is 10 to 20% below
the MAWP.

Figure 2.
Revision 1

Relationships between test pressures, the MAWP, and MOP.

8

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UCRL-MA-133867

Provide positive protection against overpressure by installing a relief device

set at a pressure not exceeding the MAWP of the vessel.
Design all barricades for remote-operation pressure systems in accordance
with the requirements in Ref. 5.
4.4

Calculation Guide for Ductile Vessels

Equations (1), (2), (3), and (4) are based on the maximum allowable circumferential (or
hoop) stress, not on the true combined stress condition of the vessel. The actual stress
near a weld joint or in any area of stress concentration will be considerably higher than
the "average" stress that results from applying these equations. However, proper
application of these equations will result in a vessel of ASME code-equivalent safety.
(See Appendix C for help in locating information in the ASME Boiler and Pressure
Vessel Code.1 For additional design information, see Section 8.0, "References."
The following notations apply to the equations given in this section:
C
d
E

hG

k
P
ri
ro
R
Sa
SFu
u
y
t
U
v
W

Revision 1

= attachment coefficient (see Fig. 3).

= internal diameter of vessel, in inches or meters.
= joint efficiency factor, usually 1, except for welded
vessels. (See Ref. 1, Table UW-12 in Appendix F, for
welded joint efficiencies.)
= radial difference between the bolt circle and the
pressure-seal circle on a bolted-end enclosure. inches
or meters.
= ratio of specific heats, cp/c v .
= maximum allowable working pressure, psig or Pa.
= inner radius, inches or meters.
= outer radius, inches or meters.
= ro/ri.
= allowable stress of material, psi or Pa.
= safety factor based on ultimate strength of the
material.
= ultimate strength of material, psi or Pa.
= yield strength of material, psi or Pa.
= wall thickness, inches or meters.
= energy, ft-lb or joules.
= volume, in.3 or m3.
= total bolt load for circular heads, lb or N. (Pressure
force plus required gasket sealing force.)

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UCRL-MA-133867

CENTER OF LAP

CENTER OF WELD
L
t
s

TANGENT
LINE

tf
tf MIN = 2ts

MIN
r = 3t

L
ts

ts
t

TAPER

tf MIN = ts

C = 0.25 or
C = 0.15
(a)

C = 0.25
(b-1)

MIN r = 1.5tf
for the case
where tf = ts see
fig.UW-13.3 (a)
and (b)

MIN
r = 3t

t
C = 0.30 or
C = 0.20
(c)

tw = 2tr MIN not less than 1.25ts'

but need not be greater than t

0.7ts

0.7ts

MIN
r=1 t
4

MIN
r = 3t

C = 0.5
C
= 0.3
MIN
(b-2)

0.7ts

TANGENT
LINE

PROJECTION
BEYOND WELD IS OPTIONAL

0.7ts

ts

ts

C = 0.20
(d)

(e)

CONTINUATION
OF SHELL
OPTIONAL

d
t

ts

(f)
Figs. (e) (f) (g) circular covers, C = 0.5 m, C MIN = 0.3

BEVEL
OPTIONAL
45 MAX

t
(g)

See Fig. UW-13.2

(A) to (g) inclusive
for details of
welded joint

See Fig. UW-13.2

(A) to (g) inclusive
for details of
welded joint ts
not less than 1.25 t
r

0.7ts
hG

hG
ts

ts

d
t

C = 0.5
(h)

C = 0.3
(j)

C = 0.5 m
CMIN = 0.3
(i)

RETAINING
RING

C = 0.3
(K)

THREADED
RING
d

d
t

d
t

t
C = 0.30
(n)

C = 0.30
(m)

C = 0.30
(o)

30 MIN
45 MAX

ts

tI
30 MIN
45 MAX
t
d

C = 0.25
(p)

Figure 3.

Revision 1

C = 0.75
NOTE: When pipe threads are
used, see Table UG-43
(q)

C = 0.50
(r)

MIN tI = t or ts
whichever
is greater

Seal weld
3
4
t MIN

MIN
0.8ts

t
or
d

ts

C = 0.50
(s)

Some acceptable types of unstayed flat heads and covers. The symbol
"m" is the ratio tr/ts, where tr is the required shell thickness, exclusive
of corrosion allowance. Designs, other than those shown, that meet the
requirements of UG-34 are also acceptable. (This figure was reproduced
from Fig. UG-34 in Ref. 1, with the permission of the ASME.)

10

December 19, 2001

UCRL-MA-133867

For thin-wall vessels, where R is less than 1.1, use Eq. (1) or (2) to calculate p (the
MAWP) (Ref. 6, chapter 12).
For cylinders,
S Et
Et
P= a
or u .
ri
SFu ri

(1)

For spheres,
P=

2Sa Et
2 u Et
or
.
ri
SFu ri

(2)

For medium-wall vessels, where R is between 1.1 and 1.5, use Eq. (3) or (4) to calculate
the MAWP (Ref. 1, par. UG-27).
For cylinders,
P=

Sa Et
u Et
or
.
ri + 0.6t
SFu ( ri + 0.6t )

(3)

For spheres,
P=

2Sa Et
2 u Et
or
.
ri + 0.2 t
SFu ( ri + 0.2 t )

(4)

For thick-wall vessels, where R is between 1.5 and 2.0, use Eq. (5), (6), (7), or (8) to
calculate the MAWP.
For cylinders,
u ( ro2 ri2 )
ro2 ri2 )
(
.
P = Sa 2 2 or
(ro + ri ) SFu (ro2 + ri2 )

(5)

2 y
y
2
ln R .
3 SFu
u

(6)

P=

For spheres,
ro3 ri3 )
2 u ( ro3 ri3 )
(
.
P = 2Sa 3
or
(ro + 2ri3 ) SFu (ro3 + 2ri3 )
P=

Revision 1

(7)

2 y
y
2
ln R .
SFu
u

(8)

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December 19, 2001

UCRL-MA-133867

For thick-wall vessels, where R is over 2.0, use Eqs. (5) and (7) only to calculate
the MAWP.
Medium- and thick-wall vessels of certain materials may also be designed in accordance
with the rules in Section VIII, Division 2, of the ASME Boiler and Pressure Vessel Code1
and the requirements in Section 4.9 (SF-3 Pressure Vessels) of this document.
For flat, circular end-closures, use Eq. (9) or (10) to calculate the required thickness.
(See Ref. 1, par. UG-34, and Fig. 3). If no bending moment is imposed on the end-closure
when securing it (i.e., welded, intergral, ring-retained; see Fig. 3[a through i] and 3[m
through s]), then use
t=d

CP
CSFu P
or d
.
Sa E
uE

(9)

If a bending moment is imposed on the end-closure when securing it (i.e., bolted; see
Fig. 3[j] and [k]), then use
t=d

CP 1.9 Wh G
+
or
Sa E
Sa d 3E

t=d

CSFu P 1.9 Wh G SFu

+
.
uE
u Ed 3

(10)

Note: Refer to par. UG-34 of Ref. 6 for special calculation requirements.

The analysis described above only addresses hoop stress in a vessel wall and the
thickness of end closures. Any number of other design features could be critical to safe
design of a pressure vessel. These include the shear stress in threads, the tensile
strength of bolt cross-sections, the strength of weldments, and the effect of vessel
openings, nozzles, and supports. Therefore, a thorough analysis should be performed
for these features if they are included in the vessel design.
For other vessels, such as multi-wall cylinders and other end-closure designs, see the
references at the end of this document. Where stresses in a large high-pressure vessel
appear to be complex or excessive, contact a qualified applied mechanics authority for
assistance with performing a finite element analysis.

4.5

Stored Energy

Calculate the energy contained in the fully pressurized vessel and include the
calculation in the ESN. Compare this value with the 3.42 106 ft-lb (4.63 106 J)
potential energy of 2.2 lb (1 kg) of TNT.

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UCRL-MA-133867

For example, using Eq. (11), a fully charged, standard size 1 cylinder of nitrogen gas
contains energy equivalent to about 0.5 lb (0.25 kg) of TNT. This calculation is based on
reversible adiabatic (isentropic) expansion of the confined gas. Note that if pressure (p1
and p 2) and volume (v1) are expressed in megapascals and cubic centimeters,
respectively, then the energy (U) is in joules (see Ref. 7, p. 4-25 for more details).
k 1

P1v1 P2 k
U=
1
.
k 1 P1

(11)

k = 1.66 for He gas;

k = 1.41 for H2, O2, N2, and air
(from Ref. 7, p. 4-25).
P1 = Vessel pressure
P2 = Atmospheric pressure

Note:

For the same volume charged with water to the same pressure, the stored energy is
considerably less. For this case, Eq. (12) may be used to determine the liquid stored
energy content.
U=

1 P12 v
,

2 B

(12)

where B = Liquid bulk modulus, psig,

= 300,000 psig for water.
This calculation yields a value of 1,742 ft. lb. (0.51 gms of TNT).

4.6

Testing
All LLNL-designed or operated pressure vessels that require an ESN must be
remotely pressure tested. Whenever practical, take pressure vessels to the ME
High-Pressure Test Facility for pressure testing.
Hydrostatic test (preferred) or gas test all manned-area pressure vessels at
150% of their MAWP. If the vessel body material has a yield strength less
than about 55% of its ultimate strength (as with annealed 300 series stainless
steel), use the equation on p. 69 of Ref. 8 (the Maximum Energy of Distortion
Theory) to make sure that the combined stresses at 150% of the MAWP do not
exceed the yield strength of the body material. If they do, reduce the test
pressure accordingly (but do not reduce below 125% of the MAWP) and
include the supporting calculation in your ESN. (See Appendix B for a sample
calculation and Fig. 2 for the relationships between different pressures.)

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UCRL-MA-133867

Hydrostatic test or gas test all remote-operation pressure vessels at 125% of

its MAWP unless your division leader specifically approves the use of a
different test pressure.
If extreme conditions are involved in vessel operation, simulate these
conditions during testing, or if simulation is impractical, consider the
weakening effect of these conditions when assigning the test pressure. For
instance, if it is not practical to test a high-temperature, high-pressure vessel
at its working temperature, then test it at 150% of its MAWP times the ratio of
its allowable stress at the test temperature to its allowable stress at the
maximum working temperature.
4.7

Retesting and Inspection

The pressure inspector performs pressure inspections and records any findings on Form
LL-3586. The Responsible Individual then signs the completed form and sends it to the
LLNL pressure safety manager for permanent recordkeeping. The vessel or system is
then tagged with the appropriate pressure label (Figs. 4, 5, or 6).
LLNL PRESSURE TESTED

LLNL PRESSURE TESTED

FOR MANNED AREA

ASSY.

FOR REMOTE OPERATION ONLY

ASSY.

SAFETY NOTE

SAFETY NOTE

M.A.W.P.

PSIG.

M.A.W.P.

FLUID

FLUID

TEMP.

TO

TEMP.

REMARKS
T.R.

TEST NO.

EXPIRATION DATE

Figure 4.

TO

REMARKS

TEST NO.

BY

PSIG.

T.R.

EXPIRATION DATE
DATE

BY

LLNL pressure tested label

for manned-area operation
(silver on black).

Figure 5.

DATE

LLNL pressure tested label

for remote operation only
(silver on red).

FOR
REMOTE OPERATION
ONLY
Figure 6.

Revision 1

Remote operation label

(silver on red).

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UCRL-MA-133867

All pressure vessels and systems designed for operation at LLNL that require
documentation shall be pressure tested remotely before being operated in a manned
area. Once tested, an LLNL pressure-tested label shall be attached to the pressure vessel
or system. Documented and labeled pressure vessels or systems and their integral
pressure-relief devices shall be maintained by the Responsible Individual and inspected
by a qualified independent LLNL pressure inspector every three years as recommended
by NBIC. Inspection intervals for pressure vessels will be determined using in-service
inspection criteria in the NBIC inspection code. Depending on the type of vessel service,
the intervals may range from two years to a maximum of 10 years. Relief devices on
pressure vessels shall be inspected every 3 years. In addition, pressure systems and
vessels will be reinspected whenever they are disassembled and moved or redesigned,
or when the application changes, even if the working pressure is reduced.

4.8

Expansion and Compression of Gases

The ideal gas law and empirical data relating to the expansion and compression of
gases are generally in fair agreement in the low- and intermediate-pressure ranges. This
agreement varies according to the gas in question. The Amagat chart (Fig. 7) is provided
as a means for calculating the expansion or compression of nitrogen, helium, and
hydrogen at a constant temperature of 25C. Similar information for ammonia, carbon
dioxide, carbon monoxide, nitrogen, air, argon, and several other gases can be found
in Ref. 9.

4.9

SF-3 Pressure Vessels

The design of pressure vessels for manned-area operation normally requires a safety
factor of at least 4 based on the known or calculated failure pressure of the vessel or the
ultimate strength of the material. For certain special applications, designs using a safety
factor as low as 3 are warranted and can be approved by the division leader. The division
leader shall appoint qualified personnel to perform a peer review before approving the
vessel. Pressure vessel designs involving brittle materials or with a safety factor less than
3 require a peer review and approval by the ME Deputy Associate Director.
4.9.1

Materials

Select a ductile material that will have at least the following properties in the final heattreated or work-hardened condition, and include a copy of the certified chemical
analysis in the ESN:
1.

Ultimate tensile and yield strengths equal to or exceeding those used in the vessel
calculations.

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15

December 19, 2001

Figure 7.

Revision 1

16

100

200

300

400

500

600

700

800

900

4
6

10
12

Nitrogen (N2)

3. Enter chart with final Amagat number, 2

to find final pressure, P2

2. Find final Amagat number, 2 by solving:

2 = 1 V1 / V2 where: V1 = initial volume
V2 = final volume

Directions for use

1. Enter chart with initial pressure P1 ( at initial
volume, V1 ) to find initial Amagat number, 1

14

Amagat numbers
0

10

15

20

25

30

35

18
20
16
Pressure 1000 psia

Helium (He)

22

100

300

400

24

26

28

Pressure 1000 psia

200

Hydrogen (H2)

H2

30

500

He

32

600

34

UCRL-MA-133867

Amagat chart.

December 19, 2001

Amagat numbers

UCRL-MA-133867

2.

Reduction of area of at least 40%.

3.

Percent elongation of at least 15%.

4.

A complete fracture evaluation and proper design selection to ensure "leak-beforebreak" criteria are met.

5.

Demonstrated compatibility with the pressure media, or protection from the

pressure media by such means as a compatible liner/end closure or bladder vessel.

4.9.2

Tensile Testing

Tensile specimens of the heat-treated or work-hardened material from each lot (material
from the same heat that is processed identically at the same time and under the same
conditions) shall be tested to confirm compliance with the first three material
requirements listed in Section 4.9.1. At least three reliable test results shall be
numerically averaged to determine compliance with each requirement. Specimens shall
be taken from locations and orientations of maximum calculated stress. Specimens for
large, thick-wall cylindrical and spherical designs shall be transversed and, where
possible, should be taken from outer-, inner-, and mid-wall locations. Refer to
Section 4.9.5 (Welded Vessels) of this document for tensile testing requirements for
structural welds.
4.9.3

Toughness Testing

At least one specimen (but preferably three or more) from each lot of material shall be
tested to confirm compliance with the fourth requirement in Section 4.9.1 (Materials) of
this document. To meet this requirement, the material shall comply with the criteria in
Section 4.2 (Material Selection) of this document, except that a safety factor of 3 will be
accepted on a "through-the-thickness" flaw size. Any deviation from this requirement
shall have a signed statement from the division leader and approval by the Mechanics
of Materials Group, Nondestructive and Materials Evaluation Section, Manufacturing
and Materials Engineering Division (MMED) personnel.
4.9.4

Compatibility

A statement affirming compliance with the fifth requirement in Section 4.9.1 shall be
included in the ESN, including copies of any supporting certification.

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UCRL-MA-133867

4.9.5

Welded Vessels

The following additional requirements apply to all certified vessels containing

structural welds:
All welding shall be done by qualified LLNL workers, DOE contractors or
subcontractors, or DOE production facility welders in accordance with
approved welding procedures, or by certified ASME welders in accordance
with Section IX of the ASME Boiler and Pressure Vessel Code. 1
Only welds done by the TIG, MIG, EB, EBCWF (electron beam, cold wire
feed), shielded metal arc, and submerged arc methods are permitted.
The procedure for confirming the assumed efficiency of welds for each lot (including
typical degradation of physical properties in the heat-affected zone) requires that a
facsimile of each welded section be welded at the same time and under the same
conditions as the parent weld. Each welded section shall be metallographically
sectioned, and three tensile specimens shall be prepared and tensile tested. At least one
prototype vessel shall be burst tested. Test results shall verify the weld efficiency used
in the final vessel design calculation.
4.9.6

Nondestructive Testing

Each welded vessel shall be 100% radiographed or ultrasonically inspected, and all
structural welds shall be 100% dye-penetrant or magnetic-particle inspected, as
required, to confirm weld quality, depth of weld penetration, and absence of
unacceptable voids, cracks, and inclusions. Where practical, a radiograph window (a
small but detectable annular groove that will be fused by welding of acceptable
penetration) should be designed into girth-weld joints to facilitate the determination of
weld penetration.
4.9.7

Pressure Testing and Labeling

Each finished vessel shall be pressure tested at 150% of the MAWP unless the
Maximum Energy of Distortion Theory analysis of combined stresses indicates that the
vessel will yield at this test pressure. In this case, testing shall be at a pressure slightly
below theoretical yielding but not less than 125% of the MAWP.
The LLNL pressure-tested label (see Fig. 4 and 5) shall be marked "SF-3" in the remarks
section. Refer to Document 18.3, "Pressure Testing," in the ES&H Manual for specific
testing requirements.

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UCRL-MA-133867

4.10

War Reserve Vessels

This section covers documentation and handling requirements for LLNL war reserve
pressure vessels and assemblies. These pressure vessels are normally designed and
fabricated at other DOE/DoD facilities and are usually pressurized before arrival
at LLNL.
4.10.1 Documentation
If the subject vessel or assembly would require a Mechanical Engineering ESN if it were
designed locally, an ESN is required. This ESN must be prepared, reviewed, and
approved by the same technical and management levels required of other "ESNrequired" vessel designs.
4.10.2 Design Criteria
War reserve vessels fabricated by high-energy-rate forging (HERF) from
21Cr6Ni9Mn, 304L, or JBK75 stainless steel of work-hardened yield strength less than
122,000 psig are considered safe for manned-area operation, provided the burst safety
factor is at least 3. War reserve vessels with a lower safety factor require approval by an
LLNL Department Head or Associate Director.
4.10.3 Handling
Before handling a war reserve vessel in a manned area, the responsible designer or
Responsible Individual must verify that the equipment is not pressurized at over its
room temperature MAWP. Certification of the charged pressure from the supplier is
normally required. Identification of the person responsible for the charge pressure and
the method for confirming it must be included in the ESN. If the vessel or assembly
cannot be approved for manned-area operation, it must be enclosed in a containment
vessel (see Section 5.0 of this document for details) or have the charge pressure reduced
to an acceptable level before transport to LLNL.

5.0 Design Controls Gas-Pressure Containment Vessels

The requirements in this section apply to equipment used as protective enclosures for
gas-pressurized vessels, including those that contain toxic, radioactive, corrosive, or
flammable materials. These types of equipment must be designed to protect personnel
from the hazards of pressure-vessel failure (e.g., blast pressure and flying fragments). If
hazardous materials could escape from the contained vessel (in case of media leakage),
the containment vessel must be designed to prevent subsequent leakage to the
atmosphere.

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UCRL-MA-133867

5.1

Special Shipping Requirements

Only DOT- or DOE-approved containers shall be used for offsite shipment of pressure
vessels containing radioactive materials. See Ref. 10 for DOT shipping regulations;
Ref. 11 (or Materials Management) for DOE requirements; and Ref. 12 for information
about gas-sampling cylinders where only small quantities of radioactive materials are
involved in a shipment.

5.2

Design Safety Factors

If the contained pressure vessel is of ductile material and has been approved by LLNL
for a manned-area MAWP of at least the maximum pressure to which it could be
subjected inside the containment vessel, the containment vessel shall be designed to an
ultimate or burst safety factor of at least 4. If the contained pressure vessel has not been
LLNL-approved for a manned-area MAWP of at least the maximum pressure to which
it is to be subjected inside the containment vessel, the containment vessel for mannedarea operation shall be designed to an ultimate or burst safety factor of at least 8.

5.3

General Design Requirements

The following requirements apply to all gas-pressure containment vessels, including

those designed, specified, or used by LLNL personnel, that will contain toxic,
radioactive, corrosive, or flammable materials.
Design the containment vessel using the appropriate safety factor specified in
Section 5.2 (Design Safety Factors). Base the design on the maximum
equilibration pressure expected if the contained pressure vessel is heated to
the highest temperature expected within the containment vessel or to 130F
(55C), whichever value is higher.
In selecting materials of satisfactory fracture toughness, assume a minimum
operating temperature of nil ductility temperature (NDT) (40F), unless a
lower temperature is required and specified.
If offsite transportation is to be permitted, design the containment vessel to
withstand the normal conditions of transport, as listed in Annex 1 of Ref. 11.
This includes heat, cold, pressure, vibration, water spray, free drop, corner
drop, penetration, and compression. Annex 1 requirements also state that the
contained vessel shall be mounted securely inside the containment vessel.
Include a compound pressure/vacuum gauge for periodically monitoring the
internal pressure of the containment vessel. This gauge shall be graduated to
at least 120% but not over 200% of the containment vessel MAWP. The
highest credible equilibration pressure is the MOP of the containment vessel.

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UCRL-MA-133867

Include two separate valve entries for safely introducing, exhausting,

monitoring, and flushing gas through separate lines.
Include suitable covers and shields to protect all valves and gauges from
damage. Cap or plug all terminal valve ports. Provide accommodations for
locking or wiring valve handles closed or having valve handles removed during
shipment to prevent unauthorized operation or tampering.
If the contained vessel has not been LLNL-approved for a manned-area MAWP
of at least the maximum pressure to which it could be subjected inside the
containment vessel, refer to Section 5.1 of Ref. 1. Show that credible flying
objects would not penetrate the containment vessel if it failed catastrophically.
5.4

Testing and Labeling

Pressure test the containment vessel at 150% of its maximum possible
equilibration pressure. To determine the maximum equilibration pressure,
assume that the most energetic contained vessel specified equilibrates into the
containment vessel, which is then heated to 130F (55C), unless a higher
temperature is specified. No detectable plastic strain is permitted, as
determined by measurements to within 0.001 in. (0.025 mm), both before and
after testing.
After successful pressure testing, leak check the containment vessel at the
maximum possible equilibration pressure with a leak detector capable of
detecting leakage of 1 108 atm cm3/sec. No detectable leakage is permitted.
Specify contained vessel rupture testing of the containment vessel if necessary.
After successful testing and leak checking, make sure the pressure inspector
affixes a label to the containment vessel indicating the following:

The working pressure used as the basis for the design calculation and test.
A working temperature range of 20F to 130F (29C to 55C), unless a
wider temperature range is required or specified.

6.0 Design Controls for Pressure Systems

6.1

Precautions

The following precautions shall be observed when designing, installing, or operating a

pressure system.
Be sure that the MAWP and MOP are on all pressure system assembly
drawings.

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UCRL-MA-133867

Limit pressure sources to the MAWP of the lowest rated system component.
Do not consider a pressure regulator by itself as satisfactory overpressure
protection.
When pressure sources cannot be limited to less than the MAWP of every
system component, include pressure-relief devices (relief valves or rupturedisc assemblies) to protect those components that are rated at less than the
system supply pressure. All gas pressure vessels used for manned-area
operations must have a relief device that is set at a pressure not exceeding the
MAWP of the vessel.
Do not use the following:

6.2

Steel threaded fittings at pressures over 1 MPa (150 psig) or brass

threaded fittings at pressures over 0.83 MPa (125 psig) unless the
stamped rating, manufacturer's catalog, or other reference states they
have a higher pressure rating.
Tubing or pipe at pressures above those listed in this document unless
such use is specifically covered by an approved ESN.
Threaded pipe other than seamless Schedule 80 (at least) for 1.7 MPa
(250 psig) steam service or 0.7 MPa (100 psig) service with water over
105C (220F).

Pipe and Tubing

Use pipe and tubing rated at or above the required MAWP. If you plan to use pipe or
tubing at pressures above the listed values, include calculations in an ESN to justify
your selections.
When selecting pipe or tubing, consider the following:
Operating pressure and temperature.
Fluid compatibility.
Installation/maintenance requirements.
Proper hardness.
Use the American National Standard Institute Code for pressure piping, ANSI B31.1, or
a reliable reference to determine the MAWP for low- and intermediate-pressure pipe
and tubing. Refer to the tables in Appendix D for pressure ratings for various pipes
and tubings.

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UCRL-MA-133867

6.3

Pipe and Tube Support

Secure all components of pressure systems.
Support and secure hose and tubing at least every 7 feet (2 m) in manned
areas. Support and secure pipes in manned areas as specified in Table 2.
Locate supports to limit strain on fittings and minimize overhang at bends.
Consider that pipe and tubing expand and elongate when heated and
contract when cooled. Use additional supports for heavy system components.
Use adequate machine screws (or bolts) and nuts to secure all components.
Wood screws are not considered adequate.

Table 2.

Suggested pipe support spacing (Ref. 13).

Suggested Maximum Span

Nominal pipe size

Water Service

Steam, gas, or air service

(in)

(ft)

(m)

(ft)

(m)

1
2
3
4
6
8
12
16
20
24

7
10
12
14
17
19
23
27
30
32

2.1
3.0
3.7
4.3
5.2
5.8
7.0
8.2
9.1
9.8

9
13
15
17
21
24
30
35
39
42

2.7
4.0
4.6
5.2
6.4
7.3
9.1
10.7
11.9
12.8

NOTES:
(1) Suggested maximum spacing between pipe supports for horizontal straight runs of standard and heavier pipe at maximum
operating temperature of 750F (400C).
(2) Does not apply where span calculations are made or where there are concentrated loads between supports, such as flanges,
valves, specialties, etc.
(3) The spacing is based on a fixed beam support with a bending stress not exceeding 2,300 psig (15.86 MPa) and insulated pipe
filled with water or the equivalent weight of steel pipe for steam, gas, or air service, and the pitch of the line is such that a
sag of 0.1 in. (2.5 mm) between supports is permissible.

6.4

Fittings

When selecting a fitting, consider the following:

Rated working pressure of the fitting and system.
Compatibility and operating temperature of the fitting material with the
system fluid.
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UCRL-MA-133867

Availability of replacement units or component parts.

Proven quality, dependability, and cost of the fitting in relation to its required
performance.
Assume that all steel pipe fittings (unless otherwise marked or identified) are rated at
150 psig and all brass pipe fittings are rated at 125 psig. A fitting or valve marked "125
WOG" is good for up to 125 psig of water, oil, or gas at room temperature. A fitting
marked "150" may be good for up to 275 psig of gas pressure, but it is not to be used at
pressures over 150 psig unless the higher pressure rating can be proved. Refer to the
manufacturer's catalog or other in-house reference for more details.
In the following text regarding fittings, the MAWP will usually be determined by tube
size (i.e., outside diameter, o.d; inside diameter, i.d). However, if the fitting incorporates
a "weaker element," such as in a tube-to-pipe adapter, the pipe thread will usually have
a lower MAWP than the tubing used. Therefore, the lower MAWP must be used.
6.4.1

National Pipe Taper Thread (NPT) Fittings

These fittings seal by interference fit and require use of sealant or lubricant. Do not
interchange these fittings with National Pipe Straight thread (NPS). Forged fittings are
available for MAWPs of 1,000; 2,000; 3,000; 4,000; and 6,000 psig. Never use fittings at
pressures over 10,000 psig.

6.4.2

Straight-Thread (Face Seal) Fittings

These fittings (shown below) are made of stainless steel and require a gasket or
elastomer sealing device. They are used for ultra-clean vacuum and pressure systems.
Refer to the manufacturer's catalog for the working pressures.

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UCRL-MA-133867

6.4.3

Flare Fittings

There are two common types of flare fittings (shown below). The characteristics of each
are listed below.
45 flare

Two-piece. Used with copper, brass, aluminum and welded steel

hydraulic tubing.
Tube end flared to seal on mating part.
Pressure rating determined by tube dimensions.

37 flare

Three-piece. Used with brass, aluminum, steel, and stainless steel.

Pressure rating determined by tube dimensions.
The minimum and maximum wall thickness for an efficient 37 flare
joint are as follows:
Material: Steel, stainless steel, brass,
aluminum

Revision 1

Tubing o.d.
(inches)

Wall thickness
(inches) (Min./Max.)

1/8, 3/16

.010/.035

1/4, 5/16, 3/8

.020/.065

1/2

.028/.083

5/8

.035/.095

3/4, 7/8

.035/.109

.035/.120

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Do the following to assemble flare fittings:

Cut the tubing off squarely.
Remove burrs and clean the tubing.
Install gland nut and collar.
Flare the fitting to the correct angle; use the proper tools.
Assemble completely and tighten the fittings.
Disassemble and check the fitting, then reassemble and retighten about 1/8
turn past finger tight. If required, refer to the manufacturer's assembly torque
specifications.
6.4.4

Flareless or Bite-Type Fittings

These fittings (shown below) are made of steel, stainless steel, or copper. The pressure
seal for these fittings is achieved by a single or two-piece ferrule system that either bites
or deforms the tube o.d. as the fitting is tightened.

When using flareless or bite-type fittings,

Consider proper hardness when selecting the tubing.
Do not interchange different manufacturer's components.
Determine the pressure rating by tube dimensions.
Following are the minimum and maximum wall thicknesses for an efficient bite-type
joint:
Material: Steel, stainless steel, copper

Revision 1

Tubing o.d.
(inches)

Wall thickness
(inches) (Min./Max.)

1/8

.028/.035

3/16

.028/.049

1/4

.028/.065

3/8

.035/.065

1/2

.049/.083

3/4

.065/.109

.083/.120

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UCRL-MA-133867

Do the following to assemble bite-type flareless fittings:

Cut the tubing off squarely.
Remove the burrs and clean tubing.
Install the gland nut and the sleeve (or ferrules).
Place the end of the tubing into the fitting body and tighten the gland nut
until the tubing will not rotate by hand. A drop of oil on the male threads will
help.
Tighten 1-1/4 turns.
Disassemble and check the fitting, then reassemble and retighten about 1/8
turn past finger tight.
Note: Assembly and reassembly procedures may vary between manufacturers with
regard to fitting design, tube diameter, tube wall thickness, etc.
Flareless fittings made of stainless steel may be used for pressures up to 15,000 psig
MAWP. Fittings for 1/16 in. and 1/8 in. o.d. tubing are standard (see Fig. 8). Flareless
fittings employ a single sleeve that "clamps" onto tubing, and the gland nut will "bottom
out" when the assembly is made properly.
Following are the minimum and maximum wall thicknesses for an efficient bite-type
joint on higher pressure fittings:
Material: Stainless steel
Tubing o.d.
(inches)

Wall thickness
(inches) (Min./Max.)

1/16

.017/.028

1/8

.032/.053

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; ;; tubing
;
; ; ;; ;1/16-in.-o.d.
Figure 8.

Revision 1

Typical 1/16-in. high-pressure compression fitting.

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UCRL-MA-133867

6.4.5
Coned and Threaded Connections

Coned and threaded fittings (Figs. 9 and 10) may be used to 150,000 psig MAWP
depending on the manufacturer's design. Coning provides line-contact sealing,
resulting in a minimal seal area. Threading locks the tube to the fitting using a collar.
Fittings for 1/4-, 3/8-, and 9/16-in.-o.d. tubing are standard. The tubing and collar are
left-hand threaded, and two to three threads are exposed at the tube end when the
collar is screwed tightly onto a properly threaded tube. Because there are several types
of coned and threaded connections, it is important that the correct tubing, collars, and
gland nuts are used and are not interchanged. Special hand tools are available for
coning and threading high-pressure tubing.

Body

Collar

Figure 9.

Figure 10.

Revision 1

28

Nut

1/4-in.-o.d. tube

Typical 1/4-in. high-pressure coned and threaded fitting (60,000 psig).

Body

60 min

Tube

59 max

Typical high-pressure coned and threaded connection (to 60,000 psig).

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6.5

Valves

Valves (shown below) are used to control the flow of fluids. Many types of valves are
available and their applications frequently overlap.

The most common types of valves in the low- to intermediate-pressure range include
ball, plug, metering, and diaphragm valves. These are available for a wide variety of
applications and have various end connections. Always refer to manufacturer's catalog
for specific use.
Valves in the higher pressure range (up to 150 ksi) typically employ coned and
threaded connections (see Fig. 11). Nonrotating stems are commonly used to minimize
leaks, and this results in a longer service life of the equipment. A variety of stem tips
and body patterns are available depending on flow requirements (see Fig. 12).
Consider the following when selecting a valve:
Operating pressure/temperature.
Flow requirements.
Fluid compatibility.
Connection type and size.
Flow pattern.
Flow control (i.e., shut off, regulating, metering).

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Gland nut

Locking device

Packing washer
Packing
Body316 ss

Stem316 ss

Figure 11.

Revision 1

Type 1 high-pressure valve.

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Two-port valves

P
P
Type 1. Straight-through valve.

Type 2. Angle valve.

Three-port valves

P
P
P

P
P

P
Type 3. Two ports to pressure.

Figure 12.

Type 4. One port to pressure.

High-pressure valve body patterns.

Note: All pressure ports are marked "P"; nonpressure ports are unmarked. When
valves are CLOSED, pressure ports are not exposed to valve-stem packing. Other
ports are always exposed to valve-stem packing when the valve is OPEN or
CLOSED.

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6.6

Relief Devices

Pressure sources are to be limited to the MAWP of the lowest rated system component.
When sources cannot be limited, the use of a pressure-relief device is required.
Common relief devices (shown below) include a spring-loaded relief valve and a
rupture disc assembly.

The following precautions apply to all pressure relief devices:

Protect all manned-area pressure vessels by a relief device set at a pressure
not exceeding the MAWP of the vessel.
Whenever possible, use ASME code-approved (ASME UG-125-136) or
specially stocked relief devices.
Inspect, reset, or replace all relief devices on a periodic basis. A 3-year
minimum interval is required. If an outside contractor installed the relief
devices, have them rechecked at the end of the contract period.
Never place a valve between a relief device and the component it is installed
to protect.
Never set a relief device above the MAWP of the lowest rated system
component(s) it is installed to protect.
Locate and orient relief devices so that their discharge is not hazardous to
personnel.
Install relief devices of adequate total flow capacity. When all supply ports
are open, the pressure must never exceed 110% of the MAWP.
Do not reset relief devices unless specifically authorized to do so. No LLNL
worker is permitted to set, seal, or stamp relief devices on utility water boilers,
steam boilers, and compressed-air receivers that are under the jurisdiction of the
State of California. Only authorized workers in Bldgs. 511 and 875
(Maintenance) and Bldg. 343 (High-Pressure Test Facility) are permitted to set
and seal relief devices on noncoded pressure vessels and systems.

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6.7

Pressure Gauges

Pressure gauges (shown below) are precision instruments that indicate system pressure.
These gauges are available with a variety of end connections, levels of accuracy,
materials of construction, and pressure ranges.

When selecting or installing a pressure gauge, consider the following:

Use gauges graduated to about twice the MAWP of the system; never use gauges
less than 1.2 times the MAWP. Be sure that gauge materials are compatible with
the system fluid. (These rules apply to liquid as well as gas pressure gauges.)
Use safety-type gauges (with shatter-proof faces, solid fronts, and blowout backs)
or protect operators with a tested, approved gauge safety shield. This applies to
all gas pressure gauges more than 4 inches (100 mm) in diameter and graduated
to over 200 psig (1.4 MPa), gas pressure gauges less than 4 inches in diameter and
graduated to over 5000 psig (34.5 MPa), and all liquid pressure gauges more than
4 inches in diameter and graduated to over 20,000 psig (138 MPa).
Protect a gauge that is subject to excessive pressure surges or cyclic pulses by
installing a throttling device, such as a pulsation dampener (preferred), a
pressure snubber, a gauge saver, or a restricting orifice. Some gauges use a
throttle screw in the tube socket to dampen surges.
Make sure there is no oil or organic materials in gauges used on oxygen
systems, because hydrocarbons and oxygen can combine explosively. Never
use a gauge for oxygen that has been previously used on any other service.
Clean all gauges used on high-purity gas systems.

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Protect gauges with a relief device to prevent the pressure from exceeding the
full-scale reading of the gauge.
Never use liquid-filled gauges with strong oxidizing agents such as oxygen,
chlorine, or nitric acid.
6.8

Flexible Hose

Use a flexible hose (shown below) only where it is impractical to use metal tubing or
pipe. Flexible hoses have a limited life, dependent on a given service, and failure to
follow the manufacturer's recommended actions can result in a shortened service life or
failure of the hose. The maximum recommended shelf life for rubber hose is
approximately 8 years.

When specifying and installing a flexible hose, consider the following:

Rated working pressure. Do not use flexible hoses at pressures over 1/4 of
the minimum rated burst pressure stated by the manufacturer.
Fluid compatibility. Do not use toxic or radioactive fluids since gases tend to
permeate through hoses. Specially approved hoses may be used in certain
flammable gas applications.
Sharp bends. Do not bend or flex hose to a radius smaller than
recommended; do not subject hose to torque or tension.
Hose ends. Secure all hose ends with a hose restraint to prevent "whipping"
in the event the hose or fitting fails. This requirement also applies where two
hoses are coupled together.
Hose length and routing. Keep the hose length as short as possible. Consider
length changes under pressure, motion, and vibration. Protect or guide the
hose to minimize abrasion, kinking, or excessive flexing.
Periodic inspection. Have maintenance personnel perforate inert gas hose to
prevent blistering. Repair or replace any hose showing leaks (pinholes),
burns, wear blistering, or other defects.

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6.9

Flash Arrestors and Check Valves

Equip every flammable gas-drop regulator hose connection with a flash
arrestor or check valve. If the flammable gas is to be (or could be) crossconnected with oxygen or compressed air, install a flash arrestor in the
flammable gas line and place a check valve in the oxygen or compressed air
line (see "Laboratory Gas Systems," PEL-M-13200). This requirement applies
to all single- and multiple-station installations and to all portable equipment.
Equip all oxygen drops with a check valve. This requirement applies to
single- and-multiple-station installations and portable equipment.

6.10

Regulators

The distribution systems for gas cylinders consist of a regulator (shown below) and a
manifold. For a cylinder to be effective and safe, the regulator must take in gas from the
cylinder and reduce the pressure to a low working pressure while simultaneously
controlling the flow rate. It is important to obtain the correct regulator and ensure it is
consistent with the gas involved and the operation intended. Manifolds distribute and
control the gas flow from regulators.

The following precautions apply to all regulators:

Do not consider a pressure regulator by itself as satisfactory over pressure
protection.
Never attempt to repair regulators. This shall only be done by authorized
maintenance workers.
Before installation, take all regulators to authorized personnel for inspection,
adjustment, and tagging.
For temporary storage, place used regulators in plastic bags to keep them clean.
Survey work areas periodically for surplus regulators. Send all surplus
regulators to authorized maintenance personnel for examination, cleaning,
adjustment, repair, and tagging for future use.

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When removing regulators from flammable, toxic, or radioactive systems, make

sure that all hazardous gas has been safely vented (and purged if required)
from the entire regulator.
Use only regulators that are designed and approved for the gas and cylinder
with which they are used. Make sure that the Compressed Gas Association
connection on the regulators corresponds with that on the cylinder valve outlet.
Never force connections that do not fit. Make sure the cylinder valve and
regulator connections are free of dirt, oil, grease, and any other foreign material.
Use only oxygen regulators for oxygen service.
Do not lubricate any part of the regulator or cylinder valve.
Properly label regulators with the fluid being used.
Only use line regulators up to a maximum pressure of 150 psig (1 MPa) for
inline installations.
Immediately replace damaged, defective, or unreliable regulators.
Single-stage cylinder regulators (except acetylene regulators) are equipped with a single
relief device that is set to open at a value below the highest graduation on the low-side
gauge. Authorized maintenance workers may also adjust these regulators to limit the
output pressure to 75% of the highest output-gauge reading.
Two-stage regulators for inert gas are equipped with two relief valves that protect the
regulator diaphragms and gauges from excessive overpressure. Relief valves on
regulators for use with flammable, toxic, or radioactive gases must be safely vented.
At LLNL, two-stage regulators are adjusted so that the output pressure does not exceed
75% of the highest output-gauge reading. The low-side relief valve is set to open at a
value below the highest graduation on the low-side gauge.
In several facilities, authorized maintenance workers will adjust two-stage regulators so
that the output pressure does not exceed 75% of the highest output-gauge reading.
These workers will also set the low-side relief valve to open at a value below the highest
graduation on the low-side gauge.

6.11

Manifolds

6.11.1 Industrial Gas Cylinder Manifolds

Before submitting a job order for a manifold, make arrangements with the Supply and
Distribution Department of the Industrial Gas Section to obtain the gas cylinder supply
needed and the storage requirements.

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UCRL-MA-133867

The Laboratory's requirements for high-pressure manifolds is that only qualified LLNL
craftsmen (LLNL pressure installers and inspectors) shall be responsible for these
manifolds because of the high pressures involved. Therefore, all compressed-gas
cylinder manifolds for both job-order work and purchase-order contract work shall be
supplied, inspected, pressure tested, and tagged by these workers. An assembled
manifold provided by LLNL can be installed as a unit by others (from "Laboratory Gas
Systems," PEL-M-13200).
Do not leave manifold pigtails disconnected; insects can clog them. Insects in oxygen
pigtails can cause spontaneous ignition, creating enough heat and overpressure to burst
the pigtail, valve, or manifold. Either replace empty cylinders immediately, or have the
excess pigtails and valves removed or capped to keep the system clean.
6.11.2 Safety Manifolds
Authorized workers in Mechanical or Plant Engineering can provide safety manifold
systems (see Fig. 13). These systems are designed to reduce the pressure from a
standard cylinder and provide relief protection (relief device) for down-stream systems.
Safety manifolds can be used for low-pressure (0150 psi) applications that do not
require formal documentation; at higher pressures, however, additional documentation
(e.g., ESN or OSP) is required.

6.12

Temperature Considerations

Pressure hardware is usually rated at ambient temperature of 70F (21C). Sometimes

manufacturers will designate an MAWP based on a lower or higher operating
temperature. In general, the MAWP will decrease as the operating temperature
increases. When selecting components, always ensure the fitting material as well as any
seals and packing meet temperature requirements.
Following are temperature and working pressures for various sizes of copper-solder
fittings:
Solder
95/5
(Tin-Antimony)

Revision 1

Size
(in)

Temperature
(F)

Working pressure
(psig)

1/4 to 1

100

500

150

400

200

300

250

200

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UCRL-MA-133867

Gas cylindervalve

Test gauge*
(optional)

Safety manifold
(3000-psig WP)
Regulator valve
Fill valve

Vessel
or
system
Relief valve
(set at not over
MAWP)

Vent
valve

* If a test gauge of over 4-in. in diameter is required,

it must be of the safety-type with blow-out back
and securely attached plastic face. The scale
should be about double the test pressure, but
never less than 1.2 times the maximum test
pressure.

Barricade

Nitrogen, helium, argon,

compressed air, or house air

I strongly recommend that you have

pressure regulators inspected by our Instrument
Shop in Building 511, or the High Pressure
Testing Facility in Building 343. The personnel
there will test this equipment for proper relief
device settings, safety and reliability. They can
also provide you with a safety manifold and a
properly set relief device for your particular
application.

Chuck Borzileri
Pressure Safety Manager
Extension 2-6076

Figure 13.

6.13

Safety manifold system.

Installing Pressure Systems

All work on pressure equipment that requires an ESN must be done by or technically
supervised by a certified LLNL pressure inspector, a pressure installer, or a closely
supervised installer-in-training, under the direction of a responsible designer or
responsible user.

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UCRL-MA-133867

6.14

Pressure Testing

Pressure test all systems in accordance with requirements in Document 18.3.

7.0 Work Standards

7.1

Work Smart Standards

8 CCR 450-560, "Unfired Pressure Vessel Safety Orders (propane tanks, Air
Receivers)."
29 CFR 1910.101, "Compressed Gases General Requirements."
29 CFR 1910.103, "Hydrogen."
29 CFR 1910.110, "Storage and Handling of Liquified Petroleum Gases."
29 CFR 1910.132, Subpart I, "Personal Protective Equipment."
29 CFR 1910.146, "Permit-required Confined Spaces."
29 CFR 1910, Subpart J, "General Environmental Controls."
49 CFR 100-199, "Hazardous Materials Transportation."
ANSI/B 31.1, "Power Piping Code."
ASME Boiler and Pressure Code, Section VIII, Division 1 "Rules for Construction of
Pressure Vessels, and Division 2 "Alternative Rules" (latest version).
ACGIH TLVs and BEIs: Threshold Limit Values for Chemical Substances and Physical
Agents, American Conference of Government Industrial Hygienists.
Compressed Gas Association (CGA), Guidelines for handling of compressed gas cylinders.
Pressure relief devices for large nonCode storage or process tanks.
Compressed Gas Association, Pamphlet 1, "Safe Handling of Compressed Gases in
Containers," 1991.
Compressed Gas Association, Pamphlet S-1.2, "Pressure Relief Device Standards" Part 2
Cargo and Portable Tanks for Compressed Gases, 1995.
Compressed Gas Association, Pamphlet S-1.3, "Pressure Relief Device Standards" Part 3
Compressed Gas Storage Containers, 1995.
Compressed Gas Asscoiation, Pamphlet P-12, "Safe Handling of Cryogen Liquids."
LLNL Pressure Safety Standard, Lawrence Livermore National Laboratory, Livermore,
CA, UCRL-AR-128970.
NFPA 45, "Standard on Fire Protection for Laboratories Using Chemicals."
NFPA 51, "Standard for the Design and Installation of Oxygen-Fuel Gas Systems for
Welding, Cutting, and Allied Processes."

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UCRL-MA-133867

NFPA 51B, "Standard for Fire Prevention in Use of Cutting and Welding Processes
(1999)."
Public Law 91-596 (5)(a)(1), OSHA General Duty Clause.
7.2

Other Required Standards

Plant Engineering Department, "Laboratory Gas Systems," Lawrence Livermore

National Laboratory, Livermore, CA, PEL-M-13200.

8.0 References
1.

ASME Boiler and Pressure Vessel Code, Section VIII, "Pressure Vessels," American
Society of Mechanical Engineers, New York (latest version).

2.

ASTM Standards, Vol. I, "Ferrous Metals," American Society for Testing and
Materials, Philadelphia, PA. (latest version).

3.

Strength of Metal Aircraft Elements, Armed Forces Supply Support Center,

Washington, D. C., Spec. MIL-HDBK-5 (latest version).

4.

Steel Forgings Alloy, High Yield Strength, Bureau of Ships, Department of the Navy,
Washington, D. C., Spec. Mil-S-23009 (April 1965).

5.

ME Design Safety Standards, Lawrence Livermore National Laboratory, Livermore,

CA, M-012 ( latest version).

6.

R. J. Roark, Formulas for Stress and Strain, (McGraw-Hill, New York, 1954), TS 265
R6 1954.

7.

T. Baumeister, Marks' Mechanical Engineers' Handbook (McGraw-Hill, New

York,1966), TJ 151 M486 1966.

8.

F. B. Seely, Advanced Mechanics of Materials, (John Wiley and Sons, Inc., New York,
1952), 2nd ed.

9.

F. Din, Thermodynamic Functions of Gases, (Butterworth Scientific Publications,

London, 1956).

10. 49 CFR 100199, "Research and Special Programs Administration."

11. Safety Standards for the Packaging of Fissile and Other Radioactive Materials,
Chapter 0529, U. S. Department of Energy, Washington, DC.
12. W. A. Burton, ME Safety Note ENS 73-948, "Gas Sampling Cylinders for LLL
Shipments Containing Small Amounts of Radioactive Materials,"
December 10, 1973.
13. ANSI/ASME B31.1, Power Piping, Parts 121.5, "Hanger Spacing," p. 44
(1986 edition).

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UCRL-MA-133867

9.0 Resources for More Information

9.1

Contacts

For additional information about this document, contact the pressure safety
manager or the pressure consultant.

9.2

Lessons Learned

For lessons learned applicable to pressure vessels and systems, refer to the following
Internet address:
http://www-r.llnl.gov/es_and_h/lessons/lessons.shtml
9.3

Other Sources

Air-Conditioning and Refrigeration Institute (ARI) Standards.

ASME Boiler and Pressure Vessel Code, Section VIII, "Pressure Vessels," Division 2, and
Section X, "Fiber-Reinforced Plastic Pressure Vessels,"American Society of
Mechanical Engineers, New York (latest version).
G. H. Bhat and D. V. Lindh, "Evaluation of Ultra-High Strength Steels for ThinWalled
Pressure Vessels and Rocket Motor Cases," ASME Paper No. 62-MET-16 (1962).
R. Chuse, "Unfired Pressure Vessels," Nuclear Science Series TS-283-A (F. W. Dodge
Corporation, New York, 1960).
E. W. Comings, High Pressure Technology (McGraw-Hill, New York, 1956).
J. P. Den Hartog, Advanced Strength of Materials (McGraw-Hill, New York, 1952), TA 405
D4, 1952.
T. J. Dolan, "Significance of Fatigue Data in Design of Pressure Vessels," Welding J. 35,
255s (1956) [ASME Paper No. 57-A-15 (1957)].
J. H. Faupel, Engineering Design (John Wiley and Sons, Inc., New York, 1964), TA 175 Fl,
1964.
G. Geroard, Structural Significance of Ductility in Aerospace Pressure Vessels, College of
Engineering, New York, University, Tech. Rept. SM-60-8 (1960).
R. Gorcey, "Filament-Wound Pressure Vessels," Design News, Rocketdyne Division,
North American Avation (January 1962).
J. F. Harvey, "Pressure Vessel Design: Nuclear and Chemical Applications," Nuclear
Science Series TS-283-H2 (Van Nostrand Company, Princeton, N. J., 1963).
A. Hurlich and J. Balsch, "Titanium Pressure Vessels," J. Metals, 12, 136 (1960).

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UCRL-MA-133867

G. R. Irwin, "Fracture of Pressure Vessels," in Materials for Missiles and Spacecraft, E. R.

Parker, Ed. (McGraw-Hill, New York, 1963), pp. 204229.
N. L. Svensson, "The Bursting Pressure of Cylindrical and Spherical Vessels," ASME J.
Appl. Mech. 25, 89 (1958).
H. Thielsch, Defects and Failures in Pressure Vessels and Piping (Reinhold Publishing
Corporation, New York, 1965), TS 283 T3 1965.
S. Timoshenko, "Strength of Materials, Part 11." Advanced Theory and Problems (Van
Nostrand Company, Princeton, N. J., 1956).
D. A. Wruck, "Titanium Pressure Vessels," Machine Design, 33, 144 (1971).

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Appendix A
Terms and Definitions
Brittle vessel

A pressure vessel fabricated from materials that do not

yield extensively before failure when overstressed at any
temperature within the specified working temperature
range of the vessel. Materials that exhibit less than a 5%
plastic strain to rupture are generally considered brittle.

Ductile vessel

A pressure vessel fabricated from materials that yield

extensively before failure when overstressed at any
temperature within the specified working temperature
range of the vessel. Materials that exhibit greater than a 5%
plastic strain to rupture are generally considered ductile.
Some of these materials are listed in the ASME Boiler and
Pressure Vessel Code, Section VIII (Division 1,
Subsection C), and in Table 1 of this document.

Engineering Safety Note

(ESN)

A management-approved (by division leader or higher)

document that describes the anticipated hazards associated
with a piece of equipment or a process. It describes the
Responsible Individual's approach, analysis, and rationale
used to assure the design safety of the equipment, system
or process. An ESN does not have to be prepared by a
member of the Engineering Directorate as long as the
individual is technically qualified to prepare the ESN.

High pressure

Gas pressure greater than 3000 psig (20 MPa gauge), or

liquid pressure greater than 5000 psig (35 MPa gauge).

Intermediate pressure

Gas pressure from 150 to 3000 psig (120 MPa gauge), or

liquid pressure from 1500 to 5000 psig (1035 MPa).

Low pressure

Gas pressure less than 150 psig (1 MPa), or liquid pressure

less than 1500 psig (10 MPa).

Manned-area operation

Pressurization in environments where vessel failure might

cause personal injury. Such vessels or systems have been
approved for operation, within specified limits, with
personnel present.

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Manned-area vessel/
system

Pressurized vessels or systems approved for operation

within specified limits and with personnel present.

Maximum allowable
working pressure
(MAWP)

The maximum pressure at which a vessel is designed to

operate safely. Working pressure, rated pressure, service
pressure, and design pressure are the same as MAWP.
Note: The setting of vessel or system pressure-relief
devices must not exceed this MAWP (see Fig. 2).

Maximum operating
pressure (MOP)

The maximum pressure at which a pressure component is

normally operated, usually 1020% below the MAWP.

Pressure vessel

A relatively high-volume pressure component (such as a

spherical or cylindrical container) that has a cross section
larger than the associated pipe or tubing.

Remote operation

Pressurization in environments where vessel or system

component failure would not cause personal injury.
Remote operation equipment must be installed in test cells
or behind certified barricades or must be operated from a
safe location. Manned area operation (of a remoteoperation vessel or system) for the purpose of leak
checking or troubleshooting is limited to a maximum of
20% of the established and previously attained MAWP or
20% of the successful test pressure. Refer to Document 18.3,
"Pressure Testing," in the ES&H Manual for pressuretesting and leak-checking requirements.

Safety factor

The ratio of the calculated failure pressure (or actual failure

pressure if known) to the MAWP. A safety factor related to
other than the failure pressure should be so identified with
an appropriate subscript, i.e., SFy for a safety factor based
on the yield strength of the material, and SFu for a safety
factor based on its ultimate strength.

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Appendix B
Example of an Engineering Safety Note
An engineering safety note is a management-approved (by division leader or higher)
document that describes the anticipated hazards associated with a piece of equipment
or a process. It describes the Responsible Individual's approach, analysis, and rationale
used to assure the design safety of the equipment, system or process. An ESN does not
have to be prepared by a member of the Engineering Directorate as long as the
individual is technically qualified to prepare the ESN.
The new designations for ESNs are as follows:
Mechanical Engineering Safety Note, MESN 99-001-OA
Electronic Engineering Safety Note, EESN 99-001-OA
Livermore Laboratory Safety Note, LLSN 99-001-OA
Assignment of a safety note number is controlled by the Engineering Records Center,
Building 131, Room 1518.
http://www.llnl.gov/eng/MMED/home1.shtml

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MESN 99-001-0A

Mechanical Engineering Safety Note

500 PSIG Test Vessel

by
David C. Holten

October 1999

Approved by:
Responsible Individual
Pressure Consultant
Division Reviewer
Division Leader

Distribution
HPL Library
Engineering Records Center
Pressure Safety Manager
Responsible Individual
Pressure Consultant
Division Reviewer
Division Leader
System Users
Interested Parties

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500 PSIG Test Vessel

A.

Description

This Safety Note covers test vessel used to contain inert, liquid, or gas at pressures up to
500 psig. The vessel comprises a cylindrical section made of machined stainless steel
pipe (8-inch nominal pipe size, schedule XXS) with a threaded/welded bottom and
flanged/o-ring sealed lid. Three feed-throughs enter the lid via threaded pipe
connections (2 ports are 1/2 inch pipe size; 1 port is 1/8 inch pipe size). LLNL Drawing
Number AAA88-111390 (attached) describes this vessel.
B.

Hazard

This vessel represents a potential hazard to personnel and equipment when pressurized
to 500psi with liquid or gas. The latter case involves the greater stored energy and will
therefore be calculated. The energy contained in the gas, assuming a reversible adiabatic
(isentropic) expansion, is given by:
K 1

P1V1 P2 K
E=
1

K 1 P1

(Page C-11, Ref. [11])

Where

P1
P2
V1
K
E

= MAWP
= Atmospheric pressure
= Volume of the vessel
= Cp/Cv = Ratio of specific heats
= Stored energy

For this design:

P1
P2
V1
K

=
=
=
=

500 psia
14.7 psia
11,305 cc
1.4 for air or nitrogen (worst case)

Adjusting this equation for the proper units and substituting values gives:
K 1

K
P ( psi)V1(cc)
P
1 2
E(gmTNT) = 1.492 10 6 1

K 1
P1

1.4 1

1.492 10 6 500 11, 305 14.7 1.4

1
E(gmTNT) =
500

1.4 1

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E(gmTNT) = 13.4 (gmTNT)

C.

Calculations

For this vessel, the following design features will be analyzed:

1. Cylindrical hoop stress
2. Bottom thickness
3. Bottom thread shear
4. Lid thickness
5. Lid feed-throughs
6. Bolt/nut thread stress
4

Design details for this vessel are as follows:

32F to 130F temperature operation
Gasket seal = o-ring
Vessel materials

Revision 1

Cylinder: 304 stainless steel per SA-479

Allowable stress: Sa-v = 18.800 psig (Ref. 2)

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MESN 99-001-0A

Yield stress: Sy = 30,000 psig

Allowable stress: Sa-v = 18.800 psig (Ref. 3)

Bolts
8 each 3/4-10UNC Soc. HD
LLNL S/N 5305-20496
S(ultimate = 160,000(psig) = Su-b

(Ref. [11])

S
S(allowable) = u b = 40, 000( psi) = Sa b
4
Detail of Vessel/Lid Seal
9.750 BC
7.540
7.335
7.130

1"

.640

di =
6.985

do =
7.625

Nuts
LLNL S/N 5310-21810
S(ultimate = 90,000(psig) = Su-n

Revision 1

(Ref. [10])

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MESN 99-001-0A

S
S(allowable) = u n = 22, 500( psi) = Sa n
4
Thickness of nut = Tn = .640
C.1

Cylindrical Hoop Stress

ro = 7.625/2

= 3.8125

ri = 6.925/2

= 3.4925

R = ro/ri

= 3.8125/3.4925 = 1.092 . . . (use thin-wall equation)

S Et
P = av
ri

(pg. E-8, Eq.[1]. Ref. [1])

Where

= .320 in.

E = joint efficiency = 1*
*This vessel contains no structural welds. In this design no strength credit is
taken for the bottom seal weld. Rather, its only purpose is to provide a gas seal.
The pressure load is fully taken by the 712 thread support.
Substituting values gives
P=

18, 800 .320

= 1, 723( psi)
3.4925

Vessel (based on hoop stress) is good to 1,723(psig)

Vessel MAWP = 500 psig OK
C.2

Bottom Thickness
T = 1.0
T=d
i

(pg. E-10, Eq. [9], Ref. [1])

CP
Sa E

Where

C = Attachment coefficient
= .75

(Case Q, pg. E-11, Ref. [1])

Solving for P gives

T
S
P = a
C di
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MESN 99-001-0A

Substituting values gives

P=

18, 000 1 2
= 516( psi)
.75 6.985

Vessel (based on hoop stress) is good to 516 (psig)

Vessel MAWP = 500 psig OK
C.3

Bottom Thread Shear

Bottom thread is 7-12-2A 1'' long.

Thread form is
has = .02706

(pg. 62, Ref. [4])

Dm = Major diameter (external thread)

= 7.000
Dp

= Pitch diameter
= 7,000 2 (.02706)
6.94558

Shear stress in the threads is given by

s =

F
As

[1]

Where F = Force tending to shear the threads

= Design pressure Xs area of bottom
2
Dm
4
A = Shear area of thread
= P

[2]
(pg 103, Ref. [5])

EL e
2
Where E = Minimum thread pitch diameter
=

[3]

= D p (from page 6)
= 6.94558

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Le = Length of engagement
= Bottom thickness
= 1.0
Limiting this shear stress to one-half the design stress, as
s =

design stress
2

(Part 1, pg. 5, Ref. [6])

S
s = a v
2

[4]

Combining equations 1, 2, 3, and 4, and solving for P gives

S EL
P = a 2 e
Dm

[5]

Substituting values into equation 5 gives

P=

18, 800 6.94558 1

= 2, 665( psi)
72

Threads in vessel bottom good to 2,665 (psig)

Vessel MAWP = 500 psig OK
C.4
Lid Thickness
Cited references are from ASME Boiler and pressure Vessel Code, Section VIII,
Division 1, 1992, (Ref. 7) unless otherwise stated.
The vessel lid thickness is
Wh g
CP
T=d
+ 1.9
Sa E
Sa Ed 3

(Eq. [10], pg. E-10, Ref. [1])

Where
C =

attachment coefficient

E =

.3

E =

hg =

Radial difference between bolt circle and pressure seal circle

(flange moment arm)

Revision 1

(Case K, pg. E-11, Ref. [1])

(pg E-13, Ref. [1])

(9.75-7.335)/2 = 1.2075

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MESN 99-001-0A

d =

pressure seal diameter = 7.335

W =

flange design bolt load

Solving for P gives

T 2 1.9Wh g Sa v
P= 2

Sa v d 3 C
d

[6]

(Appendix 2, para. 2.5, pg. 312)

C.4.1 Determination of W
W

Wm1 (operating conditions)

l arg est of
Wm2 (gasket sealing)

Wm1 =
H+Hp
Hp = for self-energizing seals (o-ring)

Where

= hydrostatic end force

=

(Eq. [1], pg. 313)

(Para C3a, pg. 313)

2
G P
4

(Eq. [1], pg. 313)

= d = 7.335

Substituting values gives

Wm1 =

7.3352 500 = 21,128(lbs)

4

Wm2 = 0 for self-energizing seals (o-rings)

W

(Para. C3b, pg. 313)

= Wm1 = 21,128(lbs) (operating conditions)

C.4.2 Bolt
XS areas are determined as
Am

(pg. 310 and Para. C3d, pg. 313)

= total required XS area of bolting

=

A m1 (operating conditions)
l arg er of
A m2 (gasket sealing)

Am1

Wm1
Sb

Sa

= Allowable bolt stress at atmospheric temperature

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MESN 99-001-0A

Sb

= Allowable bolt stress at operating temperature

Sa

= Sb = S a-b

Substituting values gives

Am1

21,128
= 0.5282(in 2 )
40, 000

Am2

Wm 2
=0
Sa

Am

= Am1 = 0.5282(in2)

Ab

= actual total XS area of bolting

(from above)

= 8 XS area of 3/4-10 bolt

= 8 .334 (pg. 8-12. Ref. [8])
= 2.672(in2)
Ab Am OK

(Para. C3d, pg. 313)

C.4.3 W for Gasket Seating

W=

(A m + A b )Sa

(Eq. [4], pg. 319)

The above equation applies to hard gaskets to protect them from over tightening and
flange overloading. This equation does not apply to self-energizing seals (o-rings), as
gasket seating loads are considered zero.
Thus,
W

= Wm1 = 21,128 (lbs).

Finally, values are substituted into Eq. 6, page 8, to determine lid thickness, as:
1 2 1.9 21,128 1.2075 18, 800
P=

= 755( psi)

18, 800 7.3353 .3

7.335
Vessel lid is good to 755 (psig)
Vessel MAWP = 500 psig OK

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MESN 99-001-0A

C.5

Lid Feed-Throughs

Three male threaded pipe feed-throughs are installed in the vessel lid. These stainless
steel fittings have pressure ratings in excess of 3,000 (psig). The corresponding
internally threaded holes in the vessel lid will be evaluated for their pressure rating
based on thread shear stress. A conservative, approximate analysis for a tapered pipe
thread can be made by using the minimum pitch diameter, Eo, outside pipe diameter,
D, hand tight engagement length, L, and the equations of paragraph C.3, on page 6.
Pipe Size

Eo = E

L1 = Le

1/8

.36351

.405

.1615

1/2

.75843

.840

.320

(pg. 1363, Ref. [9])

As in paragraph C.3, Eq. 5, page 7,

S EL
P = av2 e
D
Substituting values gives
P(1/8thd) =

18, 800 .3635 .1615

= 6, 729( psi)
.4052

P(1/2thd) =

18, 800 .75843 .320

= 6, 466( psi)
.840 2

Vessel feed-through connections are good to 6,466(psig)+

Vessel MAWP = 500 psig OK
C.6

Bolt/Nut Thread Stress

Eight each 3/4-10 UNC nuts and bolts fasten the vessel lid to the vessel. As in equation
[5], page 7, the pressure-stress relationship for this thread system can be shown to be:
Bolts
S EL
P = 8 a b 2 e
D

Where

E = pitch diameter of the external thread (bolt)

= .6773

Revision 1

(Ref. [4])

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MESN 99-001-0A

Le = thickness of the nut

= .640

(Ref. [10])

D = o-ring seal diameter

= 7.335

(Ref. pg. 4)

Substituting values gives

40, 000 .6773 .640
P = 8
= 2, 578( psi)
7.3352

Bolts are good to 2,578(psig).

Vessel MAWP = 500 psig OK
Nuts
S EL
P = 8 a n 2 e
D

Where

E = pitch diameter of the external thread (nut)

= .6850

(Ref. [4])

Substituting values gives:

22, 500 .6850 .640
P = 8
= 1, 467( psi)
7.3352

Bolts are good to 1,467(psig).

Vessel MAWP = 500 psig OK

D.

Pressure Testing

The assembled vessel shall be pressure tested as follows:

1. Pressure test with helium to 1.5 times MAWP; i.e., 1.5 500 = 750(psig). Hold
pressure a minimum of 30 minutes.
2. Leak check with helium to 1 times MAWP; i,e, 500(psig). Any leakage
detectable with a mass spectrometer leak detector hand probe is
unacceptable.

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MESN 99-001-0A

All tests shall be performed by a high-pressure technician and witnessed by an LLNL

pressure inspector.
D.1

Maximum Energy of Distortion Analysis

To ensure that this vessel does not yield during this 1.5 times MAWP pressure
test, the following "Maximum Energy of Distortion Analysis" calculation is
performed.
(Reference pg. E-25, Ref [1])
Stress at test pressure = S vm (combined Von Mises stress)

1
(S1 S2 )2 + (S2 S3 )2 + (S3 S1 )2
2

Svm =

[7]

r
3.8125 2
Define Z = o =
= 1.192
3.4925
r1
S1

P
Z 1

750
1.192 1

= 3,906(psig)
S2

Z + 1
P
Z 1

1.192 + 1
750
1.192 1

= 8,562(psig)
S3

= -P
= -750(psig)

Substituting into equation [7] gives the following

Svm

= 8,064(psig)

= Ratio of yield strength to combined stress

1 to ensure no yielding

Sy

= 30,000(psig)

Revision 1

(from pg. 3)

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MESN 99-001-0A

30, 000
= 3.72
8, 064

Cylindrical vessel section will not yield during 1.5 times MAWP pressure test.

E.

Re-test/Re-inspection

This system requires a re-inspection every three years and a re-test every six years.
These shall be performed by an LLNL high-pressure technician and witnessed by an
LLNL pressure inspector. Re-testing shall be done at 1 times the manned area MAWP
previously defined in paragraph D.

F.

Labeling

The pressure inspector will certify the inspection of this system by completion of an
LLNL Pressure Test/Inspection Record, Form LL3586, and by attaching an LLNL
Pressure Tested Label, filled out as follows:

LLNL PRESSURE TESTED

FOR MANNED AREA

ASSY.

AAA 88-111930

SAFETY NOTE
M.A.W.P
FLUID

MESN 99-001-0A
PSIG.

500
INERT LIQUID / GAS

TEMP.

TO

32

130

REMARKS
TEST NO.

T.R.

ME 1343

EXPIRATION DATE
BY

G.

DATE

Special Use Label

This item may be part of the High Pressure Testing Facility equipment inventory. In this
category, it is maintained, utilized, and controlled by that facility. Such equipment may
be made available, on a loan basis, to other LLNL projects. If in this category, the
following label will be affixed:

Revision 1

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MESN 99-001-0A

HPL S/N

001

PROPERTY OF LLNL
HIGH PRESSURE LABORATORY
RETURN TO BUILDING 343
WHEN NOT IN USE
H.

I.

Associated Documentation
1. AAA 88-111390

500(psig) test vessel

2. M.E. 1343

M.E. Test/Inspection Record for 500(psig) test vessel.

References
1. DOE Pressure Safety Manual, December 1993.
2. ASME Boiler and Pressure Vessel Code, Section 2, part D, subpart 1, table 1A,
page 98.
3. ASME Boiler and Pressure Vessel Code, Section 2, part D, subpart 1, table 1A,
page 98.
4. ASA B1.1 1960, Unified Screw Threads, ASME.
5. NBS 1963 Supplement to Screw-thread Standards for Federal Service, 1963
Supplement to H-28.
6. NBS Screw Thread Standards for Federal Service, Handbook H-28 (1957), part 1.
7. ASME Boiler and Pressure Vessel Code, Section VIII, Division 1, 1992.
8. Marks Standard Handbook for Mechanical Engineers, 9th edition.
9. Machinery Handbook, 22nd edition.
10. LLNL ESR #354-5A.
11. LLNL ESR #283-1C.

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Revision 1

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Revision 1

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Revision 1
5

6
1

2) ENGINEERING SAFETY NOTE FOR THIS

VESSEL IS ENO 88 - 929

1) MAXIMUM ACCEPTABLE TOTAL OUTLEAKAGE DATE OF ASSEMBLED

ENCLOSURE SHALL NOT EXCEED
1105 ATMOSPHERIC -CC/SEC OF
HELIUM.

NOTES:

2.SURFACE TEXTURE PER ANSI 846.11978.

1.DIMENSIONING AND TOLERANCING PER

ANSI Y1 4.3M1982.

NOTES
UNLESS OTHERWISE SPECIFIED,

MESN 99-001-0A

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Appendix C
ASME Pressure Vessel Code Guide
Table C-1 contains references to generally used information in the ASME Boiler and
Pressure Vessel Codes, Section VIII, Division 1, "Pressure Vessels" (1992 edition):
Table C-1.

References to general pressure vessel information.

Section

Subject

Page

US-23

Maximum allowable stress values (Subsection C starts on p. 141)

20

UG-27

Thickness of shells under internal pressure

23

UG-32

Formed heads, pressure on concave side

33

UG-34

Unstayed flat heads and covers (see Fig. UG-34, p. 4-48)

38

UG-101

Proof tests to establish Maximum Allowable Working Pressure

77

UG-125
to UG-136

Pressure relief devices

87-100

UW-9

Design of welded joints

107

UW-12

Joint efficiencies (see Table UW-12, p. 4-54)

109

Requirements pertaining to classes of materials (References

Section II, Part D for maximum allowable stress values)

157

Supplementary design formulas (mandatory)

291

App. VI

Methods for magnetic particle examination (MT)

343

App. G

Suggested good practice regarding design of supports

477

App. L

Examples illustrating the application of code formulas and rules

481

Subsection C
App. I

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Appendix D
Piping and Tubing Pressure Ratings
This appendix contains the maximum allowable working pressures (MAWP) for pipe
and tubing generally available within the Department of Energy complex. The MAWP
values shown were obtained using calculation methods and material properties taken
from ANSI/B31.1, "Code for Power Piping (1989). A safety factor of 4 (5 for brass) is
already calculated in these values.
The listed working pressures are for work temperatures up to 200C (400F) for ferrous
pipe and tubing, and up to 120C (250F) for nonferrous pipe and tubing. These are
given in both SI [megapascals (Mpa)] and English units [thousands of pounds per
square inch (ksi)].

D.1

Threaded Pipe

Determine the MAWP of straight lengths of 1-in.-diameter, Schedule 40, UNS Alloy
C23000, threaded brass pipe for a working temperature of 120C. Use the following
equation (see ANSI B31.1):
P=

2 SE (t m A)
,
Do - 2y(t m A)

where
SE = Allowable stress at 120C (250F) [ANSI B31.1, App. A, pp. 182, 183] = 8.0 ksi.
tm = Minimum wall thickness allowed under the specification = nominal wall
thickness less wall tolerance = 0.126 0.007 = 0.119 in. (approximate value).
Note: To determine exact values, use the following.
For pipe tm = 87.5% tn (for brass pipe, use 94.5%).
For tubing tm = 92.5% tn (for stainless steel, use 87.5%).
A

= Thread depth for 1-in.-o.d. pipe ["Dimension h," ANSI B2.1, Table 2, p. 7] =
80% of thread pitch; 1" pipe has 11.5 threads/in., so 80% (1/11.5) = 0.070 in.

Do = Tabulated o.d. of 1-in. pipe = 1.315 in.

y

= Coefficient for nonferrous pipe [ANSI B31.1] = 0.4. (Also for ferrous pipe.)

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Substituting known values, the equation becomes

P=

2 8000 (0.1190 070)

= 615 psig.
1.315 2 0.4 (0.1190 070)

In other units, this may be expressed as 0.61 ksi or 4.21 MPa.

D.2

Unthreaded Pipe

If the pipe in the previous example were assembled by brazing (A = 0.000), the MAWP
would be 10.76 MPa (1.56 ksi).
P=

2SE (t m A)
,
Do - 2y(t m A)

P=

2 8000 (0.1190 000)

= 1561 psig,
1.315 2 0.4 (0.1190 000)

or

or 1.56 ksi, or 10.76 MPa, which (in this case) is about 2.5 times its threaded rating.

D.3

Pipe Listing
Table No.

Revision 1

Type of piping

D-1.

Aluminum alloy, Schedule 40

D-2.

Brass, regular strength

D-3.

Brass, extra strength

D-4.

Copper, regular strength

D-5.

Copper, extra strength

D-6.

Black steel, Schedule 40

D-7.

Black steel, Schedule 80

D-8.

Carbon steel

D-9.

Stainless steel, Schedule 40

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MESN 99-001-0A

Aluminum Alloy Pipe

Drawn, extruded, seamless.

6061-T6, Schedule 40 (UNS A96061).
Per ASTM B241.
Allowable stress: SE = 10500 psi (less than 1 in. IPS) or 9500 psi (1 in. or
greater IPS).

Table D-1.

Aluminum alloy, Schedule 40.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/4

0.540

0.088

1.34

9.24

3.38

23.31

3/4

1.050

0.113

0.86

5.93

2.14

14.76

1.315

0.133

0.68

4.69

1.80

12.41

1-1/2

1.900

0.145

0.58

4.00

1.34

9.24

2.375

0.154

0.53

3.66

1.13

7.79

3.500

0.216

0.49

3.38

1.07

7.38

5.563

0.258

0.43

2.97

0.79

5.45

6.625

0.288

0.42

2.90

0.72

4.97

Revision 1

MAWP
Threaded

67

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Brass Pipe

Seamless, annealed, regular strength.

CDA Alloy 230 (UNS C23000).
Per ASTM B43.
Allowable stress: SE = 8000 psi.

Table D-2.
IPS

Brass, regular strength.

o.d.

Nominal
wall
thickness

MAWP
Threaded

Plain

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8
1/4
3/8
1/2
3/4
1
1-1/4
1-1/2
2
2-1/2
3
3-1/2
4
5
6

0.405
0.540
0.675
0.840
1.050
1.315
1.660
1.900
2.375
2.875
3.500
4.000
4.500
5.562
6.625

0.062
0.082
0.090
0.107
0.114
0.126
0.146
0.150
0.156
0.187
0.219
0.250
0.250
0.250
0.250

1.17
1.02
1.02
0.87
0.80
0.61
0.67
0.62
0.53
0.43
0.50
0.56
0.49
0.39
0.33

8.07
7.03
7.03
6.00
5.52
4.21
4.62
4.28
3.66
2.97
3.45
3.86
3.38
2.69
2.28

2.58
2.57
2.24
2.12
1.79
1.56
1.42
1.27
1.04
1.03
0.99
0.99
0.87
0.70
0.58

17.79
17.72
15.45
14.62
12.34
10.76
9.79
8.76
7.17
7.10
6.83
6.83
6.00
4.83
4.00

Brass Pipe

Seamless, annealed, extra strength.

CDA Alloy 230 (UNS C23000).
Per ASTM B43.
Allowable stress: SE = 8000 psi.

Table D-3.
IPS

Brass, extra strength.

o.d.

Nominal
wall
thickness

MAWP
Threaded

Plain

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/4
1
2
3

0.540
1.315
2.375
3.500

0.123
0.182
0.221
0.304

2.38
1.32
0.98
0.89

16.41
9.10
6.76
6.14

4.15
2.33
1.51
1.40

28.62
16.07
10.41
9.66

Revision 1

68

December 19, 2001

MESN 99-001-0A

Copper Pipe

Seamless, drawn, regular strength.

UNS Alloy C12200.
Per ASTM B42.
Allowable stress: SE = 11300 psi (1/8 to 2 in. IPS), 9000 psi (2-1/2 to 12 in. IPS).

Table D-4.

Copper, regular strength.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8

0.405

0.062

1.64

11.31

3.63

25.03

1/4

0.540

0.082

1.44

9.93

3.62

24.97

3/8

0.675

0.090

1.43

9.86

3.15

21.72

1/2

0.840

0.107

1.23

8.48

2.99

20.62

3/4

1.050

0.114

1.13

7.79

2.52

17.38

1.315

0.126

0.86

5.93

2.19

15.10

1-1/4

1.660

0.146

0.95

6.55

2.00

13.79

1-1/2

1.900

0.150

0.87

6.00

1.78

12.28

2.375

0.156

0.74

5.10

1.46

10.07

2-1/2

2.875

0.187

0.49

3.38

1.16

8.00

3.500

0.219

0.56

3.86

1.11

7.66

3-1/2

4.000

0.250

0.63

4.34

1.12

7.72

4.500

0.250

0.55

3.79

0.98

6.76

5.562

0.250

0.44

3.03

0.79

5.45

6.625

0.250

0.37

2.55

0.66

4.55

Revision 1

MAWP
Threaded

69

Plain

December 19, 2001

MESN 99-001-0A

Copper Pipe

Seamless, drawn, extra strength.

UNS Alloy C12200.
Per ASTM B42.
Allowable stress: SE = 11300 psi (1/8" to 2" IPS), 9000 psi (2-1/2" to 12" IPS).

Table D-5.

Copper, extra strength.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/2

0.840

0.149

2.44

16.83

4.36

30.07

3/4

1.050

0.157

2.09

14.41

3.57

24.62

1.315

0.182

1.86

12.83

3.28

22.62

1-1/4

1.660

0.194

1.63

11.24

2.73

18.83

1-1/2

1.990

0.203

1.52

10.48

2.47

17.03

2.375

0.221

1.38

9.52

2.13

14.69

2-1/2

2.875

0.280

1.08

7.45

1.79

12.34

3.500

0.304

1.01

6.97

1.58

10.90

4.500

0.341

0.92

6.34

1.37

9.45

Revision 1

MAWP
Threaded

70

Plain

December 19, 2001

MESN 99-001-0A

Black Steel Pipe

Seamless, Schedule 40.

Carbon steel.
Per ASTM A53, Grade B.
Allowable stress: SE = 15000 psi.

Table D-6.

Black steel, Schedule 40.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8

0.405

0.068

2.27

15.66

4.94

34.07

1/4

0.540

0.088

1.92

13.24

4.82

33.24

3/8

0.675

0.091

1.67

11.52

3.92

27.03

1/2

0.840

0.109

1.40

9.66

3.73

25.72

3/4

1.050

0.113

1.24

8.55

3.05

21.03

1.315

0.133

1.08

7.45

2.84

19.59

1-1/4

1.660

0.140

0.96

6.62

2.34

16.14

1-1/2

1.900

0.145

0.92

6.34

2.11

14.55

2.375

0.154

0.83

5.72

1.78

12.28

2-1/2

2.875

0.203

0.83

5.72

1.95

13.45

3.500

0.216

0.77

5.31

1.69

11.66

3-1/2

4.000

0.226

0.75

5.17

1.54

10.62

4.500

0.237

0.72

4.97

1.43

9.86

5.563

0.258

0.69

4.76

1.26

8.69

6.625

0.280

0.66

4.55

1.14

7.86

Revision 1

MAWP
Threaded

71

Plain

December 19, 2001

MESN 99-001-0A

Black Steel Pipe

Seamless, Schedule 80.

Carbon steel.
Per ASTM A53, Grade B.
Allowable stress: SE = 15000 psi.

Table D-7.

Black steel, Schedule 80.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8

0.405

0.095

4.38

30.21

7.35

50.69

1/4

0.540

0.119

3.65

25.17

6.83

47.10

3/8

0.675

0.126

3.18

21.93

5.62

38.76

1/2

0.840

0.147

2.76

19.03

5.25

36.21

3/4

1.050

0.154

2.36

16.28

4.29

29.59

1.315

0.179

2.09

14.41

3.96

27.31

1-1/4

1.660

0.191

1.83

12.62

3.28

22.62

1-1/2

1.900

0.200

1.73

11.93

2.98

20.55

2.375

0.218

1.59

10.97

2.57

17.72

2-1/2

2.875

0.276

1.53

10.55

2.69

18.55

3.500

0.300

1.44

9.93

2.38

16.41

3-1/2

4.000

0.318

1.38

9.52

2.20

15.17

4.500

0.337

1.34

9.24

2.07

14.28

5.563

0.375

1.27

8.76

1.85

12.76

6.625

0.432

1.30

8.98

1.79

12.37

Revision 1

MAWP
Threaded

72

Plain

December 19, 2001

MESN 99-001-0A

Carbon Steel Pipe

Seamless, cold drawn, stress relieved.

Carbon steel, AISI MT-1016 1018.
Per ASTM A106, Grade C.
Allowable stress: SE = 17500 psi.

Table D-8.

Carbon steel.

IPS

o.d.

Nominal
wall
thickness

MAWP*

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8

0.405

0.068

2.71

18.67

5.83

40.18

1/4

0.540

0.088

2.25

15.51

5.63

38.84

3/8

0.675

0.091

1.93

13.30

4.56

31.43

1/2

0.840

0.109

1.66

11.44

4.37

30.14

3/4

1.050

0.113

1.44

9.94

3.56

24.58

1.315

0.133

1.27

8.76

3.33

22.98

1-1/4

1.660

0.140

1.14

7.83

2.74

18.93

1-1/2

1.900

0.145

1.07

7.40

2.47

17.02

2.375

0.154

0.98

6.73

2.08

14.34

2-1/2

2.875

0.203

0.97

6.66

2.27

15.68

3.500

0.216

0.91

6.26

1.98

13.62

3-1/2

4.000

0.226

0.87

6.01

1.80

12.42

4.500

0.237

0.85

5.87

1.67

11.55

5.563

0.258

0.81

5.56

1.47

10.12

6.625

0.280

0.78

5.38

1.33

9.20

Threaded

Plain

Based on SAE J 1397, MT-1016.

Revision 1

73

December 19, 2001

MESN 99-001-0A

Stainless Steel Pipe

Seamless, annealed, Schedule 40.

CRES, Type 304.
Per ASTM A312.
Allowable stress: SE = 18800 psi.

Table D-9.

Stainless steel, Schedule 40.

IPS

o.d.

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(ksi)

(MPa)

1/8

0.405

0.068

2.84

19.59

6.18

42.62

1/4

0.540

0.088

2.40

16.55

6.03

41.59

3/8

0.675

0.091

2.08

14.34

4.91

33.86

1/2

0.840

0.109

1.76

12.14

4.66

32.14

3/4

1.050

0.113

1.55

10.69

3.82

26.34

1.315

0.133

1.35

9.31

3.55

24.48

1-1/4

1.660

0.140

1.20

8.28

2.92

20.14

1-1/2

1.900

0.145

1.15

7.93

2.64

18.21

2.375

0.154

1.04

7.17

2.23

15.38

2-1/2

2.875

0.203

1.04

7.17

2.44

16.83

3.500

0.216

0.97

6.69

2.11

14.55

3-1/2

4.000

0.226

0.93

6.41

1.93

13.31

4.500

0.237

0.90

6.21

1.79

12.34

5.563

0.258

0.86

5.93

1.57

10.83

Revision 1

MAWP
Threaded

74

Plain

December 19, 2001

MESN 99-001-0A

D.4

Tube Listing
Table No.
D-10.
D-11.
D-12.
D-13.
D-14.
D-15.
D-16.
D-17.
D-18.
D-19.
D-20.

Type of tubing
Aluminum alloy
Brass, hard drawn
Copper, H58 drawn, 12-ft lengths
Copper, annealed, 50-ft coils, general use
Copper, annealed, 50-ft coils, refrigeration
use
Copper, drawn temper, 20-ft lengths
Copper, Type K
Copper, Type L
Copper, Type M
Carbon steel
Stainless steel

Aluminum Alloy Tubing

Seamless, drawn.
6061-T6 alloy (UNS A96061).
Per ASTM B210.
Allowable stress: SE = 10000 psi.

Table D-10.

Aluminum alloy.

o.d.

Nominal
wall
thickness

(in.)

(in.)

(ksi)

(MPa)

0.375
0.375
0.375
0.500
0.500
0.500
0.625
0.625
0.750
0.750
0.750
0.750
0.750
0.875

0.035
0.049
0.058
0.035
0.049
0.065
0.049
0.065
0.035
0.049
0.058
0.065
0.083
0.065

1.79
2.58
3.09
1.32
1.88
2.56
1.48
2.01
0.86
1.22
1.45
1.65
2.18
1.40

12.34
17.79
21.31
9.10
12.97
17.66
10.21
13.86
5.93
8.41
10.00
11.38
15.03
9.66

Revision 1

MAWP

75

o.d.

Nominal
wall
thickness

1.000
1.000
1.125
1.250
1.250
1.250
1.500
1.500
1.625
2.000
2.000
2.500
3.500

0.065
0.083
0.058
0.049
0.065
0.083
0.065
0.083
0.058
0.049
0.065
0.065
0.065

MAWP

1.21
1.60
0.94
0.72
0.96
1.26
0.79
1.04
0.64
0.44
0.59
0.47
0.33

8.34
11.03
6.48
4.97
6.62
8.69
5.45
7.17
4.41
3.03
4.07
3.24
2.28

December 19, 2001

MESN 99-001-0A

Brass Tubing

Seamless, hard drawn.

CDA Alloy 280.
Per ASTM B111.
Allowable stress: SE = 10000 psi.

Table D-11.

Brass, hard drawn.

o.d.

Nominal
wall
thickness

(in.)

(in.)

(ksi)

0.125
0.188
0.188
0.188
0.250
0.250
0.313
0.375
0.375
0.500
0.500
0.625
0.625
0.625
0.750
0.750
0.750
0.875
0.875
0.875
1.000
1.000
1.000
1.125
1.250
1.250
1.250
1.375
1.375
1.500
1.500
1.500
1.750
1.750
1.750
2.000
2.000

0.035
0.022
0.035
0.049
0.035
0.065
0.035
0.035
0.065
0.035
0.065
0.035
0.065
0.125
0.035
0.065
0.125
0.035
0.065
0.083
0.035
0.065
0.125
0.035
0.035
0.065
0.125
0.065
0.125
0.035
0.065
0.125
0.035
0.065
0.125
0.035
0.065

6.53
2.38
4.01
5.99
2.89
5.96
2.26
1.85
3.68
1.37
2.66
1.08
2.08
4.34
0.89
1.71
3.52
0.76
1.45
1.89
0.66
1.26
2.55
0.59
0.53
1.00
2.00
0.91
1.80
0.44
0.83
1.64
0.38
0.71
1.40
0.33
0.62

o.d.

Nominal
wall
thickness

(MPa)

(in.)

(in.)

(ksi)

(MPa)

45.05
16.39
27.63
41.33
19.92
41.07
15.58
12.79
25.36
9.42
18.35
7.45
14.37
29.94
6.17
11.81
24.25
5.26
10.03
13.01
4.58
8.71
17.57
4.06
3.65
6.90
13.78
6.25
12.43
3.03
5.71
11.33
2.59
4.87
9.62
2.26
4.25

2.000
2.125
2.250
2.250
2.500
2.500
2.500
2.625
2.750
2.750
2.875
3.000
3.000
3.000
3.000
3.250
3.250
3.500
3.500
3.750
4.000
4.000
4.250
4.500
4.500
4.750
5.000
5.000
5.250
5.500
6.000
6.500
6.750
7.000
7.250
8.250

0.125
0.125
0.065
0.125
0.035
0.065
0.125
0.125
0.065
0.125
0.065
0.035
0.065
0.125
0.187
0.065
0.125
0.065
0.125
0.125
0.065
0.125
0.125
0.065
0.125
0.125
0.065
0.125
0.125
0.125
0.125
0.125
0.125
0.125
0.125
0.125

1.21
1.14
0.55
1.07
0.26
0.49
0.96
0.91
0.45
0.87
0.43
0.22
0.41
0.80
1.21
0.38
0.73
0.35
0.68
0.63
0.30
0.59
0.56
0.27
0.52
0.50
0.24
0.47
0.45
0.43
0.39
0.36
0.35
0.33
0.32
0.28

8.36
7.84
3.77
7.39
1.80
3.38
6.62
6.30
3.07
6.00
2.93
1.50
2.81
5.48
8.34
2.59
5.05
2.40
4.68
4.36
2.10
4.08
3.84
1.86
3.62
3.42
1.67
3.25
3.09
2.95
2.70
2.49
2.39
2.31
2.23
1.95

MAWP*

MAWP*

Based on MIL-T-46072.

Revision 1

76

December 19, 2001

MESN 99-001-0A

Copper Tubing

Seamless, H58 drawn, 12-ft straight lengths.

Copper, UNS C12200, general use.
Per ASTM B75.
Allowable stress: SE = 9000 psi.

Table D-12.

Copper, H58 drawn, 12-ft lengths.

o.d.

Nominal
wall
thickness

o.d.

Nominal
wall
thickness

(in.)

(in.)

(ksi)

(MPa)

(in.)

(in.)

(ksi)

(MPa)

0.125

0.020

2.74

18.90

1.000

0.035

0.58

4.00

0.125

0.032

5.12

35.31

1.000

0.065

1.15

7.93

0.188

0.028

2.73

18.83

1.000

0.129

2.45

16.90

0.188

0.032

3.23

22.28

1.250

0.065

0.91

6.28

0.250

0.035

2.56

17.66

1.500

0.065

0.75

5.17

0.250

0.049

3.88

26.76

1.750

0.065

0.64

4.41

0.250

0.065

5.51

38.00

2.000

0.065

0.56

3.86

0.313

0.035

2.00

13.79

2.000

0.083

0.72

4.97

0.375

0.035

1.64

11.31

2.500

0.065

0.43

2.97

0.375

0.065

3.39

23.38

2.500

0.083

0.56

3.86

0.500

0.035

1.21

8.34

2.500

0.125

0.87

6.00

0.500

0.065

2.45

16.90

3.000

0.083

0.46

3.17

0.625

0.035

0.96

6.62

3.000

0.120

0.69

4.76

0.625

0.065

1.92

13.24

3.500

0.065

0.30

2.07

0.625

0.083

2.53

17.45

4.000

0.125

0.53

3.66

0.750

0.035

0.78

5.38

5.000

0.250

0.88

6.07

0.750

0.065

1.56

10.76

6.000

0.250

0.73

5.03

0.750

0.083

2.04

14.07

Revision 1

MAWP

77

MAWP

December 19, 2001

MESN 99-001-0A

Copper Tubing

Seamless, 060 soft annealed, 50-ft coils.

Copper, UNS C12200, general use.
Per ASTM B75.
Allowable stress: SE = 6000 psi.
Table D-13.

Copper, annealed, 50-ft coils,

general use.

o.d

Nominal
wall
thickness

(in.)

(in.)

(ksi)

(MPa)

0.188

0.032

2.15

14.83

0.250

0.049

2.58

17.79

0.375

0.049

1.63

11.24

0.375

0.065

2.26

15.59

0.500

0.032

0.73

5.03

0.500

0.065

1.63

11.24

MAWP

Copper Tubing

Seamless, soft annealed, 50-ft coils.

Copper, UNS C12200, refrigeration use.
Per ASTM B280.
Allowable stress: SE = 6000 psi.

Table D-14.

Copper, annealed, 50-ft coils, refrigeration use.

o.d

Nominal
wall
thickness

o.d

Nominal
wall
thickness

(in.)

(in.)

(ksi)

(MPa)

(in.)

(in.)

(ksi)

(MPa)

0.125

0.030

3.13

21.59

0.750

0.035

0.52

3.59

0.187

0.030

2.00

13.79

0.750

0.042

0.64

4.41

0.250

0.030

1.44

9.93

0.875

0.045

0.58

4.00

0.312

0.032

1.22

8.41

1.125

0.050

0.50

3.45

0.375

0.032

1.00

6.90

1.375

0.055

0.45

3.10

0.500

0.032

0.74

5.10

1.625

0.060

0.42

2.90

0.625

0.035

0.64

4.41

Revision 1

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MESN 99-001-0A

Copper Tubing

Seamless, drawn temper, 20-ft straight lengths.

Copper, UNS C12200, air conditioning use.
Per ASTM B280.
Allowable stress: SE = 9000 psi.

Table D-15.

Copper, drawn temper, 20-ft lengths.

o.d

Nominal
wall
thickness

(in.)

(in.)

(ksi)

0.375
0.500
0.625
0.750
0.875
1.125
1.375

0.030
0.035
0.040
0.042
0.045
0.050
0.055

1.34
1.19
1.10
0.96
0.87
0.76
0.68

o.d

Nominal
wall
thickness

(MPa)

(in.)

(in.)

(ksi)

(MPa)

9.24
8.21
7.59
6.62
6.00
5.24
4.69

1.625
2.125
2.625
3.125
3.625
4.125

0.060
0.070
0.080
0.090
0.100
0.110

0.63
0.55
0.51
0.48
0.47
0.45

4.34
3.79
3.52
3.31
3.24
3.10

MAWP

MAWP

Copper Tubing

Seamless, hard drawn, 20-ft straight lengths.

Copper, UNS C12200, Type K, plumbing use.
Per ASTM B88.
Allowable stress: SE = 6000 psi.*

Table D-16.

Copper, Type K.

Water
tube
size

o.d

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

1/4
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2

0.375
0.500
0.625
0.750
0.875
1.125
1.375
1.625

0.035
0.049
0.049
0.049
0.065
0.065
0.065
0.072

1.06
1.16
0.91
0.75
0.89
0.68
0.55
0.51

Water
tube
size

o.d

Nominal
wall
thickness

(MPa)

(in.)

(in.)

(in.)

(ksi)

(MPa)

7.31
8.00
6.28
5.17
6.14
4.69
3.79
3.52

2
2-1/2
3
3-1/2
4
5
6
8

2.125
2.625
3.125
3.625
4.125
5.125
6.125
8.125

0.083
0.095
0.109
0.120
0.134
0.160
0.192
0.271

0.44
0.41
0.40
0.38
0.37
0.36
0.36
0.38

3.03
2.83
2.76
2.62
2.55
2.48
2.48
2.62

MAWP

MAWP

Annealed properties assumed.

Revision 1

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MESN 99-001-0A

Copper Tubing

Seamless, hard drawn, 20-ft straight lengths.

Copper, UNS C12200, Type L, plumbing use.
Per ASTM B88.
Allowable stress: SE = 6000 psi.*

Table D-17.

Copper, Type L.

Water
tube
size

o.d

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

1/4
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2

0.375
0.500
0.625
0.750
0.875
1.125
1.375
1.625

0.030
0.035
0.040
0.042
0.045
0.050
0.055
0.060

0.89
0.79
0.67
0.64
0.58
0.50
0.45
0.42

Water
tube
size

o.d

Nominal
wall
thickness

(MPa)

(in.)

(in.)

(in.)

(ksi)

(MPa)

6.14
5.45
4.62
4.41
4.00
3.45
3.10
2.90

2
2-1/2
3
3-1/2
4
5
6
8

2.125
2.625
3.125
3.625
4.125
5.125
6.125
8.125

0.070
0.080
0.090
0.100
0.110
0.125
0.140
0.200

0.37
0.34
0.32
0.31
0.30
0.27
0.25
0.28

2.55
2.34
2.21
2.14
2.07
1.86
1.72
1.93

Water
tube
size

o.d

Nominal
wall
thickness

MAWP*

MAWP*

Annealed properties assumed.

Copper Tubing

Seamless, hard drawn, 20-ft straight lengths.

Copper, UNS C12200, Type M, plumbing use.
Per ASTM B88.
Allowable stress: SE = 6000 psi.*

Table D-18.

Copper, Type M.

Water
tube
size

o.d

Nominal
wall
thickness

(in.)

(in.)

(in.)

(ksi)

(MPa)

(in.)

(in.)

(in.)

(ksi)

(MPa)

3/8
1/2
3/4
1
1-1/4
1-1/2
2

0.500
0.625
0.875
1.125
1.375
1.625
2.125

0.025
0.028
0.032
0.035
0.042
0.049
0.058

0.56
0.50
0.40
0.34
0.34
0.34
0.30

3.86
3.45
2.76
2.34
2.34
2.34
2.07

2-1/2
3
3-1/2
4
5
6
8

2.625
3.125
3.625
4.125
5.125
6.125
8.125

0.065
0.072
0.083
0.095
0.109
0.122
0.170

0.27
0.25
0.25
0.25
0.23
0.22
0.23

1.86
1.72
1.72
1.72
1.59
1.52
1.59

MAWP*

MAWP*

Annealed properties assumed.

Revision 1

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December 19, 2001

MESN 99-001-0A

Carbon Steel Tubing

Seamless, cold drawn, stress relieved.

Carbon steel, AISI MT-1016/1018.
Per ASTM A519.
Allowable stress: SE = 15000 psi.

Table D-19.

Carbon steel.

o.d

Nominal
wall
thickness

(in.)

(in.)

(ksi)

0.250
0.500
0.500
0.500
0.625
0.750
0.750
0.750
0.875
0.875
1.000
1.000
1.000
1.125
1.250
1.375
1.375
1.500
1.500
1.500
1.625
1.750
2.000
2.000
2.250
2.250
2.375
2.500

0.065
0.035
0.049
0.065
0.065
0.035
0.065
0.1875
0.065
0.120
0.035
0.065
0.1875
0.065
0.065
0.065
0.120
0.065
0.120
0.1875
0.065
0.250
0.065
0.375
0.120
0.250
0.4375
0.049

8.93
2.02
2.88
3.93
3.08
1.32
2.53
8.38
2.15
4.17
0.98
1.87
5.96
1.65
1.48
1.34
2.55
1.22
2.33
3.77
1.12
4.37
0.93
6.04
1.56
3.41
5.92
0.55

o.d

Nominal
wall
thickness

(MPa)

(in.)

(in.)

(ksi)

(MPa)

61.60
13.93
19.86
27.10
21.24
9.10
17.45
57.79
14.83
28.76
6.76
12.90
41.10
11.38
10.21
9.24
17.59
8.41
16.07
26.00
7.72
30.14
6.41
41.06
10.76
23.52
40.81
3.79

2.500
2.500
2.500
2.750
3.000
3.000
3.000
3.125
3.250
3.750
3.750
3.750
4.000
4.000
4.000
4.000
4.000
4.250
4.750
5.000
5.250
5.500
5.500
6.000
6.000
6.750
8.000
10.000

0.120
0.3125
0.375
0.120
0.120
0.313
0.438
0.120
0.065
0.250
0.375
0.625
0.065
0.120
0.188
0.250
0.500
0.250
0.120
0.250
0.250
0.120
0.250
0.188
0.375
0.250
0.375
0.250

1.40
3.88
4.76
1.27
1.16
3.18
4.61
1.11
0.57
1.97
3.04
5.36
4.90
0.86
1.315
1.84
3.88
1.73
0.72
1.46
1.39
0.62
1.32
0.90
1.84
1.07
1.37
0.71

9.66
26.76
32.83
8.76
8.00
21.93
31.79
7.66
3.93
13.59
20.97
36.97
33.80
5.93
9.48
12.69
26.76
11.93
4.97
10.07
9.59
4.28
9.10
6.21
12.69
7.38
9.45
4.90

MAWP*

MAWP*

Based on SAE J 1397, MT-1016.

Revision 1

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MESN 99-001-0A

Stainless Steel Tubing

Seamless, annealed, cold drawn, pickled.

Type TP 304, UNS S30400.
Per ASTM A213.
Allowable stress: SE = 18800 psi.

Table D-20.

Stainless steel.

o.d

Nominal
wall
thickness

o.d

Nominal
wall
thickness

(in.)

(in.)

(ksi)

(MPa)

(in.)

(in.)

(ksi)

(MPa)

0.125

0.016

4.63

31.89

1.000

0.065

2.24

15.45

0.188

0.016

2.98

20.53

1.250

0.049

1.33

9.14

0.250

0.020

2.79

19.22

1.250

0.065

1.78

12.24

0.250

0.035

5.11

35.21

1.500

0.049

1.10

7.58

0.250

0.049

7.47

51.53

1.500

0.065

1.47

10.14

0.250

0.065

10.46

72.10

1.500

0.083

1.89

13.06

0.313

0.020

2.20

15.20

1.500

0.095

2.18

15.03

0.313

0.035

4.00

27.57

1.625

0.065

1.35

9.34

0.313

0.049

5.31

36.62

1.750

0.065

1.23

8.65

0.375

0.020

1.82

12.57

2.000

0.035

0.58

4.02

0.375

0.035

3.29

22.65

2.000

0.065

1.09

7.54

0.375

0.049

4.73

32.63

2.000

0.109

1.86

12.85

0.375

0.065

6.49

44.75

2.000

0.120

2.06

14.21

0.500

0.035

2.42

16.70

2.500

0.035

0.47

3.21

0.500

0.049

3.46

23.87

2.500

0.065

0.87

6.01

0.500

0.065

4.71

32.44

2.500

0.120

1.63

11.27

0.500

0.109

8.46

58.36

3.000

0.065

0.72

4.99

0.625

0.065

3.69

25.44

3.000

0.120

1.35

9.34

0.750

0.035

1.59

10.94

4.000

0.065

0.54

3.73

0.750

0.049

2.25

15.53

4.000

0.083

0.69

4.78

0.750

0.065

3.04

20.93

6.000

0.083

0.46

3.17

1.000

0.049

1.67

11.51

Revision 1

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82

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MESN 99-001-0A

Appendix E
Metric Guide
The alphabetical list of units in this appendix was extracted from the Metric Practice
Guide, E 380-74, published by the American Society for Testing and Materials (ASTM).
An asterisk (*) in the "Multiply by" column indicates that the conversion factor is exact
and that all subsequent digits are zero. Because the footnotes are typically historical and
are not generally important to LLNL engineers, they have not been included. They are
available in the ASTM Metric Practice Guide for those interested.
For those unfamiliar with computer exponent notation, following is an example of how
to use this list to convert a number expressed in an English unit to the corresponding
number in System International (SI) units.
Suppose you want to express a bar of pressure in SI units. The list heading
says: "To convert from bar to pascal (Pa), multiply by 1.000 000*E+05," or
by 1 105. Therefore, 1 bar = 1 105 Pa = 100 000 Pa, which is also 100 kPa,
or 0.1 MPa.
The basic SI pressure unit is the pascal (Pa), which is equal to 0.000145
psig (1 psig = 6895 Pa). One kilopascal (kPa) is equal to 0.145 psig. Notice
that 100 kPa absolute = 14.5 psia = 1 bar, which is approximately equal to
1 atmosphere of pressure. One megapascal (MPa), which is 106 Pa, is equal
to 145 psig.

Revision 1

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MESN 99-001-0A

ALPHABETICAL LIST OF UNITS

(Symbols of SI units given in parentheses)
To convert from

to

Multiply by

abampere

ampere (A)

1.000 000* E+01

abcoulomb

coulomb (C)

1.000 000* E+01

abfarad

farad (F)

1.000 000* E+09

abhenry

henry (H)

1.000 000* E09

abmho

siemens (S)

1.000 000* E+09

abohm

ohm ()

1.000 000* E09

abvolt

volt (V)

1.000 000* E08

acre foot (U.S. survey)

meter3 (m3)

1.233 489 E+03

acre (U.S. survey)

meter2 (m2)

4.046 873 E+03

ampere hour

coulomb (C)

3.600 000* E+03

are

meter2 (m2)

1.000 000* E+02

angstrom

meter (m)

1.000 000* E10

astronomical unit

meter (m)

1.495 979 E+11

atmosphere (standard)

pascal (Pa)

1.013 250* E+05

atmosphere
(technical = 1 kgf/cm2)

pascal (Pa)

9.806 650* E+04

bar

pascal (Pa)

1.000 000* E+05

barn

meter2 (m2)

1.000 000* E28

barrel (for petroleum, 42 gal)

meter3 (m3)

1.589 873 E01

board foot

meter3 (m3)

2.359 737 E03

British thermal unit

(International Table)

joule (J)

1.055 056 E+03

British thermal unit (mean)

joule (J)

1.055 87 E+03

British thermal unit

(thermochemical)

joule (J)

1.054 350 E+03

British thermal unit (39F)

joule (J)

1.059 67 E+03

Revision 1

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December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

British thermal unit (59F)

joule (J)

1.054 80 E+03

British thermal unit (60F)

joule (J)

1.054 68 E+03

Btu (International
Table)ft/hft2F
(k, thermal conductivity)

watt per meter kelvin

(W/mK)

1.730 735 E+00

Btu (thermochemical)ft/hft2F
(k, thermal conductivity)

watt per meter kelvin

(W/mK)

1.729 577 E+00

Btu (International
Table)in/hft2F (k, thermal
conductivity)

watt per meter kelvin

(W/mK)

1.442 279 E01

Btu (thermochemical)in/hft2F
(k, thermal conductivity)

watt per meter kelvin

(W/mK)

1.441 314 E01

Btu (International
Table)in/sft2F (k, thermal
conductivity)

watt per meter kelvin

(W/mK)

5.192 204 E+02

Btu (thermochemical)in/sft2F
(k, thermal conductivity)

watt per meter kelvin

(W/mK)

5.188 732 E+02

Btu (International Table)/h

watt (W)

2.930 711 E01

Btu (International Table)/s

watt (W)

1.055 056 E+03

Btu (thermochemical)/h

watt (W)

2.928 751 E01

Btu (thermochemical)/min

watt (W)

1.757 250 E+01

Btu (thermochemical)/s

watt (W)

1.054 350 E+03

Btu (International Table)/ft2

joule per meter2 (J/m2)

1.135 653 E+04

Btu (thermochemical)/ft2

joule per meter2 (J/m2)

1.134 893 E+04

Btu (thermochemical)/ft2h

watt per meter2 (W/m2)

3.152 481 E+00

Btu (thermochemical)/ft2min

watt per meter2 (W/m2)

1.891 489 E+02

Btu (thermochemical)/ft2s

watt per meter2 (W/m2)

1.134 893 E+04

Btu (thermochemical)/in2s

watt per meter2 (W/m2)

1.634 246 E+06

Btu (International Table)/hft2F

(C, thermal conductance)

watt per meter2 kelvin

(W/m2K)

5.678 263 E+00

Btu (thermochemical)/hft2F (C,

thermal conductance)

watt per meter2 kelvin

(W/m2K)

5.674 466 E+00

Revision 1

85

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

Btu (International Table)/sft2F

watt per meter2 kelvin

(W/m2K)

2.044 175 E+04

Btu (thermochemical)/sft2F

watt per meter2 kelvin

(W/m2K)

2.042 808 E+04

Btu (International Table)/lb

joule per kilogram (J/kg)

2.326 000* E+03

Btu (thermochemical)/lb

joule per kilogram (J/kg)

2.324 444 E+03

Btu (International Table)/lbF (c,

heat capacity

joule per kilogram kelvin

(J/kgK)

4.186 800* E+03

Btu (thermochemical)/lbF
(c, heat capacity

joule per kilogram kelvin

(J/kgK)

4.184 000* E+03

bushel (U.S)

meter3 (m3)

3.523 907 E02

caliber (inch)

meter (m)

2.540 000* E02

calorie (International Table)

joule (J)

4.186 800* E+00

calorie (mean)

joule (J)

4.190 02 E+00

calorie (thermochemical)

joule (J)

4.184 000* E+00

calorie (15C)

joule (J)

4.185 80 E+00

calorie (20C)

joule (J)

4.181 90 E+00

calorie (kilogram, International

Table)

joule (J)

4.186 800* E+03

calorie (kilogram, mean)

joule (J)

4.190 02 E+03

calorie (kilogram,
thermochemical)

joule (J)

4.184 000* E+03

cal (thermochemical)/cm2

joule per meter2 (J/m2)

4.184 000* E+04

cal (International Table)/g

joule per kilogram (J/kg)

4.186 800* E+03

cal (thermochemical)/g

joule per kilogram (J/kg)

4.184 000* E+03

cal (International Table)/gC

joule per kilogram kelvin

(J/kgK)

4.186 800* E+03

cal (thermochemical)/gC

joule per kilogram kelvin

(J/kgK)

4.184 000* E+03

cal (thermochemical)/min

watt (W)

6.973 333 E02

Revision 1

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December 19, 2001

MESN 99-001-0A

To convert from

to

cal (thermochemical)/s

Multiply by

watt (W)

4.184 000* E+00

cal (thermochemical)/cm2min

watt per meter2 (W/m2)

6.973 333 E+02

cal (thermochemical)/cm2s

watt per meter2 (W/m2)

4.184 000* E+04

cal (thermochemical)/cm2sC

watt per meter2 kelvin

(W/mK)

4.184 000* E+02

kilogram (kg)

2.000 000* E+04

carat (metric)
centimeter of mercury (0C)

pascal (Pa)

1.333 22 E+03

centimeter of water (4C)

pascal (Pa)

9.806 38 E+01

centipoise

pascal second (Pas)

1.000 000* E03

centistokes

meter2 per second (m2/s)

1.000 000* E06

circular mil

meter2 (m2)

5.067 075 E10

clo

kelvin meter2 per watt

(Km2/W)

2.003 712 E01

cup

meter3 (m3)

2.365 882 E04

becquerel (Bq)

3.700 000* E+10

day (mean solar)

second (s)

8.640 000 E+04

day (sidereal)

second (s)

8.616 409 E+04

degree (angle)

radian (rad)

1.745 329 E02

degree Celsius

kelvin (K)

tK = tC + 273.15

degree centigrade

kelvin (K)

tK = tC + 273.15

degree Fahrenheit

degree Celsius

tC= (tF 32)/1.8

degree Fahrenheit

kelvin (K)

tK = (tF + 459.67)/1.8

degree Rankine

kelvin (K)

tK = tR/1.8

curie

Fhft2/Btu (International Table)

(R, thermal resistance)

kelvin meter2 per watt

(Km2/W)

1.761 102 E01

Fhft2/Btu (thermochemical) (R,

thermal resistance)

kelvin meter2 per watt

(Km2/W)

1.761 280 E01

Revision 1

87

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MESN 99-001-0A

To convert from
denier

to

Multiply by

kilogram per meter (kg/m)

1.111 111 E07

newton (N)

1.000 000* E05

dynecm

newton meter (Nm)

1.000 000* E07

dyne/cm2

pascal (Pa)

1.000 000* E01

dyne

electronvolt

joule (J)

1.602 19 E19

EMU of capacitance

farad (F)

1.000 000* E+09

ampere (A)

1.000 000* E+01

volt (V)

1.000 000* E08

EMU of inductance

henry (H)

1.000 000* E09

EMU of resistance

ohm ()

1.000 000* E09

ESU of capacitance

farad (F)

1.112 650 E12

EMU of current
EMU of electric potential

ESU of current

ampere (A)

3.335 6 E10

volt (V)

2.997 9 E+02

ESU of electric potential

ESU of inductance

henry (H)

8.987 554 E+11

ESU of resistance

ohm ()

8.987 554 E+11

erg

joule (J)

1.000 000* E07

watt per meter2 (W/m2)

1.000 000* E03

watt (W)

1.000 000* E07

erg/(cm2s)
erg/s
faraday (based on carbon-12)

coulomb (C)

9.648 70 E+04

faraday (chemical)

coulomb (C)

9.649 57 E+04

faraday (physical)

coulomb (C)

9.652 19 E+04

fathom

meter (m)

1.828 8 E+00

fermi (femtometer)

meter (m)

1.000 000* E15

meter3 (m3)

2.957 353 E05

foot

meter (m)

3.048 000* E01

foot (U.S. survey)

meter (m)

3.048 006 E01

foot of water (39.2F)

pascal (Pa)

2.988 98 E+03

ft2

meter2 (m2)

9.290 304* E02

fluid ounce (U.S.)

Revision 1

88

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

ft2/h (thermal diffusivity)

meter2 per second (m2/s)

2.580 640* E05

ft2/s

meter2 per second (m2/s)

9.290 304* E02

meter3 (m3)

2.831 685 E02

ft3/min

meter3 per second (m3/s)

4.719 474 E04

ft3/s

meter3 per second (m3/s)

2.831 685 E02

meter4 (m4)

8.630 975 E03

ft/h

meter per second (m/s)

8.466 667 E05

ft/min

meter per second (m/s)

5.080 000* E03

ft/s

meter per second (m/s)

3.048 000* E01

ft/s 2

meter per second2 (m/s2)

3.048 000* E01

footcandle

lux (lx)

1.076 391 E+01

footlambert

candela per meter2 (cd/m2)

3.426 259 E+00

ftlbf

joule (J)

1.355 818 E+00

ftlbf/h

watt (W)

3.766 161 E04

ftlbf/min

watt (W)

2.259 697 E02

ftlbf/s

watt (W)

1.355 818 E+00

ftpoundal

joule (J)

4.214 011 E02

free fall, standard (g)

meter per second2 (m/s2)

9.806 650* E+00

gal

meter per second2 (m/s2)

1.000 000* E02

gallon (Canadian liquid)

meter3 (m3)

4.546 090 E03

gallon (U.K. liquid)

meter3 (m3)

4.546 092 E03

gallon (U.S. dry)

meter3 (m3)

4.404 884 E03

gallon (U.S. liquid)

meter3 (m3)

3.785 412 E03

gallon (U.S. liquid) per day

meter3 per second (m3/s)

4.381 264 E08

gallon (U.S. liquid) per minute

meter3 per second (m3/s)

6.309 020 E05

ft3 (volume; section modulus)

ft4 (moment of section)

Revision 1

89

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

meter3 per joule (m3/J)

1.410 089 E09

gamma

tesla (T)

1.000 000* E09

gauss

tesla (T)

1.000 000* E04

gilbert

ampere (A)

7.957 747 E01

gill (U.K.)

meter3 (m3)

1.420 654 E04

gill (U.S.)

meter3 (m3)

1.182 941 E04

grad

degree (angular)

9.000 000* E01

grad

radian (rad)

1.570 796 E02

kilogram (kg)

6.479 891* E05

kilogram per meter3

(kg/m3)

1.711 806 E02

gram

kilogram (kg)

1.000 000* E03

g/cm3

kilogram per meter3

(kg/m3)

1.000 000* E+03

gram-force/cm2

pascal (Pa)

9.806 650 E+01

hectare

meter2 (m2)

1.000 000* E+04

horsepower (550 ftlbf/s)

watt (W)

7.456 999 E+02

horsepower (boiler)

watt (W)

9.809 50 E+03

horsepower (electric)

watt (W)

7.460 000* E+02

horsepower (metric)

watt (W)

7.354 99 E+02

horsepower (water)

watt (W)

7.460 43 E+02

horsepower (U.K.)

watt (W)

7.457 0 E+02

hour (mean solar)

second (s)

3.600 000 E+03

hour (sidereal)

second (s)

3.590 170 E+03

hundredweight (long)

kilogram (kg)

5.080 235 E+01

hundredweight (short)

kilogram (kg)

4.535 924 E+01

meter (m)

2.540 000* E02

gallon (U.S. liquid) per per hph

(SFC, specific fuel
consumption)

grain (1/7000 lb avoirdupois)

grain (lb avoirdupois/7000) gal
(U.S. liquid)

inch

Revision 1

90

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

inch of mercury (32F)

pascal (Pa)

3.386 38 E+03

inch of mercury (60F)

pascal (Pa)

3.376 85 E+03

inch of water (39.2F)

pascal (Pa)

2.490 82 E+02

inch of water (60F)

pascal (Pa)

2.488 4 E+02

in2

meter2 (m2)

6.451 600* E04

in3 (volume; section modulus)

meter3 (m3)

1.638 706 E05

meter3 per second (m3/s)

2.731 177 E07

meter4 (m4)

4.162 314 E07

in/s

meter per second (m/s)

2.540 000* E02

in/s2

meter per second2 (m/s2)

2.540 000* E02

kayser

1 per meter (1/m)

1.000 000* E+02

kelvin

degree Celsius

in3/min
in4 (moment of section)

tC = tK 273.15

kilocalorie (International Table)

joule (J)

4.186 800* E+03

kilocalorie (mean)

joule (J)

4.190 02 E+03

kilocalorie (thermochemical)

joule (J)

4.184 000* E+03

kilocalorie
(thermochemical)/min

watt (W)

6.973 333 E+01

kilocalorie (thermochemical)/s

watt (W)

4.184 000* E+03

newton (N)

9.806 650* E+00

newton meter (Nm)

9.806 650* E+00

kilogram (kg)

9.806 650* E+00

kgf/cm2

pascal (Pa)

9.806 650* E+04

kgf/m2

pascal (Pa)

9.806 650* E+00

kgf/mm 2

pascal (Pa)

9.806 650* E+06

meter per second (m/s)

2.777 778 E01

newton (N)

9.806 650* E+00

joule (J)

3.600 000* E+06

kilogram-force (kgf)
kgfm
kgfs2/m (mass)

km/h
kilopond
kWh

Revision 1

91

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

kip (1000 lbf)

newton (N)

4.448 222 E+03

kip/in 2 (ksi)

pascal (Pa)

6.894 757 E+06

meter per second (m/s)

5.144 444 E01

knot (international)
lambert

candela per meter2 (cd/m2)

l/

* E+04

lambert

candela per meter2 (cd/m2)

3.183 099 E+03

langley

joule per meter2 (J/m2)

4.184 000* E+04

league

meter (m)

light year

meter (m)

9.460 55 E+15

liter

meter3 (m3)

1.000 000* E03

maxwell

weber (Wb)

1.000 000* E08

mho

siemens (S)

1.000 000* E+00

microinch

meter (m)

2.540 000* E08

micron

meter (m)

1.000 000* E06

mil

meter (m)

2.540 000* E05

mile (international)

meter (m)

1.609 344* E+03

mile (statute)

meter (m)

1.609 3 E+03

mile (U.S. survey)

meter (m)

1.609 347 E+03

mile (international nautical)

meter (m)

1.852 000* E+03

mile (U.K. nautical)

meter (m)

1.853 184* E+03

mile (U.S. nautical)

meter (m)

1.852 000* E+03

mi2 (international)

meter2 (m2)

2.589 988 E+06

mi2 (U.S. survey)

meter2 (m2)

2.589 998 E+06

mi/h (international)

meter per second (m/s)

4.470 400* E01

mi/h (international)

kilometer per hour (km/h)

1.609 344* E+00

mi/min (international)

meter per second (m/s)

2.682 240* E+01

mi/s (international)

meter per second (m/s)

1.609 344* E+03

Revision 1

92

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

millibar

pascal (Pa)

1.000 000* E+02

millimeter of mercury (0C)

pascal (Pa)

1.333 22 E+02

minute (angle)

radian (rad)

2.908 882 E04

minute (mean solar)

second (s)

6.000 000 E+01

minute (sidereal)

second (s)

5.983 617 E+01

month (mean calendar)

second (s)

2.628 000 E+06

ampere per meter (A/m)

7.957 747 E+01

ohmmeter (m)

1.000 000* E02

ohm millimeter2 per meter

(mm 2/m)

1.662 426 E03

ounce (avoirdupois)

kilogram (kg)

2.834 952 E02

ounce (troy or apothecary)

kilogram (kg)

3.110 348 E02

ounce (U.K. fluid)

meter3 (m3)

2.841 307 E05

ounce (U.S. fluid)

meter3 (m3)

2.957 353 E05

ounce-force

newton (N)

2.780 139 E01

ozfin

newton meter (Nm)

7.061 552 E03

oz (avoirdupois)/gal
(U.K. liquid)

kilogram per meter3

(kg/m3)

6.236 021 E+00

oz (avoirdupois)/gal
(U.S. liquid)

kilogram per meter3

(kg/m3)

7.489 152 E+00

oz (avoirdupois)/in 3

kilogram per meter3

(kg/m3)

1.729 994 E+03

oz (avoirdupois)/ft2

kilogram per meter2

(kg/m2)

3.051 517 E01

oz (avoirdupois)/yd2

kilogram per meter2

(kg/m2)

3.390 575 E02

meter (m)

3.085 678 E+16

meter3 (m3)

8.809 768 E03

pennyweight

kilogram (kg)

1.555 174 E03

Revision 1

93

oersted
ohm centimeter
ohm circular-mil per foot

parsec
peck (U.S.)

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

perm (0C)

kilogram per pascal second

meter2
(kg/Pasm2)

5.721 35 E11

perm (23C)

kilogram per pascal second

meter2
(kg/Pasm2)

5.745 25 E11

permin (0C)

kilogram per pascal second

meter
(kg/Pasm)

1.453 22 E12

permin (23C)

kilogram per pascal second

meter
(kg/Pasm)

1.459 29 E12

lumen per meter2 (lm/m2)

1.000 000* E+04

pica (printers)

meter (m)

4.217 518 E03

pint (U.S. dry)

meter3 (m3)

5.506 105 E04

pint (U.S. liquid)

meter3 (m3)

4.731 765 E04

point (printers)

meter (m)

3.514 598* E04

pascal second (Pas)

1.000 000* E01

pound (lb avoirdupois)

kilogram (kg)

4.535 924 E01

pound (troy or apothecary)

kilogram (kg)

3.732 417 E01

lbft2 (moment of inertia)

kilogram meter2 (kgm2)

4.214 011 E02

lbin2 (moment of inertia)

kilogram meter2 (kgm2)

2.926 397 E04

lb/fth

pascal second (Pas)

4.133 789 E04

lb/fts

pascal second (Pas)

1.488 164 E+00

lb/ft 2

kilogram per meter2

(kg/m2)

4.882 428 E+00

lb/ft 3

kilogram per meter3

(kg/m3)

1.601 846 E+01

lb/gal (U.K. liquid)

kilogram per meter3

(kg/m3)

9.977 633 E+01

lb/gal (U.S. liquid)

kilogram per meter3

(kg/m3)

1.198 264 E+02

phot

poise (absolute viscosity)

Revision 1

94

December 19, 2001

MESN 99-001-0A

To convert from
lb/h

to

Multiply by

kilogram per second (kg/s)

1.259 979 E04

kilogram per joule (kg/J)

1.689 659 E07

lb/in3

kilogram per meter3

(kg/m3)

2.767 990 E+04

lb/min

kilogram per second (kg/s)

7.559 873 E03

lb/s

kilogram per second (kg/s)

4.535 924 E01

kilogram per meter3

(kg/m3)

5.932 764 E01

poundal

newton (N)

1.382 550 E01

poundal/ft2

pascal (Pa)

1.488 164 E+00

pascal second (Pas)

1.488 164 E+00

newton (N)

4.448 222 E+00

newton meter (Nm)

1.355 818 E+00

newton meter per meter

(Nm/m)

5.337 866 E+01

newton meter (Nm)

1.129 848 E01

lbfin/in

newton meter per meter

(Nm/m)

4.448 222 E+00

lbfs/ft 2

pascal second (Pas)

4.788 026 E+01

lbfs/in2

pascal second (Pas)

6.894 757 E+03

lbf/ft

newton per meter (N/m)

1.459 390 E+01

lbf/ft2

pascal (Pa)

4.788 026 E+01

lbf/in

newton per meter (N/m)

1.751 268 E+02

pascal (Pa)

6.894 757 E+03

newton per kilogram

(N/kg)

9.806 650 E+00

meter3 (m3)

1.101 221 E03

lb/hph (SFC, specific fuel

consumption)

lb/yd3

poundals/ft 2
poundforce (lbf)
lbfft
lbfft/in
lbfin

lbf/in2 (psig)
lbf/lb [thrust/weight (mass) ratio]
quart (U.S. dry)

Revision 1

95

December 19, 2001

MESN 99-001-0A

To convert from

to

Multiply by

meter3 (m3)

9.463 529 E04

gray (Gy)

1.000 000* E02

rhe

1 per pascal second (1/Pas)

1.000 000* E+01

rod

meter (m)

quart (U.S. liquid)

rad (radiation dose absorbed)

roentgen
second (angle)
second (sidereal)

coulomb per kilogram

(C/kg)

2.58 E04

radian (rad)

4.848 137 E06

second (s)

9.972 696 E01

section

meter2 (m2)

shake

second (s)

1.000 000* E08

kilogram (kg)

1.459 390 E+01

slug/fts

pascal second (Pas)

4.788 026 E+01

slug/ft 3

kilogram per meter3

(kg/m3)

5.153 788 E+02

statampere

ampere (A)

3.335 640 E10

statcoulomb

coulomb (C)

3.335 640 E10

statfarad

farad (F)

1.112 650 E12

stathenry

henry (H)

8.987 554 E11

statmho

siemens (S)

1.112 650 E+12

statohm

ohm ()

8.987 554 E+11

statvolt

volt (V)

2.997 925 E+02

stere

meter3 (m3)

1.000 000* E+00

stilb

candela per meter2 (cd/m2)

1.000 000* E+04

meter2 per second (m2/s)

1.000 000* E04

tablespoon

meter3 (m3)

1.478 676 E05

teaspoon

meter3 (m3)

4.928 922 E06

kilogram per meter (kg/m)

1.000 000* E+06

slug

stokes (kinematic viscosity)

tex

Revision 1

96

December 19, 2001

MESN 99-001-0A

To convert from

to

therm

Multiply by

joule (J)

1.055 056 E+08

ton (assay)

kilogram (kg)

2.916 667 E02

ton (long, 2240 lb)

kilogram (kg)

1.016 047 E+03

ton (metric)

kilogram (kg)

1.000 000* E+03

ton (nuclear equivalent of TNT)

joule (J)

4.184 E+09

ton (refrigeration)

watt (W)

3.516 800 E+03

meter3 (m3)

2.831 685 E+00

kilogram (kg)

9.071 847 E+02

ton (long)/yd3

kilogram per meter3

(kg/m3)

1.328 939 E+03

ton (short)/yd 3

kilogram per meter3

(kg/m3)

1.186 553 E+03

kilogram per second (kg/s)

2.519 958 E01

newton (N)

8.896 444 E+03

kilogram (kg)

1.000 000* E+03

ton (register)
ton (short, 2000 lb)

ton (short)/h
ton-force (2000 lbf)
tonne
torr (mm Hg, 0C)

pascal (Pa)

township

meter2 (m2)

unit pole

weber (Wb)

1.256 637 E07

Wh

joule (J)

3.600 000* E+03

Ws

joule (J)

1.000 000* E+00

W/cm 2

watt per meter2 (W/m2)

1.000 000* E+04

W/in2

watt per meter2 (W/m2)

1.550 003 E+03

yard

meter (m)

9.144 000* E01

yd2

meter 2 (m2)

8.361 274 E01

yd3

meter 3 (m3)

7.645 549 E01

meter3 per second (m3/s)

1.274 258 E02

year (365 days)

second (s)

3.153 600 E+07

year (sidereal)

second (s)

3.155 815 E+07

year (tropical)

second (s)

3.155 693 E+07

yd3/min

Revision 1

97

1.333 22 E+02

December 19, 2001

MESN 99-001-0A

Appendix F
Joint Efficiencies
Table 2.

Maximum allowable joint efficiencies for arc and gas-welded joints (reproduced from
Table UW-12 in ASME Boiler and Pressure Vessel Code).
Degree of Examination

No. Type of Joint Description

Limitation

(a)
(b)
(c)
Fully
Spot
Not Spot
Radio- Examined 2 Examined 3
graphed1

(1)

Butt joints as attained by None

double-welding or by
other means which will
obtain the same quality of
deposited weld metal on
the inside and outside
weld surfaces to agree
with the requirements of
UW-35. Welds using metal
backing strips which
remain in place are
excluded.

1.00

0.85

0.70

(2)

Single-welded butt joint (a) None except as in (b) below

with backing strip other
(b) Butt weld with one plate offthan those included under
setfor circumferential joints
(1)
only, see UW-13(c) and Fig. UW13.1 sketch (k).

0.90

0.80

0.65

(3)

Single-welded butt joint

without use of backing
strip

Circumferential joints only, not over

5/8-in. thick and not over 24 in.
outside diameter.

0.60

(4)

Double fill fillet lap joint Longitudinal joints not over 3/8-in.
thick. Circumferential joints not over
5/8-in. thick.

0.50

(5)

Single fill fillet lap joints (a) Circumferential joints4 for

with plug welds
attachment of heads not over 24
conforming to UW-17
in. outside diameter to shells not
over 1/2-in. thick.
(b) Circumferential joints for the
attachment to shells of jackets not
over 5/8 in. in nominal thickness
where the distance from the
center of the plug weld to the
edge of the plate is not less than
1 1/2 times the diameter of the
hole for the plug.

Revision 1

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MESN 99-001-0A

Table 2.

Maximum allowable joint efficiencies for arc and gas-welded joints (reproduced from
Table UW-12 in ASME Boiler and Pressure Vessel Code) (cont'd).
Degree of Examination

No. Type of Joint Description

Limitation

(6) Single full fillet lap joints (a) For the attachment of heads
without plug welds
convex to pressure to shells not
over 5/8 in. required thickness,
only with use of fillet weld on
inside of shell; or

(a)
(b)
(c)
Fully
Spot
Not Spot
Radio- Examined 2 Examined 3
graphed1

0.45

(b) For attachment of heads having

pressure on either side, to shells
not over 24 in. inside diameter
and not over 1/4 in. required
thickness with fillet weld on
outside of head flange only.
(1) See UW-12(a) and UW-51.
(2) See UW-12(b) and UW-52.
(3) The maximum allowable joint efficiencies shown in this column are the weld joint efficiencies multiplied by 0.80 (and
rounded off to the nearest 0.05), to effect the basic reduction in allowable stress required by this division for welded vessels
that are not spot examined. See UW-12(c).
(4) Joints attaching hemispherical heads to shells are excluded.

Revision 1

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December 19, 2001

MESN 99-001-0A

Appendix G
High-Pressure Drawing Symbols
The following high-pressure drawing symbols are standard in all LLNL engineering
drawings.
Fittings
Tee

Cross

Ell

Adapter or coupling

Manual valves
Two-way (two-port) valves

Three-way (three-port) valves

Type 1

Type 2

Type 3

Type 4

Straight-through
valve

Angle valve

Two ports
to pressure

One port
to pressure

Remote-operation valves
Electrical
Pneumatic

Solenoid

Motorized

Explosive (squib)

(show min. operating

pressure required)
MTR 12 V

ATO 50 psig

110 V

2A

NO

ATC = air to close

ATO = air to open

NC

NC

(Show operating voltage)

(Show min. firing current required)
Indicate NC or NO, where applicable.
NC = normally closed when power is off.
NO = normally open when power is off.

Revision 1

100

December 19, 2001

MESN 99-001-0A

Automatic valves (shown assembled to a tee)

Pressure switch

Pressure controller

15,000 max

Flow switch

100015,000

6 gpm

PS

FS

(Show range
or limit
of control)

(Continue line
to unit being
controlled)

(Show
limiting
flow)

Relief devices (shown assembled to a tee)

Spring-loaded relief valve

Rupture disc

Spring-loaded relief valve

with integral rupture disc

Rupture disc backed

with fusible metal

35,000
2500

30,000

30,000

20,000

(Show set relief pressure

and/or disc burst pressure)

Regulators and gauges

Regulator
(adjustable)
4000

Reducer
(nonadjustable)

020,000

1500
4000

(Show max
gauge readings)

Revision 1

Gauge
Transducer
(shown on a valve)
TCR

50,000

500

(Show set pressures)

101

(Show pressure ranges)

December 19, 2001

MESN 99-001-0A

Flowrater or
flow indicator

Filter

Heat exchanger

Check valve

HX
F
IN

OUT

Arrows indicate normal flow

Revision 1

102

December 19, 2001