Environmental Management

Specifying Vessels for

High-Pressure
Dust Collectors
Todd Russelburg
Flex-Kleen Div., Met-Pro Corp.

any chemical processes employ dust

collectors operating at high pressures
(>15 psig) to remove dust or fine particulates from exhaust streams in order to prevent downstream contamination or reclaim a
valuable material. Such systems must use vessels that conform to the strict codes and standards published by the American Society of
Mechanical Engineers (www.asme.org). These
high-pressure dust collectors are significantly
different from their counterparts employed in
processes operating at lower pressures.
The ASME Boiler and Pressure Vessel Code
(BPVC) covers virtually every aspect of the highpressure dust collector vessel (sidebar, p. 52).
Design characteristics such as construction materials, wall thicknesses, bolting patterns, access
doors, inspection ports, pipe connections, reinforcing rings, etc., must be incorporated within a
complex framework. Although these design considerations are independent and must be accounted for individually, most are interrelated and
therefore must also be determined based upon
overall vessel and/or system requirements.
The design and construction of code dust collector vessels involves two major phases. The
first phase deals with process engineering and
external parameters, such as design pressure,
process temperature, materials of construction,
etc. The second phase is the mechanical design to
specify such features as required strength, wall
thicknesses, nozzle fitting reinforcements, flange
connections, gaskets, valves, joints, fittings, and

ASME codes and standards govern

the design, fabrication, testing
and certification of high-pressure
dust collector vessels.
This article will assist you in
working with a code vessel designer
and/or manufacturer.

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ASME Code Requirements for Pressure Vessels

he ASME defines pressure vessels as containers for the
containment of pressure, either internal or external. This
pressure may be obtained from an external source, or by the
application of heat from a direct or indirect source, or any combination thereof.
The most recent revisions to the codes and standards related
to high-pressure dust collector vessels are included in the ASME
Boiler and Pressure Vessel Code (BPVC) Section VIII, Rules for
Construction of Pressure Vessels, Division 1 (BPVC-VIII 2004).
Also known as the U Code, it is divided into three subsections:
mandatory and non-mandatory appendices; Part UG, which covers the general requirements applicable to all pressure vessels;
and Part UW, which covers specific requirements applicable to
various fabrication methods.
The U Code covers vessel design issues, such as overall size,
materials, operating pressure and pressure relief, as well as fabrication, inspection, testing, certification and documentation. While
it does not address all aspects of these activities, it makes clear
that those aspects which are not specifically addressed should
not be considered prohibited, and that engineering judgment
must be consistent with the philosophy of this Division. It also
addresses the responsibility of the user (or designated agent)
with regard to establishing design requirements for pressure vessels from the perspective of their operation, including such con-

other accessories. After that, fabrication begins, and all subsequent work focuses on the mechanical integrity of the vessel.
The design process usually starts with the vessel manufacturers engineering staff reviewing performance requirements
with the customer. The manufacturer performs preliminary
calculations based on the application requirements and appropriate code standards, and generates drawings for the customers approval. The drawings are then further evaluated to
determine practicality and cost effectiveness, and to ensure
that critical issues such as reinforcement pads, wall thicknesses, accessories, operating conditions, and other factors are
resolved prior to construction. If the vessel user has developed
its own specifications for a particular vessel, the manufacturer
must review those in the context of applicable standards.

Materials of construction
The construction material selected for a particular vessel
will depend on operating pressure, temperature, and the
process and/or material for which the vessel is being used.
The process itself must be given prime consideration. Will
corrosion be a factor? Is the process carried out at high temperatures? These are critical issues, because the vessels useful
life will be affected by the corrosive nature of the process. At
higher temperatures, corrosion rates increase, further affecting
the life of the vessel and the need for corrosion protection.
Typical plate materials (Table) include stainless steel,
Hastalloy, Monel, Inconel, and Code-quality carbon steel (e.g.,
SA-516-70 or SA-285C). Section II of BPVC addresses this
subject in detail. Tables and charts in Section II give design
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ditions as startup and shutdown, and abnormal conditions which

may become a governing design consideration.
Much latitude exists in the design and construction of code
vessels. For example, a vessel may be designed and constructed using any combination of the methods of fabrication and the
classes of materials covered by this Division provided the rules
applying to each method and material are complied with and the
vessel is marked as required by UG-116.
Annual addendums present formulas and guidelines for determining the precise vessel design based upon application requirements. These formulas cover vessel configuration, wall thickness,
maximum allowable stress, accessories, construction materials,
and other matters. Individual appendices also define specific
design functions, such as configuring dished heads, doors,
flanges and other construction features not included in the main
body of the Code.
For information on purchasing codes and standards, contact
ASME at 1-800-843-2763 or infocentral@asme.org. For other
information or questions about a specific ASME code or standard,
call 1-212-591-8500 or e-mail cs@asme.org. Another important
resource for obtaining specific ASME Code information is the
Linda Hall Library (Kansas City, KS; 1-800-662-1545; www.lindahall.org), which operates a public search service and provides various documents related to ASME Codes and Standards.

stress values and strength properties for various materials.

Part UW of BPVC Section VIII describes acceptable welding materials and procedures. Testing and certification methods are covered in Section IX. It is important to understand
these, since cost and vessel integrity may be affected.
Non-destructive testing (NDT) is used to discover discontinuities in a weld. Radiography (X-ray) requires access to both
sides of a weld joint. Small vessels and vessels without access
to both sides can be inspected by ultrasonic testing (UT),
which requires access to only one side. Liquid penetrant
inspection (LPI) requires a smooth surface, and is generally
not used on a finished weld, but rather just the root pass.
Magnetic particle (MP) testing involves placing a magnetic
charge on the ferrous base metal; it is not used on austenitic
stainless steels (300 series), which are not magnetic.
Some NDT is mandated by the Code. For example, vessels
in lethal service and thick weld joints require a 100% X-ray
check for approval. Other applications may need only spot
X-rays, while still others may forego weld X-rays altogether.
Not all of the above-mentioned tests may be required by
the ASME Code. However, the vessels user may still request
that the fabricator conduct them.
The ASME Code contains data used in design equations
to arrive at weld efficiency factors. These are used to calculate the allowable stresses to be placed on the vessel or any
of its components. The maximum allowable stress on a
weld is known as SE, which is calculated by multiplying
the maximum allowable stress on the material (S) by the
weld efficiency (E). For example, double-welded butt joints

Table. Material requirements

depend on the nature of the process.

Process

Recommended
Material

Comments

Exhaust gas
from a
pharmaceutical
spray dryer

Type 316
stainless steel

Sanitary application

Process
manufacturing
pool chemicals

Hastalloy C276

Corrosion resistance
to chlorine

Exhaust gas from

brick/tile
manufacturing
kilns

Hastalloy C276

Corrosion resistance
to HCl

Fluid-bed
PVC powder
drying systems

Type 317
stainless steel

Corrosive
environment

Waste incineration

Inconel

High temperature

without radiography examination have a weld efficiency

factor of 0.7, so the allowable stress on the weld must be
reduced by 30% as a conservative measure.

Design and construction differences

among code vessels
A process with a code dust collector vessel may be
changed from positive to negative pressure. To accommodate the operating differences, special design considerations
apply to these applications.
For instance, a vessel under negative pressure may
require stiffening rings around its housing to accommodate
compressive forces encountered during operation. Such rings
may not be required on positive-pressure vessels, since they
are not subject to the same stresses. In addition, vessel wall
thickness in vacuum applications can be higher than in positive-pressure applications.
Most code vessels have openings such as doors or access
ports (for inspection, cleaning, filter bag replacement, etc.).
Because these openings are generally considered weak
points in the vessel structure, they are usually reinforced to
maintain the integrity of the vessels pressure rating. This is
sometimes accomplished with a reinforcing ring around the
nozzle opening and may require finite element analysis due
to the unusual geometry.
Structural reinforcement can also be accomplished on nozzles by specifying an increased wall thickness. For example, if
the calculated thickness requirement of a nozzle shell is 0.18
in., the designer might specify a heavier schedule. That excess
thickness helps to reinforce the vessel opening, and may be
strong enough to accommodate an access port without the need
for a separate reinforcement ring. This type of construction
lowers costs without affecting vessel performance or integrity.
As might be expected, there are usually substantial differ-

ences between code vessels designed for operation at pressure

extremes e.g., 15 psig and 250 psig even though the vessel sizes might be the same. Operating pressures are typically
considered the main determining factors for wall thicknesses,
flanges, reinforcement pads and other accessories, as well as
materials of construction, which are also a function of the specific process. Thus, it is important to work with a manufacturer
experienced in dust collector vessels, since through its expertise
and knowledge of your application it can suggest many practical and cost-effective design and/or construction alternatives.
Safety is the main consideration any time a dust collector
vessel is required, especially when the vessel is located inside a
building. Some code vessels, referred to as containment vessels, are considerably overbuilt, and are designed for explosion-proof operation above 50 psig. For situations where
explosive dust cannot be vented safely, the only practical solution is to design the vessel to withstand an explosion. A reasonable design standard for a containment vessel is ASME Code.
Many code vessel manufacturers also produce non-code dust
collector vessels for low-pressure applications, yet still use
ASME Code calculations for unusual configurations and/or performance requirements. In addition, for safety reasons (and
most likely legal, as well), some companies elect to have their
low-pressure vessels constructed to meet Code even though a
code stamp is not required. Since ASME Code dictates virtually
every construction characteristic of the vessel, everything is
clearly defined and well-documented with regard to engineering
calculations and safety issues. The code stamp provides peace
of mind and assures high performance and a long useful life.

Handling variable process pressures

If a dust collector vessel will be subjected to variable
process pressures, even if the pressure will remain below 15
psig, it is still prudent to build it to Code. This subject is covered in the BPVC Section VIII Division 2, Appendix 5. This
appendix discusses such issues as the infinite numbers of
cycles based on a peak cycle pressure of 10 psig. Specifically,
it addresses the cyclic nature of the pressure loading and discusses variable process pressure, not only for the vessels shell
but also non-pressure appurtenances such as lugs and supports.
While the Code gets into further detail, it is important to
emphasize here that when dust collector vessels (whether
operating at high or low presssures) are subjected to repeated
expansion and contraction cycles, unusual stresses are placed
on them, and these must be factored into the design and construction calculations. The vessel cannot be designed only for
the static conditions.
Dust collector code vessels require certain types of header
configurations for instance, headers must not protrude from
the shell (e.g., to accommodate hardware such as elbows or
ducting for the pulsing filter-cleaning assemblies). However, a
variety of standard couplings (not specifically included in
Code requirements) are allowed. Many code vessels do not
require flanged couplings, and can use standard couplings
rated for operation to 150 psi. Quick-connect couplings rated

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Environmental Management

to 500 psi are also allowed, even though they are not specifically mentioned in the Code. This is another area in which an
experienced and knowledgeable code vessel manufacturer can
help make cost-effective design choices.

Door shapes matter

Virtually every dust collector vessel (high-pressure or lowpressure) requires access to internal components such as filter
media for periodic maintenance. This access is through doors
or ports, depending upon the vessel configuration. For example, vessel housings from which filter bags are removed from
the dirty air side require access doors, whereas other vessels
may incorporate lift-off heads for access from the clean side.
In general, round, elliptical or oblong doors are most often
used on code vessels. This is done to avoid the possible concentration of stress, and thus propagation of stress cracks, on
openings with 90-degree angled corners.
Other safety considerations include davit assemblies (i.e.,
door supports, or swing arms, to hold the door when opened),
which might be required on heavy doors to make it easier for
workers to handle them. Many code vessels with walk-in
plenums fit into this category.
Filter media for high-pressure dust collectors
Filter media used in code dust collector vessels are generally the same as for low-pressure vessels. Filter tubes, sheets or
bags are not considered high-pressure-bearing components, so
there are no Code requirements for them.
Process temperatures, as well as the composition of the
specific dust being filtered, generally determine filter media
requirements. For example, polyester and polypropylene are
typically used for standard applications. Polytetrafluoroethylene (PTFE; Teflon) may be used when high-efficiency
bags are required, while heat-resistant materials such as nylon
(Nomex), fiberglass and polyphenylene sulfide (PPS; Ryton)
are suitable for high-temperature bags.
Fiberglass dust collector filters and filter bags that perform
well at temperatures up to 700F (371C) are also available.
These cost substantially less than sintered metal/ceramic filter
media, and they eliminate the need for expensive upstream
pretreatment equipment, such as the coolers, quenchers,
sprayers and chillers typically used to cool dust-laden gases
prior to reaching the filter media.
Enforcing ASME requirements
In order to maintain a license and the authority to construct
code vessels, manufacturers must be audited, licensed and
continuously monitored to assure their products conformance
to all ASME Codes and Standards. Various entities may be
responsible for these procedures, including consultants hired
by insurance companies or a government agency. These
inspectors are responsible for final approval of U-stamped
(Code-approved) dust collector vessels.
In addition to the familiar U stamp that the manufacturer
applies to the code vessel, users of high-pressure dust collectors should be aware of the R stamp. Governed by the National
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Board of Inspection Code (NBIC) and post-construction standards of the American Petroleum Institute (API), the R stamp
is essentially a repair authorization. It allows an organization to
access the appropriate formal specifications and standards from
the ASME and to facilitate the appropriate repair.
For example, a facility may require a new nozzle for a
code vessel to accommodate a process revamp. The plant
engineering/maintenance staff and ordinary maintenance contractors are prohibited from simply cutting an opening in the
vessel and welding or bolting on new hardware. The upgrade
or repair must be done by a licensed ASME Code shop (R
stamp), which may or may not be a manufacturer permitted to
build ASME Code vessels (U stamp).
A completed code vessel undergoes stringent hydro-testing
procedures to assure its integrity and determine its performance
parameters with regard to Code compliance. The hydrostatic
pressure to be used for this test is calculated by multiplying the
maximum allowable working pressure (MAWP) by the ratio of
allowable stress at the test temperature to allowable stress at
the design temperature, and increasing that by one-third.
If the actual test pressure exceeds the calculated pressure
and distortion is observed at that higher pressure, the inspector
may reject the vessel. However, the inspector is not required
to reject the vessel, and in fact, the manufacturer may apply
the stamp if the inspector concurs.

Final thoughts
ASME Code requirements may determine that a particular
application requires a certain construction material, that all
seams must be welded and tested to a particular standard, that
flanges must be a certain diameter and/or thickness, that the
vessel walls must be a precise thickness, and so on. But while
this information is critical, it may not tell the whole story.
Code calculations may not automatically lead to the conclusion that at this pressure rating, for this process, at this temperature, in this configuration, this material must be used.
Thats why it is important to work closely with a knowledgeable manufacturer at the early stages of the code vessel
design cycle. While the fundamentals of capturing dust or particulate fines under high pressure may not be the most esoteric
subject, there is still much science, knowledge, experience and
expertise that goes into designing and producing safe, reliable
and long-lasting dust collector code vessels.
A Code-stamped vessel provides a safety net with
regard to possible future liability for its manufacturer, owner
and virtually everyone else associated with it. In todays litigious environment, indemnifying those involved with the vessel becomes important.
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TODD RUSSELBURG, P.E., is the engineering manager at Flex-Kleen Div., MetPro Corp. (Itasca, IL; Phone: 1-800-621-0734; E-mail: trusselburg@metpro.com). He has 10 years of experience in pressure vessel and dust
collector design. He earned a BS in mechanical engineering from the Univ.
of Louisville (KY), is a registered professional engineer, and is a member
of the National Society of Professional Engineers and the National Fire
Protection Association.