Vessel Part 1 – Brownell & Young

Equipment Design • Fa c t o r I n f l u e n c i n g
t h e d e s i g n o f Ve s s e l s
• C r i t e r i a i n Ve s s e l
Design
 Factor Influencing the
Vessel design of Vessels
Equipment Design
1 . S e l e c t i o n o f t h e t y p e o f Ve s s e l
2. Method of Fabrication
3 . C r i t e r i a i n Ve s s e l d e s i g n
4. Economic consideration
 Factor Influencing the design FR
of Vessels
Ty p e o f Ve s s e l

Close Vessel/Pressure Vessel

Flat-bottomed, vertical
cylindrical tanks, conical roof
Open Tanks Storage, surge,
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settling tank, etc
 Factor Influencing the design FR
of Vessels
Ty p e o f Ve s s e l

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Factor Influencing the design FR
of Vessels
Ty p e o f Ve s s e l
What shape of pressure vessel uses the least amount of
metal to contain a given volume, pressure?

Why is this shape not more widely used?

Vessel Diameter gets very expensive if > 13.5 ft. Why?

Height (length) gets very expensive if > 180 ft. Why?

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 Factor Influencing the design FR
of Vessels
M et h o d o f Fa b r i c at i o n
Extensively used for
fabrication and erection
of large-size process
equipment in the field;
Fusion Welding
1. The Gas Welding
process
Welding Standards
2. The Electric-arc
Welding process

Type of
Welded Joints
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 Factor Influencing the design FR
of Vessels
M et h o d o f Fa b r i c at i o n

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 Factor Influencing the design FR
of Vessels
C r i te r i a i n Ve s s e l D e s i g n
• Selection of vessel type is based primarily upon
the functional services required of the vessel
• The functional requirement impose certain
operating condition (pressure, temperature,
dimensional limitations and various loads)
• If vessel not design properly to accommodate the
requirement, it may fail in service.
• Failure may occur in one or more manners:
✓ Plastic deformation resulting from excessive
stress
✓ Rupture without plastic deformation
✓ Elastic instability
✓ Corrosion and fatigue
• Design of the vessel to protect against such failure
involved consideration of this factor and physical
properties of the materials. 8
Factor Influencing the design FR
of Vessels
G e o m et r y :
O r i e nt at i o n fo r
C y l i n d r i c a l Ve s s e l

Vertical vessels
Easier to distribute fluids across a smaller cross section
Smaller plot space
Horizontal vessels
To promote phase separation
Increased cross section = lower vertical velocity = less entrainment
Decanters, settling tanks, separators, flash vessels
To allow internals to be pulled for cleaning
Heat exchangers

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Factor Influencing the design FR
of Vessels
G e o m et r y : M a i n
C o m p o n e nt o f ve s s e l

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Factor Influencing the design FR
of Vessels
G e o m et r y : M a i n
C o m p o n e nt o f ve s s e l

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Factor Influencing the design FR
of Vessels
G e o m et r y : H e a d
( C l o s u re ) D e s i g n
Hemispherical
Good for high pressures
Higher internal volume
Most expensive to form & join to shell
Half the thickness of the shell

Ellipsoidal
Cheaper than hemispherical and less internal
volume
Depth is half diameter
Same thickness as shell
Most common type > 15 bar

Torispherical
Part torus, part sphere
Similar to elliptical, but cheaper to fabricate
Cheapest for pressures less than 15 bar 12
Factor Influencing the design FR
of Vessels
Ta n ge nt a n d We l d L i n e s We l d e d J o i nt s
Butt weld

Single fillet
lap weld

Double fillet
lap weld

• Tangent line is where curvature begins Double fillet

• Weld line is where weld is located corner joint
• Usually they are not the same, as the head is
fabricated to allow a weld away from the
geometrical joint 13
Factor Influencing the design FR
of Vessels
G a s kete d J o i nt s • Used when vessel must be opened frequently for cleaning,
inspection, etc.
• Also used for instrument connections
• Not used at high temperatures or pressures (gaskets fail)
• Higher fugitive emissions than welded joints

(a) Full face gasket

(b) Gasket within bolt circle
(c) Spigot and socket
(d) O-ring

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Factor Influencing the design FR
of Vessels Nozzle Reinforcement
N oz z l e s
• Vessel needs nozzles for
• Feeds, Products
• Hot &/or cold utilities
• Manways, bursting disks, relief
valves
• Instruments
• Pressure, Level, Thermowells
• Sample points
• More nozzles = more cost • Shell is weakened around nozzles, and
• Nozzles are usually on side of must also support eccentric loads
vessel, away from weld lines, from pipes
usually perpendicular to shell • Usually weld reinforcing pads to
• Nozzles may or may not be flanged thicken the shell near the nozzle. Area
(as shown) depending on joint type of reinforcement = or > area of nozzle:
• The number & location of nozzles as per Code requirements
are usually specified by the process
engineer
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Factor Influencing the design FR
of Vessels
Swa ge d Ve s s e l s

• Vessel does not have to be constant diameter

• It is sometimes cheaper to make a vessel
with several sections of different diameter
• Smaller diameters are usually at the top, for
structural reasons
• ASME BPV Code gives rules for tapered
sections

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Factor Influencing the design FR
of Vessels
Ve s s e l S u p p o r t s
• Supports must allow for thermal expansion in
operation
• Smaller vessels are usually supported on
beams – a support ring or brackets are welded
to the vessel
• Horizontal vessels often rest on saddles
• Tall vertical vessels are often supported using a
skirt rather than legs.

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Factor Influencing the design FR
of Vessels
Ve s s e l I nte r n a l s
• Most vessels have at least some internals
– Distillation trays
– Packing supports
– Distribution grids
– Heating or cooling coils
• These may require support rings welded to the
inside of the vessel

• The internals & support rings need to be

considered when calculating vessel weights for
stress analysis
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 Factor Influencing the design FR
of Vessels
Ec o n o m i c
C o n s i d e rat i o n

Steel Pricing;
Warehouse Pricing

Fabrication Costs;
Fabrication
Procedure; Man
hours and Materials

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 Criteria in Vessel Design
Vessel Considering :
Equipment Design
✓ Excessive Elastic Deformation
✓ Elastic Instability
✓ Plastic Instability
✓ Brittle Rupture
✓ Creep
✓ Corrosion
✓Excessive Elastic Deformation FR
→ By load (Ex: Weight of the material, fluid pressure, wind, etc), when load removed
it resume to its original shape
Induced → Tensile Stress, Compressive Stress, Shear Stress, Bending Stress, Torsion Stress
Stresses

Modulus of
Elasticity
→ Sufficient rigidity must be incorporated in design, to restrict deformation
→ Proportionality constant between stress & strain under axial loads
Elastic (Modulus Elasticity)
Bending

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 FR
✓Elastic Instability

Column
Instability

Vessel Shells
under axial
loads
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✓Plastic Instability FR

Stress-Strain
Relationship

Allowable
Stress
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 FR
✓Brittle Rupture

Hydrogen
Notch Repeated
Embrittlement
Brittleness Cyclic loading
& Blistering

Temper
Strain Aging
Embrittlement

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✓Creep FR

Creep test

Creep
Rupture test

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✓Creep FR

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✓Creep FR

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 FR
✓Corrosion

Uniform Impingement Concentrasion-cell

Corrosion Attack Attack

Deposit Galvanic-cell Stress

Attack Attack Corrosion

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Strength of Materials
FR
Stress and Strain
L0
F F  = F /A

ε = (L – L0)/L0

Cross-sectional area A

• Stress  = force divided by area over which it is applied

• Area = original cross section in a tensile test
• Stress can be applied directly or can result from an applied strain
• Examples: dead weight, internal or external pressure, etc.
• Strain ε = distortion per unit length
• Strain = elongation divided by original length in tensile test
• Strain can be applied directly or can result from an applied stress
• Example: thermal movement relative to fixed supports
Typical Stress-Strain Curve FR
for a Mild Steel
Creep FR
Low Temp High Temp Fracture

Stress or Strain

Stress or Strain
Stress Stress

Strain Strain

Time Time

• At high temperatures, strain can continue to increase over time

under constant load or displacement
• Creep strain = increase in strain at constant load
• Creep relaxation = reduction in stress at constant displacement
• Accumulated creep strain can lead to failure: creep rupture
 FR
Failure of Materials
Failure of materials under combined tensile and shear stresses is not simple to predict.
Several theories have been proposed:
• Maximum Principal Stress Theory
• Component fails when one of the principal stresses exceeds the value that causes failure in
simple tension
• Maximum Shear Stress Theory
• Component fails when maximum shear stress exceeds the shear stress that causes failure in
simple tension
• Maximum Strain Energy Theory
• Component fails when strain energy per unit volume exceeds the value that causes failure in
simple tension
• BPV Code gives values for maximum allowable stress for different materials as a
function of temperature, incorporating a safety factor relative to the stress that
causes failure (ASME BPV Code Sec. II)
• Failure in compression is by buckling, which is much harder to predict than tensile
failure. The procedure in the Code is iterative. This should definitely be left to a
specialist

Loads Causing Stresses on Pressure Vessel Walls
• Internal or external pressure
• Dead weight of vessel
• Weight of contents under normal or upset
conditions
• Weight of contents during hydraulic testing
• Weight of internals
• Weight of attached equipment (piping, decks,
ladders, etc)
• Stresses at geometric discontinuities
All these must be combined to determine principal stresses
FR
• Bending moments due to supports
• Thermal expansion, differential thermal
expansion
• Cyclic loads due to pressure or temperature
changes
• Wind & snow loads
• Seismic loads
• Residual stresses from manufacture
• Loads due to friction (solids flow)
 FR
Example: Wind Load
• Wind exerts a pressure on one side of the
vessel
• Resulting force acts like a uniform beam
Wind

load and exerts a bending moment on

vessel
• Windward wall is placed in tension,
leeward in compression
Bending
• Vortex shedding can cause vibration
moment • Hence spirals on chimneys
• Usually not needed for columns due to
ladders, pipes, decks, etc.
Thin Cylinder Subject to Internal Pressure
Inside diameter, D
• Forces due to internal pressure are balanced by shear
stresses in wall
Wall thickness, t
• Horizontal section:

 D2
P L  D t
4
Height, h

PD
L • Vertical section: L =
4t

H
Ph D =H 2h t
PD
Longitudinal stress, L H =
2t
Hoop stress, H

• Similar equations can be derived for other geometries

such as heads
Vessel Specifications FR
Vessel Specifications Set By the Process Engineer
• The process engineer will usually specify the following
parameters based on process requirements:
• Vessel size and shape (volume, L and D)
• Vessel orientation and elevation
• Maximum and minimum design pressure
• Maximum and minimum design temperature
• Number of nozzles needed (& location)
• Vessel internals
And often also:
• Material of construction
• Corrosion allowance
• There is often a lot of dialogue with the mechanical engineer
to set the final specifications
 FR
Design Pressure
• Normal operating pressure
• The pressure at which you expect the process to usually be operated
• Maximum operating pressure
• The highest pressure expected including upset conditions such as startup,
shutdown, emergency shutdown
• Design pressure
• Maximum operating pressure plus a safety margin
• Margin is typically 10% of maximum operating pressure or 25 psi, whichever
is greater
• Usually specify pressure at top of vessel, where relief valve is located
• The BPV Code Sec. VIII Div. 1 doesn’t say much on how to set the
design pressure
• “..a pressure vessel shall be designed for at least the most severe condition
of coincident pressure and temperature expected in normal operation.”
 FR
Design for Vacuum
• The minimum internal pressure a vessel can experience is full
vacuum (-14.7 psig)
• Vacuum can be caused by:
• Intentional process operation under vacuum (including start-up and
shutdown)
• Cooling down a vessel that contains a condensable vapor
• Pumping out or draining contents without allowing enough vapor to enter
• Operator error
• Vacuum puts vessel walls into compressive stress
• What happens if vessel is not designed for vacuum conditions?
 FR
Vessel Subjected to Excess Vacuum

• Normal practice is to design for vacuum if it can be expected to occur

 FR
Design Temperatures
• Maximum:
• Highest mean metal temperature expected in operation, including
transient conditions, plus a margin
• Margin is typically plus 50F
• Minimum
• Lowest mean metal temperature expected in operation, including
transient conditions, upsets, auto-refrigeration, climatic conditions,
anything else that could cause cooling, minus a margin
• Margin is typically -25F
• MDMT: minimum design metal temperature is important as metals
can become brittle at low temperatures
• Designer should allow for possible failure of upstream
equipment (e.g., loss of coolant on upstream cooler)
 FR
Design Temperature Considerations
• Due to creep, maximum allowable stress drops off rapidly at higher temperatures
• Forces designer to use more expensive alloys
• BPV Code Sec. VIII Div.2 cannot be applied for design temperatures > 900F (no
creep safety factor in Div.2)
• The Code allows design of vessels with different temperature zones
• Very useful for high temperature vessels
• Not usually applied to medium temperature vessels such as heat exchangers, distillation
columns
 FR
Design Temperature & Pressure

• What is the design pressure?

100 psig
180 F 120 + 25 = 145 psig
• What is the design temperature?
340 + 50 = 390F

120 psig
340 F
 FR
Design Temperature & Pressure
Oil Steam
400 psig 40 barg • What is the shell-side design pressure?
120 F 482 F
588 + 58 = 646 psig
• What is the tube-side design
temperature?
482 + 50 = 532F

390 psig
450 F
Materials of Construction FR
Materials Selection Criteria
• Safety
• Material must have sufficient strength at design conditions
• Material must be able to withstand variation (or cycling) in process conditions
• Material must have sufficient corrosion resistance to survive in service between inspection
intervals
• Ease of fabrication
• Availability in standard sizes (plates, sections, tubes)
• Cost
• Includes initial cost and cost of periodic replacement
 FR
Commonly Used Materials
• Steels
• Carbon steel, Killed carbon steel – cheap, widely available
• Low chrome alloys (<9% Cr) – better corrosion resistance than CS, KCS
• Stainless steels:
• 304 – cheapest austenitic stainless steel
• 316 – better corrosion resistance than 304, more expensive
• 410

• Nickel Alloys
• Inconel, Incolloy – high temperature oxidizing environments
• Monel, Hastelloy – expensive, but high corrosion resistance, used for strong
acids
• Other metals such as aluminum and titanium are used for special
applications. Fiber reinforced plastics are used for some low
temperature & pressure applications.
 FR
Relative Cost of Metals
Metal Type or grade Price Max allowable stress Relative cost rating

($/lb) (ksi = 1000 psi)

Carbon steel A-285 0.27 12.9 1

Austenitic stainless steel 304 0.90 20 2.2
316 1.64 20 4
Aluminum alloy A03560 1.27 8.6 2.4
Copper C10400 3.34 6.7 27
Nickel 99%Ni 8.75 10 48
Incoloy N08800 3.05 20 7.5
Monel N04400 6.76 18.7 20
Titanium R50250 9.62 10 27

• The maximum allowable stress values are at 40ºC (100ºF) and are taken from ASME
BPV Code Sec. II Part D. The code should be consulted for values at other
temperatures. Several other grades exist for most of the materials listed.
• Finished vessel relative costs are not the same as materials relative costs as vessel
cost also includes manufacturing costs, labor and fabricator’s profit
 FR
Corrosion Allowance
• Wall thicknesses calculated using BPV Code equations are for the fully corroded
state
• Usually add a corrosion allowance of 1/16” to 3/16” (1.5 to 5 mm)
• Smaller corrosion allowances are used for heat transfer equipment, where wall
thickness can affect heat transfer
Pressure Vessel Design Rules: FR
Determining Wall Thickness
• Under ASME BPV Code Sec. VIII D.1, minimum wall thickness is 1/16” (1.5mm) with
no corrosion allowance
• Most pressure vessels require much thicker walls to withstand governing load
• High pressure vessels: internal pressure usually governs
• Thickness required to resist vacuum usually governs for lower pressure vessels
• For vessels designed for low pressure, no vacuum, then analysis of principal stresses may be
needed
• Usual procedure is to design for internal pressure (or vacuum), round up to nearest available
standard size and then check for other loads
 FR
Design for Internal Pressure
• ASME BPV Code Sec. VIII D.1 specifies using the larger of the shell thicknesses
calculated
• For hoop stress
Pi Di
t=
2SE − 1.2 Pi
• or for longitudinal stress
Pi Di
t=
4 SE + 0.8 Pi
S is the maximum allowable stress
E is the welded joint efficiency
• Values of S are tabulated in ASME BPV Code Sec.II for different materials as function
of temperature
 FR
Some Maximum Allowable Stresses
Under ASME BPV Code Sec. VIII D.1, Taken From Sec. II Part D
Material Grade Min Tensile Min Yield Maximum Maximum allowable stress at temperature F
strength strength temperature (ksi = 1000 psi)
(ksi) (ksi) (ºF) 100 300 500 700 900

Carbon steel A285 45 24 900 12.9 12.9 12.9 11.5 5.9

Gr A
Killed carbon A515 60 32 1000 17.1 17.1 17.1 14.3 5.9
Steel Gr 60
Low alloy steel A387 60 30 1200 17.1 16.6 16.6 16.6 13.6
1 ¼ Cr, ½ Mo, Si Gr 22
Stainless steel 410 65 30 1200 18.6 17.8 17.2 16.2 12.3
13 Cr
Stainless steel 304 75 30 1500 20.0 15.0 12.9 11.7 10.8
18 Cr, 8 Ni
Stainless steel 347 75 30 1500 20.0 17.1 15.0 13.8 13.4
18 Cr, 10 Ni, Cb
Stainless steel 321 75 30 1500 20.0 16.5 14.3 13.0 12.3
18 Cr, 10 Ni, Ti
Stainless steel 316 75 30 1500 20.0 15.6 13.3 12.1 11.5
16 Cr, 12 Ni, 2 Mo
 FR
So..
• The process design engineer needs to understand pressure vessel
design in order to generate good cost estimates (e.g. in Aspen ICARUS)
• Costs can vary discontinuously with vessel design
• A 10C change in temperature could double the vessel cost if it causes a change in code!
• Adding a component could cause a change in metallurgy that would mean moving to a more
expensive code design

• The process engineer will end up specifying the main constraints on

the vessel design: if you don’t know how to do this properly, you can’t
really design anything

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Vessel Thank You.
Ika DW
Equipment Design
+6285813659134
Ika.widharyanti@universitaspertamina.ac.id
www.universitaspertamina.ac.id