University of Technology

Chemical Engineering Department

Equipment Design
Vessels
By
Dr. Riyadh S. Almukhtar
 Vessels
Vessels in chemical processing service are of two
kinds:-
1-Vessels without internals The main functions of
this kinds, called drums or tanks, are intermediate
storage or surge of a process stream for a limited or
extended period or to provide a phase separation by
settling. Their sizes may be established by definite
process calculations or by general rules based on
experience.
 Vessels
2- Vessels with internals. The second category
comprises the shells of equipment such as heat
exchangers, reactors, mixers, fractionators, and other
equipment whose independently of whatever
internals are necessary
 Vessels
Drums and Tanks
The distinction between drums and tanks is that of
size and is not sharp. Usually they are cylindrical
vessels with flat or curved ends, depending on the
pressure, and either horizontal or vertical.
 Drums
Drums have a holdup of a few minutes. They are
located between major equipment or supply feed or
accumulate product. Surge drums between
equipment provide a measure of stability in that
fluctuations For example, reflux drums provide surge
between a condenser and its tower and d. DRUMS P
(psig) Liquid drums usually are placed horizontal and
gas-liquid separators vertical,
The length to diameter ratio range 2.5-5.0,
the smaller diameters at higher pressures and for be
the consequences of downstream equipment running
dry downstream equipment;
 CODES AND STANDARDS
The following codes and standards shall be followed
unless otherwise specified:
ASME SEC. VIII DIV.1 / For Pressure vessels IS: 2825
ASME SEC. VIII DIV.2 For Pressure vessels (Selectively
for high pressure / high thickness / critical service)
ASME SEC. VIII DIV.2 For Storage Spheres
ASME SEC. VIII DIV.3 For Pressure vessels (Selectively
for high pressure)
API 650 / IS: 803 For Storage Tanks.
API 620 For Low Pressure Storage Tanks
•
MECHANICAL DESIGN OF PROCESS
VESSELS
•MECHANICAL DESIGN OF PROCESS VESSELS
Process design of vessels establishes the pressure and
temperature ratings, the length and diameter of the shell,
the sizes and locations of nozzles and other openings,
all internals, and possibly the material of construction
•.
and corrosion allowance
 Material of Construction
The materials that are used in pressure vessel
construction are:
_ Steels ( carbon steel ,stainless steel etc )
_ Nonferrous materials such as aluminum and copper
_ Specialty metals such as titanium and zirconium
_ Nonmetallic materials, such as, plastic, composites
and concrete
_ Metallic and nonmetallic protective coating
 The Mechanical Properties
The mechanical properties that generally are of interest are:
_ Yield strength
_ Ultimate strength
_ Reduction of area (a measure of ductility)
_ Fracture toughness
_ Resistance to corrosion
Mechanical loads on the pressure vessel include those due
to:
_ Pressure
_ Dead weight
_ Piping
wind loadings should be considered
 Vessel DESIGN CRITERIA
Equipment shall be designed in compliance
with the latest design code requirements,
and applicable standards/ Specifications.
4-1 Pressure
Pressure for each vessel shall be specified in
the following manner:
Operating Pressure Maximum pressure likely
to occur any time during the lifetime of the
vessel
 VESSEL DESIGN CRITERIA
Design Pressure
a) When operating pressure is up to 70 Kg./cm2 g ,
Design pressure shall be equal to operating pressure
plus 10% ( minimum 1Kg./cm2 g ).
b) When operating pressure is over 70 Kg./cm2 g ,
Design pressure shall be equal to operating pressure
plus 5% ( minimum 7 Kg./cm2g).
c) Vessels operating under vacuum / partial vacuum
shall be designed for an external pressure of 1.055
Kg./cm2 g.
 DESIGN CRITERIA
Test Pressure
a) Pressure Vessels shall be hydrostatically tested in the
fabricators shop to 1.5 /1.3/ 1.25 (depending on design
code) times the design pressure corrected for temperature.
b) In addition, all vertical vessels / columns shall be
designed so as to permit site testing of the vessel at a
pressure of 1.5/ 1.3 / 1.25 (depending on design code)
times the design pressure measured at the top with the
vessel in the vertical position and completely filled with
water. The design shall be based on fully corroded
condition.
c) Vessels open to atmosphere shall be tested by filling with
 VESSAL DESIGN CRITERIA
4-2 Temperature
Temperature for each vessel shall be specified in the following
manner:
Operating Temperature Maximum / minimum temperature
likely to occur any during the lifetime of vessel.
Design temperature
a) For vessels operating at 0C and over:
Design temperature shall be equal to maximum operating
temperature plus 15 C.
b) For Vessels operating below 0C:
Design temperature shall be equal to lowest operating
temperature.
 VESSAL DESIGN CRITERIA

4-3 Wind Consideration

Wind load shall be calculated on the basis of IS : 875 /
site data.
a) Drag coefficient for cylindrical vessels shall be 0.7
minimum.
b) Drag coefficient for spherical vessel shall be 0.6
minimum.
4-4 Earthquake Consideration :
Earthquake load shall be calculated in accordance
with IS : 1893 / site data if specially developed and
available
 VESSAL DESIGN CRITERIA

• 4-5 Maximum Allowable Stress (Nominal Design

Strength)
• For design purposes, it is necessary to decide a
value for the maximum allowable stress (nominal
design strength) that can be accepted in the
material of construction.
 VESSAL DESIGN CRITERIA

Major Loads
1. Design pressure: including any significant static head of liquid.
2. Maximum weight of the vessel and contents, under operating
conditions.
3. Maximum weight of the vessel and contents under the hydraulic
test conditions.
4. Wind loads.
5. Earthquake (seismic) loads.
6. Loads supported by, or reacting on, the vessel.
 VESSAL DESIGN CRITERIA

Subsidiary Loads
1. Local stresses caused by supports, internal structures, and
connecting pipes.
2. Shock loads caused by water hammer or by surging of the
vessel contents.
3. Bending moments caused by eccentricity of the center of
the working pressure relative to the neutral axis of the vessel.
4. Stresses due to temperature differences and differences in
the coefficient of expansion of materials.
5. Loads caused by fluctuations in temperature and pressure.
•
 VESSAL DESIGN CRITERIA
4-6 Welded-Joint Efficiency and Construction Categories
The strength of a welded joint will depend on the type of joint
.and the quality of the welding
4-7 Corrosion allowance :
Unless otherwise specified by Process Licensor, minimum
corrosion allowance shall be considered as follows :
-Carbon Steel, low alloy steel column, Vessels, Spheres : 2 mm
-- Storage Tank, shell and bottom : 2 mm
- Storage tank, Fixed roof / Floating Roof : Nil
 VESSAL DESIGN CRITERIA
4-8 Tank Capacity
Capacity shall be specified as Nominal capacity and
stored capacity
Nominal capacity for fixed roof tanks be volume of
cylindrical shell.
Nominal capacity for floating roof tanks shall be volume
of cylindrical shell minus free board volume.
Stored capacity shall be 80-90% of Nominal capacity.
Sphere Stored capacity shall be 85% of nominal
capacity.
 VESSAL DESIGN CRITERIA
4-9 Manholes :
a) Vessels and columns with diameter between 900
and 1000 mm shall be
provided with 450 NB manhole. Vessels and columns
with diameter greater than 1000mm shall be provided
with 500 NB manhole. However, if required vessels
and columns with diameter 1200mm and above may
be provided with 600NB manhole.
 VESSAL DESIGN

THE DESIGN OF THIN-WALLED VESSELS UNDER

INTERNAL PRESSURE
VESSAL DESIGN CRITERIA
 VESSAL DESIGN CRITERIA

Choice of Closure
Flat plates are used as covers for manways and as the
channel covers of heat exchangers. Formed
flat ends, known as “flange-only” ends, are
manufactured by turning over a flange with a small
radius on a flat plate,
 VESSAL DESIGN CRITERIA

The ASME BPV Code specifies the minimum thickness as

where C = a design constant, dependent on the edge
constraint
De = nominal plate diameter
S = maximum allowable stress
E = joint efficiency
Bolted cover with a full face gasket (see Section 14.10), C =
0.25 and De is the bolt circle diameter (the diameter of a
.circle connecting the centers of the bolt holes)
 Design of Domed Ends
Code and should be used for detailed design

Hemispherical Heads
For equal stress in the cylindrical section and
hemispherical head of a vessel the thickness of the
head need only be half that of the cylinder;
 Design of Domed Ends
Code and should be used for detailed design
Ellipsoidal Heads
Most standard ellipsoidal heads are manufactured
with a major and minor axis ratio of 2:1.
For this ratio, the following equation can be used to
calculate the minimum thickness required (ASME BPV
Code Sec. VIII D.1 Part UG-32):
 Design of Domed Ends
Code and should be used for detailed design

Torispherical Heads
A torispherical shape is formed from part of a torus
and part of a sphere. The shape is close to that of an
ellipse but is easier and cheaper to fabricate.
 Design of Domed Ends
Code and should be used for detailed design
Standard torispherical heads (dished ends) are the most
commonly used end closure for vessels up to operating
pressures of 15 bar. They can be used for higher pressures, but
above 10 bar their cost should be compared with that of an
equivalent ellipsoidal head.
Above 15 bar an ellipsoidal head will usually prove to be the
most economical closure to use.
A hemispherical head is the strongest shape, capable of resisting
about twice the pressure of a torispherical head of the same
thickness. The cost of forming a hemispherical head will,
however, be higher than that for a shallow torispherical head.
Hemispherical heads are used for high pressures.
Example
Estimate the thickness required
for the component parts of the
vessel shown in the diagram. The
vessel is to operate at a pressure
of 14 bar (absolute) and
temperature of 300 C. The
material of construction will be
plain carbon steel. Welds will be
fully radiographed.
.And prepare a data sheet for
the equipmen