PRESSURE VESSEL ENGINEERING: PETROCHEMICAL INDUSTRY

PRACTICES IN NORTH AMERICA

by

Aleem Jan

Submitted

in partial fulfillment of the requirements

for the degree of

MASTER OF ENGINEERING

Major Subject: Petroleum Engineering

at

DALHOUSIE UNIVERSITY

Halifax, Nova Scotia October, 2008

© Copyright by Aleem Jan, 2008

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 IV

DEDICATED

TO

ALLAH,

MY PARENTS, MY SON MUHAMMAD SULAYMAN KHAN & FAMILY

& PROFESSOR RAFIQUL ISLAM, Ph. D.

 V

Acknowledgements

The author would like to acknowledge all these people whose help, support and guidance
was indispensable in preparation of this report:

First and foremost to Prof. Rafiqul Islam (Department of Civil & Resource Engineering
for supervising this work. Thanks are due to Mr. Arshad for co-supervising this work.
Thanks are also due to Mr. Richard Ericson, P.E. (Department Manager-Mechanical
Equipment, KBR Engineering Services, Inc., Houston, TX), to Mr. Ivette Rodriguez
(American Society of Mechanical Engineers, New York, NY), to Mr. Howard Pouncy
(President, Disasu Software Inc., Cypress, TX) and to Mr. Mark Giffin, (General Manager,
Pressure Vessel Engineering Limited, Waterloo, ON).
 VI

Abstract

Mechanical design of pressure vessels has been one of the most challenging jobs in an
overall design of process plants, including petroleum / petrochemical plants. The failure
of a pressure vessel has catastrophic consequences both in terms of risks to life and
property; therefore, the design of the same requires a foolproof design approach.

In North America, the mechanical design of pressure vessels is carried out through
American Society of Mechanical Engineers' (ASME) Boiler and Pressure Vessel Code
(BPVC); which has been constantly developed and refined since 1915. The mechanical
design of pressure vessels used in the petroleum and petrochemical industry employ
Section VIII Division 1 and Division 2 of the ASME BPVC.

The design is mostly performed through different software; developed not only by stand
alone software developing companies, but individual engineering design companies use
their own written / developed software as well. However, spreadsheets and hand
calculations are still considered to be one of the most reliable tools in the hand of a
designer.

The important aspect in the design of a pressure vessel is that a better design is not
dependant on the designer's knowledge of ASME BPVC or particular software alone; a
good design depends upon designer's skills, experience, knowledge and engineering
judgment, along with better interaction with other design groups, such as process, process
systems, piping, and other related work groups.

This report gives a synopsis and an overall view of the mechanical design process of a
pressure vessel as a whole, and provides a firsthand look at the documents that are mostly
available to the professionals working in this field. Manual calculations and introduction
to one of the most widely used software in this field is also a part of this report.
 vii

Table of Contents
Acknowledgements v
Abstract vi
List of Figures ix
Chapter 1: Introduction 1
1.1 Background 1
1.2 Objectives 4
1.3 Introduction to the topics of the report 5
Chapter 2: Pressure Vessels in Petroleum and Petrochemical Industry 7
Chapter 3: Vessel Mechanical Engineering - Basic Design Documents 12
Chapter 4: Vessel Designing & ASME BPVC 30
4.1 Key Design Parameters 30
4.1.1 Operating Pressure 30
4.1.2 Design Pressure 30
4.1.3 Vessel Loading 31
4.1.4 Design Temperature 31
4.1.5 Maximum Allowable Working Pressure (MAWP) 33
4.1.6 Maximum Allowable Stress Values 34
4.1.7 Hydrostatic Test Pressure 38
4.2 Vessel Design Data 42
4.2.1 Specifications of Shell and Head 43
4.2.2 Materials of Construction 44
4.2.3 Shell, Head and Nozzle Thicknesses 45
4.2.4 Corrosion Allowance 46
4.2.5 Weld Joint Categories 47
4.2.6 Nozzles and Openings' Sizes and Specifications 48
4.2.7 Minimum Design Metal Temperature (MDMT) 49
4.2.8 Reinforcement of Openings 50
Chapter 5: Design Software 56
Chapter 6: Design Calculations 72
 viii

6.1 Material Properties: 74

6.1.1 Head and Shell: 74
6.1.2 Flanges / Couplings: 74
6.1.3 Nozzles 74
6.1.4 Saddles 75
6.2 Calculations: 75
6.2.1 Thicknesses: 75
6.2.2 Calculations for Flanges 88
6.2.3 Vessel Weight and Volume 92
6.2.4 Zick Analysis - Saddle Support Calculations 93
Chapter 7: Concluding Remarks 99
References & Recommended Readings: 101
Appendix A: Authorization from ASME to reproduce Parts from ASME BPVC Section
VIII Division 1 102
Appendix B: Authorization from KBR Engineering Inc. to Reproduce Engineering
Sample Documents 103
Appendix C: Authorization from DISASU Software Inc. to Reproduce Screenshots from
DISASU Software 104
Appendix D: Authorization from Pressure Vessel Engineering Ltd. to Reproduce Data
and Methods of Calculations 106
Appendix E: Governing Codes Related to Design & Construction of Pressure Vessels in
North America 107
Appendix F: List of Major Pressure Vessels Design Software 108
 ix

List of Figures

Figure 1.1: Procedure for design process (Chattopadhyay, 2005) 3

Figure 3.1: Coating, Insulation and Fireproofing Data Sheet 15
Figure 3.2: Vessel Design Data and Connection Summary 16
Figure 3.3: Vertical Pressure Vessel Data Sheet - Page 1 17
Figure 3.4: Vertical Pressure Vessel Data Sheet - Page 2 18
Figure 3.5: Vertical Pressure Vessel Data Sheet - Page 3 19
Figure 3.6: Vertical Pressure Vessel Data Sheet - Page 4 20
Figure 3.7: Vertical Pressure Vessel Data Sheet - Page 5 21
Figure 3.8: Vertical Pressure Vessel Data Sheet - Page 6 22
Figure 3.9: Vertical Pressure Vessel Data Sheet - Page 7 23
Figure 3.10: Vertical Pressure Vessel Data Sheet - Page 8 24
Figure 3.11: Vessel Sketch for Instrument Connection 25
Figure 3.12: Vessel Load Sheet - Page 1 26
Figure 3.13: Vessel Load Sheet - Page 2 27
Figure 3.14: Piping and Instrumentation Diagram 28
Figure 3.15: Process Flow Diagram 29
Figure 5.1: Starting Page 60
Figure 5.2: New File 60
Figure 5.3: Creating New File 61
Figure 5.4: Section Properties 61
Figure 5.5: Head Properties 62
Figure 5.6: Shell Properties 62
Figure 5.7: Shell Configured 63
Figure 5.8: Cone Properties 63
Figure 5.9: Cone Configured 64
Figure 5.10: Shell 2 Properties 64
Figure 5.11: Shell 2 Configured 65
Figure 5.12: Bottom Head Properties 65
Figure 5.13: Bottom Head Configured 66
Figure 5.14: Skirt Support Properties 66
Figure 5.15: Skirt Support Configured 67
 X

Figure 5.16: Menu Bar-File 67

Figure 5.17: Menu Bar-Edit 68
Figure 5.18: Menu Bar - Components 68
Figure 5.19: Menu Bar - Supports 69
Figure 5.20: Menu Bar - Nozzles 69
Figure 5.21: Menu Bar -Lad/Plat/SL 69
Figure 5.22: Menu Bar - Stiffeners 70
Figure 5.23: Menu Bar - Internals 70
Figure 5.24: Menu Bar - Tabular Input 70
Figure 5.25: Menu Bar - Action 71
Figure 5.26: Menu Bar-View 71
Figure 6.1: Dimensions of Head 77
Figure 6.2: Dimension of Flange 89
Figure 6.3: Horizontal Vessel - 1 93
Figure 6.4: Horizontal Vessel - 2 93
 1

Chapter 1: Introduction

1.1 Background

A pressure vessel is a container that has a pressure differential between its interior and
exterior; usually the internal pressure is higher than the external pressure. These vessels
are widely used in the process industry in the form of drums, columns and tanks etc.
Depending upon the process units these pressure vessels are operating in, they may be
used as reactors, separators, fractionators and settling drums etc. and perform a wide
variety of processes. Usually, these processes are performed at elevated temperatures and
pressures and often they are carried out by chemicals that need to be prevented from
leaking into the atmosphere.

The design of pressure vessels is mainly focused on rupture or buckling of pressure

vessels in high pressure - high temperature scenarios, where failure can cause an
explosion and create a major safety issue. The overall design of pressure vessel has many
facets; two of the most important are analytical design and mechanical design.

In North America, the mechanical design of pressure vessels is governed by rules

prescribed in ASME (American society of mechanical engineers) BPVC (Boiler and
pressure vessel code) Section VIII, Division I, II, and III. Division I (henceforth,
described as the code), is related to unfired pressure vessels. Its creation dates back to
1915, when the first ASME "code" called "ASME Rules for Construction of Stationary
Boilers and For Allowable Working Pressures, 1914 Editions" was approved.

It was in the aftermath of the ever increasing number of boiler explosions and resulting
casualties, when individual states in US started adopting different rules and regulations to
avoid these accidents. The problem with those rules and regulations w a s that the pressure

vessel construction companies, which were operating nationwide, had to construct

pressure vessels according to varying sets of rules, depending upon the jurisdiction of the
state where the pressure vessel was supposed to operate. In this scenario the ASME led
the effort and started working on developing a US code in 1911. By the year 1915, it
delivered the "ASME Rules for Construction of Stationary Boilers and For Allowable
 2

Working Pressures, 1914 Editions". From 1915 onwards, the code has been in the process
of constant progressive refinement and with the developments in the related fields of
engineering and technology, major changes have been made from time to time. One of
the most important changes has been the gradual reduction of design factor from 5 to 3.5
(in the code) in the last seventy years.

It is important to mention here that ASME BPVC only applies to the vessels where the
design pressure is in between 15 psi and 3,000 psi. Vessels with design pressures beyond
this range will not be designed with the code and Division II. There are other limitations
on the applications of the code such as it will only be applied to the vessel through the
first circumferential joint, with welded end connections, through the first threaded joint
for screwed connections, through the face of the first bolted flange joint for flanged
connections or through the first sealing surface for special (also called proprietary)
connections.

The code and Division II are not applied to internal and external non-pressure
components of the vessels; however, these are applied to the weld that joins the non-
pressure part to the pressure part of the vessel. Piping and piping related components,
fired boilers, and integral pressure parts of pumps, blowers, compressors and turbines etc.
are also not covered by the same.

It is appropriate to mention here that the code formulates empirical solutions to the design
problems of pressure vessel and is borne out of the experiences of the industry with
pressure vessels. On the other hand, Division II of ASME BPVC provides alternative
rules for materials, design, inspection, testing and construction. The formulation of this
division has been a conscious engineering effort on the part of ASME to develop a code
compatible with the technological developments and competitiveness with European
codes (at least in terms of design factors). In ASME BPVC Division II, the testing rules
are stricter as compared to the code and along with design by rule method (a
characteristic of the code) the designer is allowed to make use of the FEA (Finite element
analysis) as well. The design factor is also reduced to 2.4 (comparable to most European
 3

codes' design factor of 2.4). Both Division I and Division II are extensively used by the
process industry, around the world.

The third of these ASME BPVC Divisions is called Division III, and it is related to very
high pressure containing vessels, where the internal or external operating pressures are in
the vicinity of 10,000 psi. These vessels are usually used in nuclear power plants and not
in the process/ petroleum/ petrochemical industry; therefore, Division III is beyond the
scope of this report and will not be discussed at all. Division II will also be only
described for comparison purposes and in very limited scope.

The design of pressure vessels according to both Divisions I and Division II is complex;
and a unique set of design, operational and functional data may give rise to many
different sets of solutions; depending specifically on the designer's approach to the
specific design problem.

There are various software (e.g. DISASU, CodeCalc, PVElite etc) to help the designer
with the design process, although, it is more desirable for a vessel designer to employ his
knowledge, skills, experience and engineering judgment to perform the calculations
manually or through spread sheets or at least carry out manual verification of the results
provided by the software.

The designing process in vessel mechanical engineering is closely linked to overall unit's
design process and it is carried out in close collaboration with other design groups, such
as process engineering, vessel analytical engineering, systems engineering, metallurgical
engineering and piping engineering.

The design process in vessel mechanical engineering starts with relevant data collection
and its organization into a proper format; including design and operational pressures and
temperatures, materials of construction, corrosion allowances, specific gravities, heat
treatment requirements, radiography requirements, hydrostatic test requirements,
painting, insulation and fireproofmg information, and wind and earthquake design
information. All this data is used in mechanical design of pressure vessels; which is
basically a process of determining the vessel's shell and heads' thicknesses, computing
 4

different stress values at design conditions for these thicknesses, calculations of vessels
weight and design of other individual components such as nozzles, flanges and supports
etc. to conform to the requirements, size, and shape of pressure vessel and service to be
performed. These design parameters are checked against different failure criteria such as
stress distribution etc. The whole design process could be described as follows:

Functions
h I Establish Operation

1
Operation Material

1
1 Design
l-l Structural

I
Final

Figure 1: Procedure for design process (Chattopadhyay, 2005)

The procedures for design of pressure vessel according to the code is focused on specific
and individual vessels, however they are a part of the overall design of a complete plant,
and they are designed in the same perspective.

1.2 Objectives

This report will have the following objectives:

i. To produce a document where all the necessary information, related to the

practices of Petroleum and Petrochemical industry in the design and construction
of pressure vessels in North America, is documented.

ii. To introduce in this document the basics of pressure vessels engineering in the
backdrop of petroleum and petrochemical industry, to enable the reader to
appreciate the design process of pressure vessels in an EPCM (Engineering,
Procurement, and Construction Management) company environment.
 5

iii. To describe in this document the different types of pressure vessels used in
different units and processes and define pressure vessels in light of ASME Section
VIII Division I.

iv. To introduce different technical documents in this report which are used by
EPCM (engineering, procurement and construction management) companies, in
the whole design process.

v. To briefly describe the overall mechanical design process of pressure vessel and
define design parameters.

vi. To introduce one of the software used in the design process of pressure vessels,
such as DISASU.

vii. To present basic calculations used in the actual mechanical design of pressure
vessel in present EPCM industry.

1.3 Introduction to the topics of the report

This report will describe the above-mentioned in different chapters and these chapters
will be as follows:

Chapter 1: Introduction
A brief description of pressure vessels, mechanical design synopsis and introduction to
the ASME BPVC, is a part of this chapter along with a brief discussion of some refinery
processes.

Chapter 2: Pressure Vessels in Petroleum and Petrochemical Industry

A synopsis of pressure vessels used in the petrochemical industry is presented in this
chapter.

Chapter 3: Vessel Mechanical Engineering - Basic Design Documents

Vessel mechanical engineering is explained in the backdrop of overall working of an
EPC (engineering, procurement, and construction) company. Different pressure vessels
are also explained in this chapter.
 6

Chapter 4: Vessel Designing & ASME BPVC

An overview of the ASME BPVC Sections VIII Division 1 and the design guidelines
prescribed in the code. The excerpts from the code are reproduced with permission of
ASME.

Chapter 5: Design Software

This chapter mentions the names of the design software, that are currently used by the
industry and one of them DISASU is briefly introduced in here.

Chapter 6: Design Calculations

In the backdrop of the fact that most of the design work is carried out through software,
hand calculations according to the code are described in this chapter, along with excerpts
from the code.

Chapter 7: Concluding Remarks

The conclusions are made in the light of the discussion in the report.

Chapter 8: References
 7

Chapter 2: Pressure Vessels in Petroleum and Petrochemical Industry

(The excerpts from ASME BPVC Section VIII Division I are reproduced with permission
of American Society of Mechanical Engineers - ASME. All rights reserved.)

In the previous chapter, pressure vessels have been described in different processes, this
chapter will describe these vessel from the standpoint of pressure vessel engineering. In
the first chapter the pressure vessels are defined as "A pressure vessel is a container that
has a pressure differential between its interior and exterior and where the internal
pressure is usually higher than the external pressure". This indeed is a very broad
definition and it may include even the pipelines and valves etc. Thus, it is appropriate to
mention the conditions prescribed by the code for a container to be called a pressure
vessel.

Part U-1(a)(2) of the code explains: "For the scope of this Division, pressure vessels are
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."

Part U-3(c)(2) of the code mentions: "Based on the Committee's consideration, the
following classes of vessels are not included in the scope of this Division; however, any
pressure vessel which meets all the applicable requirements of this Division may be
stamped with the Code U Symbol:

(a) those within the scope of other Sections;

(b) fired process tubular heaters;

(c) pressure containers which are integral parts or components of rotating or reciprocating
mechanical devices, such as pumps, compressors, turbines, generators, engines, and
hydraulic or pneumatic cylinders where the primary design considerations and/or stresses
are derived from the functional requirements of the device;
 8

(d) except as covered in U-l(f), structures whose primary function is the transport of
fluids from one location to another within a system of which it is an integral part, that is,
piping systems;

(e) piping components, such as pipe, flanges, bolting, gaskets, valves, expansion joints,
fittings, and the pressure containing parts of other components, such as strainers and
devices which serve such purposes as mixing, separating, snubbing, distributing, and
metering or controlling flow, provided that pressure containing parts of such components
are generally recognized as piping components or accessories;

(f) a vessel for containing water under pressure, including those containing air the
compression of which serves only as a cushion, when none of the following limitations
are exceeded:

(1) a design pressure of 300 psi (2 MPa);

(2) a design temperature of 210°F (99°C);

(g) a hot water supply storage tank heated by steam or any other indirect means when
none of the following limitations is exceeded:

(1) a heat input of 200,000 Btu/hr (58.6 kW);

(2) a water temperature of 210°F (99°C);

(3) a nominal water containing capacity of 120 gal (450 L);

(h) vessels not exceeding the design pressure, at the top of the vessel, (see 3.2) limitations
below, with no limitation on size [see UG-28(f), 9-1(c)]:

(1) vessels having an internal or external pressure not exceeding 15 psi (100 kPa);

(2) combination units having an internal or external pressure in each chamber not
exceeding 15 psi (100 kPa) and differential pressure on the common elements not
exceeding 15 psi (100 kPa) [see UG-19(a)];
 9

(i) vessels having an inside diameter, width, height, or cross section diagonal not
exceeding 6 in. (152 mm), with no limitation on length of vessel or pressure;

(j) pressure vessels for human occupancy."

Furthermore, pressure vessels are categorized in many types e.g. based on their
geometrical shape, they can be cylindrical, spherical, or conical etc. and based on their
layout, they can be vertical or horizontal. The horizontal vessels are supported with
saddles, while the vertical vessels are commonly supported through skirts, legs or lugs.
Based on function they may be separators, reactors, treaters, or fractionators etc.

Distillation is by far one of the most important processes in a refinery. This process
involves thermal separation. It is carried out in two different system units, which are
usually classified according to the operation process - such as atmospheric distillation
column and vacuum distillation column. Other distinctions form the basis of
classifications, as well: based on operation method - such as batch columns and
continuous columns, based on the type of feed stream/s - such as binary and multi-
component, based on the number of components in the product streams - such as single
and multi-components columns, based on the extra feed exits - such as extractive and
azeotropic and based on the internals type - such as tray columns and packed columns.

In atmospheric columns the distillation is carried out at around the atmospheric

conditions, while in vacuum columns the distillation is carried out at vacuum. In batch
type columns, the feed is processed in batches and once a batch is being processed no
second batch is allowed in the column. In the continuous column however the inlet
stream in continuously processed and this is the most widely used method in crude oil
distillation.

The continuous type columns are further divided into many categories; if the inlet stream
to the distillation column carry two components, this type of column is called binary, if
the inlet stream carry more than two components, it is called multi-components, on the
same level, if the outlet stream contains more than two components, it is called
 10

multiproduct column. When the extra feed is allowed to be taken off at the top, it is called
azeotropic column and when it is in the bottom, it is called extractive column.

However, after operating conditions classification of distillation column, where columns

are categorized as atmospheric and vacuum distillation columns, the second most
important classification is based on the type of internals of a column. If the column has
trays as its internals separation mechanism, it is called tray column (or also as staged
contact columns), and if it has packing, it is called as packing columns (or also as
continuous contact column).

In tray columns, different types of tray geometry and design, such as bubble cap trays,
valve trays and sieve trays are used to maximize contact between vapors and liquid by
holding up the liquid comparatively longer to manage better separation. Design of tray is
dependent on the distribution of liquids and vapors; the more the contact between the
vapor and the liquid the better the separation.

In packing columns, the packing supplement the trays and they provide an increased area
for liquid and vapor contact. Packing columns are comparatively efficient and shorter in
height.

Drums are another widely used category of pressure vessels and they are used as a
temporary storage media. The difference between a drum and a tank is that the length to
diameter ratio of a drum is from 2.5 to 5.0 and the number of minutes in the half-full
volume basis is from 5 to 10 minutes (except for the fired heater feed surge drum, where
it could be from 10 to 30 minutes and compressor feed liquid knockout drum, where it is
from 10 to 20 minutes).

Another important class of pressure vessels is called separators and this class includes
scrubber or knockout, three phase separators, liquid-liquid separators, filter separators,
line drip, slug catcher, flash vessel, and expansion vessel.

Scrubbers are also known as knockouts, these vessels are used to process feed stream
with higher gas to liquid ratios.
 11

Three phase separators are used for feed streams containing components in three phases,
e.g. one as gas and the other two as immiscible liquid phases such as water and oil.

Gas liquid separators are used for the separation of gases from liquid streams; these
separators are designed for very high velocities. The separation process in these
separators is less complicated as the difference between the two components of the feed
stream is very high.

Liquid-liquid separators are essentially the same as the gas-liquid separators, except for
the fact that these are used when the feed stream has its components as two immiscible
liquid phases such as water and oil.

Filter separators are two chambered vessels, where the first chamber has a coalescent
element that allows the liquid particles to be coalesced into larger droplets and the second
chamber which is characterized by mist extractor where these large droplets are taken out
of the feed stream.

Flash vessels are low pressure oil and gas separators. These separators are flashed with
liquid from high pressure separators and the liquid processed in this separator is
transported to the storage tanks.
 12

Chapter 3: Vessel Mechanical Engineering - Basic Design Documents

(The figures in this chapter are being reproduced with permission of KBR Engineering
Services Inc. All rights reserved.)

Engineering design of petroleum plant is defined by different diagrams such as electrical

flow diagrams, piping isometric diagrams, instrumentation lines diagrams, plans and
elevations diagrams, block flow diagrams, process flow diagrams, mechanical flow
diagrams and utility flow diagrams. The later for are the most important and describe the
whole process of petrochemical plant in numbers, words and sketches from raw material
input to finished product. These flow diagrams diagrammatically elaborate on the
equipment, the units, items, instruments, piping etc., represent the sequence of operations,
describe the characteristics of different chemical processes, and evaluate the performance
of the plant etc.

The basic flow diagrams described above are the most important documents from the
stand point of vessel mechanical engineering design:

3.1 Coating, Insulation, and Fireproofing Data Sheet

This document has the information about the need and types of painting, insulation and
fireproofing details for the vessel to be designed (Fig. 3.1).

3.2 Vessel Design Data and Connection Summary

This document describes the vessel connections, type of service, size, class, schedule, and
construction etc of the nozzles (Fig. 3.2). Design pressure and maximum temperature at
design pressure, maximum and minimum operating pressure, and vacuum design pressure
etc. This document allows the vessel mechanical designer to keep the nozzle elevations
and orientations in perspective in the design process of the whole vessel.

3.3 Pressure Vessel Data Sheet

This is the primary document in the mechanical design process of a pressure vessel Figs.
3.3 - 3.10). It combines all the information available in other documents mentioned
 13

above. This document mentions design conditions in terms of pressure and temperature,
minimum design metal temperature, operating conditions, corrosion allowance
information, post weld heat treatment requirements, radiography requirements, and wind
and earthquake information etc. Most importantly, it mentions material for pressure
components and parts welded to pressure components, e.g. shell and head material, flange
and fittings materials, nozzle and shell attachments (plate, pipe and structural shapes)
materials. This document also mentions materials for parts not welded to pressure
components, such as materials for base rings, plate, pipe, pressure bolting, and demisters,
permanent and removable internals and gasket materials.

3.4 Vessel Sketch for Instrument Connection

These diagrams represent all the instruments that are to be located on the pressure vessel
(Fig. 3.11). The location, elevation, type, connection type, size, class and schedule of the
instrument connections are described.

3.5 Vessel Load Sheet

Primarily this document belongs to the vessel analytical group and describes the result of
analytical design of the vessel; it describes the vessel loads, flow rates in and out of the
vessel etc. (Figs. 3.12-3.13).

3.6 Mechanical Flow Diagrams

Mechanical flow diagrams are also called process and instrumentation diagrams (P&ID).
Apart from civil and mechanical structures, operating conditions and flow rates these
diagrams provide an actual, complete and detailed description of all the processes,
equipments, pipes, instruments and valves etc. (Fig. 3.14).

3.7 Utility Flow Diagrams

Utility flow diagrams are the same as mechanical flow diagrams (P&ID) except that they
are created for utilities such as steam, steamed condensate, quitting water, compressed
air, fuel, refrigerants and their connections with main process units through piping.
 14

3.8 Process Flow Diagrams

Process flow diagrams account for material and mass balance, describe the sizing of
different equipment such as separators, reactors, drums, heat exchangers, pumps, and
tanks etc. and provide flow rates, and different chemical and physical properties such as
fluid stream composition and design temperatures and pressures etc. (Fig. 3.15).

3.9 Block Flow Diagrams

The process design of the petrochemical plant starts with the block flow diagram. These
diagrams represent the processes or operations as a whole in the form of blocks where
individual blocks representing single unit or process and the lines going into and coming
out of the blocks representing the main flow streams along with their properties and
quantities. Block flow diagram represent individual units or equipments by blocks only
and the fluid stream properties are mentioned for each line.

3.10 Material Selection Diagrams

This document has all the material of construction information, corrosion allowance
information and the decision if post weld heat treatment should be carried out on some of
the parts or the complete vessel.
 15

COATING, INSULATION, A N D FIREPROOF1NG DATA SHEET

Document No.: V10-15-MD01 Page 1 of 1

Number 0 1 Job Number 123
Date 18 Jul OS 13 Nov 07 Job Name ABC
Revisions

By RED EES Client

XYZ
Checked EES JTP Location
Approved RR RR Tag Number 15-MD01
Issue IFD IFC Tag Name Scrub Column

EQUIPMENT DATA
Equipment Type/Configuration Vertical Vessel, Skirt Supported
External Material of Construction Vessel SS, Skirt SS/CS
Operating Temperature (°C) (in/out) Top: -55
Bottom: 82
Cyclic or Intermittent Conditions (°C)
Note: Any changes to the equipment data above may result in a corresponding change to the data below

REFERENCE SPECIFICATIONS Specifications Apply To:

S (Fabricator's Shop),
F (Field/Site)
V22-1TS-6404, Fire Protection of Structural Steel (Including Steel Vessel Supports) S, F
V40-1TS-6404, High Temperature Insulation F
V40-2TS-6404, Low Temperature Insulation F
V42-1TS-6404, General Coating Procedures S, F
V42-2TS-6404, Field Coating Procedures F
PV-AAA-V10-006, Coating System 6, Epoxy + Epoxy S, F

WORK SCOPE AND LOCATION

Support
Painting Insulation
Fireproofing

& Notes*
& Notes*
Location

Location

Location
& Notes*
Coating
System

Surface Description

(mm)
Type

Thk
Top head, upper shell, transition, and lower shell down to 6 S 7 70 - —
support on skirt
Bottom head and internal skirt down to insulation support 6 S 1 30 — —
NPS 12 nozzies off bottom head 6 s 1 30 - -
Internal skirt surface below insulation support 6 s ~ — - None —
External skirt surfaces below insulation support S1 S1 - „
- 8.24 S2, F1

* Work areas are: S in Fabricator's Shop, M in Module Yard, F in Field/Site. Suffix indicates notes
(S) Notes, Fabricator's Shop:
5 1 Surfaces to be fireproofed shall be abrasive blast cleaned in accordance with SSPC-SP 10 and primed with International's
Intergard 251 applied to a DFT of 50 to 75 um. DFT shall not exceed 75 um,
5 2 External skirt surfaces shali be shop fireproofed with intumescent fireproofing, Chartek 1709, applied in accordance with
V22-1TS-6404. Fireproofing support studs are not required for this fireproofing system. Chartek 1709 shall be top coated
with two {2) coats of International's Interzone 954 applied to a DFT of 375 to 500 um per coat. Areas which are not
fireproofed (edge of base plate and anchor bolt nut/washer seating areas on continuous ring) shall also be top coated with
two coats of International's Interzone 954.

(F) Notes, Field (Site):

F1 Field shall apply Chartek 1709 fireproofing to the skirt area above the nut seating surface, as shown in V22-1TS-5404,
Figure 6,

Figure 3.1: Coating, Insulation and Fireproofing Data Sheet

 16

VESSEL DESIGN DATA AND CONNECTION SUMMARY ITEM NO. 15-MD01

r v •••» r% JOB ^0. fl 23

NO. 0 1 2 3 CLIENT Age

REVISIONS

DATE 24-Feb-06 12-May-OB l-Nov-07 19-Feb-OS LOCATION XYZ

BY KIC SA LML SJP UNIT 15 - Liquefaction

CHK. MES MES MES MES VESSEL DESCRIPTION Scaib Column

APPO- PB PB SM SM PSIDSO. PR-15-SYPI-002

VESSEL CONNECTIONS CONNECTING PIPE

REMARKS REV
NOZZLE SIZE (SCH) (CONST)
SE RV!CE IDENTIFICATION CLASS
LABEL (IN) RATING FACING

A NGOut NG-15003 36 6RGJL 600# RF

B Feed Gas In NG-15001 36 6R0JL 600# RF

C Reflux in LP-15002 10 6R0JL 600# RF

D LNG Out LP-15004 12 6R0JL eoo# RF

e Vent - 2 6R0JL eoo# RF

F Drain - 3 6RQJL 800# RF

G Reboller Feed LG-15222 30 6R0JL 600# RF

Keboiler Vapor
H LG-15207 20 8R0JL 600# RF 3
Return
1 DELETED

PRESS: BARG
DESIGN DATA UNITS
TEMP: B
C NOTES
REV 1. 8EVEL DETAILS SHALL CONFORM TO KBR STD P4-6TS FOR SIZE AND SCH. LISTED.
DESIGN PRESSURE 75 2. INSTRUMENT CONNECTIONS BY CONTROL SYSTEMS ENG.
MAX. TEMP. (8 DESIGN PRESSURE 120 3. CONSULT SYSTEMS WORK GROUP LEADER. ENTRY AT 30% IS MADE FOR
THE FOLLOWING TO BE PROVIDED ONLY IF APPLICABLE (NOTE 3|
DIV. 2 VESSELS ONLY.
VACUUM DESIGN PRESSURE (% FULL VACUUM)

MIN OPERATING TEMP. / COINCIDENT PRESS.

STEAM-OUT OR DRY-OUT TEMP. 1 PRESS.

REGENERATION OR ALTERNATE TEMP.; PRESS.

DEPRESSURING POINTS IONLY IF REQ.) (NOTE 3) TEMP.

30% DESIGN PRESSURE -62-6
60% DESIGN PRESSURE -68.7
47.6% DESIGN PRESSURE -75.8
35% DESIGN PRESSURE -84.4
30% DESIGN PRESSURE

0% DESIGN PRESSURE -1382

Figure 3.2: Vessel Design Data and Connection Summary.

 17

Page 1 ofB
KBR
Eogis^ajsiig S*r,-!Kas by IIE5, Tats
VERTICAL PRESSURE VESSEL DATA SHEET
REFERENCE DOCUMENT SUMMARY
Revisions |

Number A 0 1 2 Document Number MD2-15-MD01

Date I6-Aug-C« 5-Dec-D7 15-May-08 27-Jun-08 Job Number 123
By MPH HHR MPH MPH Client ABC
Chk MH KAT HHR HHR
Appd WTM SGP SGP SGP Location XYZ
Quality Purpose IFI iFP IFP iFP Item Number I5-MD01
Item Name SCRUB COLUMN

REFERENCE DATA SHEETS & DRAWINGS

No. of Rev. Date
Rev Document Number Description
Pages issued Issued
7 MD2-I5-MD01 Scrub Column 2
8 27-Jun-OS
2 MD2-15-MD01-01 Assembly Drawing - Scrub Column 1 27-Jun-OS
2 MD2-15-MD01-02 Miscellaneous Details - Scaib Column 1 27-Jun-OB
2 MD2-15-MDQI-03 Miscellaneous Details - Scrub Column 9 27-Jun-OS
R20-15-PR-MD01-SHTO2 Valve Tray - Two Flow - Scrub Column a 22-Jun-06
R20-15-PR-MD01-SHT03 Tray Elevation - Two Flow - Scrub Column 0 22-Jun-06
R20-15-PR-MD01-SHTM Valve Tray - Four Flow - Scrub Column 0 22-Jun-08
R20-15-PR-MD01-SHT05 Tray Elevation - Four Flow - Scrub Column 0 ^•: . M I - ' .
V10-15-MD01 Coating, Insulation, ami Fireproofing Data Sheet 1 13-NOV-Q7
PV-AAA-V10-006 Coating Data Sheet 1 21-Jan-OB

REFERENCE SPECIFICATIONS & STANDARD DRAWINGS

No. of Rev. Date
Rev Document Number Description
Pages Issued Issued
SDR-2MD-MD0Q8 Deleted
SDR-2MDT-MD031 Deleted
SDR-3 Deleted

PRIO'I Requirements and Coordination Procedure Between ARA, Purchaser (KBR) & Supplier 60 5 17-Apr-08
PR102 Purchaser's Quality Requirements For Suppliers 16 2 1Q-OCI-07

MD1-4TS Export Protection and Packaging. Class MD: Converters, Reactors, Regenerators, S — 1-Apr-Q3
and Pressure Vessels; Class MF: Tanks
MD20-1CS Vessel Trays, Leveling and Leakage Testing 3 1-Apr-03
MD20-2F Vessel Trays and Internals 13 . „ 1-Sep-03
MO20-2PS Purchasing Requirements for Vessel Trays and Internals 6 ... 1-Apr-03
MD40-1F-8404 Pressure Vessels 33 r> t 15-Aug-07
MD40-1PS-6404 General Purchasing Requirements for Pressure Vessels 8 0 15-Auq-07
MD-AAA-G2Q-002-6404 Stainless Steel Vessels and Exchangers e 0 15-.Auq-Q7
PT-AAA-G20-003 Equipment Nozzle Allowable Loads 7 1 25-Oct-O?
SDR-1IM General Document Deliverable Requirements 6 i5 7-Apr-08
SDR-1MDMF Supplier Drawing/Data Requirements for Pressure Vessels, API Tanks, Vessel Trays 7 — 1-Apr-03
and Internals
V22-1TS-6404 Fire Protection of Structural Steel (Including Steel Vessel Supports) 17 5 29-Jan-OS
V40-1TS-8404 High Temperature Insulation 33 3 I7-NOV-07
2 V40-2TS-I3404 Low Temperature Insulation 43 4 24Jun-08
V42-1TS-6404 General Coating Procedures 13 1 27-Sep-07
2-1TS Alloy Verification 14 ... 1-Mar-05
4-7TS General Welding Requirements 17 _ 1-NOY-G5
9-4O-6404 Design Requirements for Wind Loads 3 2 9-Apr-Oe
8-15D-6404 Design Requirements for Earthquake Loads for LNG Facilities 4 2 21-Apr-0a

MD-AAA-MD2-Q06 Skirt Vents and Access Opening Details 1 1 lt-Jan-08

MO-AAA-MD2-004 Grounding Luq Detail 1 0 14-Aucj-07

MD-AAA-MD2-Q01 Insulation and Fireproofing Support Standard Details - Vertical Vessels 1 0 14-Auq-07
MD-AAA-MO2-0Q2 Insulation aiKi Fireproofing Support Standard Details - Vertical Vessels 1 0 14-Aug-07
MD-AAA-MD2-003 Cryogenic Vessel Clip Details 1 0 14-Aug-07
2 MD-491-D03 Integral Start Details I 0 16-Dec-Q2
MD-494-Q04 Large Pipe Support Clips for Hot or Cold Temperature Service 1 0 28-Feb-05
MD-494-D05 Large Pipe Guide Clips for Hot or Cold Temperature Service ! 0 28-Feb-05

Figure 3.3: Vertical Pressure Vessel Data Sheet - Page 1

 18

KJsin VERTICAL PRESSURE VESSEL DATA SHEET

Page 2 of 8

REFERENCE DOCUMENT SUMMARY

Document Number MD2-15-MD01 Rev 2
Job Number 123
Client SBC

Location XYZ
Stem Number 15-MO01
Stem Narrre SCRUB COLUMN
REFERENCE SPECIFICATIONS & STANDARD DRAWINGS (Continued)
No. of Rev. Date
Rev- Document Number Description
Pages Issued Issued
MD-495-DC1 Manway Details 1 0 14-Auq-03

MD-496-D01 internal Piping Details I 0 14-Sep-Q4

MD-496-D02 internal Details 1 0 e-Dec-05
MD-498-D03 DemSstmg Pad Details 1 0 20-Auq-03

MD-498-DQ2 Tailing Lug Detail 1 0 18-Dec-02

Figure 3.4: Vertical Pressure Vessel Data Sheet - Page 2

 19

Etffnl Page 3 of 8
Document Number M D 2 - 1 5 - M D 0 1 R e v 2
123
Job Number
VERTICAL PRESSURE VESSEL DATA SHEET Client Aac

Location XYZ
Item Number 15-MDG1
Item Name SCRUB COLUMN
Rev DESIGN DATA
Design Conditions Internal 75 bar (g) at 120 *C
External N/A bar at N/A *C
Minimum Design Metal Temp -1382 »C (MDMT) at 75 bar (g)
Operating Conditions 59.7 bar (g) (Top) at -55.3 / 82.2 "C (Top / Bottom)

Corrosion Allowance 0 mm
Liquid Specific Gravity 0.42
Vapor Static Head 0.11 bar
Pressure Drop Through Internals 0.05 bar
PWHT Required No r Service P W H T No
Radiography Requirements Full (RT-1)
Shop Hydrotest Pressure 1.5 x Design Pressure
Field Hydrotest Pressure (1.5 x Design Pressure) (Future Field - Corroded) (See General Note 31)
Painting Per V1Q-15-MD01
Insulation 70 mm Cold and 30 mm Hot: (By Others) See V10-15-MD01 for Location
Fireproofing Per V10-15-MD01
Shipping Weight 388300 Kg (Includes 14,800 Kg Shop Installed Trays)
Erection Weight 416400 Kg (includes insulation, FP, Piping, Ladders and Platforms)
Empty Weight 417100 Kg (Start-Up Ready)
Operating Weight 435200 Kfl
Test Weight (Field) 712700 Kfl
Vessel Designed For Wind 1 SO kph ASCE 7-05; 1 = 1.15: Exp "C"; SF = 0.7
Vesse! Designed For Earthquake ASCE 7-05 Ss = 0.32; SI = 0.18; Fa = 2.25; Fv = 3.26; Soil - Class E; I = 1.5; R = 3.0
Moment At POS Wind 2480 kN-m
Shear Force At POS Wind 177 kN
Moment At POS Earthquake 20515 kN-m (Operating) §9730 kN-m (Empty)
Shear Force At POS Earthquake 1405 kN (Operating) 1345 kN (Empty)

Rev DESIGN C O D E & MATERIAL SPECIFICATIONS

Construction Code 2007 ASME Section VIII Div.l With Latest Addenda C o * Stamp p' Ye<- Nations Board ^ No
Registration —
Materials for Pressure C o m p o n e n t s a n d Parts W e l d e d t o Pressure C o m p o n e n t s :
Shell and Heads SA-240-304
Standard A S M E B16.5 Weld Neck / LWN Flanges SA-182-F304 ASME B16.47 Flanges SA-336-F304
Fittings SA-403-WP304
— Self Reinforcing & Special Forgings SA-336-F3Q4
Nozzle Necks SA-312-TP304 / SA-240-TP.304
Upper 1500 mm of Skirt SA-240-304, Remainder of skirt SA-516-70
Shell Attachments Plate SA-240-304
Pipe SA-312-TP304
Structural Shapes 304ss.

Materials f o r Parts Not W e l d e d t o Pressure C o m p o n e n t s :

Base Rings / Chairs SA-516-70
Plate SA-516-70
Pipe SA-108-B
Pressure Bolting SA-320-B8. ci.21 S A - 1 9 4 - S M A
Trays 304 S.S.
Internal Bolting 304 S.S.
Internal Piping SA-312-TP304.' SA-240-304
Other Internals 304 S.S.
Demister Pad 304 S.S. w/ 304 S.S. Grids Top and Bottom
Gaskets Pressure Gaskets Spiral Wound Flexible Graphite Filler W/304 SS Windings / 304 SS Inner & Outer Rings
Non-pressure Gaskets 1.5mm Flat Ring, Flexible Graphite w/ 316 SS Insert

Figure 3.5: Vertical Pressure Vessel Data Sheet - Page 3

 20

Pag 4ofa
KBR '
6»,««,s«™b,EHi«k l i a !s„i„,!. I Document Number M D 2 - 1 5 - M D 0 1 R e v 2
Job Number H3
VERTICAL PRESSURE VESSEL DATA SHEET client ABC
XYZ
Location
Item Number 15-MD01
Item Name SCRUB COLUMN
GENERAL NOTES
1 All materials shown on this data sheet are to be furnished and installed by the Vessel Supplier unless otherwise noted.
2 Substitutions of materials will not be allowed without KBR's prior approval. This approval can only be obtained
at the time Vessel Supplier submits his quotation.
3 All thicknesses shown on data sheet and/or drawing are minimum. The Vessel Supplier shall be responsible for detail design.
4 The inside diameter of manways shall be no less than 584 mm.
5 Manways shall be furnished with Mind flange, bolts, gasket, davit, and internal manway grip.
6 Interna! ladder rungs shall be provided below the lowest shell manway on vertical vessels to permit access to the bottom head.
7 Vessel Supplier to provide Insulation supports In accordance with KBR Standard Drawings MD-AAA-MD2-0Q1 and MD-AAA-MD2-0Q2.
8 All internal elevations are to top of support ring (if required).
9 Vessel Supplier to provide vessel two (2) grounding lugs per KBR Standard Drawing MD-AAA-MD2-Q04.
10 Flange design calculations are required for ASME B16.47 flanges for both design and gasket seating conditions per ASME
Section VIII, Division 1, Appendix 2.
11 Vessel Supplier to provide and design tailing lug with skirt bracing, as required, per KBR Standard Drawing MD-498-DQ2.
12 All removable Internals shall be made In sections for removal through vessel manways.
13 Vessel Supplier to provide skirt vents, access openings and skirt sleeves in accordance with the details shown on
KBR Standard Drawing MD-AAA-MD2-006. The skirt to head attachment weld to be provided per KBR dwg. MD-431-D03 Detail "FC".
14 Nozzles shall be designed for external loads per KBR Specification PT-AAA-G20-003 as a minimum. Actual nozzle loads and
moments shall be furnished later.
15 Reinforcement of nozzles shall be Integral or by insert plates.
16 All welding shall be performed in accordance with code requirements and KBR Specification 4-7TS. General Welding
Requirements. Welding procedures Including PQR's and weld map shall be submitted for engineering review, which shali be
completed prior to commencement of fabrication.
17 Vessel Supplier shall furnish and install a full diameter demisting pad 150mm thick, 144 kg/rrt density (304S.S.) complete with
304 S.S. grids top & bottom. Demisting pad supports shall be furnished and installed by Vessel Supplier per KBR Standard
Drawing MD-496-D03.
18 Internal Supplier to design and furnish the following (shipped to Vessel Supplier):
a. One (1) 304 SS Trap Out Pan per KBR Drawing MD2-15-MDQ1-Q3. Provide beams as required.
b. One (1) 304 SS Seal Pot (SP-2) per KBR Data Sheet R20-15-PR-MD01-SHT05.
c. Nine (9) 304 SS four flow valve trays per KBR Data Sheets R20-15-PR-MD01-SHT04 and 05.
d. One (1) 304 SS Seal Pot (SP-1) Including pipe downcomers per KBR Drawing MD2-15-MD01-03.
e. Three (3) 304 SS two flow valve trays per KBR Data Sheet R20-15-PR-MD01-SHT02 and 03.
19 Internal Supplier to design the following (material furnished and installed by the Vessel Supplier):
a. Support ring and beam supports, if required, for one (1) Trap Out Pan per KBR Drawing MD2-15-MD01 -03.
b. Tray support rings for nine (9) four flow trays and one (1) seal pot (SP-2) per KBR Data Sheets R20-15-PR-MD01-SHT04 & 05.
c. Tray support rings for three (3) two flow trays and one (1) seal pot (SP-1) including pipe downcomers per KBR Data Sheets
R20-15-PR-MD01-SHT02 & 03.
20 Vessel Supplier to design, furnish, and install the following:
a. One(1)304 SS Reflux Distributor at Nozzle "C" per KBR Drawing MD2-15-MD01-02.
b. One (1) 304 S3 Feed Distributor at Nozzle "B" per KBR Drawing MD2-15-MD01 -02.
21 Vessel Supplier to Install the following:
a. One (1) Trap Out Pan. (Pan to be seal welded to support ring.)
b. One (1) Seal Pot (SP-2).
c. Nine (9) four flow valve trays.
d. One (1) Seal Pot (SP-1) including pipe downcomers.
e. Three (3) two flow valve trays.
f. One (1) Demisting Pad.
22 Head and shell thickness shown on assembly drawing are based on required shop and field hydrotests at 1.5 x design pressure with
stress limited to 95% yield strength of material.
23 All stainless steel equipment items shall be protected against direct exposure to marine atmosphere or other sources of chlorides
during fabrication, shipment, field storage, construction, and testing to minimize the risk of stress corrosion cracking.
24 Design of non-pressure parts shall be based on the guidelines from the AISC Manual for Steel Construction, latest edition and
the yield strength given in ASME Boiler and Pressure Vessel Code, Section II Materials, Part D Properties.
25 Minimum Internal bolt size is M10. All bolts (Internal and external) shall be UNC series up to M25 nominal size and 8 TPI
(Threads Per Inch) for sizes above M25.

Figure 3.6: Vertical Pressure Vessel Data Sheet - Page 4

 21

KBR Document Number MD2-15-MD01 Rev 2

Page 5 of $

Job Number 123

VERTICAL PRESSURE VESSEL DATA SHEET Client ABC

Location XYZ

Item Number 15-MD01

Item Name SCRUB COLUMN

GENERAL NOTES
26 Vessel Supplier to provide two (2) Internal tray lifting lugs per KBR Standard Drawing MD-496-D02, detail "E" and attached to
top head.
27 Vessel Supplier to furnish anchor bolt template (made in two pieces) from 25 mm plate. Template is to be bolted and doweled
together before drilling anchor bolt holes. Holes to be 2 mm larger than bolt size. Templates to be match drilled with
base plate and other template plates. Templates to be marked with orientation.
28 Vessel Supplier to design and furnish lifting cover with erection bolting for nozzle "A".
a. Design should include lifting vessel from horizontal position to vertical position.
b. Impact factor to be in accordance with KBR Specification MD4G-1F-6404.
c. Top head and nozzle to be designed for loadings Imposed during lift. Calculations to be submitted prior to material purchase.
d. Temporary erection bolting and gasket for the lifting cover shall be furnished. All erection bolting shall be painted yellow.
DO NOT USE SERVICE BOLTING AND GASKETS FOR LIFTING PURPOSES.
8. Lifting cover with erection bolting and gasket shall be shop Installed. Outlet spool to be shipped loose for field installation.
f. Lifting cover material to be SA-51S-70N; chatpy impact tested at tfC
29 Alloy verification to be performed in accordance with KBR Specification 2-1TS.
30 Deleted.
31 Vessel Supplier must calculate and check the stresses in the vessel resulting from shop hydrostatic test pressure and field
hydrostatic test pressure (corroded vessel + static head + 1/3 design wind load). See Specification MD40-1F-S404 para.
2.11.1.c and 2.12.1.c for applicable reference. These test pressures / conditions may set vessel thicknesses. The hydrostatic
test pressures shall be noted on the Supplier's vessel drawing.
32 The following spares are rsquirsd for manholes, handholes or any other blinded connections.
a) 200% gaskets.
b) 10% nuts and bolts (at least 2 nuts and 4 bolts per flange)

Figure 3.7: Vertical Pressure Vessel Data Sheet - Page 5

 22

KBR Document Number MD2-15-MD01 Rev 2

Page & of 8

iEssgaasiiag SSEVK** W KBR TsdaacsJ Services, lac

Job Number 123
VERTICAL PRESSURE VESSEL DATA SHEET Client ABC

Location x*z
Item Number 15-MDQ1
Item Name SCRUB COLUMN
R™ TABLE OF CONNECTIONS
General Notes for Table of Connections:
A. Conn ections shown in sketch are diagrammatic only. For true location see plan view, end view or orientation below.
B. S e e / Assembly Drawing MD2-15-MDQ1-01 and below for all applicable connection projections.
C. All pr essure connections are to be flanged.
D. Elevs tions in the table are to centerline of connection or face of flange unless noted otherwise.
E. F o r h II side connections see plan or plan view.
— F. Rang es over 24" shall be per ASME B16.47 Series A (See General note 10).
G. All fla nge faces shall have a stock finish.
H. F o r s pecific notes to TABLE OF CONNECTIONS see next page.
Mark Size Rating Face Service Elevation Orient Specific Notes Projection to Vessel CL
2 A 36" 800# RF NG OUT 127635 240° SEE DRAWING
2 B 36" B00# RF FEED GAS IN 118060 0* 12 3500
2 C 10" eoo# RF REFLUX IN 121760 210° 12 3475
2 D 12" 600# RF LNG OUT 105860 270' 9 SEE DRAWING
2 E 2" B00# RF VENT 128335 DWG 2 3 17 SEE DRAWING
2 F 3" 600# RF DRAIN 105485 DWG 3 18 SEE DRAWING
2 G 30" 600# RF REBOILER FEED 110717 1 so- 19 2900
2 H 20" 600# RF REBOILER VAPOR RETURN 109873 ws' 2800

2 AL 3" 600# RF LEVEL TRANSMITTER 110160 315° 22 2575

2 BL 3" 600# RF LEVEL TRANSMITTER 107460 315' 22 2575
2 CL 3" B00# RF LEVEL TRANSMITTER 110160 345' 22 2575

2 DL 3" S00# RF LEVEL TRANSMITTER 107460 345° 22 2575

2 AP 2" eoo# RF PRESSURE GAUGE 122060 105° 20 3375

2 BP 3" 600# RF PRESSURE DIFFERENTIAL TRANSMITTER 122060 75° 20 3375
2 CP 3" 600# RF PRESSURE DIFFERENTIAL TRANSMITTER 118060 75" 21 3100
2 DP 3* 600# RF PRESSURE DIFFERENTIAL TRANSMITTER 118060 105° 21 3100
2 EP 3" eoo# RF PRESSURE DIFFERENTIAL TRANSMITTER 110260 45° 22 2575

2 AT 2" 600# RF TEMPERATURE INDICATOR 120060 180° 4 20 3375

2 BT 2" 800# RF TEMPERATURE INDICATOR 116410 0° 4 22 2575
2 CT 2" 600# RF TEMPERATURE INDICATOR 115210 0° 4 22 2575
2 DT 2" eoo# RF TEMPERATURE INDICATOR 114010 0° 4 22 2575
2 ET 2" 600# RF TEMPERATURE INDICATOR 112810 0° 4 22 2575
2 FT 2" 600# RF TEMPERATURE INDICATOR 111460 0° 4 22 2575
2 DELETED

2 MHl 24" 600# RF MANWAY 121610 160° 2 5 14 23 3675

2 MH2 24" 600# RF MANWAY 118060 180° 2 5 14 23 3400
2 MH3 24" 600# RF MANWAY 110010 90° 2 5 14 23 2900

2 SA1 610 I.D. .._ SKIRT ACCESS 104700 0°

2 SA2 810 I.D. ... SKIRT ACCESS 104700 180° 24
2 SV1-10 3" _._ SKIRT VENTS BY VENDOR ... TEN REQ'D; 1ST VENT @ 0°

2 SS1 435 I.D. ... SKIRT SLEEVE AT "D" 105860 270°

2 SS2 203 I.D. ... SKIRT SLEEVE AT "BL" 107460 315°
2 SS3 203 I.D. - SKIRT SLEEVE AT "DL" 107460 345°

Figure 3.8: Vertical Pressure Vessel Data Sheet - Page 6

 23

KBR Page 7 of 8
Document Number M D 2 - 1 5 - M D 0 1 Rev 2
Job Number 123

VERTICAL PRESSURE VESSEL DATA SHEET Client ABC

XYZ
Location
Item Number 15-MD01
Mem Name SCRUB COLUMN
SPECIFIC NOTES TO TABLE OF CONNECTIONS
(All Notes Listed Hereunder Shall Apply Only If Called For By Number In The Table Of Connections)
1 Use this information for quotation purpose only.
2 Supply blind flange, bolts, nuts and gasket.
3 Elevation is given to the face of flange.
4 Nozzle size listed is minimum inside diameter of nozzle neck.
5 Furnish davit in accordance with drawing MD-495-D01.
6 Furnish hinge in accordance with drawing MD-495-D01.
7 Furnish internal pipe support in accordance with drawing MD-496-DQ1.
8 Furnish internal plate flange in accordance with drawing MD-496-D01.
9 Furnish anti-swiri baffle in accordance with drawing MD-496-D02.
10 Furnish inlet hood baffle in accordance with drawing MD-496-D02.
11 Furnish inlet distributor in accordance with drawing MD-496-D02.
12 With internal pipe per KBR Drawing MD2-15-MD01-02.
13 Davit on right side facing manway.
14 Davit on left side facing manway.
15 Hinge on right side facing manway.
1$ Hinge on left side feeing manway.
17 Nozzle located on nozzle "A"
18 Nozzle located on nozzle "D"
19 Invert of nozzle to be flush with bottom of Trap Out Sump
20 Located in 5800 ID Section
21 Located in Cone Section
22 Located in 4400 ID Section
23 See General Note 4.
24 Furnish access opening cover in accordance with drawing MD-AAA-MD2-006.

Figure 3.9: Vertical Pressure Vessel Data Sheet - Page 7

 24

P a g e 8 of 8
Document Number MD2-15-MD01 Rev 2
Job Number 123
VERTICAL PRESSURE VESSEL DATA SHEET Client ABC

Location XYZ
Item Number 15-MD01
Item Name SCRUB COLUMN

Bottom Tangent Line Elevation

"L" Thick x "J" Square Washers

With Bolt Diameter + 3 mm Hole
(Wire To Chair For Shipment)

"C" Continuous Ring

B £ ^ s
1(H-I

I.D. Baseplate
"N"!/

r Base Rate Thk

«

(=)
f POS Elevation

P.P. Skirt 10

Bolt Circle Diameter

CenterlineOf "M" Diameter Holes For "D" Diameter Bolts
To Straddle N,S.E,W Centerlines
O.D. Base Plate

SKIRT BASE DETAILS

Aft dimensions and etevations are in millimeters.

Rev
POS Elevation Bottom Tan. Line Elev C D F G H J K L M N
103800 109260 76 M76 26 140 460 140 13 26 102 13

Rev
No. Of Bolts Base Plate Thk I.D. Base Plate O.D.Skirt Bolt Circle Diameter O.D. Base Plate
20 76 4310 4560 4790 5020
Design Based On 30 N/mm2 Concrete
' Allowable Bearing Stress 10.5 N/mm2
Anchor Bolt Allowable Stress 132 N/mm2 (Based on BS 4190 Gr. 4.6 Material)

Figure 3.10: Vertical Pressure Vessel Data Sheet - Page 8

 25

VESSEL SKETCH FOR INSTRUMENT CONNECTIONS CODE DETAILS

P&IONO.: PR-15-SYPI-0Q2 ITEM NO.: 15-MD01
Instrument Connections Instrument Description Ref.
Code I C-**-^l I
Tag No. Symbol Instrument Vessel and Remarks Mote

1S-TW-1431 AT 1-2"600#RF 1-2" 600* RF THERMOWELL

1S-TW-1432 1-2"6Q0#RF 1-2™600#RF THERMOWELL
15-TW-1433 CT 1-2"60G#RF 1-2"6G0#RF THERMOWELL
;XXH
15-TW-1434 DT 1-2"600#RF 1-2"600#RF THERMOWELL
I5-TW-1064 ET 1-2" 600# RF 1-2" 600* RF THERMOWELL
15-TW-1435 FT 1-2" 800# RF 1-2* 600* RF THERMOWELL
ZHx-i
15-LT-1011 AL.BL 2-3" 800# RF 2-3"80Q#RF LEVEL TRANSMITTER
I P^Q _
15-LT-1012 CLDL 2-3" 800* RF 2-3" 600* RF LEVEL TRANSMITTER

15-PDT-1016 BP,CP 2-3"6Q0#RF 2-3" 600# RF PRESSURE DIFF. TRANSMITTER

15-PDT-1Q7Q DP.EP 2-3" 600# RF 2-3" 600# RF PRESSURE DIFF. TRANSMITTER

I5-PG-1021 AP 1-2"600#RF 1-2" 600# RF PRESSURE GAUGE ZHxH"

n-tx-j

NOTE 3

p-c=<Hk

T
ZHXr-F

NOTES:

1. LEVEL DISF1ACER MOUNTING, L-LEFT HANDED,

R-RIGHT HANDED {BY PIPING).
2. ALL ISOLATING, DRAIN AND VENT VALVES
ALONG WITH STAND PIPES ARE BY PIPING PER
THE PUD'S.
3. ALL NOZZLES USING THIS PROFILE SHALL BE A
"JIG FIT'. THE TOLERANCE SHALL BE +!• 1/16".
4. PRESSURE CONNECTION IN VAPOR SPACE.
5. LOCATE NOZZLES AS FOLLOWS:
AT-TRAY 2 DOWNCOMER TO TRAY 3 £h
BT- TRAY 4 DOWNCOMER TO TRAY 4
CT- TRA.Y 8 DOWNCOMER TO TRAY 7
DT-TRAY 8 DOWNCOMER TO TRAY 9
ET- TRAY 10 DOWNCOMER TO TRAY 11
FT-TRAY 12 DOWNCOMER TO SP-2

DESiaN CONDITIONS
TEMP: -138.3 to 120 deqC I PRESS: 75 baifqT

. SHEET 1 OF 1

BY: CJ
O I!lESinl
mr

Changes as Shown CJ KKS AJD CHK: KKS

IFI 05 May 03 CJ KKS AJD SCRUB COLUMN
APP: AJD
NO. DESCRIPTION DATE BY CHK APP IS1800-15-MD01
DATE:
REVISIONS CLASS JOB NO. SKETCH NO. REV

Figure 3.11: Vessel Sketch for Instrument Connection

 26

KBP1
K&R Teefcraeai S«vte»s, bio.
Form LS3 (Si) Od-02 A

JOB NO. i ; 3 PAGE 1 o< 4 / 2 \

CLIENT ABC PROCESS DEPARTMENT ITEM NO. 1 S - M D 0 1
LOCATION _XYZ VESSEL LOADSHEET SERVICE Scrub Column
UNIT 15 - liquefaction (EXTERNAL LOADS FOR CLASS ML) DOC. NO. PR-15-R2IM5-MD01
CASE1R5 / X "
Use Multiple Sheets if Necessary
SCHEMATIC DIAGRAM IDENTIFYING STREAMS PROCESS NOTES
{USE FORM LSI IF MORE SPACE REQUIRED)
OVHD to
15-MC05 T CC) Normal -55.3/82,2 Max. OT 126
Top/Bottom A Min. OT •',33

P (BARA) Normal 6 0 . S ? / 6 0 . 7 2 / 2 \ Max, OP 68

Top/Bottom Min. OP

NOTES:

Reflux from / 2 \ 1. Data shown based on APCI Case 1R5.

15-MJ01
2. Ten percent design margin has been added.
3- Condenser is MCHE warm bundle (not shown on Trayload Sheets).
Theoretical Stages 4. Reboiier is Stage 8 (shown on Trayload Sheets).
shown on sketch.
A 5. Place Feed nozzle and distributor above swage.
15-MC03 / i \ 6. Deleted.
7. Deleted,
8. Low tray liquid loads above Feed for Case 2R4.
<^ toRebo ler,
/ £ \ Reboiier Vapor/ < ^ -H w
9. Minimum OT for flashing refluxto 101.3 kPa Case 1R5.
/ \ Liquid Return *• * 1b-MC 16 '
10. Cases 4 and 6, formerly shown on pages 5-8. have been deleted.

r
Bot torr S t 0
15 ; i e

Note: Filter orientation " by Engineering " unless otherwise noted.

Min./Max. operation conditions are Process estimates of anticipated operating ranges.
FlOWRAfES^ PROPERTIES®
STREAM CONDITIONS Normal Conditions Normal C o n d i t i o n s
I.D. DESCRIPTION PHASE Temp. Pressure Mass Mole Volume Density Viscosity Remarks
BAR (A) KG/HR KGMOt/HR M'/HR KG/W CP

INLET

A\ fc
A f-'eed -35.15 60 6 9 830,540 451868 10411.7 79 77 00118 VapCsT

93.702 mm ? 197X1 47S.61 aosre Liquid

C Rsfiux - <- •55.33 80.67 we.eez 5227.7 3184 386.62 0.0556

0 feboBer V&psX / liquid &@ti,WT) ' »\ M 42.22 60.72 143,1)33 •198.7 1265.6 113.01 -0.3152 Vcixsr

8222 60.72 125,127 292? 2 343 2 384.03 0.043!) Uyiiid

OUTLET

a Ovhd Vapor V -39,86 BO.fs? i)25,774 $0363.0 10872.1 85.14 6.0118

£i t o f^ebofer L 42.S6 80 72 21)3,lfs0 7123.8 671 a 38B.10 0.0534

F 8s*t0tT)S PfO^tiCf L 1 8222 60.72 125, B1 29273 343.2 31)4 .$3 0.043$

REV.
fW6. c^TlRB. RVWD. AWD.
NO. BY: DATE BY-.DATE BY:DATE BY:DATE DESCRIPTION
D ADM 1*1)6 KK 1-6-06 D K M 1-S-06 Issued for Process Release
1 A D M 2-14-06 HK 2-14-06 DKM2-15-06 All Pages Revised completely. Deleted Stages to Match New Case 1R4.
2 HML 1 0 - 1 5 4 7 G M 10-16-0? U K 10-18-07 Revised for Cases 1R5 and 2R4. Reboiier return shown as single stream.

Figure 3.12: Vessel Load Sheet - Page 1

 NOTE: INTERNAL LOAD SUMMARY MUST INCLUDE VESSEL EXTERNAL LOAD SUMMARY.
m.jr wm p t A FormLS4(SI) Oct-02

JOB NUMBER 123

PvBallrii PAGE 2 Of 4 / 2 \
Engineering Services by
CLIENT .ABC KBR Technical Services, Irsc. ITEM No. 15-MD01
LOCATION va PROCESS DEPARTMENT SERVICE Scrub Cotarm
UNIT 15 - Liquefaction TOWER OR PACKED COLUMN LOADSHEET HOC. NO. PR-15-R20-15-MD01
CASE 1R5 / A INTERNAL LOAD SUMMARY
VAPOR TO TRAY LIQUID FROM TRAY ALLOWABLE

TRAY NO. TRAY TEMP PRESSURE FLOWRATE VAPOR DENSITY VISCOSITY TEHP FLOWRATE LIQUID DENSITY VISCOSITY SURFACE VELOCITY AREA
THEOR ACTUAL DESCRIPTION T P WEIGHT VOLUME ATP.T. ATP.T, T WEIGHT VOLUME ATP.T. ATP.T. TENSION Va Ao
"C 6?S!Ai m;HH y-VHR KG (HP CP *C KS'HR M"!HR KGJS" CP DYNE (CM 11/SEC M>

k' Top -34 1 60.68 882.175 11.047.9 79.3SC) 0.011S -39.9 83,063 192.48 431.54 0.068 2.528 0 145 21.135

3 Feed -28,3 60,69 S5.083 698 3 79.051 0.0117 -34,1 180.214 401.48 448.89 0.075 2.947 0.150 1293

4 -15 9 60.68 57,483 744.9 77.168 0.0120 -28.3 182.613 409,26 446.20 0.073 2.880 0 151 1.368

5 7.8 60.7C 65.393 827.2 79,052 0.0125 -15.9 190,524 431,08 441.97 0 071 2.734 0148 1 550

6 42.6 60.71 89.831 892.8 90.479 0.0136 7.9 214,962 503.28 427.12 0 064 2,161 0.133 2.CS6

7 Bottom 82 2 60.72 143,029 1285.6 113.014 0.0152 42.6 268.160 671.93 399,09 0.053 1.216 0 110 3.184

8 Reboiler 82.2 125,131 343.17 364.63 0 044 0.458

 28
Figure 3.14: Piping and Instrumentation Diagram
 29
- >
&
* ..(7).
-
..li. "
l i; .~<
<ya
Stream Number 7 4<i | 0 0 04 nt 07 5 0 2 •i 4 15-72
•s ru&Twr S SAJScnib
D F E 502 e j04 (Dun
H"
P R B
fir 6- R
Stream Doscrlp on
X 8e
Di
Oulle
f* 0 5-MCO
tlifle
MC
C
Si
r n E
E a.
*- 5
in
CokiF&re
He urn o k 8 0 0 o
Nitrogen 4 4S •K « 1
2 9 p — -, ' 24
1 Meriarte
_Et_ane
042 x. 1 9
a,, ,« «
R 4 4 2 .
V .
04
I
3^ 3^4
- _ - •
_| •
* »
3 8
9 7 ! 0 4 4 * -
.
«R -_ 0 J
»« m•> « *
9»
Buiane Q
» — „ 3 0
1
teopen atie
Peril erne
M
6
4 64
SO — ___-£ 0
0
97
120
V"
Hex arte <* 7»
«
9 0 0 U -
0 2 o
"Waie ~_ _ 2
o
2
1 t. 0
5
u KBR
aMDEA n o o 0 0 0 0 ^
Total Molar Flowrote. kroole. 4 < • 430M «e«4 •4 43t J4 45771 b 6476 0476 40
P essu e. ba a 63 6 00 „2 02 J4 •f 60. 7 f- 1 507 -0 7 1.01
Terrpe atu e C 3 1 (.90 4 822 4 9 -41.00
To a Flow a e ko
* i r
7-
, . 4
e 22" M02-0 * M02.0
7
S4 ^2*1 841012 281 \. 243782 24i782 27 0 1341301
L q u d kg h
_ .- —
30 4 W e -4
—_ . _— _ 24,7? 7 0 [16775]
Vapor, kolh 7 72 Wi 1 ;- 8 7 JT 7V, 1 7 a 7 S4 CI
K .
287 300
•tftrt
1 27 0 117355!
Dartsrtv Liouid. ko/m 4 47 b< 10 e.4G.Q0
Donsitv Vapor, kfl/rn J 30.37 57 69 40.7B 52 13 57.45 67.12 74 13 8117 85 14 88.36 8B.36 23 55 88.36 113 01 23.79 i 83 PR- i b PKJ2 CW
Molecular Weioht. ko/Hmole 20.19 19,23 19.33 ,.33 ,6 23 19.23 19.23 19.23 18.33 24.23 18.55 17.90 42.75 42.75 18.99 17.90 37.64 37 6 4 19.33 •12.75
Figure 3.15: Process Flow Diagram
 30

Chapter 4: Vessel Designing & ASME BPVC

(The excerpts from ASME BPVC Section VIII Division 1 are reproduced with permission
of American Society of Mechanical Engineers - ASME. All rights reserved.)

4.1 Key Design Parameters

The key design parameters are explained in terms of ASME BPVC Section VIII Division
1 (mentioned as 'the code') and excerpts in quotations are "Reproduced from ASME
BPVC Section VIII, Division 1 2004 with permission of the American Society of
Mechanical Engineers. All rights reserved."

4.1.1 Operating Pressure

The operating pressure is provided by the process engineering groups; it is basically the
pressure at which the vessel is considered to be operating to perform a specific process.
This term is used for the determination of design pressure of the specific pressure vessel.

4.1.2 Design Pressure

Design pressure is a key term used in calculation of the minimum allowable thickness of
different vessel parts. Part UG-21 of the code states that "DESIGN PRESSURE*": "Each
element of a pressure vessel shall be designed for at least the most severe condition of
coincident pressure and temperature expected in normal operation. For this condition and
for test conditions, the maximum difference in pressure between the inside and outside of
a vessel, or between any two chambers of a combination unit, shall be considered [see
UG-98, UG-99(e), and 3-2]." (* "It is recommended that a suitable margin be provided
above the pressure at which the vessel will be normally operated to allow for probable
pressure surges in the vessel up to the setting of the pressure relieving devices (see UG-
134)")".

The determination of design temperature of a vessel depends on specifications that vary

for each organization. Some specifications mandate that the most severe possible
temperature foreseen during the operational life of the vessel should be considered the
 31

design temperature and pressure of the vessel; some other specifications mandate the
addition of some number (for example 10% or 30 psi) to operating pressure will satisfy
most mechanical design scenarios of a pressure vessel.

4.1.3 Vessel Loading

There are many forces acting on the pressure vessel and they are summarized in the code
in part UG-22 as "LOADINGS": "The loadings to be considered in designing a vessel
shall include those from:

(a) internal or external design pressure (as defined in UG-21);

(b) weight of the vessel and normal contents under operating or test conditions (this
includes additional pressure due to static head of liquids);

(c) superimposed static reactions from weight of attached equipment, such as motors,
machinery, other vessels, piping, linings, and insulation;

(d) the attachment of:

(1) internals (see Appendix D);

(2) vessel supports, such as lugs, rings, skirts, saddles, and legs (see Appendix G);

(e) cyclic and dynamic reactions due to pressure or thermal variations, or from equipment
mounted on a vessel, and mechanical loadings;

(f) wind, snow, and seismic reactions, where required;

(g) impact reactions such as those due to fluid shock;

(h) temperature gradients and differential thermal expansion;

(i) abnormal pressures, such as those caused by deflagration."

4.1.4 Design Temperature

Temperature is another important design factor. Increase in temperature above a certain

degree may cause reduction in structural stability and strength of the pressure vessel. On
 32

the other hand decrease in temperature below a certain degree might induce brittleness
through the thickness of the vessel. Usually the design temperature is the mean metal
temperature through the thickness of the vessel wall during the normal operating
conditions; although some organizations describe the design temperature in their
specifications as the most severe anticipated operational temperature plus 50° F. The
design conditions, such as design temperature can be calculated based on thermodynamic
equations, but it can also be determined through experience with certain pressure vessel
and its operation under a specific service.

According to UG-20 of the code: "DESIGN TEMPERATURE":

"(a) Maximum. Except as required in UW-2(d)(3), the maximum temperature used in

design shall be not less than the mean metal temperature (through the thickness) expected
under operating conditions for the part considered (see 3-2). If necessary, the metal
temperature shall be determined by computation or by measurement from equipment in
service under equivalent operating conditions.

(b) Minimum. The minimum metal temperature used in design shall be the lowest
expected in service except when lower temperatures are permitted by the rules of this
Division (see UCS-66, UCS-160, and Footnote 37, UG-116). The minimum mean metal
temperature shall be determined by the principles described in (a) above. Consideration
shall include the lowest operating temperature, operational upsets, autorefrigeration,
atmospheric temperature, and any other sources of cooling [except as permitted in (f)(3)
below for vessels meeting the requirements of (f) below]. The Maximum and Minimum
Design Metal Temperature (MDMT) marked on the nameplate shall correspond to a
coincident pressure equal to the Maximum Allowable Working Pressure (MAWP). When
there are multiple MAWP's, the largest value shall be used to establish the MDMT
marked on the nameplate. Additional MDMT's corresponding with other MAWP's may
also be marked on the nameplate (see Footnote 37).

(c) Design temperatures that exceed the temperature limit in the applicability column
shown in Section II, Part D, Subpart 1, Tables 1A, IB, and 3 are not permitted. In
 33

addition, design temperatures for vessels under external pressure shall not exceed the
maximum temperatures given on the external pressure charts.

(d) The design of zones with different metal temperatures may be based on their
determined temperatures.

(e) Suggested methods for obtaining the operating temperature of vessel walls in service
are given in Appendix C.

(f) Impact testing per UG-84 is not mandatory for pressure vessel materials that satisfy all
of the following:

(1) The material shall be limited to P-No. 1, Gr. No. 1 or 2, and the thickness, as
defined in UCS-66(a) [see also Note (1) in Fig. UCS-66.2], shall not exceed that
given in (a) or (b) below:

(a) 1/2 in. (13 mm) for materials listed in Curve A of Fig. UCS-66;

(b) 1 in. (25 mm) for materials listed in Curve B, C, or D of Fig. UCS-66.

(2) The completed vessel shall be hydrostatically tested per UG-99(b) or (c) or
27-4.

(3) Design temperature is no warmer than 650°F (345°C) nor colder than -20°F
(-29°C). Occasional operating temperatures colder than -20°F (-29°C) are
acceptable when due to lower seasonal atmospheric temperature.

(4) The thermal or mechanical shock loadings are not a controlling design
requirement. (See UG-22.)

(5) Cyclical loading is not a controlling design requirement. (See UG-22)".

4.1.5 Maximum Allowable Working Pressure (MAWP)

As a common practice, the internal pressure specification is used to as the pressure at

which a vessel is loaded (at the top of the vessel, at design temperature) to the ultimate
permissible level under normal operating conditions. Top of the vessel is a general term,
 34

in actual practice MAWP is calculated for each part of the pressure vessel and the least
value is taken as MAWP. This value is also adjusted according to the differences in
static head at the top and at the bottom of the vessel, weight of the vessel, loads created
by the weight of attached equipment, such as platforms, piping, lining etc, vessel
internals, such as trays, demister pads etc. Wind, snow, seismic loads, impact loads
thermal expansion and abnormal pressures etc. MAWP is different from maximum
allowable pressure (MAP), which does not take into account all of these different loads
and only considers the pressure that could be sustained by the weakest part of a pressure
vessel.

The calculation of MAWP is important, because it is used in the designing process of

pressure safety devices such as pressure relief valves.

4.1.6 Maximum Allowable Stress Values

The information regarding maximum allowable stress values are described in part UG-
23of the code, "MAXIMUM ALLOWABLE STRESS VALUES":

"(a) The maximum allowable stress value is the maximum unit stress permitted in a
given material used in a vessel constructed under these rules. The maximum allowable
tensile stress values permitted for different materials are given in Subpart 1 of Section II,
PartD.

With the publication of the 2004 Edition, Section II, Part D is published as two separate
publications. One publication contains values only in the U.S. Customary units and the
other contains values only in SI units. The selection of the version to use is dependent on
the set of units selected for construction. A listing of these materials is given in the
following tables, which are included in Subsection C. For material identified as meeting
more than one material specification and/or grade, the m a x i m u m allowable tensile stress

value for either material specification and /or grade may be used provided all
requirements and limitations for the material specification and grade are met for the
maximum allowable tensile stress value chosen.
 35

Table UCS-23 Carbon and Low Alloy Steel (stress values in Section II, Part D, Table 3
for bolting, and Table 1A for other carbon steels) Table UNF-23 Nonferrous Metals
(stress values in Section II, Part D, Table 3 for bolting, and Table IB for other nonferrous
metals) Table UHA-23 High Alloy Steel (stress values in Section II, Part D, Table 3 for
bolting, and Table 1A for other high alloy steels), Table UCI-23 Maximum Allowable
Stress Values in Tension for Cast Iron, Table UCD-23 Maximum Allowable Stress
Values in Tension for Cast Ductile Iron, Table UHT-23 Ferritic Steels with Properties
Enhanced by Heat Treatment (stress values in Section II, Part D, Table 1 A), Table ULT-
23 Maximum Allowable Stress Values in Tension for 5%, 8%, and 9% Nickel Steels and
5083-0 Aluminum Alloy at Cryogenic Temperatures for Welded and Nonwelded
Construction.

(b) The maximum allowable longitudinal compressive stress to be used in the design of
cylindrical shells or tubes, either seamless or butt welded, subjected to loadings that
produce longitudinal compression in the shell or tube shall be the smaller of the following
values:

(1) the maximum allowable tensile stress value permitted in (a) above;

(2) the value of the factor B determined by the following procedure

where t = the minimum required thickness of the cylindrical shell or tube

R0 = outside radius of cylindrical shell or tube

E = modulus of elasticity of material at design temperature.

The modulus of elasticity to be used shall be taken from the applicable materials chart in
Section II, Part D, Subpart 3. (Interpolation may be made between lines for intermediate
temperatures.) The joint efficiency for butt welded joints shall be taken as unity. The
value of B shall be determined as follows.

Step 1. Using the selected values of t and R, calculate the value of factor A using the
following formula:
 36

A _0.125/

Step 2. Using the value of A calculated in Step 1, enter the applicable material chart in
Section II, Part D, Subpart 3 for the material under consideration. Move vertically to an
intersection with the material/temperature line for the design temperature (see UG-20).
Interpolation may be made between lines for intermediate temperatures. If tabular values
in Subpart 3 of Section II, Part D are used, linear interpolation or any other rational
interpolation method may be used to determine a B value that lies between two adjacent
tabular values for a specific temperature.

Such interpolation may also be used to determine a B value at an intermediate

temperature that lies between two sets of tabular values, after first determining B values
for each set of tabular values. In cases where the value at A falls to the right of the end of
the material /temperature line, assume an intersection with the horizontal projection of
the upper end of the material /temperature line. If tabular values are used, the last
(maximum) tabulated value shall be used. For values of A falling to the left of the
material /temperature line, see Step 4.

Step 3. From the intersection obtained in Step 2, move horizontally to the right and read
the value of factor B. This is the maximum allowable compressive stress for the values of
t and Ro used in Step 1.

Step 4. For values of A falling to the left of the applicable material /temperature line, the
value of B shall be calculated using the following formula:

AE

If tabulated values are used, determine B as in Step 2 and apply it to the equation in Step
4.

Step 5. Compare the value of B determined in Steps 3 or 4 with the computed

longitudinal compressive stress in the cylindrical shell or tube, using the selected values
of t and Ro. If the value of B is smaller than the computed compressive stress, a greater
value of t must be selected and the design procedure repeated until a value of B is
 37

obtained which is greater than the compressive stress computed for the loading on the
cylindrical shell or tube.

(c) The wall thickness of a vessel computed by these rules shall be determined such that,
for any combination of loadings listed in UG-22 that induce primary stress and are
expected to occur simultaneously during normal operation 10 of the vessel, the induced
maximum general primary membrane stress does not exceed the maximum allowable
stress value in tension (see UG-23), except as provided in (d) below. Except where
limited by special rules, such as those for cast iron in flanged joints, the above loads shall
not induce a combined maximum primary membrane stress plus primary bending stress
across the thickness which exceeds 11/2 times 11 the maximum allowable stress value in
tension (see UG-23). It is recognized that high localized discontinuity stresses may exist
in vessels designed and fabricated in accordance with these rules. Insofar as practical,
design rules for details have been written to limit such stresses to a safe level consistent
with experience.

The maximum allowable stress values that are to be used in the thickness calculations are
to be taken from the tables at the temperature which is expected to be maintained in the
metal under the conditions of loading being considered. Maximum stress values may be
interpolated for intermediate temperatures.

(d) For the combination of earthquake loading, or wind loading with other loadings in
UG-22, the wall thickness of a vessel computed by these rules shall be determined such
that the general primary membrane stress shall not exceed 1.2 times the maximum
allowable stress permitted in (a), (b), or (c) above. This rule is applicable to stresses
caused by internal pressure, external pressure, and axial compressive load on a cylinder.
Earthquake loading and wind loading need not be considered to act simultaneously.

(e) Localized discontinuity stresses [see (c) above] are calculated in Appendix 1, l-5(g)
and l-8(e), Part UHX, and Appendix 5. The primary plus secondary stresses at these
discontinuities shall be limited to SPS, where
 38

SPS p 3S, and S is the maximum allowable stress of the material at temperature [see (a)
above]. In lieu of using SPS = 3S, a value of SPS = 2SY may be used, where SY is the
yield strength at temperature, provided the following are met:

(1) the allowable stress of material S is not governed by time-dependent properties as

provided in Tables 1A or IB of Section II, Part D;

(2) the room temperature ratio of the specified minimum yield strength to specified
minimum tensile strength for the material does not exceed 0.7;

(3) the value for SY at temperature can be obtained from Table Y-l of Section II, Part D."

4.1.7 Hydrostatic Test Pressure

The hydrostatic test and all the procedures that are to be followed are stated in part UG-
99 of the code. Usually, it is 1.3 times the maximum allowable working pressure or
design pressure if maximum allowable working pressure is not calculated for the design
of a vessel. In scenarios, where the maximum allowable stress values are higher at test
temperatures as compared to the maximum allowable stress values at design temperature,
then a corresponding increase in the values is made according to:

Stress value at test temperature

Test Pressure - 1.3 x MAWP x - -

Stress value at design temperature

Or

Stress value at test temperature

Test Pressure = 1.3 x Desiqn Pressure x - -
Stress value at design temperature
Hydrostatic testing is 'the standard' for pressure vessel testing, however, there are
situations where Hydrotest is not permissible, pneumatic test could be a mean for
pressure testing the vessel such as:
• This situation arises when sometimes the materials of construction or the process
fluids are sensitive to water (when the water cannot be readily dried).
 39

• There are other conditions when the load of water could fail the supports of the
vessel.

The part of the code about Hydrotest is UG-99, states: "STANDARD HYDROSTATIC
TEST":

"(a) A hydrostatic test shall be conducted on all vessels after:

(1) all fabrication has been completed, except for operations which could not be
performed prior to the test such as weld end preparation [see U-1(e)(1)(a)], cosmetic
grinding on the base material which does not affect the required thickness; and

(2) all examinations have been performed, except those required after the test. The
completed vessels, except those tested in accordance with the requirements of UG-100
and UG-101, shall have satisfactorily passed the hydrostatic test prescribed in this
paragraph.

(b) Except as otherwise permitted in (a) above and 27-4, vessels designed for internal
pressure shall be subjected to a hydrostatic test pressure which at every point in the vessel
is at least equal to 1.3 times the maximum allowable working pressure to be marked on
the vessel multiplied by the lowest ratio (for the materials of which the vessel is
constructed) of the stress value S for the test temperature on the vessel to the stress value
S for the design temperature (see UG-21). All loadings that may exist during this test
shall be given consideration.

(c) A hydrostatic test based on a calculated pressure may be used by agreement between
the user and the Manufacturer. The hydrostatic test pressure at the top of the vessel shall
be the minimum of the test pressures calculated by multiplying the basis for calculated
test pressure as defined in 3-2 for each pressure element by 1.3 and reducing this value by
the hydrostatic head on that element. When this pressure is used, the Inspector shall
reserve the right to require the Manufacturer or the designer to furnish the calculations
used for determining the hydrostatic test pressure for any part of the vessel.

(d) The requirements of (b) above represent the minimum standard hydrostatic test
pressure required by this Division. The requirements of (c) above represent a special test
 40

based on calculations. Any intermediate value of pressure may be used. This Division
does not specify an upper limit for hydrostatic test pressure. However, if the hydrostatic
test pressure is allowed to exceed, either intentionally or accidentally, the value
determined as prescribed in (c) above to the degree that the vessel is subjected to visible
permanent distortion, the Inspector shall reserve the right to reject the vessel.

(e) Combination units [see UG-19(a) and UG-21] shall be tested by one of the following
methods.

(1) Pressure chambers of combination units that have been designed to operate
independently shall be hydrostatically tested as separate vessels, that is, each chamber
shall be tested without pressure in the adjacent chamber. If the common elements of a
combination unit are designed for a larger differential pressure than the higher maximum
allowable working pressure to be marked on the adjacent chambers, the hydrostatic test
shall subject the common elements to at least their design differential pressure, corrected
for temperature as in (b) above, as well as meet the requirements of (b) or (c) above for
each independent chamber.

(2) When pressure chambers of combination units have their common elements designed
for the maximum differential pressure that can possibly occur during startup, operation,
and shutdown, and the differential pressure is less than the higher pressure in the adjacent
chambers, the common elements shall be subjected to a hydrostatic test pressure of at
least 1.3 times the differential pressure to be marked on the unit, corrected for
temperature as in UG-99(b). Following the test of the common elements and their
inspection as required by (g) below, the adjacent chambers shall be hydrostatically tested
simultaneously [see (b) or (c) above]. Care must be taken to limit the differential pressure
between the chambers to the pressure used when testing the common elements. The
vessel stamping and the vessel Data Report must describe the common elements and their
limiting differential pressure. See UG-116(j) and UG-120(b).

(f) Single-wall vessels designed for a vacuum or partial vacuum only, and chambers of
multichamber vessels designed for a vacuum or partial vacuum only, shall be subjected to
an internal hydrostatic test or when a hydrostatic test is not practicable, to a pneumatic
 41

test in accordance with the provisions of UG-100. Either type of test shall be made at a
pressure not less than 1.3 times the difference between normal atmospheric pressure and
the minimum design internal absolute pressure.

(g) Following the application of the hydrostatic test pressure, an inspection shall be made
of all joints and connections. This inspection shall be made at a pressure not less than the
test pressure divided by 1.3. Except for leakage that might occur at temporary test
closures for those openings intended for welded connections, leakage is not allowed at
the time of the required visual inspection. Leakage from temporary seals shall be directed
away so as to avoid masking leaks from other joints. The visual inspection of joints and
connections for leaks at the test pressure divided by 1.3 may be waived provided:

(1) a suitable gas leak test is applied;

(2) substitution of the gas leak test is by agreement reached between Manufacturer and
Inspector;

(3) all welded seams which will be hidden by assembly be given a visual examination for
workmanship prior to assembly;

(4) the vessel will not contain a "lethal" substance.

(h) Any nonhazardous liquid at any temperature may be used for the hydrostatic test if
below its boiling point. Combustible liquids having a flash point less than 110°F (43°C),
such as petroleum distillates, may be used only for near atmospheric temperature tests. It
is recommended that the metal temperature during hydrostatic test be maintained at least
30°F (17°C) above the minimum design metal temperature, but need not exceed 120°F
(48°C), to minimize the risk of brittle fracture. [See UG-20 and General Note (6) to Fig.
UCS-66.2.] The test pressure shall not be applied until the vessel and its contents are at
about the same temperature. If the test temperature exceeds 120°F (48°C), it is
recommended that inspection of the vessel required by (g) above be delayed until the
temperature is reduced to 120°F (48°C) or less.
 42

CAUTION: A small liquid relief valve set to 11/3 times the test pressure is recommended
for the pressure test system, in case a vessel, while under test, is likely to be warmed up
materially with personnel absent.

(i) Vents shall be provided at all high points of the vessel in the position in which it is to
be tested to purge possible air pockets while the vessel is filling.

(j) Before applying pressure, the test equipment shall be examined to see that it is tight
and that all low-pressure filling lines and other appurtenances that should not be
subjected to the test pressure have been disconnected.

(k) Vessels, except for those in lethal service, may be painted or otherwise coated either
internally or externally, and may be lined internally, prior to the pressure test. However,
the user is cautioned that such painting / coating /lining may mask leaks that would
otherwise have been detected during the pressure test."

4.1.7.1 Hydrotest Procedure:

Maximum and minimum test pressures are referenced as prescribed by the Code and the
metal temperature is maintained to minimize risk of brittle failure. Initially the pressure is
increased to 1/2 of the calculated test pressure. It should be noted that this increase in
pressure is not abrupt and it is carried out in incremental manner where the pressure is
increased by the order of 0.1 times the test pressure. When the test pressure is reached,
the system is kept at that pressure for at least 5 minutes; afterwards it is brought back to
the maximum allowable working pressure of the vessel.

At this stage, all the vessel joints (welds) are visually inspected for any leaks or
imperfection.

4.2 Vessel Design Data

The following design parameters are to be considered in the design process:

• Specifications of Shell and Head

• Materials of Construction
 43

• Shell, Head and Nozzle Thicknesses

• Corrosion allowances for Each Section (if any)
• Weld Descriptions, Procedures and Specifications
• Nozzles and Openings' Sizes and Specifications
• Calculations for Maximum Allowable Working Pressure (MAWP) and Maximum
Temperature Allowed at MAWP
• Maximum and Minimum Design Metal Temperature (MDMT)
• Impact Testing Requirements
• Type of Supports, their location and method of attachment
• Reinforcement of Openings

4.2.1 Specifications of Shell and Head

A shell is structural element fabricated to enclose a specific space. Most of the shells are
fabricated by forming a plate. Different nozzles and openings are attached to this part of
the vessel. Most of the time the shell is a cylindrical part, but in case of a spherical
pressure vessel the shell could be a sphere.

Shapes of the heads vary according to various design considerations. The shape of the
heads used can vary. The most common head shapes are:

4.2.1.1 Hemispherical Head

In case of hemispherical heads the pressure distribution across the surface of the head is
uniform. The radius of the head is kept the same as the radius of the cylindrical shell of
the vessel.

4.2.1.2 Ellipsoidal Head

Ellipsoidal head is one of the most common types of heads used in the pressure vessel
engineering. This kind of head is also called the 2:1 Elliptical head. In case of the height
of the head crown is just 1/4 of the diameter, thus making its construction one of the
most economical one. The radius of an elliptical head changes between major and minor
axis.
 44

4.2.1.3 Torispherical Head

Torispherical types of heads have a dished geometry having a fixed radius. The size of
the fixed radius is dependent on the type of torispherical head. The transitional part of the
head where the cylinder and the head meet is called the knuckle.

4.2.1.4 Flat Head

Flat heads consist of a knuckle which connects the flat plate to the shell.

4.2.1.5 Conical Head

The conical head, as obvious from the name has conical geometry.

4.2.2 Materials of Construction

A whole section is dedicated to the materials of construction in the ASME BPVC and it is
called Section II. Part D of Section II the most "referred to" part of it. It is in the form of
tables and describes the nominal compositions of the materials, tensile and yield
strengths, and maximum allowable stress values at different temperatures. Different
organization concerned with pressure vessels has developed their own specifications that
allow the usage of certain materials under certain circumstances. For example, KBR
prefers material SA-203 grades D or E for vessel components such as shells, heads,
nozzles, manway necks and reinforcing pads, in the temperature range of -100 degrees
(Celsius) to -47 degrees (Celsius), but for the same vessel components the temperature
range of -46 degrees to 0 degrees would make SA-516 Gr. (Grade) 70N or SA-537 CI.
(Class) 1, as the material of choice.

In the temperature range of 1 degree to 425 degrees the material would be (for the same
vessel components) SA-570 Gr. 70, or SA-537 CI. 1, or SA-285 Gr. C or SA-387 Grade
5. And in the very high temperature zone, from 426 degrees to 645 degrees the materials
used are SA-387 Gr. 11, 12 or 22, for the same vessel components.
 45

4.2.3 Shell, Head and Nozzle Thicknesses

Thicknesses are calculated according to ASME BPVC Section VIII Div l's Part UG-16,
Part UG-27 and Part UG-45.

Section UG-16(b) of the code states that, "Minimum Thickness of Pressure Retaining
Components. Except for the special provisions listed below, the minimum thickness
permitted for shells and heads, after forming and regardless of product form and material,
shall be 1/16 in. (1.5 mm) exclusive of any corrosion allowance. Exceptions are:

(1) the minimum thickness does not apply to heat transfer plates of plate-type heat
exchangers;

(2) this minimum thickness does not apply to the inner pipe of double pipe heat
exchangers nor to pipes and tubes that are enclosed and protected by a shell, casing, or
ducting, where such pipes or tubes are NPS 6 (DN 150) and less. This exemption applies
whether or not the outer pipe or shell is constructed to Code rules. All other pressure
parts of these heat exchangers which are constructed to Code rules must meet the VI6 in.
(1.5 mm) minimum thickness requirements.

(3) the minimum thickness of shells and heads of unfired steam boilers shall be 1/4 in. (6
mm) exclusive of any corrosion allowance;

(4) the minimum thickness of shells and heads used in compressed air service, steam
service, and water service, made from materials listed in Table UCS—23, shall be 3/32 in.
(2.5 mm) exclusive of any corrosion allowance.

(5) this minimum thickness does not apply to the tubes in air cooled and cooling tower
heat exchangers if all the following provisions are met:

(a) the tubes shall not be used for lethal UW—2(a) service applications;

(b) the tubes shall be protected by fins or other mechanical means;

(c) the tube outside diameter shall be a minimum of 3/8 in. (10 mm) and a maximum of
11/2 in. (38 mm);
 46

(d) the minimum thickness used shall not be less than that calculated by the formulas
given in UG—27 or 1 — 1 and in no case less than the greater of the minimum thickness
calculated using a design pressure of 500 psi (3.5 MPa) at 70°F (20°C) or 0.022 in. (0.5
mm)."

••• Minimum Thickness = tMIN (UG-16(b)) = 1/16 in

Calculations for thickness according to internal pressure conditions are made according
to UG—27 (c) (1, 2), which states that, "Cylindrical Shells. The minimum thickness or
maximum allowable working pressure of cylindrical shells shall be the greater thickness
or lesser pressure as given by (1) or (2) below.

(1) Circumferential Stress (Longitudinal Joints). When the thickness does not exceed
one-half of the inside radius, or P does not exceed 0.385SE, the following formulas shall
apply:

PR SEt
t = or P= V(1)
}
SE - 0.6P R + 0.6t

(2) Longitudinal Stress (Circumferential Joints). When the thickness does not exceed
one-half of the inside radius, or P does not exceed 1.25SE, the following formulas shall
apply:

PR ISEt
t = or P= (2)"
V J
2SE + 0AP R-OAt

4.2.4 Corrosion Allowance

The corrosion allowance is described in UG-25, "CORROSION (a) The user or his
designated agent (see U-2) shall specify corrosion allowances other than those required
by the rules of this Division. Where corrosion allowances are not provided, this fact shall
be indicated on the Data Report, (b) Vessels or parts of vessels subject to thinning by
corrosion, erosion, or mechanical abrasion shall have provision made for the desired life
of the vessel by a suitable increase in the thickness of the material over that determined
 47

by the design formulas, or by using some other suitable method of protection. (See
Appendix E.)

NOTE: When using high alloys and nonferrous materials either for solid wall or clad or
lined vessels, refer to UHA-6, UCL-3, and UNF-4, as appropriate.

(c) Material added for these purposes need not be of the same thickness for all parts of
the vessel if different rates of attack are expected for the various parts, (d) No additional
thickness need be provided when previous experience in like service has shown that
corrosion does not occur or is of only a superficial nature, (e) Telltale Holes. Telltale
holes may be used to provide some positive indication when the thickness has been
reduced to a dangerous degree. Telltale holes shall not be used in vessels that are to
contain lethal substances [see UW-2(a)], except as permitted by ULW-76 for vent holes
in layered construction. When telltale holes are provided, they shall have a diameter of
1/16 in. to 3/16 in. (1.5 mm to 5 mm) and have a depth not less than 80% of the thickness
required for a seamless shell of like dimensions. These holes shall be provided in the
opposite surface to that where deterioration is expected. [For telltale holes in clad or lined
vessels, see UCL-25(b).] (f) Openings for Drain. Vessels subject to corrosion shall be
supplied with a suitable drain opening at the lowest point practicable in the vessel; or a
pipe may be used extending inward from any other location to within 1/4 in. (6 mm) of
the lowest point."

4.2.5 Weld Joint Categories

The weld joint categories are described in UG-3. "The term "Category" as used herein
defines the location of a joint in a vessel, but not the type of joint. The "Categories"
established by this paragraph are for use elsewhere in this Division in specifying special
requirements regarding joint type and degree of inspection for certain welded pressure
joints. Since these special requirements, which are based on service, material, and
thickness, do not apply to every welded joint, only those joints to which special
requirements apply are included in the categories. The special requirements will apply to
joints of a given category only when specifically so stated. The joints included in each
category are designated as joints of Categories A, B, C, and D below. Figure UW-3
 48

illustrates typical joint locations included in each category, (a) Category A. Longitudinal
and spiral welded joints within the main shell, communicating chambers,2 transitions in
diameter, or nozzles; any welded joint within a sphere, within a formed or flat head, or
within the side plates3 of a flat-sided vessel; circumferential welded joints connecting
hemispherical heads to main shells, to transitions in diameters, to nozzles, or to
communicating chambers.2 (b) Category B. Circumferential welded joints within the
main shell, communicating chambers,2 nozzles, or transitions in diameter including joints
between the transition and a cylinder at either the large or small end; circumferential
welded joints connecting formed heads other than hemispherical to main shells, to
transitions in diameter, to nozzles, or to communicating chambers.2 (c) Category C.
Welded joints connecting flanges, Van Stone laps, tubesheets, or flat heads to main shell,
to formed heads, to transitions in diameter, to nozzles, or to communicating chambers2
any welded joint connecting one side plate3 to another side plate of a flat-sided vessel.
(d) Category D. Welded joints connecting communicating chambers2 or nozzles to main
shells, to spheres, to transitions in diameter, to heads, or to flat-sided vessels, and those
joints connecting nozzles to communicating chambers2 (for nozzles at the small end of a
transition in diameter, see Category B)."

4.2.6 Nozzles and Openings' Sizes and Specifications

Openings are required to monitor the condition of the vessel's interior if subject to
corrosion, and may be necessary also for manufacture. The size and disposition of the
opening(s) depend upon the duty and size of the vessel - in a small vessel a single
handhole or a flanged- in inspection opening may be adequate whereas large vessels
require elliptical manholes, often with reinforcement / seating rings, though heads may be
flanged inwards (reverse knuckle) to provide a seating surface. The minor axis of an
elliptical opening in a cylindrical shell should lie parallel to the longitudinal axis of the
shell.

The opening is sealed usually by an internal door, a gasket and one or two bridges and
studs. The door is ellliptical to permit its removal, if necessary for remachining a
damaged gasket seating surface.
 49

The studs provide the initial sealing force, ie. the initial seating pressure on the gasket
face before the fluid is pressurised. When the fluid pressure later rises, the door tends to
be self- sealing as the pressure load on the door increases the gasket contact pressure. The
load on the studs therefore decreases, however the Code specifies that the door must
withstand simultaneously bending by both fluid pressure and maximum possible stud (or
bolt) tightening. The flat door calculation thickness t is thus given by:-

The door is equipped with a locating spigot to aid its engagement when closing. If the
door is heavy then provision must be made for supporting it during opening or closing -
any such support must not interfere with even take-up of the gasket, nor must it hinder
easy access to the vessel. The designer of the door support must visualise the door's
detailed operation.

The choice of gasket material depends upon the vessel duty - fluid, temperature and
pressure - and the flanges' surface finish and rigidity. The stiffer the gasket, the greater
must be the initial seating force and hence door thickness.

4.2.7 Minimum Design Metal Temperature (MDMT)

The minimum design metal temperature MDMT is defined as the coldest mean
temperature through the thickness of the vessel. This is the temperature below which the
vessel material can fail through brittle fracture. It should be noted though, that
sometimes the mean vessel temperature could be lower than MDMT but if the pressure at
that point is lower than the maximum allowable working pressure, the vessel can still
operate safely. The effect of the atmospheric temperature should also be given
importance; in certain cases the coldest seasonal temperature is considered to be the
MDMT.

4.2.8 Type of Supports, Their Location and Method of Attachment

The most common type of support for a horizontal pressure vessel is called saddle
support. The angle of the arc that defines the outer diameter of the horizontal vessel (the
shell wall) is usually 120 degrees. The saddle supports are always in a pair; one is fixed
and the other is sliding. The fixed saddle not only supports the weight of the vessel but
 50

also balance the axial forces to prevent movement. While the sliding saddle supports the
weight as well as allowing for the vessel movements due to thermal expansion of the
vessel. The common design calculation method for saddle supports is called "Zick's
Analysis".

The vertical vessel is supported through: skirts (rolled cylindrical/conical shell), legs or
lugs. The most common method of support for columns is skirts; the advantage is that
they are responsible for the uniform distribution of vessel loads along the full
circumference of the skirt. However, it is a more costly method of supporting a vertical
vessel, and therefore, smaller and inexpensive pressure vessels are supported through
legs. The three most common types of leg supports are braced (cross braced/sway
braced), unbraced, and stub columns.

The lug supports are the least expensive method of supporting a vertical vessel; however,
there are complications to be considered such as compressive, tensile, and shear stresses
in the vessel wall.

Other less common (comparatively) methods of vessel support are ring supports and
combination support.

4.2.8 Reinforcement of Openings

Openings are reinforced according to UG-37 of the code, "REINFORCEMENT

REQUIRED FOR OPENINGS IN SHELLS AND FORMED HEADS":

"(a) Nomenclature. The symbols used in this paragraph are defined as follows:

A- total cross-sectional area of reinforcement required in the plane under consideration

(see Fig. UG-37.1) (includes consideration of nozzle area through shell if Sn ISv <1.0)

At= area in excess thickness in the vessel wall available for reinforcement (see Fig. UG-
37.1) (includes consideration of nozzle area through shell if Sn ISv <1.0)

A2= area in excess thickness in the nozzle wall available for reinforcement (see Fig. UG-
37.1)
 51

A3- area available for reinforcement when the nozzle extends inside the vessel wall (see
Fig. UG-37.1)

A41, A42, ^43 = cross-sectional area of various welds available for reinforcement (see
Fig. UG-37.1)

A5= cross-sectional area of material added as reinforcement (see Fig. UG-37.1)

c = corrosion allowance

D = inside shell diameter

Dp = outside diameter of reinforcing element (actual size of reinforcing element may

exceed the limits of reinforcement established by UG-40; however, credit cannot be taken
for any material outside these limits)

d = finished diameter of circular opening or finished dimension (chord length at

midsurface of thickness excluding excess thickness available for reinforcement) of
nonradial opening in the plane under consideration, in. (mm) [see Figs. UG- 37.1 and
UG-40]

E = 1 (see definitions for tr and trn)

Ex = 1 when an opening is in the solid plate or in a Category B butt joint; or

= joint efficiency obtained from Table UW-12 when any part of the opening passes
through any other welded joint

F = correction factor which compensates for the variation in internal pressure stresses on
different planes with respect to the axis of a vessel. A value of 1.00 shall be used for all
configurations except that Fig. UG-37 may be used for integrally reinforced openings in
cylindrical shells and cones. [See UW-16(c)(l).]

h = distance nozzle projects beyond the inner surface of the vessel wall. (Extension of the
nozzle
 52

beyond the inside surface of the vessel wall is not limited; however, for reinforcement
calculations, credit shall not be taken for material outside the limits of reinforcement
established by UG-40.)

Ki= spherical radius factor (see definition of tr and Table UG-37)

L = length of projection defining the thickened portion of integral reinforcement of a

nozzle neck beyond the outside surface of the vessel wall [see Fig. UG-40 sketch (e)]

P = internal design pressure (see UG-21), psi (MPa)

R = inside radius of the shell course under consideration

Rn = inside radius of the nozzle under consideration

S = allowable stress value in tension (see UG-23), psi (MPa)

Sn = allowable stress in nozzle, psi (MPa) (see S, above)

Sv = allowable stress in vessel, psi (MPa) (see S, above)

Sp = allowable stress in reinforcing element (plate), psi (MPa) (see S, above)

fr = strength reduction factor, not greater than 1.0 [see UG-41(a)]

/ r i = Sn /Sv for nozzle wall inserted through the vessel wall

/ r l = 1.0 for nozzle wall abutting the vessel wall and for nozzles shown in Fig. UG-40,
sketch (j), (k), (n) and (o).

fr2 = Sn /Sv

fr3 = (lesser of Sn or Sp) /Sv

fr4 = Sp /Sv

t = specified vessel wall thickness,24 (not including forming allowances). For pipe it is
the nominal thickness less manufacturing undertolerance allowed in the pipe
specification.
 53

te = thickness or height of reinforcing element(see Fig. UG-40)

t; = nominal thickness of internal projection of nozzle wall

tr = required thickness of a seamless shell based on the circumferential stress, or of a

formed head, computed by the rules of this Division for the designated pressure, using
E= 1, except that:

(a) when the opening and its reinforcement are entirely within the spherical portion of a
torispherical head, tr is the thickness required by 1 -4(d), using M= 1;

(b) when the opening is in a cone, tr is the thickness required for a seamless cone of
diameter D measured where the nozzle axis pierces the inside wall of the cone;

(c) when the opening and its reinforcement are in an ellipsoidal head and are located
entirely within a circle the center of which coincides with the center of the head and the
diameter of which is equal to 80% of the shell diameter, tr is the thickness required for a
seamless sphere of radius KID, where D is the shell diameter and K^ is given by Table
UG-37.

tn = nozzle wall thickness.24 Except for pipe, this is the wall thickness not including
forming allowances. For pipe, use the nominal thickness [see UG-16(d)].

trn = required thickness of a seamless nozzle wall

W= total load to be carried by attachment welds (see UG-41)

(b) General. The rules in this paragraph apply to all openings other than:

(1) small openings covered by UG-36(c)(3);

(2) openings in flat heads covered by UG-39;

(3) openings designed as reducer sections covered by UG-36(e);

(4) large head openings covered by UG-36(b)(2);

(5) tube holes with ligaments between them conforming to the rules of UG-53.
 54

Reinforcement shall be provided in amount and distribution such that the area
requirements for reinforcement are satisfied for all planes through the center of the
opening and normal to the vessel surface. For a circular opening in a cylindrical shell, the
plane containing the axis of the shell is the plane of greatest loading due to pressure.

Not less than half the required reinforcement shall be on each side of the center line of
single openings.

(c) Design for Internal Pressure. The total cross-sectional area of reinforcement A
required in any given plane through the opening for a shell or formed head under internal
pressure shall be not less than

A= dtrF+2tntrF(l-frl)

(d) Design for External Pressure

(1) The reinforcement required for openings in single-walled vessels subject to external
pressure need be only 50% of that required in (c) above, where tr is the wall thickness
required by the rules for vessels under external pressure and the value of F shall be 1.0 in
all external pressure reinforcement calculations.

(2) The reinforcement required for openings in each shell of a multiple-walled vessel
shall comply with (1) above when the shell is subject to external pressure, and with (c)
above when the shell is subject to internal pressure, regardless of whether or not there is a
common nozzle secured to more than one shell by strength welds.

(e) Design for Alternate Internal and External Pressure. Reinforcement of vessels subject
to alternate internal and external pressures shall meet the requirements of (c) above for
internal pressure and of (d) above for external pressure.

(f) Details and formulas for required area and available area are given in Fig. UG-37.1.

(g) Reinforcing plates and saddles of nozzles attached to the outside of a vessel shall be
provided with at least one telltale hole [maximum size NPS 1/4 (DN 8) tap] that may be
tapped for a preliminary compressed air and soapsuds test for tightness of welds that seal
off the inside of the vessel. These telltale holes may be left open or may be plugged when
 55

the vessel is in service. If the holes are plugged, the plugging material used shall not be
capable of sustaining pressure between the reinforcing plate and the vessel wall."

4.2.9 Flanges

In a process unit the working fluid is transported to one vessel from another through
process pipes of different diameters. These process pipes are connected to the vessels
through specially designed openings called nozzles. The most common method of
connection for the process pipe and the nozzle is a bolted connection through specially
designed objects called flanges. Flanges are discs with holes for bolts and an inner
diameter equal to the inner diameter of object it is attached to. Flanges are attached
separately to both the process pipe and the vessel's nozzle through welding and then both
the process pipe flange and the nozzle flange are bolted together.

There are other openings in the vessels, which quite similar to nozzles in construction
(manways, manholes), however they are generally used for allowing the entry of personal
for cleaning/maintenance purposes of the vessel. These openings also have flanges
attached with them. They are closed with blind flanges, which are just a blank metal discs
with holes for bolts.
 56

Chapter 5: Design Software

(The screenshots and literature presented in this chapter is reproduced with permission of
DISASU Inc. All rights reserved.)

The design process of a pressure vessel is usually carried out using different software
packages, such as, DISASU, PVElite, Nozzle Pro, CodeCalc etc. The interface of all
these software is different but they follow the same rules and regulations and codes for
computations and calculations.

Of all these software, DISASU is one of the most commonly used and design process
through this software is explained in this chapter through words and screenshots.

DISASU is used for design of almost all types of pressure vessels such as fractionation
towers, reactors, multi-chambered vessels with internal heads, guided vessels, and stacks
etc. horizontal vessel on two saddles and flue gas stacks etc.

DISASU calculates thicknesses for all of vessel components such as shells, heads,
stiffeners and supports etc., and calculates MAWP (Maximum allowable Working
Pressure(s)). All head types are supported such as: 2:1 elliptical heads, flanged and
dished heads, hemispherical heads, conical heads, flat heads, flanged with blind flange
etc. Data input form fields are available for materials, diameters, corrosion allowances,
temperatures, insulation, refractory, etc.

DISASU performs selection of openings such as nozzles (i.e. slip-on, weld neck, lap
joint or van stone, long welding necks including heavy reinforced necks, bottom head
outlet with heavy neck attached to pipe or rolled plate which could be radial, eccentric,
skewed), or manways and reinforcement calculations for these openings including
determination of flange ratings. Flange ratings are according to ANSI B16.5 for flange
ratings and ANSI B 16.47 for Large Diameter flange ratings.

This software automatically selects materials of construction for pressure vessel's minor
components, once materials are specified for major components such as a shell. DISASU
 57

also performs weld sizing, path of failure, and weld size verification based on code's
minimum requirements as well as the weld strength path of failure.

Calculations are made for vessel supports such as saddles, legs or lugs etc. It also helps
calculate anchor bolt sizes, diameter of bolt circle the number of bolts required, and the
numbers of stiffeners and their location. This also performs complete analysis and re-
rating of existing vessels.

DISASU allows mechanical designing according to different codes such as ASME BPVC
Section 1, Section VIII Division 1, Division 2, STS-1 Steel Stacks, API - 650, BS5500
Pressure Vessel Code, A.D. Merkblatt and DIN 4149. Many different codes, rules and
regulations are employed for calculations of wind and seismic load calculations: IBC
2000 and Uniform Building Codes 1973, 76, 79, 82, 85, 88, 91, 94, and 1997 for wind
and seismic load calculations, ASCE 7-98 Code for static wind, seismic, and dynamic
wind loads, ASCE 7-95 Code for static wind, seismic, and dynamic wind loads, ASCE 7-
93 Code for static wind, seismic and dynamic wind loads, ASCE 7-88 Code for static
wind, seismic and dynamic wind loads, ANSI A58.1 1982 Code for static wind, seismic
and dynamic wind loadings, National Building Code of Canada 1991 and 1997 for static
wind, seismic and dynamic wind loadings, British Structural Loading Code CP-3 for
static wind, seismic and dynamic loadings, Brazil's ABNT-88 Code for wind loadings
(uses 3 second gust with modal shape factor), NEHR-94 National Earthquake Hazard
Reduction Program 1994, and as mentioned earlier ANSI B 16.5 for flange ratings and
ANSI B 16.47 for Large Diameter flange ratings.

DISASU also performs field and shop hydrotest design for either the New or future
corroded condition. Impact test requirements are automatically selected to meet the
specified low temperature.

The design process of a simple vertical vessel is described here, comprising of two
elliptical heads, two shells, a conical section and a skirt support. The screenshot of the
start of the program is shown in Fig: 5.1. The "File" is clicked Fig: 5.16 and a drop down
 58

menu are appeared, from where a new file could be created or an old file could opened
from the source along with other function that could be performed.

As soon as the new file is selected, a new dialogue box appears, is shown in Fig: 5.2, this
dialog box gives a choice for changing working units for input, creates new file, Copy
sample starter file to a new workfile, copy any existing file to new workfile, select special
prepared files, and allows to select and project directory. Clicking on the "CREATE
NEW file" opens up a new dialogue box (Fig: 5.3) which allows to change the current
project directory, chang working unit for input, allows the selection of vertical vessel
with skirt, or vertical vessel with leg support, or vertical vessel with lug support, or
horizontal vessel, or vertical heat exchanger with lug support, or horizontal heat
exchanger with saddle support, or ASME UHX tubesheet, or flange, or welding research
council bulletin 107, shop built storage tank, and vertical flare stack.

Clicking on vertical vessel with skirt support, will open a new dialogue box along with a
sidebar. This side bar allows the opening of the respective property sections for top head,
shell, bottom head, cone, skirt, additional skirt, chairs and jacket etc. And the first dialog
box allows data input four overall and ID or OD, design pressure at design temperature
external pressure at design temperature, depth of the liquid in the vessel and its specific
gravity, minimum design metal temperature (MDMT), corrosion allowance for shell and
corrosion allowance for nozzle, radiography requirements, insulation and refractory
information, and post weld heat treatment requirement. Once the primary material
information is keyed in the material information for flanges/forgings, pipe neck, rolled
plate neck half, reinforcement pads, studs, manhole covers, cladding, lining and weld
overlay material requirement and thicknesses.

Clicking on "top head" on the side bar will open a dialog box for the top head, where a
drop down menu allows for the selection of the type of head, data input form fields with
predetermined values are available four minimum thickness, thin out allowance in joints,
radiography efficiency for head and seam, dish radius, knuckle radius, and straight
flange. Data input form fields are available for materials, design stress at design
temperature, atmospheric stresses, material densities, materials chart used, yield strength
 59

at design temperature, and ultimate tensile strength are given in the other half of the
dialog box for top head.

Clicking on "shell" opens up a dialog box for properties input for shell, which has some
of the previously mentioned data input fields with the exception of a data input field for
the tangent to tangent length of the shell.

Clicking on " cone" opens up a dialog box where data input field forms are available for
length, hole size, minimum thickness, angle of the cone, top knuckle radius, bottom
knuckle radius, radiography information, material information, design stress values at
design temperature, if stress values at atmospheric pressure, material density, name of the
chart to use, yield strength and ultimate tensile strength. All of these fields are prefilled
by the program but changes can be made to them.

Bottom head is added the same way as the top head. The skirt is added to the vessel by
clicking on the "skirt", a new dialogue box appears, where data input form fields are
available four lengths, minimum thickness, wind notification factor, wind shape factor,
material, stress values, number of cans used, top OD, bottom OD, skirt angle, and number
of long seam.

Ladders, platforms and other internals and outer attachments could be added from
different menu bar items. Which are shown from Fig: 5.16 to Fig: 5.26.

A full report is published, once the design data input is completed and all design
incompatibilities addressed.
 60

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File Edit Components Supports: Nozzles Ud/Plat/SL Stiffeners Internals Tabular Input Action view Help

*MSJ J i m Mllf Ml••' •';

ZD Full! 3D Full 2 D / 3 D Full 2D

337fps

Figure 5.1: Starting Page

Y'jv.cll'i.ii'.i-iiri i. ila'l.JMI l\k.].iill)/")'Ji.'.l lo|,l

l^e Edit Components Supports Nosnles Lad/Plat/5l Stiffened Internals Tabular Input Action View Help

432fps

3, <SEU£PTSpac^Pr&pasri.FH-E'$>

H:'- n r i p \

Figure 5.2: New File

 61

'•'•null 'Jg'd.Tl. : 'li'.JUJM! nii.J.iDrirVU r>^klr,[:'.

File Edit Components Supports Nozzles Lad/Plat/SL Stlffeners Internals Tabular Input Action View Help

+ •!«.• i;ail Qftj rs

2DFultl3DFull 2D / 3D Full j 2D

• • '!. v - i LMP'.
I- " FlHll 1 i l l

• •• • " ;i '

. ' . , ' - . J . . ,.>

..:...—. i t : . . _-.....:.. .. •„:

472fps

Figure 5.3: Creating New File

VwnlPiur.rini i i|"l(l!l.M l^.iI>:j(i/"J\li';-kl'j|>\

FUe EeEt Components 5upports Nozzles tad/Plat/SL SHffeners Internals Tabular Input Action View Help

+ 'j '•- i m, a|gy ?|1

2 0 / 3 D Full 2D
n u n D ML.i

- .' ' - I *>•-•. 1 l " M Pt lip-- 1 I I ' 1 o.surai (..ii- S - I. I " l l oi r»iii|i K K I
•=.:B?.I
jT'.tol D i j i n t t " i | <:••' •> i • j »

. 1 : • •
L)T'-PI - ' . ,ur|i:c ••>! | . - i-i <"« IV. h •!••• • r : Al-i
f^r.L.,—.- ••/-..,.
F » t I •/•••• >Pi •••-.[- '- I' 1 * , - l "• [ T T F- ii.ee
I i ' | i n . l l i . pt-h | : : ; i t H | : J JO -,(i ' I K ' A:IC/.:
M i r i O - , 1-iiiM-tci IT^mp ji " F-' •i i • ' ATLF™
• M I i >,<. i c i i fl 1 I M A U I I ' ' * " j .'.'ij ri Al^'t'
:
" Ni.7,'l> |. :r:: F. -, i .. '.• Al-=
F j r l i o g l .i|ih:
I- i . i i . F ' . i i i i . i i i i t i :•. - • ' 1.1' I .'I n u nl l ' l i i ' l - . l i ' l - . " .
..]•••>:.
1 n .11 1 ^t l • •n|:- in <* f i I'C-
P - t I . K l i i i yj " r. i*| ,r. ' l.iJ llii..k
-•". - z . ' - u t
P..-.tWf I ' l H t - n t r • H . I 1 |>.0 •• 1:

Figure 5.4: Section Properties

 62

V u w l P'ffjMin '. \J»" i i l h ' i - , Vk4:IJ0/ , JU<.«.kto|i\

File Edit Components Supports Nozzles la$Piat/5l Stfffeners internals Tabular input Action view Help

+|<§>;& i'M G | « l t\

r
riim'Hil Alltiw i W i 'n Joint

F'i'l f u l l u | ' h : I t t l< IHm.y

;
r NIC A l n ) | •"}"•'•_ •" ' 30QO «fT!

S.-Min: UltHll.lt. f'-'/

Dish rfl.iiu- |7~.: (•" i

l.iiin'.l- l * Pruiiii . (77

'•1 I r l l i | l l l I I . I I 111' (" •" - " • • i1

(I

'll.it U . l - l l

'll'lt I J v ll )

•||..I . ., | . iINS Nunh-i i>c;-o:

(I FAR! [): [',ui.-':i 0 1 in,-

Figure 5.5: Head Properties

V e W - l f-ll-.'.NMII (' I P J l L - M l . ,\UtlA".tiJ >>[jt'i>ki| \

Fife Ectt Components Supports Nozzles Lad/Plat/SL Stiffeners Internals Tabular Input Action View Help

+ • * A: y§j et.esj j ;
j 2D / 3D Full ' 2D

LU1LD

•* ± -a
sii r I ii "'t.iiu i. ni i • ASMfJI fi,.(* '.~. tlnll ill l-l

i .iK|i h •.-, .i • x n r j
Km rtiukii-i-. i "r7" i
l'.i<li'i.|i .iph -U Lt I A105

1 ••mi • - ~ '•-. A106E

•ill Hi• • ' i-. AE 16 0

hin.l Mult F.v-tfi .' ~ AE Is" 0

UinU -h i p - r.*< t . . i i '
_
A l 93 7

ri'i ..i Mi-11 . .in • | ~ •»• ii'iu Al

i" ri.'l . . I I i •• i n . i 'ifl j . tHOvsrl

Ii.t...;.) [J.-. i h i n . ut- :

• I.i.l I In. t- n ... p.aoo

Figure 5.6: Shell Properties

 63

V n w I'lui'.lam. L.-lDOl U.'.il 1 •Lk.i.lU(l>*-JJtsk1U|."l

F.ip £4,* /-^-.^p-pijg syppofts Nozzles iad/Plat/5l Stiffeners Internals Tabular Input Action View Hefip

* * ? •
t . l l l l l j Mi"!

[Click and hold left mouse and drag to Orbit. Click righb mouse on an object For properties.

Figure 5.7: Shell Configured

l'.' M'l l>r.Ji;i.iin ( U)(i['IIUI • IUi.i.iS['."<vlJi-i|.u.|il
Fite Edit Components Supports Nozzles Lad/Plat/SL stiffeners Internals Tabular Input Action : View Help

Hhi<»IOI l i l l l SUM. Jj
* ± ? K|2D/3DFuli;zD
i'.IIIIU Mo, 11

* * ? * * ?H
«-• t n i l l : ( i | iitlll IV'llip- I'KI f
• ; L ' l - i . o o / v . o o m vi•» m
I., n.jthf j . . . _ .-• • ' [ • • • • |AE.:f.V.-|
r
' '- Hin lhn.kiiir'<s 1 s=o L.J
^tm-io S t !•?»•» | :•'"• • • r'?i
/••n-il* • .» ll.it 1 l ^ n s i t y [J - 3 : ' - :
c
| lup l.rill'.l< I * Rel-I.
'Put. Kiin..kl.- F.1.1. t l d ( < U n > | •"-?.-';:• -- | rso: r *\ i n
l'..iil K>'ji . i p l r Ul I MIMI'.J • ' . :•""• -."i
1.1 M i l '
Hi ml Mull F.n. t m
Kni'i Mi-ip* FJ-.IHI : T:
I.' ,. •:„., i •

1 ; -„-••. l:.. HI• " •'

, . ..-, ,VI«I KiuK.k i . f r i i - . | j ) I h. mi *t I y • I' '•' !• " ' • !
H o i , M l f -. •' 0
l'.''FT [1: P -JTTT Lim-f"
F. Mil I'" (.'II.'?

Figure 5.8: Cone Properties

 64

1i".:t\ I ' l c i y n m : .U;Q.IJMI 1 ikn>i.jli/')ll'i".kl>iii\

Fife Edit CnrnDorwnts Supports Nozzles LatJ/Plat/SL Stiffeners Internals Tabular Input Action View Help

+ * •• ija| gigtj ?j
* ±"?'•""
L'UILD M. .11

Figure 5.9: Cone Configured

..ll'"...i;r mi 1 UiliCiJM' l\h.i..!:.VJ'J'(-,kli'|i\

File Edit Components Supports Nozzles Lad/Plat/5l Softeners; Internals; Tabular Input Action

Fl.nl i n ' i t . i p l i : SRgas/Foig>ng JAIOS

I n i l (J • pe Necks i (A106B
iiii-th- - [•" "''. fell£fiPlateNe>ck| |AB1670
t.'niO Hult F-JI. * . ' . i | j " '.0 asirifRads | |A51670
Wind '^h.ipM I-.ii t > u f .'n •a* j (A193B7
IIII .it -.ht-i i i mis fT ••!-. i>(i(

* M'lL'.ui'i v . - . m , i ."N f - C l a d / L i n l rig/He I d O v e r l a y -

[••I : ' . ' I N.i T h i i i . m l f :"
Clad Thickness (oT?
|c|cLADw/shesrtest-TAKE Credit

Figure 5.10: Shell 2 Properties

 65

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File Eat Components supports Nozzles lad/Plat/SL 5ttffeners .internals! tabular input Action View-He.^.-

+.<e>ift. uni Q » | ?|
* * •>

1'iiiifj n,„i

Figure 5.11: Shell 2 Configured

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File Edit Components.-Supports Ncartes Lad/Playa . Stiffeners Internals. TabutarJnput Action Vtew Help

\ I H I . I- 1 " F'.l-f I I I . p"

tiai'iht rhuK|o|n. | i:
!.'•• . M . • - •- '

.1.1 I l.|Ml.l H. .1,1

I i.t HD. SHL -HI.- Thk I h-mi ^t i y: .i'LJ' sL^.
i . . II. .i I i II'i IIII', Ntimtvi
(I r.ipr_[>- P.I.|. iT--- 1 HI- l~

Figure 5.12: Bottom Head Properties

 66

Vcssi-I I'lui'.l'im. I..MJUI.I IMI •' 'il«iiitl.</'i'J)i:Nklii|u

File Ecfit Components Supports Nozzles:: Ud/Plafe/St SUffeners Internals fabtiar input Action View Help.

Figure 5.13: Bottom Head Configured

I I'.iv.r.im C \I>LKl!Ml 1Ut.KiliU/V'Jj.-skr

File Edit Components Supports Nozzles lad/Plet/SL Stiffeners Internals Tabular Input Action view Help

BUliB Hod

'.kn l>.tt.i'.l,
t —11-11 h i'" "
M m I mil id Thl< k n - '. f . •/"•
•.: iii.i Hull h i . i cT'i':":'
'.•.'1ml S h i p IF.tit
•I-
M V ' K ' j t l =."'D- il-lll f """l
.Ml-.w;ti •.'••••Hin-i. {"'«•«
t\~i•r;ti M«iim)..
i l i i •• v i m i t i • •.['• J i K . t ' . •'"
Nl!lllt>-l ' 'HIS [ - j
'..[i T..f I ~
0 1.1 P.jtti.m
''-V I I t •*> 11 rj t • | ' ~
Svi.L'iu:.'J.i.' '-•Li' fT|_
Nn. ut l.iMij'>tm. \.

Figure 5.14: Skirt Support Properties

 67

• . . • i l W . M i u . ( MSnriiMl - I-JUMBO? W r t k i o | j t i

File Edt Components Supports Nozzles Lad/Plat/a, Stffeners Internals Tabular Input Action Vtew Help

+ *••-• i n RjjUjs
* ? ;<
T
n u u D H....I
i . i •.

' •. •- - i

LSklEt

Figure 5.15: Skirt Support Configured

ssel Progmm: C:\DOCUME • I\kaa8029\l)esktop\Ml.NG.INI>

H Edit Components Supports Nozzles Lad/Plat/SL Stiffeners Internals
New |
Open
Text Editor
RenameCurrentFile
EditOldOutput
Process
Save

I Exit

| C:\DISASU\VESSEL.INP
| C: \DOCUME~ 1 \kaa8029\Desktop\ 110C0005. INP
C:\DISASU\TOWERl.INP

Figure 5.16: Menu Bar - File

 68

Stii
File Components Supports Nozzles Lad/Plat/5L Stiffeners Internals

Client Data
CODE Reqt
WIND Reqt
SEISMIC Reqt
Rigging Analysis
SHOP/FieldTest
V NozzleReinf Options
Set Reference Line

Bj ElevBaseAboveGrade
MI-Dist loadings
C Output Requirements
Wave Motion Loads
•-,[ Fatigue Analysis

A' Database
Q System Config

Figure 5.17: Menu Bar - Edit

ssel Pioyiom: C.:WuaJME~1\k.id80?9\Desklop\MFN

File Edit Components Supports Nozzles Lad/Plat/SL Stiffeners

Lift Lug
T i 2D
BUILD Mod
Section ^ p p
Tun Hf!.id

Figure 5.18: Menu Bar - Components

 69

Vessel Pioj>r<im: C:M)OCUMr- 1\kcid80?9\T)eskto|>\M[NG.INP

File Edit Components Sup sorts Nozzles Lad/Plat/SL Stiff eners Internals
Review Components |
Change to Lug Supt
Change to Leg Supt
BUILD Mod! Change to Skirt Supt
3ectionFvgp. Change to Balerina Skirt

Top Head
Snell
Figure 5.19: Menu Bar - Supports

Vessel Progidm: C:\UOCUMi: ItoddBO^UJcskloiAMrNG.INP

File Edit Components Supports Nozzles Lad/Plat/SL Stiffeners Internals
i
rm,<
* <»'£ i nm mm Review Nozzles
Tabular Input Nozzles
<

T ± ? X | 2D/3DF Equal Distribute

BUILD Mod

Tnn H e a d
Shell
RottuITi H e ^ d

Figure 5.20: Menu Bar - Nozzles

' Vessel Piugrdin: C:\DOCUM[-1M«ciC0?9\ne^lop\MENG.INP

File Edit Components Supports Nozzles La1/P'ar/SL Stiffeners Internals Tabular Input

Figure 5.21: Menu Bar - Lad/Plat/SL

 70

C:UJOCUMt'1\kaaC079\DesktopWNG.INP

Supports Nozzles Lad/Plat/SL >tiffeners Internals Tabular Input

Review Vacuum Stiffeners ;

?!!
Tabular Input V5 \—
2D I 3D Full

Figure 5.22: Menu Bar - Stiffeners

:WOCUMF--1 Vitw80J!9\Desktu|riMIN*: INI>

Supports Nozzles Lad/Plat/SL Stiffeners ••mals Tabular Input Action View

Review Internals t
Add Tray(s)
Add Packing Bed |
Add Demister Pad

Figure 5.23: Menu Bar - Internals

Nozzles Lad/Plat/SL Stiffeners Internals TdLuar tiput Action View Help

NozzleManhole ;
LadderPlatforms
Special Loads
Misc. Clips
Trays/Packing/Fluid Beds
Vacuum Stiffeners

Figure 5.24: Menu Bar - Tabular Input

E~ 1 \k<id8029\Desklop\MrNG. INP
Nozzles Lad/Plat/SL Stiffeners Internals Tabular Input View Help

Figure 5.25: Menu Bar - Action

Lad/Plat/SL Stiffeners Internals Tabular Input Action Help

Review/Print Output
Display...
View Data File

Redraw Vessel
ZOOM Extents
Orange Peel

Figure 5.26: Menu Bar - View

 72

Chapter 6: Design Calculations

(The Proprietary data, figures and calculation methods/procedures described in this

chapter are reproduced with permission of Pressure Vessel Engineering Limited,
Waterloo, ON. All rights reserved.)

Mechanical design of pressure vessel is done with ASME BPVC (Boiler and Pressure
Vessel Code) Section VIII Division 1, 2 or 3. In this chapter pressure vessel design
calculation would be carried out using only ASME Section VIII Division 1 (henceforth
called the code). The basis of calculations at each step is supported with excerpts from
the code.

The first step in vessel design is to collect all of the date that needed for mechanical
design of a vessel. If the design calculations are carried out for a vertical vessel with two
simple nozzles and a main way, the design data required is as follows:

• Design pressure
• Design temperature
• Material specifications
• With j oint efficiencies
• Diameter (internal or external)
• Corrosion allowance (if any)
• Vessel attachments data
• Wind, snow and earthquake data/specifications
• Vessel service specifications
• Vessel internals
• Vessel connection summary (nozzle information)
• Painting, insulation and fireproofing information

Based on this data the vessel mechanical group prepares a datasheet, which is the
collection of all this information. With the help of this information, calculations for
thicknesses for shell and heads are carried out, along with MAWP (maximum allowable
working pressure). Then calculations for nozzles, flanges, and saddles are carried out.
 73

It is appropriate to mention here that the actual design process is sometimes much more
complicated and the calculation sample presented here is just a synopsis of actual design
procedure. It is also stated here that designing pressure vessels, isn't the only job
performed by the vessel mechanical engineers, checking vendors' data and design
parameters and procedures is almost as important as the design process itself. In the later
case, the vessel mechanical engineers check vendors' drawings, and individual
components, such as nozzle design, flange design or saddle design etc.

In this chapter calculations are made for a horizontal vessel with a cylindrical shell and
elliptical heads with two nozzles, one mainway and saddles. The horizontal vessel is
chosen as it allows the opportunity to mention the Zick Analysis method for the design of
saddles.

The supposed data for the vessel is as follows:

Outside Diameter = D0 = 96 in
Straight Shell = Ls = 120 in
Volume = VS = 640 ft3
Fluid = Water
Fluid Height in the Vessel = Hv = 8.0 ft
Fluid Density = p = 1.00 kg/m3
Maximum Internal Pressure = Pt=15 psig @ 150 °F
External Pressure = Pe = 0.0 psi
••• Design Pressure = Pd = Pt + 0.4331 x p x Hv
Pd = 75 + 0.4331 x 1 x 8
Pd = 78.465 psi
Maximum Temperature = Tmax = 150 °F @ 75 psi
Minimum Design Metal Temperature = TMDMT = —20 °F
Design Temperature = Td = 150 °F
Seismic Zone = 3
Foundation Factor =1.5
 74

6.1 Material Properties:

6.1.1 Head and Shell:

Material of Construction: SA516-70 Plate

Ambient Strength = 20,000 psi
Design Strength = 20,000 psi
Strength Ratio = 1.00
Maximum Temperature = 1000 °F
External Graphs: CS-2

6.1.2 Flanges / Couplings:

Material of Construction: SA105 Forging

Ambient Strength = 20,000 psi
Design Strength = 20,000 psi
Strength Ratio = 1.00
Maximum Temperature = 1000 °F
External Graphs: CS-2

6.1.3 Nozzles

Material of Construction: SA106 B Seamless Pipe

Ambient Strength =17,100 psi
Design Strength =17,100 psi
Strength Ratio = 1.00
Maximum Temperature = 1000 °F
External Graphs: CS-2
 75

6.1.4 Saddles

Material of Construction: SA/CSAG40-21 - 44 W

Ambient Strength = 17,100 psi
Design Strength = 17,100 psi
Strength Ratio = 1.00
Maximum Temperature = 650 °F
External Graphs: CS-2

6.2 Calculations:

All the material, sizing, service, operation and design data and conditions are provided to
a vessel mechanical engineer and the mechanical design calculations are performed. It is
mentioned here that these calculations are according to ASME BPVC Section VIII, Div I
- 2007 edition, no addenda. The first step is the calculations for thicknesses.

6.2.1 Thicknesses:

6.2.1.1 Shell:

ti = iPd x Ri) /(SxEl- 0.6 x P d )

ti = (78.465 x 47.687)/(20000 x 0.7 - 0.6 x 78.465)
ti = 0.268 in

tc = (P d X Ri) /(SXEI- 0.6 X Pd)

tc = (78.465 x 47.687)/(2 x 20000 x 0.7 - 0.4 X 78.465)
tc = 0.133 in

As tmin = Max (t/, £f,,tMIN(UG_16(b)))

=>
tmi„ = 0.268 in
 76

(The suffix "1" denotes longitudinal joints and the suffix "c" denotes circumferential
joints).

Pt = (SxElx nt)/(Ri + 0.6 x nt)

Pt = (20000 x 0.7 x 0.313)/(47.687 + 0.6 X 0.313)
Pi = 91.5 psi

Pc = (2 x 5 x Ec x n t ) / ( f y - 0.4 x nt)
Pc = (2 x 20000 x 0.7 x 0.313)/(47.687-0.4 x 0.313)
Pc = 184.3 psi

P = Min{Pl,Pc)
P = 91.5 psi

tri = ( ^ x ^ ) / ( S x l - 0 . 6 x P d )
t r l = (78.465 x 47.687)/(20000 x 1 - 0.6 x 78.465)
t r l = 0.188 in

.-. /? ; = (D0 - n t ) / 2
i?; = (96 - 0.313)/2
Rf = 47.8435 in

Elongation = e% = ((50 x nt)/Rf) x (1 - 0)

e0/o = ((50 x 0.313)/47.8435) x (1 - 0)
e0/o = 0.3 %

As the calculated elongation (0.3 %) is less than the maximum allowable elongation
(5%), and according to the "testing conditions", stress relief operations will not be
performed.
6.2.1.2 Head:

After calculations for the shell, the next step is calculations for the head. In this case,
elliptical head is selected for this vessel. The data for the elliptical head is as follows:

Thickness of the head = thead = 0.375 in

Outside Diameter = D0 = 96 in
Minor axis of the outer elliptical surface = h0 = 24.14 in
Minor axis of the inner elliptical surface = h = 23.859 in
Thickness before forming = tb =0.313 in
Thickness after forming — tf = 0.282 in
Corrosion allowance for head = Acorr head = 0.0 in
Straight Skirt Length = Lskirt = 1.5 in
Efficiency = Ehead = 0.85

D = D0 - (2 x tf)
D = 96 - (2 X 0.282)
D = 95.44 in

Thickness

Figure 6.1: Dimensions of Head

h0 = h + t
hn = 23.859 + 0.282
h0 = 24.14 in

D/2h = 95.437/(2 X 23.859)

 78

D/2h = 2.00

D0/2h0= 96/(2x24.141)
D0/2h0 = 1.98

K = 1.00 (internal interpolated value from table 1 — 4.1 of the code)

Ki = 0.90 (spherical interpolated value from table UG — 37 of the code)
KQ = 0.895 (external interpolated value from table UG — 33.1 of the code)

(The abovementioned tables could be consulted from the code, directly)

t — tf — Acorr Jxea(i

t = 0.282 - 0
t = 0.282 in

These could be summed up in this equation:

Ro=K0x D0
R0 = 0.895 x 96
R0 = 85.896 in

Interior pressure calculations for the heads are carried out according to appendix l-4(c)
and (d):
T • < t
1
min — •'
= > Tmin < 0.282
Tmin = {P X D X K)/(2 X S X E - 0.2 X P)
Tmin = (78.465 x 95.437 x l ) / ( 2 X 20000 X 0.85 - 0.2 x 78.465)
T • = 0 220
l
min v-t't'U
' mm — v

PMCIX ^ P

Puax ^ 7 8
Puax = (2 x E x S x t)/(K x D + 0.2 x t)
PMUX = (2 x 0.85 x 20000 x 0.282)/(l x 95.437 + 0.2 x 0.282)
 79

PMax = 100.3 psi

•'• PMax ^ P

Minimum Sphere Zone Thickness = TSpZone

TSv.Zone =(P*DX K1)/(2 X S X E - 0.2 X P)
TSp.zone = (78.465 x 95.437 x 0.9)/(2 x 20000 x 1 - 0.2 x 78.465)

Tsplone = 0.169 in

P Max ^ P

P M a x = ( 2 x 5 x £ x t)/(K x D + 0.2 x t)

^Ma^ = (2 x 20000 x 0.85 x 0.282)/(l x 95.437 + 0.2 x 0.282)

PMOX = 100.3 psi

•'• PMax ^ 7 8

Required sphere zone thickness = rSpI = (P x D x Kone )/(2 x 5 x E - 0.2 x P)

Tspi = (78.465 x 95.437 x 0.9)/(2 x 20000 x 1 - 0.2 x 78.465)

TSpI = 10.169 in

Head Stress Relief calculations are carried out according to UCS-79(d), UNF-79(d),
UHA-44(d) of the code:
Elongation =e% = ((75 x t)/h) x (1 - 0)

e% = ((75 x 0.282)/23.859) x (1 - 0)

e0/o = 1.0

As the calculated elongation (1 %) is less than the maximum allowable elongation (5 %),
and according to the "testing conditions", stress relief operations will not be performed.

6.2.1.3 Nozzle

Now for the nozzle design calculations, the following data is assumed:
 80

Shell material - SA-516-70

Shell allowable stress level = Sv = 20,000 psi
Efficiency of shell at nozzle = E1 = l .00
Shell wall thickness (uncorroded, UT removed) = Vi = 0.282
Required shell wall thickness internal pressure = t r = 0.220
Required shell wall thickness external pressure = t re = 0.000
Shell corrosion allowance = Acorrosion sheu = 0.000 in
Min allowed wall per UG-16(b) = tuc-i6(6) = 0.063 in

Nozzle material: SA-106B

Allowable stress level = Sn = 17,100 psi
Nozzle efficiency = E = 1.00
Internal design pressure = P = 78.5 psi
External design pressure = Pa= 0 psi
Outside diameter = D0 = 6.625
Internal diameter of the hillside nozzle = dh = 6.5 in
Wall thickness (un-corroded) = Nt= 0.432
Under-tolerance (%) = UTP = 12.5 %
Nozzle corrosion allowance = Acorrosion .nozz/e -0 in
Exterior projection = L = 2.0 in

Interior projection = lp = 1.0 in

Reinforcing information:
Size of weld fillet = Leg41 = 0.313
Size of weld fillet = Leg42 =0.313
F=1.0

Variables:
Under-tolerance = UT = Nt x UTP
UT = 0.432x0.125
 81

UT = 0.054

Effective Radius = Rn =D0/(2 - (Nt - n c o r r a ) + UT)

Rn = 6.625/(2 - (0.432 - 0) + 0.054)
Rn = 2.935 in

Effective Shell Thickness = t = Vt- Acorrosion . sheU

t = 0.2817-0
t = 0.282 in

Nominal Thickness of Internal Projections = tt = Nt — (2 x Acorrosion nozzie )

tt = 0.432 - (2 x 0)
tt = 0.432 in

Available Nozzle Thickness (No UT) = tn= Nt — Acorr .nozz/e

tn = 0.432 - 0
tn = 0.432 in

frl = MIN(Sn/Sv,l)
frl = MIN (17,000/20,000,1)
frl = 0.855

fr2 = MIN(Sn/Sv,l)
fr2 = MIN (17,000/20,000,1)
fr2 = 0.855

tcLeg41 = MIN (0.25,0.7 x MIN (0.75, tn, t e ))

tcLeg41 = MIN (0.25,0.7 x MIN (0.75,0.438, 0.5))
tcLegA1 = 0.250
 82

h = MIN[(lp - Acorrosion . shell), (2.5 x t), (2.5 x t,)]

ft = MIN[(1 - 0), (2.5 x 0.282), (2.5 x 0.432)]
h= MIN[1,0.705,1.08]
/i = 0.705

tcLeg41 = MIN[(0.25,0.7 x MIN(0.7S, tn, t)]

t c41 = M/N[(0.25,0.7 x M/yV(0.75,0.432,0.282)]
t c41 = 0.197

tcLeg43 = MIN[(0.25,0.7 x MIN(0.75, t,tn)]

t c43 = M/yV[(0.25,0.7 x MW(0.75,0.282,0.432)]
t c43 = 0.197

F = MIN(Fenterered,Y)
F = 1.000

Required Pipe Wall Thickness:

t r n : For internal pressure; t rnE : for external pressure
LD0 = L/D0
LD0 =0.302

D0t = D0/tmE
D o t = 0.0

Wall Thickness from Internal Pressure = trn= (P X i ? n ) / ( 5 n x i? - 0.6 X P)

t r n = (78.5 x 2.935)/(17100 x 1 - 0.6 x 78.5)
trn= 0.014 in

Wall Thickness from External Pressure = trnE = (3 x D0 x P a )/(4 x B) < tn - UT

trnE = (3 X 6.625 X 0 ) / ( 4 X 1)
 83

trng — U ITl

Geometry Constraints:

0.7xLe#41 >t C 4i

0.7x0.313 > 0.197

0.219 > 0.197 Acceptable

0.7*Leg43 > t c 4 3

0.7x0.313 > 0.197

0.219 > 0.197 Acceptable

•^Required (internal ) = 1-0 X d X t r X F + 2 X t n X t r X F X ( 1 — / r l )

^Required (internal ) = 1-0 X 6 . 5 X 0 . 2 2 X 1 + 2 X 0.432 X 0.22 X 1 X ( 1 - 0.855)

=
^Required (internal ) 1-460

=
•"Required (external ) 0 . 5 X {d X trg X 1 + 2 X tn X trg X 1 X (1 — / r i ) )

^Required (external ) = 0.5 X ( 6 . 5 X 0 X 1 + 2 X 0 . 4 3 2 X 0 X 1 X ( 1 - 0.855))

=
•"Required (external ) 0.000

At = MAX[d, 2 x (t + tn)] x [(£"! x t - F x tr) - 2 x tn x (F x x t - F x t r ) x

(l-/rl)]
 84

A± = MAX[6.S, 2 x (0.282 + 0.432)] x [(1 x 0.282 - 1 x 0.22) - 2 x 0.432 x (1 x

0.282 - 1 x 0.22) x (1 - 0.855)]

Ax = 0.391

Ale = MAX[d, 2 x (t + tn)] x [ ( ^ xt-F x trE) - 2 x t n x ( E 1 x t - F x trE) x

(l-/n)]

Ale = MAX[6.S, 2 x (0.282 + 0.432)] x [1 x 0.282 - 1 x 0) - 2 x 0.432 x (1 x

0.282 - 1 x 0) x (1 - 0.855)]

Ale = 1.796

A2 = MlN[(tn -trn)x fr2 x MIN(S x t,2 x V),(tn - trn) x fr2 x MIN(5 xtn,2x

A2 = MIN[(0A32 - 0.014) x 0.855 X MIN(5 x 0.282,2 x 2), (0.432 - 0.014) X

0.855 x M/JV(5 x 0.432,2 x 2)]

A2 = 0.504

A2e = MIN[(tn - trnE) x fr2 x MIN(5 x t, 2 x L), (t n - trnE) x fr2 x M/iV(5 x

tn,2xL))

= MIN[(0A32 - 0) x 0.855 x MIN(S x 0.282, 2 x 2), (0.432 - 0) x 0.855 x

MIN(S X 0.432, 2 X 2)]

A2e = 0.520

A3 = MIN[S x t x tt x fr2,S x tt x tt x fr2,2xhxttx fr2)

 85

= MIN[S x 0.282 X 0.432 x 0.855,5 X 0.432 X 0.432 X 0.855,2 X 0.704 X 0.432 X

0.855)

A3 = 0.520

4 4 1 = (LegA{)2 x fr2

A4l = (0.313) 2 X 0.855

A41 = 0.084

A43 = (Leg43-nca)2 x fr2

A43 = (0.313 - 0) 2 X 0.855

A43 = 0.084

^Actual (internal) = Actual Area = At + A2 + A3 + A41 + A43

^Actual {internal ) = 0.391 + 0.504 + 0.520 + 0.084 + 0.084

^Actual (internal ) l.bbd

=
^Excess (internal) Excess Area = Actual Area — Required Area

—
^Excess (Internal ) ^Actual (internal ) -"Required (internal )

=
^Excess (Internal ) 1-583 — 1.460

^Excess (internal) = 0.123 Acceptable

 86

•"Actual (external ) — •"le "•"-™2e "•'•"3

^Actual (external ) = 1 - 7 9 6 + 0 . 5 2 0 + 0 . 5 2 0

•"Actual (external ) = 3.004

^Excess (External) = Excess Area = Actual Area — Required Area

"Excess {External ) — •"/Ictua/ (External) ~ -"Required (External )

"Excess (External ) = 3.004 — 0

A
Excess (External) = 3.004 Acceptable

r std = Standard pipe wall thickness from chart

Tstd = 0.280

Required Exterior Pressure = Swre = (tr x Pa)/P

Swre = (0.22 X 0)/78.465

S =0

Actual Wall Thickness - Nact = Nt x (1 - UTp)

Nact = 0.432 x ( 1 - 0 . 1 2 5 )

Nact = 0.378

0.8
Thread (According to UG - 31(c)(2)) = Tt = — •
 87

0.8
T
'=T
Tt = 0.000

To satisfy the conditions prescribes in UG-45 of the code:

UG-45 = MAX[UG- 45(a), UG - 45(6)] < Nact

According to UG-45 (a) of the code:

UG- 45(a) = MAX[trn,trnE] + Nca + Tt

UG - 45(a) = MAX[0.014,0] + 0 + 0

UG - 45(a) = 0.014

According to UG-45(b) of the code:

UG-45(b) = MIN[UG-4S(bXl),UG-43(b)(2),UG-4-S(b)(3),UG-
43(b)(4)]

.: According to UG — 45(b)(1) of the code:

UG-45(b)(1) = MAX[tr + ScaiTMINUG_16(b) + Sca]

UG-45(b)(1) = MAX[0.22 + 0,0.063 + 0]

UG - 45(b)(1) = 0.220

According to UG - 45(b)(2) of the code:

UG-45(b)(2) = MAX[Swre + Sca,Tmin + Sca)

 88

UG — 45(b)(2) = Undetermined

According to UG — 45(b)(3) of the code:

UG-45(b)(3) = MAX[UG - 45(b)(1), £/G - 45(b)(2)]

UG - 45(b)(3) = MAX[0.22,Undetermined]

UG - 45(b)(3) = 0.22

According to UG — 45(b)(4) of the code:

UG- 45(b)(4) = (Tstd x 0.875) + Nca

UG - 45(b)(4) = (0.28 X 0.875) + 0

UG- 45(b)(4) = 0.245

••• UG - 45(b) = MIN[UG - 45(b)l, UG - 45(b)2, UG - 45(b)3, UG - 45(b)4]

UG - 4 5 ( b ) = MIN[0.22,0.063,0.22,0.245]

UG- 45(b) = 0.220

.-. UG - 45 = MAX[UG - 45(a), UG - 45(b)] < JVact

= M^X[0.014,0.22] < 0.378

Calculations for UG — 45 = 0.220

6.2.2 Calculations for Flanges

The flange is selected according to category (which in this case is SA); material type
(most often Forged).
 89

Material for the flange = SA-105

Pressure Class =150

Nominal Size = 6.00

:r~ T'~"T
W.Z.

F2
F1

rf^g F2
F1

F2 F1

Figure 6.2: Dimension of Flange

Nozzle

Nozzle Wall Thickness (inch) = tn = 0.432

Required Nozzle Wall Thickness (inch)= tnr = 0.014

Operating Conditions

Temperature = Top = 150 -F

Pressure = Pop = 78.5 psig

Corrosion Allowance — Acorriosion Allowance -Flange

= 0.000

Flange Welds:

Flange Weld calculations are carried out according to UW-15 (c) of the code:
 90

Pipe Fillet Size = F1 = 0.250

Setback = SB = 0.250

Flange Fillet Size = F2 = 0.250

Allowable Stresses for Pipe (at maximum Temperature 1000 °F) = Sp = 17,100 psi

Allowable Stresses for Flange (for pipe OD: 6.625) = Sf = 20,000 psi

Geometry Constraint: (According to Part UW-21 (b) of the code)

c = MIN(tn,tx)

c = MIN^(0.432,0.027)

c = 0.027

tx — Z X trn

tx = 2 x 0.014

tx = 0.027

Weld Throat = Wtmin = 0.7 x c

Wtrnin = 0.7 X 0.027

Wtmin = 0.019

Weld Throat = Wt = 0.7 x MIN(FVF2)

Wt = 0.7 x M/N(0.25,0.25)
 91

Wt = 0.175

Maximum setback = SBmax = c + 0.25

SBmax = 0.027 + 0.25

SBmax = 0.277

Weld Strength:

Sa.min = MIN(Sp,Sf)

Sa. min = M/JV(17100,20000)

Sa. min = 17100 psi

Maximum Weld Stress = Smax = Sa x 0.49

Smax = 17100 x 0.49

Smax = 8,379 psi

Weld Load = Wt = (P0D)2 xpix P/4

Wi = (6.625) 2 xpix 78.465/4

Wt = 2,705

Weld Area =WA= P0D xpix (Ft - Acorrosion . Flange + F2)

WA = 6.625 xpix (0.25 - 0 + 0.25)

 92

WA = 10.407 in2

Weld Stress = WJWA

Weld Stress = 2705/10.407

Weld Stress = 260 psi

6.2.3 Vessel Weight and Volume

6.2.3.1 Volume:

Fluid Specific Gravity = 1.00

Volume/head = 72.06 ft3

Total Volume for Heads (2 in numbers) = 144.11 ft3

Volume of Shell = 496.12 ft3

Total Volume of the Vessel = 144.11 + 496.12

Total Volume of the Vessel = 640.24 ft3

Total Fluid Weight = 39,931 lb

6.2.3.2 Construction:

Each Head weight = 945.29 lb

Head Weight (2 Heads) = 1890.58 lb

Shell Weight = 3202.22 lb

Miscellaneous Weight = 1300 lb

 93

Total Vessel Weight = 1890.58 + 3202.22 + 1300

Total Vessel Weight = 6,3 9 3 lb

Combined Vessel and Fluid Weight = 39,931 + 6,393

Combined Vessel and Fluid Weight = 46,324 lb

6.2.4 Zick Analysis - Saddle Support Calculations

h H H M

Vi
ft
J 1

Figure 6.3: Horizontal Vessel - 1

Figure 6.4: Horizontal Vessel - 2

 94

Length = L = 123.000 in

Radius of Shell = Rshell = 48.000 in

Depth of Head = H = 24.000 in

Saddle Contact Angle = 9 = 120.000

Saddle Width = b = 12.000 in

Overhang = A = 12.000 in

Nominal Shell Thickness^ ts =0.313 in

Nominal Head Thickness = t h =0.313 in

Load on one saddle = Q = 23,162 lb

Design Pressure = P = 78.5 psi

Shell Material: SA-516-70

Allowable Shell Stress = Sa= 20,000 psi

Yield Point = Sy = 38,000 psi

Comp Limit for Shell = 11,500 psi

Circ Joint Efficiency = E = 0.70

K Factors - From Charts

Kl = 0.335, K4 = 0.880, K5 = 0.401, K7 = 0.760

K2 = 1.171, K3 = 0.319, K6= 0.013, K8 = 0.603

 95

6.2.4.1 Stress - Longitudinal Bending - Tension

Sla (for top saddle) = ((Q x A)(KX x (Rshell)2 x ts)) x (x (1 - (1 - (A/L) +

ttRshea)2 ~ (H) 2 )/(2 x A x L))/(l + (4 x H)/(3 x L))))

5 la = (23162.1340737743 x 12/(0.335 x (48)2 x 0.313)) x (1 - (1 - 12/123 +

((48)2 - (24)2)/(2 x 12 x 123)/(1 + (4 x 24)/(3 x 123)

S la = -208

Slb (for bottom, saddle) = ((Q x A)(KQ x (RSheii)2 x

ts)) x (x (1-(1-A/L +
((Rshell)2 ~ (H)2)/(2 XAX L))/(l + (4 x H)/(3 x L))))

Slb = (23162.1340737743 x 12/(0.603 x (48) 2 x 0.313)) x (1 - -(1-12/123 +

(48) 2 - (24) 2 /(2 x 12 x 123)/(1 + (4 x 24)/(3 x 123)

Slb=-U5

Slc (formidspan) = ((Q x L/4)/(TT X (Rsheii)2 x ts)) x (1 + (2 x ((Rsheii)2 -

(H)2)/(L)2/(1 + (4 x H)/(3 x L)) - (4 x A/L))

Slc = ((23162.1340737743 x 123/4)/(3.14 x (48) 2 x 0.313)) x (1 + (2 x

((48) 2 - (24) 2 )/(123) 2 /(l + (4 X 24)/(3 X 123)) - (4 X 12/123))

5 l c = 249

= MAX(Sla,Slb,Slc)

Simax = MAX (-208, -115,249)

 96

Slp = P X i?/(2 X ts)

Slp = 78.4648 x 48/(2 x 0.313)

Slp= 6,016

Sitotai = 249 + 6016

=
Sitotal 6,265

SILimit = Sa x E

= 20000 x 0.7

SILimit = 14,000 Acceptable

6.2.4.2 Stress - Longitudinal Bending - Compression

4 = 0.125/(i?/t)

A = 0.125/(48/0.313)

4 = 0.00082

MaxComp = MAX(Slb,Slc)

= Max(-115,249)

Max Comp = 249

 97

Comp Limit = 11,500 Acceptable

6.2.4.3 Stress - Tangential Shear - Shell

S2a (in Shell) = ((K2 x Q)/(R x ts)) x ((L - 2 x A)/(L + 4/3 x H)

S2a = ((1.171 x 23162.134)/(48 x 0.313)) x ((123 - 2 x 12)/(123 + 4/3 x 24))

S 2a = 1,153

S2b (in Shell) = ((K3 x Q)/(R x t s )) x ((L - 2 x A)/(I + 4/3 x H)

S2b = ((0.319 x 23162.134)/(48 X 0.313)) X ((123 - 2 x 12/(123 + 4/3 x 24)

S2b = 314

S2c (in Shell) = (K4 x Q)/(R x ts)

S2c = (0.88 x 23162.134)/(48 x 0.313)

S2c = 1,357

S2d (in Head) = (K4 x Q)/(R x th)

S2d = (0.88 X 23162.134)/(48 X 0.313)

S2d = 1,357

S2e (A > R/2) = MAX(S2a,S2b)

 98

S2e = AL4X(1153,314)

S2e = 1A53

S2f(A<R/Z) = MAX(S2c,S2d)

S2f = MAX(1357,1357)

S2f = 1,357

52 = UseS2f

S2 = 1,357

S2 limit = 0.8 x Sa

= 0.8x20000

S2 limit = 16,000 Acceptable

 99

Chapter 7: Concluding Remarks

i. There are various books available in the market on the topic of pressure vessel
designing and construction. However, this report is different in a sense that in
here, all the relevant information practically used by the Petroleum and
Petrochemical industry (EPC environment) in the design and construction of
pressure vessels in North America, is collected in one document. Therefore, the
newly graduated engineers in North America, experienced engineers in the field
of pressure vessel engineering from foreign countries and anyone having an
interest in this field will benefit from it.

ii. The explanation of basic principles of pressure vessels engineering in this report
is written in the context of the actual practices of the industry petroleum and
petrochemical industry (EPC environment).

iii. This report documents the characteristics of different types of pressure vessels
such as drums, columns etc. along with the purposes they serve when operating in
different kinds of units. This method allows for the understanding of the overall
process of petroleum or a petrochemical plant in light of ASME Section VIII
Division I.

iv. The technical documents used by pressure vessel engineers in the field are
included in this report. These are reprinted with exclusive permission from KBR
engineering services, Inc. Houston, TX. These documents help in understanding
the practical side of technical documents.

v. The description of the overall mechanical design process of pressure vessel in this
report serves the purpose of building an understanding of the technical challenges
involved in this process. The definition of design parameters in this process is also
part of this document.
(
vi. One of the design software called DIS ASU is introduced in this report, along with
the screen shots. A brief description of the designing methodology along with the
explanation of the menu bar for this software is also a part of this report.
 100

vii. The sixth chapter of this report documents the manual calculations for the design
of a horizontal pressure vessel. This allows for understanding the design process
of pressure vessel in EPCM industry in mathematical terms.
 101

References & Recommended Readings:

Azbel, D. J. (1982). Chemical and Process Equipment Design: Vessel Design and
Selection. Ann Arbor, MI: Ann Arbor Science Publishers.

Bednar, H. H. (1991). Pressure Vessel Design Handbook. Malabar, FL: Krieger

Publishing Company.

Chattopadhyay, S. (2005). Pressure Vessels: Design and Practice. Boca Raton, FL: CRC
Press.

Ellenberger, J. P., Chuse, R., Carson, B., & Carson, B. S. (2004). Pressure Vessels: The
ASME Code Simplified. New York, NY: McGraw-Hill Professional.

Farr, J. R., & Jawad, M. H. (2001). Guidebook for the Design of ASME Section VIII
Pressure Vessels. New York, NY: ASME Press.

Forman, B. F. (1981). Local Stresses in Pressure Vessels. Tulsa, OK: Pressure Vessel
Handbook Publishing, Inc.

Gill, S. S. (1970). The Stress Analysis of Pressure Vessels and Pressure Vessel
Components. New York, NY: Pergamon Press.

Mahajan, K. K. (1985). Design of Process Equipment. Tulsa, OK: Pressure Vessel

Handbook Publishing, Inc.

Megyesy, E. F. (2005). Pressure Vessel Handbook. Tulsa, OK: Pressure Vessel

Handbook Publishing, Inc.

Moss, D. R. (2004). Pressure Vessel Design Manual: Illustrated Procedures for Solving
Major Pressure Vessel Design Problems. Houston, TX: Gulf Professional Publishing.

Pullarcot, S. (2002). Practical Guide to Pressure Vessel Manufacturing. Boca Raton, FL:
CRC Press.

Rao, K. R. (2002). Companion Guide to the ASME Boiler & Pressure Vessel Code:
Criteria and Commentary on Select Aspects of the Boiler & Pressure Vessel and Piping
Codes. New York, NY: ASME Press.

Zeman, J. L., Rauscher, F., & Schindler, S. (2006). Pressure Vessel Design: The Direct
Route. St. Louis, MO: Elsevier.
 102

Appendix A: Authorization from ASME to reproduce Parts from ASME BPVC

Section VIII Division 1.

On Sat, Jul 12,2008 at 12:24 PM, Ivette Rodriguez <[email protected]> wrote:

Dear Mr. Jan:

ASME hereby grants you permission to use the material listed in the manner described
below provided you include this notice - "Reproduced from ASME BPVC Section VIII,
Division 1 2004 with permission of the American Society of Mechanical Engineers. All
rights reserved.'

Sincerely,

Ivette Rodriguez/MM

On Sat, August 09, 2008 at 10:29 AM, Aleem Jan <[email protected]> wrote:

Dear Mr. Ivette,

Referring to our past correspondance, I wish to inform you that the list of the parts of the
ASME BPVC Section VIII Division 1 (2004), that I have reproduced in the final draft
of my Masters in Engineering thesis is as follows:
Part U-1(a)(2), UG-3, UG-16(b), Part UG-20, Part UG-21, Part UG-22, Part UG-23,
UG-25, UG-27 (c) (1, 2), UG-37, Part UG-99.
I will take this opportunity to thank you once again for all the help that you have
extended to me.
With regards,
Aleem Jan
 103

Appendix B: Authorization from KBR Engineering Inc. to Reproduce Engineering

Sample Documents

From:Richard Ericson
Sent: Tuesday, July 15, 2008 12:03 PM
To: Aleem Jan
Subject: KBR's Documents in Masters in Engineering Thesis.
Aleem,
Go ahead and use the documents that you show for your Thesis.
The only condition is that references to clients and locations need to be removed.
I would also ask that you do not use examples of KBR proprietary equipment (like some
of our Ammonia equipment).
Good luck with it.

Regards,

Rich Ericson PE
Department Manager-Mechanical Equipment
KBR
601 Jefferson Ave
Houston, Texas 77002
[email protected]
Phone 713-753-8266
Fax 713-753-7356
 104

Appendix C: Authorization from DISASU Software Inc. to Reproduce Screenshots

from DISASU Software.

From: [email protected] [mailto:[email protected]]

Sent: Wednesday, July 16, 2008 8:30 PM
To: Aleem Jan
Subject:Re: Permission to reproduce Screenshots and literature from DISASU software.
Hello Aleem,
Wednesday, July 16, 2008, 10:30:02 AM, you wrote:

Hi Howard,
I hope you are doing fine.
My name is Aleem Jan, and I am working for KBR (in Houston, TX) as Technical
Professional (Mechanical). I have been working for petroleum and petrochemical related
industries (especially in EPCM environment) for quite some time now.
I am doing my MENG (Master in Engineering) in Petroleum Engineering at Dalhousie
University, Halifax, NS. I have completed all my course work, and now I'm writing up
my thesis on the topic of "Vessel Mechanical Engineering: Petrochemical Industry
Practices in North America". I'm writing on this topic because, there are not many
students at my university Dalhousie University, Halifax, NS, (if any) who would be
interested in joining the petroleum and petrochemical industry as a pressure vessels
engineer; the only reason being that lack of awareness. In my report I'm going to
highlight of different features of petrochemical in petroleum industry (with a EPC
perspective), so more and more people at my university join this field, which offers not
only very well paid jobs but also a challenging and fun environment to work in. I intend
to give a couple of presentations to Mechanical Engineering, Chemical Engineering and
Petroleum Engineering students at Dalhousie university to introduce this field to as many
future engineers as possible, so that more and more brilliant young engineers would think
about serving in this field in the future. I wish to clarify that my thesis and these
presentations will be a completely academic pursuit and not a single penny will be
charged.
 105

Now, I wish to include some material form the industry in my thesis and for that purpose,
I got permission from ASME to reproduce parts of ASME BPVC and permission from
another engineering organization to use their proprietary data in my thesis, and
permission from KBR to use some of their documents, but I need to include an
introduction to at least one pressure vessel design in my report, such as, DISASU,
PVElite, Nozzle Pro etc.
I have been working with DISASU for some time and I like it a lot and I thought of
introducing this software in my thesis.
I ask for your permission to allow me to use some "screen shots" of your software in my
thesis and explain some basic features of your software. I wish to tell you once again that
my thesis is strictly for academic purpose and will not be permitted to be reproduced or
re-published.
It would be mentioned very clearly that screenshots from DISASU are "Reproduced with
permission of DISASU. All rights reserved".
Thanks and Regards,
Aleem Jan
Cell: 832-482-8889

Mr. Aleem Jan

I am encouraged by your enthusiasm and wish you well with your thesis.
The permission you have requested is hereby granted.

Regards

Howard Pouncy
Disasu Software
President

Best regards,
Disasu mailto:[email protected]
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Appendix D: Authorization from Pressure Vessel Engineering Ltd. to Reproduce

Data and Methods of Calculations.

From: Aleem Jan [mailto:[email protected]]

Sent: Monday, June 30, 2008 9:06 AM
To: Info
Subject: Authorization
Hi,
My name is Aleem Jan, I am doing my Masters in Mechanical Engineering from
Dalhousie University, Halifax, Nova Scotia. I am working on my thesis now and wish to
include one of your Horizontal Vessel Calculations in my report and I was just wondering
if you would kindly give me authorization to do that. My thesis is purely for educational
purposes and I assure you that a proper reference to your organization will be made.
Regards,
Aleem Jan

From: Mark Giffin <[email protected]>

Date: Wed, Jul 2, 2008 at 4:18 PM
Subject: RE: Authorization
To: [email protected]

Hi Aleem,
You have authorization to proceed.

Regards,

Mark Giffin, General Manager,

PVEng Ltd.
 107

Appendix E: Governing Codes Related to Design & Construction of Pressure

Vessels in North America

ASME BPVC Section II Material Specifications

ASME BPVC Section

Rules for Construction of Pressure Vessels
VIII Division I
ASME BPVC Section
Alternative Rules for Construction of Pressure Vessels
VIII Division II

ASME BPVC Section IX Welding and Brazing Qualifications

Pipe Flanges and Flanged Fittings - NPS lA through NPS 24

ASME B 16.5
Metric/Inch Standard
Large Diameter Steel Flanges - NPS 26 through NPS 60
ASME B 16.47
Metric/Inch Standard

ASME: American Society of Mechanical Engineers

BPVC: Boiler and Pressure Vessel Code

NPS: Nominal Pipe Size

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Appendix F: List of Major Pressure Vessels Design Software

• CODECALC
• PVElite
• COMPRESS
• DISASU

• CODECALC

CODECALC is windows based software and it is used for the design as well as the rating
of pressure vessels, shell & tube heat exchangers, flanges and piping. This software is
updated from time to time to keep up with the changes suggested by ASME BPVC. This
software has the complete data for the materials suggested in ASME BPVC Section II.

Comprehensive design calculations (including in interactive on-screen mode) are

produced which could be printed out on all standard paper sizes. The routines for the
latest version are encrypted to 32-bit, and the data entry is carried out in user friendly
graphical mode for all pressure vessel components.

(http://www.coade.com/product description.asp?varflag=CodeCalc&varflagmaster=Cod
eCalc)

• PVElite

PVElite is windows based user friendly software with tools for a comprehensive
mechanical design for both towers (columns) and horizontal vessels. The unique feature
of PVElite is that it has CodeCalc as its supplementary part for the purpose of component
design and analysis.

Like any other design software, PVElite is also used for not only designing but also re-
rating of pressure vessels. This software also includes all the latest addenda to the ASME
BPVC and include calculations for Section II, and Section VIII Division I and II.

(http://www.coade.com/product_overview.asp?varflag=pvelite)
 109

• COMPRESS

Compress is another widows based pressure vessel design software, with multi-user
networking option. This software perform the design of pressure vessels, according to
ever updating ASME BPVC Section VIII, Division I (both US and customary units),
ASME BPVC Section VIII, Division II (optional), Section II (Materials Specifications),
including analysis of designs through finite element method. Compress has the ability to
convert the drawings and calculations into many different modes such as AutoCAD
drawings, and spreadsheets enabling the user to further process the drawings and data.

(http://www.codeware.com/)

• DISASU

Please, refer to chapter 5 of this report.