Guidance with

Patience

To

Learn with Passion

PVELITE TRAINING – PRESSURE VESSEL

DESIGN

Practice and make perfect

High structure integrity, safety and cost

optimized static equipment
 Table of Content

Item Description Page

1. Chapter 1: Static equipment, piping and storage tank. 2- 3

Relevant Code and Standards. Design Software

2. Chapter 2: Pressure Vessel Design , 2.1 Design by Rules 4-7

or Formula, 2.2 Design by Analysis

3. Chapter 3: Types of loadings at Pressure Vessel 8-11

4. Chapter 4: Type of Stresses at Pressure Vessel 12-20

5. Chapter 5: Basic feature and Operation of PVElite 21-28

6. Chapter 6: Common Design Code for Pressure Vessel 29-31

7. Tutorial 1: Vertical Pressure

1 PVElite Training – Basic

1
 Chapter 1 : Types of Equipment and Facilities,
Design codes and Application software

Chimney stack Horizontal

pressure vessel

Vertical pressure
vessel

Piping

Process column

2 PVElite Training – Basic

Shell & Tube
Heat Exchanger
Air fin cooler

Above round
storage tank
Spherical
storage tank

Figure 1: Group of equipment and facilities at oil refinery plant

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 A process plant (Oil & Gas refinery, petrochemical, chemical and others) shall consists
of following equipment and facilities.

Code & Equipment or facilities detail Recommen

Standard ded
defector
software
Pressure ASME Sec VIII  Process Vessels – Trayed columns, reactors, PVElite ®,
Vessel Div 1 or Div 2, packed columns Nozzle Pro,
PD5500,  Drums and Miscellaneous Vessels – Horizontal FEpipe
EN13445 and vertical vessels
 Storage Vessels – Bullet and spheres tanks

Storage API 650, API 620  Cone roof tank ( Self supported and Supported)
Tank ,API630  Dome roof tank
TANK®
 Flat roof tank
 Floating roof tank (not in software yet)

3 Heat TEMA,  PVElite Training

Shell and Tube heat exchanger (Various – Basic
Mech - PVElite
Exchanger PD5500,ASME configuration ) ®
UHX, ASME  Hairpin Heat Exchanger
Thermal &
Appendix A  Jacketed Pipe Heat Exchanger
flow- HTRI®-
Xist, Xhep and
etc

Piping  ASME B31.1 ( Power piping) CAESAR II®

 ASME B31.3 (Process piping)
 ASME B31.4 (Pipeline Transportation Systems for Liquid
Hydrocarbons and Other Liquids)
 ASME B31.5 ( Refrigeration Piping and Heat Transfer Components)
 ASME B31.8 (Gas Transmission and Distribution Piping Systems)

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 Chapter 2 : Pressure Vessel Design
There are two types of mechanical design methods for pressure vessel , namely design
by formula (DBF) and design by analysis (DBA).

2.1 Design by Rule or Formula (DBF)

Design formula is governed by mandatory national code and standards to ensure safety
performance. Most the pressure vessels are designed based on the concept of Design
by Formulae (DBF), which involves relatively simple calculations to achieve the required
component thicknesses via simple formulae or diagrams and by usage of the concept of
the nominal design stress, also termed as allowable stress, allowable working stress, or
limiting stress intensity; pressure vessel design codes like ASME Div VIII Section 1 and
Section 2, PD 5500 and EN 13445 use the principle of thin wall structure membrane
stress for determining the minimum thickness of structure such as cylindrical shell ,
conical shell, body flange and dish head thickness due to various loading conditions.
The great benefit of the DBF approach is still its simplicity, only in the recent past the
formulae and calculations in DBF have become more and more elaborate, pretending
accuracy that is often not there (Josef L. Zeman, 2004).

The basic idea of design by rule is that once the leading scantlings are fixed in this way
4 the designer simply obeys the rules laid down in the procedures for specified
PVElite Training – Basic
components such as nozzles, dish head, shells, etc. The methodology or reasoning
behind the rules will not always be apparent as we shall see. However, this is the most
common approach used in all national design codes.

The design by rule approach has the great advantage of simplicity and being backed up
by the long experience of users in many cases. The greatest disadvantage is that the
approach cannot easily be extended either to different geometries or additional
loadings beyond the normal pressure cases, elastic –plastic and plastic state. For
example, ASME VIII Div 1, the design rules and formulas consider mainly the loadings
due to static internal pressure and external pressure within elastic limit.

4
 2.1.1 Design by Rule or Formula (DBF) using PV Elite

Conventionally, most of the previous design of pressure vessel is done using

spreadsheet like Microsoft Excel to perform structural thickness calculation and
analysis for pressure vessel components. Nevertheless, this option can save some initial
cost compare to commercial design software like PVElite, but it will be comparatively
non cost effectiveness in the long run. This is obvious, when we compare PVElite to
Microsoft Excel formatted design spreadsheet in term of the quantity and quality of the
performance. Some of the points below are elaborate for getting better understanding
about the advantages of using PVElite in pressure vessel design.

 PVElite is “ user friendly” for both new and experienced user, where the input
menu is ready available in a systematic arrangement ( if spreadsheet is used,
you might enter the information to the wrong cell at spreadsheet that will cause
a wrong output or even damage the whole program due to your carelessness ).
User just enter the information as stated in the design datasheet and
specification. Furthermore, if the user are doubt about the input , just press
function key f1 to get technical advice from the help menu with useful
statement, diagram , graph and table relevant to design requirement or
national standard code ( if spreadsheet is used, you have to refer to the hard
copy of design codes which will spent time in searching for the details .)

5  PVElite is “design oriented”, where the features allow PVElite Training

the user – Basic
to maximize
their time to design or re-rating the pressure vessel to achieve cost- optimum
design. That mean, minimize the time spent in searching, confirming and
entering the design parameters for design calculation. To achieve this, PVElite
performs calculation base on various type of design codes and corresponding
material code with various addendum (ASME Sec VIII Div 1, Div 2 , PD5500 and
EN13445), hence designer will be able to change and compare the pressure
vessel design base on different standards easily . In addition, user can select
various national codes for external loadings due to wind and/or seismic forces
(ASCE, UBC, NCB ,IS , GB and etc.), nozzle loadings (WRC 107 , PD5500 Annex B
and etc), and tubesheet design (TEMA, ASME UHX, BS5500, ASME appendix A)
Secondly, PVElite provides a good traceability for the calculation results where
a negative answer is alerted in “red warning “, that the designer has the
possibility to understand which are parameters to be changed in order to get
the checking. While, a positive answer shows the result the degree of possible
overdesign, in order to give the designer the possibly of decreasing excess
thickness when they are not needed.

5
  PVElite interfaces with others popular software packages for finite element
analysis (Nozzle-Pro), heat exchanger design (HTRI), pressure vessel drafting and
material take off (PV fabricator) and foundation design and drafting. PVElite also
shares a bi-directional link to COADE’s CADWorx Equipment module. The
significant benefit of this feature is the designer will be able to convert the
preliminary design into drawings and MTO for cost estimation and proposal
purposes using PV fabricator. In addition, the changes made in the PVElite in
pressure vessel design will update the engineering drawing and bill of material
correspondently. The mathematical model of the pressure vessel in the graphic
form can be exported to Nozzle-Pro for meshing and generating finite element
model for stress analysis such as nozzle to shell intersection, dome to shell
intersection, skirt to shell and etc. After the heat and fluid flow analysis of heat
exchanger using HTRI software, some relevant information can be transfer to
PVElite for stress analysis for tubesheet, tube, tube to tubesheet joint and other
components. The nozzle loading from CAESAR II can be transfer to PVElite for
WRC 107 or annex B local stress analysis.

 CodeCalc is an additional programs available within PVElite to analysis the

vessel components separately or things that haven’t be included in PVElite .
Typical cases would be full-jacketed vessel, non-circular vessel, Lifting lugs and
turnion design, API579 (Fitness For Service), large opening at shell, floating
6 PVElite Training – Basic
head and etc.

2.2 Design by Analysis (DBA)

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 Design by analysis (DBA) is mainly used to check the design of pressure vessel which is
operated under serve conditions like extreme high pressure, and extreme high or low
temperature where DBF cannot be used due to its limitations in design calculation, data
and coverage (Design by Analysis, 2004). The design by analysis can be categorized into
two: design base on elastic analysis, and design base on plastic analysis. It is
implemented to avoid eight possible failure modes at pressure vessel by detail stress
analysis as stated as in ASME sec VIII Division 2 and subsequently BS 5500 Appendix A
and EN13445-3 Annex B (Direct Route Method) and EN13445-3 Annex C ( Elastic analysis
& stress Categorization). The failure modes considered are (base on ASME section VIII Div
2, Part 5) :-

 All pressure vessels within the scope of this Division, irrespective of size
or pressure, shall be provided with protection against overpressure in
accordance with the requirements of this Part.
 Protection Against Plastic Collapse – these requirements apply to all
components where the thickness and configuration of the component is
established using design-by-analysis rules.
 Protection Against Local Failure – these requirements apply to all
components where the thickness and configuration of the component is
established using design-by-analysis rules. It is not necessary to evaluate
the local strain limit criterion if the component design is in accordance
with Part 4 (i.e. component wall thickness and weld detail per paragraph
4.2).
 Protection Against Collapse From Buckling – these requirements apply to
7 PVElite Training – Basic
all components where the thickness and configuration of the component
is established using design-by-analysis rules and the applied loads result
in a compressive stress field.
 Protection Against Failure From Cyclic Loading – these requirements
apply to all components where the thickness and configuration of the
component is established using design-by-analysis rules and the applied
loads are cyclic. In addition, these requirements can also be used to
qualify a component for cyclic loading where the thickness and size of
the component are established using the design-by-rule
Requirements. Part 4.

PVElite can only dealt with requirements that are directly addressed by the code and
for cases where limitations prevent you from obtaining the necessary result, a viable
alternative would be to turn to FEA (finite element analysis). PVElite does have
interfaces with an FEA program termed Nozzle-Pro and this is beyond the scope of his
manual.

3.0 Type of loadings at Pressure Vessel

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 All structure include pressure vessel are subjected to two basic types of loading: Steady or
static and unsteady (variable, cyclic or impact). Figure 3.1 shows loadings which are grouped
into steady and unsteady loads. Most of the pressure vessels encounter variable or cyclic
loading, may assumed to be statically load without introducing serious error. This is
significantly stated in the standard ( ASME Section VIII, Division 2, AD-160) that the fatigue
analysis is required provided the conditions of the cyclic loading are exceed the limits at the
fatigue evaluation stage. These limits is depend upon the number of cycle loads in term of
fluctuate operating pressure and temperature, as well as the degree of the cyclic load which is
mainly due to the gap of maximum and minimum operating pressure or temperature. Figure
3.2 shows types of general loads and local loads at pressure vessel.
Internal pressure load is common for all the pressure vessel above, since all the static
equipment operates at certain elevated pressure and temperature due to chemical processes
and hydrostatic pressure of storage content ( ASME Section VIII, Division 1, Part UG20 and
UG21, 2007). In addition, hydrotest pressure load is elevated at 30% from the vessel working
pressure at corroded or new condition as stated in ASME Division 1, Part UG99.
Despite the availability of vacuum valve, the external pressure is considered for
pressure vessel design in vacuum condition where the outlet nozzle is connected to pump. The

8 atmosphere pressure is sufficient to compressively deform a pressure vessel

PVElite due –toBasic
Training large
volume vessel with insufficient thickness and/or stiffener, furthermore metallic materials have
relatively low compressive strength compare to its tensile strength (ASME Section VIII Division
1, Part UG28, 2007).
External load like wind and seismic load is more critical for process vessels like process
columns and reactor. The deflection and vibration analysis of tall slender column (H/D>15) are
commonly checked to ensure the structural is not over deflected. In conjunction, the stresses
induced by wind and seismic loads are always combined with other stresses (i.e. longitudinal,
circumferential and shear stress) due to internal pressure, external pressure, and hydro test
pressure to ensure the possible combined stresses are not more than allowable stress (ASME
Section VIII Division 1, Part UG22-23, 2007).

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 Types of loading

Steady load – long-term Non steady loads—short term

duration, continuous duration, variable

Pressure loads – Internal or Shop and field hydrotest

external pressure (design,
operating, and hydrostatic
head of liquid) Dynamic/ impact load

Dead weight, vessel content Lifting and erection

Loadings due to attached Start up, shut down.

piping and equipment.

9 PVElite Training – Basic

Loadings to and from vessel Transportation
support

Thermal load – Head to skirt Thermal load – short term

joint, piping expansion load during service or testing
at nozzle.

Wind load Earthquake, Vibration

Upset, emergency
Constant cyclic pressure or
thermal load

Figure 3.1: Types of Loading at pressure vessel

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 Categories of loading at
pressure vessel

General loads – Load Local loads – Load applied to a small

applied continuously across portion .of the vessel and normally
a vessel section. fall off rapidly in distance of applied
load.

Pressure loads-Internal or external Pressure radial loads-Internal and

pressure load (design, operating, external pressure for thick wall
hydrotest, and hydrostatic head or pressure vessel.
liquid.)

Shear loads- Longitudinal and

Moment loads- Bending moment circumferential shear at shell, dish
due to wind, seismic, erection, head and conical section, where
10 transportation and horizontal saddle and support PVElite
lugs, andTraining
nozzle – Basic
support. to shell juncture.

Compressive/tensile loads- Due to Torsional loads- torsional load at

dead weight, installed equipment, vessel nozzle due to the twist of
ladders, platforms, piping, and external piping.
vessel content.

Thermal loads- Skirt to head Moment loads- load due to moment

attachment. at discontinuities, nozzle to shell
section.

Thermal loads- Thermal expansion

restricted regions likes piping at
nozzle connection.

Figure 3.2: Categories of Loading at pressure vessel

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 In addition to the above major analysis, nozzle opening reinforcement at shell is
important to avoid mechanical failure due to internal pressure, external pressure and nozzle
loading due to external piping connection and other equipment likes reboiler due to various
forces and moment at nozzle to shell junctures (K.R.Wichman., A.G. Hoper., J.L.Mersho, 1979).
This concept is applicable to other attachments at the pressure vessel walls which have
rectangular, square or circular cross sectional area.
For horizontal supported pressure vessel, the distributed weight implement bending
load at the mid span of the pressure vessel and the saddle support. Furthermore, the
concentrated load at the horn of saddle and the tip of the wear plate. The above loads are
significant for large diameter and long horizontal pressure vessel.
(L.P. Zick, 1951)
Local stresses analysis is important for lifting lugs and turnion to ensure safe lift during the site
installation.
Fatigue analysis is performed for those pressure vessels which have severe and
significant cyclic loadings in the form of fluctuating pressure and temperature condition. These
cyclic loads would decrease the service life of a pressure vessel as stated in the S-N curve of
specific material. (ASME Section VIII, Division 2, Appendix 5)

11 Thermal loads is only concerned for DBF likes ASME DivisionPVElite

for tube sheet–design.
Training Basic
ASME Division 2, part 5 – Design By Analysis Requirements (2007) checks the stresses induced
by cyclic thermal loads, and the ratcheting for pressure vessel components.

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 4 Type of stresses at Pressure Vessel
Generally the design of pressure vessel is to decide the minimum thickness which will
fulfill the design requirement as per design code through DBF or DBA. The pressure
vessel components thickness are depend upon the stress(es) incurred at the material
due to internal pressure, external pressure and other external forces. It is not necessary
to find every stress but rather to know the governing stresses and how they related to
the pressure vessel and its respective parts, attachments, and supports. Hence, the
basic understand of the stresses at pressure vessel is importance for design and they
are further elaborated as below. Generally, there are three types of stresses:-

- General Primary Stress

- Secondary Stress
- Peak Stress

12 PVElite Training – Basic

4.1 General Primary Stress

These stresses act over a full cross section of the vessel and they are produced by the imposed
loading (load-induced) and are necessary to satisfy the law of equilibrium. In addition, they are
the most hazardous of all types of stress.
The basic characteristic of primary stresses that it is not self limiting (i.e. they are not
reduced magnitude by the deformation they produced). Hence, the gross distortion or failure
of the structure will occur if its value substantially exceeds the yield stress . In the other word, if
a primary stress exceeds the yield strength of the material through entire thickness, the
prevention of failure is entirely dependent on the strain- hardening properties of the material
or stress distribution. Primary stress are generally due to internal or external pressure or
produced by sustained external forces and moment.
The primary stress is divided into two subcategories in ASME Sec VII-Div 2. They are
primary general membrane and primary general bending stresses. Primary general membrane
stress ,Pm. This stress occursd across the entire cross section of the vessel. It is remote from
discontinuities such as head-shell intersections, cone-cylinder- intersections, nozzles, and

12
 supports. For instance, circumferential and longitudinal stress due to pressure; compressive
and tensile axial stresses due to wind or seismic; longitudinal stress due to the bending of the
horizontal vessel over the saddles; membrane stress in the center of the flat head; membrane
stress in the nozzle wall within the area of reinforcement due to pressure or external loads and
axial compression due to the weight.

13 PVElite Training – Basic

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14 PVElite Training – Basic

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15 PVElite Training – Basic

Figure 3.3: General membrane stress at the pressure vessel parts

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 Primary general bending stress, P b. Primary bending stresses are due to sustained loads
and are capable of causing collapse of the vessel. There are relatively few areas where primary
bending occurs. For instance, bending stress in the center of the flat head or crown of a dished
head; bending stress in a shallow conical head and bending stress in the ligaments of closely
spaced openings.

16 PVElite Training – Basic

16
 Local primary membrane stress, PL. Local It is a combination of two stresses, primary
17 PVElite Training – Basic
membrane stress, Pm, plus secondary membrane stress, Q m which is produced from sustained
loads. These have been grouped together in order to limit the allowable stress for this
particular combination to a level lower than allowed for other primary and secondary stress
application. It was felt that local stress from sustained not self-limiting loads presented a great
enough hazard for the combination to be classified as a primary stress. Examples of primary
local membrane stresses are primary membrane stress plus membrane stresses at local
discontinuities (i.e. head to shell juncture and nozzle to shell juncture), primary stress plus
membrane stresses from local sustained loads (i.e. platform and ladder support; piping and
equipment attached to the nozzle).

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18 PVElite Training – Basic

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 4.2 Secondary Stress
Secondary stress is developed when the deformation of a component due to the applied loads
is restrained by other components. It must satisfy an imposed strain pattern rather than being
equilibrium with an external load. Secondary stress is self-limiting (i.e. they are reduced
magnitude by the deformation they produced) in that local yielding can be redistribute the
stress to a tolerable magnitude without causing failure.
Secondary mean stresses are developed at the junctions of major components of a
pressure vessel. Secondary mean stresses are also produced by sustained loads rather than
internal or external pressure. Secondary stresses are strain-induced stresses.
Secondary stresses are divided into two additional groups, membranes and bending.
Examples of secondary membrane stress are axial stress at the juncture of the flange and the
hub of the nozzle; thermal stresses due to restricted expansion; membrane stress in the
knuckle area of the head and membrane stress due to local relenting (self-limiting) loads.
Examples of secondary bending stress, Q b are bending stress at a gross structural discontinuity
(i.e. nozzle and lugs); the non-uniform portion of the stress distribution in a thick walled vessel
due to internal pressure; the stress variation of the radial stress due to internal pressure in
thick- walled vessels; discontinuity stresses at stiffening or support rings.
19 PVElite Training – Basic

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20 PVElite Training – Basic

4.3 Peak Stress

Peak stress is the highest stress in the region under consideration. The basic characteristic of
peak stress is that it causes no significant distortion and is objectionable mostly as sources of
fatigue failure. It applies to both sustained load and self- limiting load. Peak stress is additive to
primary and secondary stress present in the point of the stress concentration. Peak stress is
only significant in fatigue conditions or brittle materials. It is the sources of fatigue cracks and
applies to membrane, bending, and shear stress. Example are stress at the corner the
discontinuity; thermal stresses in a wall caused by the sudden change in the surface
temperature; thermal stresses in cladding or weld overlay; stress due to the notch effect .

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 5 Basic features and operation of PV Elite
Generally, there are five major input processors in PVElite. There are

i) Heading
ii) Design Constraint
iii) General Input
iv) Load Cases
v) Seismic Data
vi) Wind Data

21 PVElite Training – Basic

Figure 4.1: Input Processors for the Pressure Vessel design

Before the user start to enter the design parameters into the input processors as stated above ,
it is important to configure the settings at the start. The configuration is at the tools option
control utility processor as shown in figure 2.2.

21
 5.1 Configuration

22 PVElite Training – Basic

Figure 4.2 : Configure the settings of PVElite behaves when analyzing a vessel

It is important to configure the settings at the start. From the tools option control utility
processor, options are given to customize how PVElite behaves when analyzing a vessel. The
settings are related to the pre and post processing of the design or analysis for pressure vessel.
Pre-processing is the settings of the design requirements before the analysis, likes alternative
rules in design of pressure vessel components (i.e. use ASME Code case2260/2261, 2286, 2004-
A06 Addenda for Division 2, pre-99 Addenda (Division 1 only) , Eigen solver and use OD as the
basis for shell radius for Zick’s analysis) or the setting allowable value such as material
database, graph for determining MDMT and allowable tower deflection. In addition, post –
processing involves filter or keep certain results or details to be appear in the report such as no
MDMT, no MAWP calculation, print equation and substitution. It is important for the user to
be familiar to the design standards, practice and client required specification before perform
any setting in the configuration section.

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 5.2 Design/ Analysis Constraints

23 PVElite Training – Basic

Figure 4.3: Design constraints for setting general design information for pressure vessel

5.3 Design Data

23
 The input screen is divided into two areas. They are design data and design modification. The
design data section is related to general design parameter like internal and external pressure
/temperature, hydrotest type and position, projection from to/ bottom for UG99-C . This
information is very common seen and indicated in the design data of vessel GA drawing and
this core information for pressure vessel design. The user can specific their client preferred
MAWP, MAPnc and hydrotest pressure, where these values will overwrite/ replace the
calculated values. Others inputs like construction type, special service, degree of radiography
are just for information only, it is reported in the report echo.

If the user check the box of “Use Higher Longitudinal Stresses ?”, PVElite will use higher
allowable longitudinal stress for combined stresses analysis . The ASME Code Section VIII,
Division 1, Paragraph UG-23(d) allow the allowable stress for the combination of earthquake
loading, or wind loading with other loadings to be increased by a factor of 1.2.

If the user check the box of “Consider Vortex Shedding ?”, PVElite will compute fatigue stresses
based on loads generated by wind flutter. In addition, the program will compute the number of
hours of safe operation remaining under the wind vibration conditions. This section is suitable
for high column design with h/d (overall high over the vessel diameter) equal or more than 15.
For low vertical vessel like drum, it is advisable not to check the box because the program will
generate extreme non logical high value which will cause overdesign for the structure.

If the user check the box of ”Is This a Heat Exchanger ?”, PVElite will write out an ASCII text file
that contains the geometry and loading information for this particular vessel design.

24 PVElite
If user check the box of “Hydrotest allowable is 90% yield”, PVElite will Training
consider 90%– Basic
of the
material yield stress for the hydrostatic test allowable. This will generate higher allowable
stress for hydrotest than the normal value which is 1.3 time the material minimum allowable
stress. ( This applies only for Division 1 vessel design).

If user is designing a cylindrical ASME stack steel stack and wish to have PVElite analyze
allowable and stress combinations per ASME STS-2003(a), then check this box. (This applies for
Division 1 vessel design).

The 2009 version do not allow any modification of design code in this input screen, but it is
shown at the column for information. The reason of this new feature is to remind the designer
to select the design code at the earlier stage (Refer to figure 2.4).

24
 Figure 4.4: Selection of design code at “New” column and pull down menu

Any modification at design data will affect design of the whole pressure vessel and it
25 components. For example, the change of internal design pressure and PVElite Training – at
temperature Basic
this
section will generate global change for all the components of the pressure vessel at general
input processor. In addition, the change of design code for whole vessel is done by reselecting
the required design code at pull down menu. However, the user needs to reselect the material
before running the analysis.

5.4 Design Modification

Design modification provides the user with the option to intelligently design the vessel
whenever a specific section fails the code. The program will prompt a thickness that will be
suitable for use or a location (s) of stiffening rings so that the code requirement can be met.
For the stiffening rings, the program will allocation the ring(s) after run the analysis, where the
program will ask for user permission before the changes take place.

(Note: For most Advance users, the options included are usually not used.)

5.5 Load Cases

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26 PVElite Training – Basic

Figure 4.5: Load cases for stress combination at pressure vessel

5.5.1 Stress Combination Load Cases

This input processor is used to deal with various combinations of loads that contribute
toward the membrane stress of the vessel at longitudinal direction. The calculated
maximum principle stresses based on different combination of loads will be compared
with the corresponding allowable stress.

There can be as many as twenty cases, combining pressure loads, weight loads, and
moments in various ways. Generally, the load cases stated are more than adequate to
deal with all the combinations that the user are likely to encounter in both operational
and hydrotesting conditions.

A fairly complete set of load cases is included as a default:

26
 The difference between wind loads and hydrotest wind loads is simply a ratio
(percentage) defined by the user. This percentage is specified in the Wind Data
definition of Global Data - usually about 33% (thus setting the hydrotest wind load at
33% of the operating wind load). Likewise, the hydrotest earthquake load is a
percentage of the earthquake load; this percentage is defined in the Seismic Data
definition of Global Data. Some steps that are not applicable for horizontal vessels,
such as natural frequency, will not be printed. Also, if a vessel has no supports, then
27 there will be no calculations that involve wind or seismic loads. PVElite Training – Basic

5.5.2 Nozzle Design Options

The nozzle design option dealt with the design criteria that determine the selection of
nozzle wall thickness and reinforcement pad. The top deals with design pressure that is
used to calculate the thickness (nozzle or clip) base on MAWP+ Static head to Bottom
Element, Design Pressure + Static head, Overall MAWP + Static head (governing
Element), MAWP + Static head to Nozzle (note: user must select either one for their
vessel’s nozzle design). The least of the boxes is optional for vessel design.

27
 If the user checks the box of ”Consider MAPnc in Analysis “, PVElite will check to see if
the nozzle is reinforced adequately using MAPnc generated during the internal
pressure calculation. When the area of replacement calculations are made for this case,
cold allowable stresses are used and the corrosion allowance is set to 0. Designing
nozzles for this case helps the vessel to comply with UG99 or appropriate (hydrotest)
requirements.

If the user check the box of “Modify Tr based on the Maximum Stress Ratio”, PVElite
will looks at all of the defined load cases (combined stresses) and select the highest
stress ratio (actual stress/ allowable stress). It will then use this number as a multiplier
on the shell thickness. Thus the nozzle design is based on the precise loading at the
bottom of that shell course. The reason for the above work is to comply with ASME
Section VIII Division 1 paragraph UG-22 that deals with supplemental loadings. One
factor in ASME nozzle design is the required thickness of the shell (tr). Usually internal
pressure (hoop stress) governs. In some cases, such as when a nozzle is located on a
shell course at the bottom of a tall tower, longitudinal stresses will govern. In this case
the shell required thickness must be based on longitudinal stresses and not the hoop
stress.

28 PVElite Training – Basic

6 Common design Code for Pressure Vessel

ASME Section VIII Div 1, Ed 2007, Ad 09

ASME Div 1 is the most common use standard for pressure vessel design, the following
are some of the common consideration in pressure vessel design.

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29 PVElite Training – Basic

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30 PVElite Training – Basic

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Tutorial (1) : Design for vertical pressure vessel

31
 Tasks to be complete :

To determine the structural thicknesses of cylindrical shell and semi ellipse head
due to internal and hydrostatic pressure conditions.
Check shell thickness against hydrotest pressure.
MDMT checking for all pressure vessel components.
To determine the allowable external pressure of the structure and compare to the
actual external pressure load due to vacuum condition at pressure vessel.
Design skirt support and base ring design for vertical pressure vessel due to wind
and seismic load. (refer to PVElite database or handbook data if possible).
Nozzle reinforcement at dome shell due to shell opening, Nozzle minimum
thickness.
Installation of internals – trays and packing, platform and ladder, longitudinal. After
that determine the combined stresses condition at bottom structure. Do the
necessary correction, if there is a need.
Perform rigging analysis to check the shear stress and bending stress of the vertical
vessel during critical lifting position.

Learning Outcome:

After completion of this topic, student will be able to use PVelite for :
Input all the design parameters to the correct input cursor.
Run the analysis and correct the design error by adjusting the design parameter
accordingly.
32 Obtaining an cost optimize design for pressure vessel componentsPVElite Training – Basic
due to internal
pressure, external pressure, nozzle reinforcement , external loadings and skirt
support. (target :+-10% greater than actual load/stress/deflection rate)
(Note: Indicate the results with yellow highlight for printed copy and save a PVE. file
in CD for further evaluation)

Tutorial (1) : Vertical pressure vessel

Design Parameter Variable
1) Vessel name / number Distillation column / WRG-100

32
 2) Design Code & Addenda ASME Section VIII Division 1, Addendum 2007
3) Operating Pressure & Temperature 10 bar (internal), 300oC / -1 bar (vacuum), 300oC
4) Vessel Design Pressure & Temperature 15 bar (internal), 300oC/ -1 bar (vacuum), 300oC

5) Minimum Metal design Temperature MDMT = -25oC

6) Vessel dimension ( Inside Diameter (ID) x 3500 mm (diameter) x 30,000 mm (L)
Length tangent to tangent (L)) 2500 mm (diameter ) x 10,000 mm (L)
Conical sectional height (L) 1500 mm (L)
7) Design Liquid Level / 3500 mm from bottom TL / 0.85
content specific gravity
8) MAWP / MAP(N &C) ( ) N/mm2
9) Hydrotest pressure (shop/field) UG99(b), Shop ( )N/mm 2
10) Heat treatment ( Applicable/ Not Applicable0
11) Joint Efficiency Dome end : meridoinal seam (Full RT)
circumferential seam ( spot RT)
Cylindrical shell : meridoinal seam (spot RT)
circumferential seam ( spot RT)
11) Corrosion Allowance 3 mm for all parts
12) Material
- Cylindrical shell SA 516 GR70
- Dome end SA 516 GR70
- Nozzle SA 106 GR B
- Nozzle flange SA 105
- Bolting SA193/ SA194
33 - Skirt SA283 GRC PVElite Training – Basic
13) Weights Fabrication : ( ) tones
Empty: ( ) tones
Operating: ( ) tones
Test: ( ) tones
14) Wind load Wind Design Code: ASCE-93
Wind for Hydrotest: 33%
Design Wind Speed: 120 km/hr
Base Elevation : 3 meters from sea level
Important factor: 1, Roughness factor: 1
15) Seismic load Seismic Design Code: ASCE-93
Seismic for Hydrotest: 0%
Seismic Coefficient Av: 0.2
Seismic Coefficient Cc: 2
Performance Factor: 1

2:1 Semielliptical Head, N

SF=50mm, min thk ( ) mm, 1

Nominal thk ( )mm.

(Indicate the shell thickness of the
33 shell section)

2,500 mm
10,000mm
 ID =3,500 mm

34 PVElite Training – Basic

Nozzle Detail

No Nozzle Dia x Sch X L Pound rating Orientation Elevation from

Description (#) lower SF
1
34
 1. Inlet ( N1) 18” x sch 40 x ANSI, WNRF , 600 from Top dish head
200L 300# CL (120o)
3. Outlet (N2) 20” x sch 10 x ANSI, CL Bottom dish
250L WNRF,f150# head
4. Manhole (M1) 24” x 12thk x ANSI, 0o 5000 mm
300L WNRF 150#

35 PVElite Training – Basic

Tutorial (2): Design for horizontal pressure vessel

Tasks to be complete :

Internal pressure, hydrotest , external pressure calculation as practical 1.

Nozzle opening and reinforcement , Nozzle loading WRC 107 checking.

35
 Longitudinal stresses at horizontal supported pressure vessel at the mid span and saddle
support during the operation and hydrotest respectively. Tangential stress at the shell at
saddle support, Circumferential compression at bottom of shell and in plane of saddle
and circumferential bending at horn of saddle. Corrective methods in reducing the stress
at horn of saddle – add wear plate, increase the contact angle and support
width, move saddle toward the head, add stiffer ring at the saddle, add the
saddle support(s).
Design for the saddle support, base plate, rib plate, wed plate.

Learning Outcome:

After completion of this topic, student will be able to use PVelite for :
Input all the design parameters to the correct input cursor.
Run the analysis and correct the design error by adjusting the design parameter
accordingly.
Obtaining an cost optimize design for pressure vessel components due to internal
pressure, external pressure, horizontal supported conditions, nozzle reinforcement , nozzle
loading, external loadings and saddle support. (target :+-10% greater than actual
load/stress/deflection rate)
(Note: Indicate the results with yellow highlight for printed copy and save a PVE. file in CD
for further evaluation)

1) Vessel name / number Slug Catcher

36 PVElite Training – Basic
2) Design Code & Addenda ASME Section VIII Division 1, latest Addendum
3) Operating Pressure & Temperature 3.5 bar (internal), 120oC / 1 bar (external),60oC

4) Vessel Design Pressure & 5.5 bar (internal), 120oC/ 1 bar (external), 60oC
Temperature
5) Minimum Metal design Temperature MDMT = -35oC
6) Vessel dimension ( Inside Diameter 4200 mm (diameter) x 18,000 mm (L)
(ID) x Length tangent to tangent (L))
7) Design Liquid Level / content specific 3800 mm from bottom / 1
gravity
8) MAWP / MAP(N &C) ( ) N/mm 2
9) Hydrotest pressure (shop/filed) UG99(c), Shop ( )N/mm 2
10) Heat treatment ( Applicable/ Not Applicable0
11) Joint Efficiency Dome end : meridoinal seam (Full RT)
circumferential seam ( spot RT)
Cylindrical shell : meridoinal seam (spot RT)
circumferential seam ( spot RT)
11) Corrosion Allowance 0
12) Material
- Cylindrical shell SA 240 SS304
- Dome end SA 240 SS304
- Nozzle SA 312 TP304

36
 - Nozzle flange SA 182 F304
- Bolting SA320 B8 with SA-194 B
- Saddle SA283 GRC
13) Weights Fabrication : ( ) tones
Empty: ( ) tones
Operating: ( ) tones
Test: ( ) tones
14) Wind load Wind Design Code: ASCE-93
Wind for Hydrotest: 33%
Design Wind Speed: 120 km/hr
Base Elevation : 3 meters from sea level
Important factor: 1, Roughness factor: 1
15) Seismic load Seismic Design Code: ASCE-93
Seismic for Hydrotest: 0%
Seismic Coefficient Av: 0.2
Seismic Coefficient Cc: 2
Performance Factor: 1
Tutorial (2) : Horizontal pressure vessel

Nozzle Detail
37 No Nozzle Dia x Sch X L Pound rating PVElitedistance
Orientation Trainingfrom
– Basic
Description (#) left SF
1. Inlet ( N1) 20” x sch 10 x ANSI, WNRF , 0O 4500 mm
200L 150#
3. Drain pipe (N2) 3” x sch 10 x ANSI, CL Boot dish head
250L WNRF,150#
4. Boot (B1) 30” x 12thk x ANSI, 0o 12,000 mm
3000L WNRF 150#

N
1

18,000 mm

3600 mm 4,200 mm

500 mm
B User estimated
1 the size,
12,000 mm thickness of the
saddle and its

SF=50mm, min thk (

37
2:1 Semielliptical Head,
) mm,
components.
The distance
Nominal thk ( )mm.
from saddle
centre line to
nearest head.
 N
2

(Indicate the shell thickness of the shell section)

Nozzle Loading (WRC 107)

Dead Weight

No Nozzle Description P (N) VL (N) Vc (N) Mt(N/m) ML(N/m) Mc(N/m)

1. Inlet ( N1) 800 1200 1200 120 150 150
3. Drain pipe (N2) 300 500 500 50 60 60
4. Boot (B1) NA NA NA NA NA NA
Thermal

No Nozzle Description P (N) VL (N) Vc (N) Mt(N/m) ML(N/m) Mc(N/m)

1. Inlet ( N1) 1,800 2,400 2,400 2,600 3,000 3,000
3. Drain pipe (N2) 750 1,000 1,000 1,115 1,300 1,300
4. Boot (B1) NA NA NA NA NA NA

Topic (3): Design of high wall thickness pressure vessel (t > 100 mm)

38 Sub-topic: PVElite Training – Basic

Dish head selection for high pressure operation.
Code case – 2260 “Alternative design rules for Ellipsoidal and Torispherical formed heads.
Saddle type nozzle/ insert plate for nozzle opening reinforcement, Support lugs design.

LOC: After completion of this topic, student will be able to

Input all the design parameters to the correct input cursor.
Run the analysis and correct the design error by adjusting the design parameter accordingly.
Obtaining a cost optimize design for pressure vessel components due to high pressure operation.

Contents
1.0 Design of high wall thickness pressure vessel (t > 100 mm) ( Division 1 , 2 and PD5500)
3.1 Dish head selection for high pressure operation - semi
ellipse, torispherical, hemispherical formed head.

3.2 Nozzle design for thick wall pressure vessel.

3.2.1 Self- reinforcement nozzle design.

38
 3.2.2 Saddle nozzle or insert plate design.

3.3 Change the previous design of ASME Div 1 to ASME Div

2 and PD 5500. Material nominal strength/ allowable
stress calculation - PD 5500 Annex K. ASME Section
VIII Div 1 and Div 2.

3.4 Support lugs design and local stress calculation

(WRC 107).

1) Vessel name / number Inlet Gas Separator

2) Design Code & Addenda ASME Section VIII Division 1, Addendum 2007
39 PVElite Training – Basic
3) Operating Pressure & Temperature 125 bar (internal), 120oC / NA(external)

4) Vessel Design Pressure & 138 bar (internal), 120oC/ NA (external)

Temperature
5) Minimum Metal design Temperature MDMT = -15oC
6) Vessel dimension ( Inside Diameter 2760 mm (diameter) x 7600 mm (L)
(ID) x Length tangent to tangent (L))
7) Design Liquid Level / content specific 2000 mm from bottom / 0.85
gravity
8) MAWP / MAP(N &C) TBA
9) Hydrotest pressure (shop/filed) TBA
10) Heat treatment As per ASME code
11) Joint Efficiency Dome end : meridoinal seam (Full RT)
circumferential seam (Full RT)
Cylindrical shell : meridoinal seam (Full RT)
circumferential seam ( Full RT)
11) Corrosion Allowance 0
12) Material
- Cylindrical shell SA 516 GR70N
- Dome end SA 516 GR 70N
- Nozzle SA 105
- Nozzle flange SA 105

39
 - Bolting SA 193
- Support Lugs SA283 GRC
13) Weights Fabrication : tones
Empty: tones
Operating: tones
Test: tones
14) Wind load Wind Design Code: ASCE-93
Wind for Hydrotest: 33%
Design Wind Speed: 120 km/hr
Base Elevation : 3 meters from sea level
Important factor: 1, Roughness factor: 1
15) Seismic load Seismic Design Code: ASCE-93
Seismic for Hydrotest: 0%
Seismic Coefficient Av: 0.15
Seismic Coefficient Cc: 2
Tutorial (3): Heavy wall pressure vessel Performance Factor: 1

40 PVElite Training – Basic

40