SRINIVASAN RAMAKRISHNAN

UNDERSTANDING ASME CODE CALCULATIONS- PRESSURE VESSELS 1

 SHELL CALCULATIONS

SRINIVASAN RAMAKRISHNAN

THIS IS NOT A COURSE ON DESIGN. WE WILL ONLY MAKE YOU TO UNDERSTAND SIMPLE
DESIGN CALCULATIONS AND IMPORTANCE OF THESE CALCULATIONS WITH REFERENCE TO
DRAWINGS.
WE WILL ILLUSTRATE THROUGH LIVE SAMPLES AND MAKE YOU TO DO CALCULATIONS USING
EXCEL SHEET.

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Categories of Joints
There are 4 Categories-A, B,C, and D
There are 6 types of joints
Type 1,2,and 3 are Butt welds
Type 4,5,and 6 are fillets. Our discussion is confined to butt welds
which we use

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Circumferential stress or Hoop stress in a cylinder

3

Or PR/t
Mostly this governs

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Longitudinal stress in a
cylinder
4

Or PR/2t

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Longitudinal stress (circumferential joints)
.
t = PR /(2SE+0.4P)

OR

P= 2SEt/R-0.4t)

When t < 0.5 R or P < 1.25SE

It means that this formula is not valid when t/R ratio

is >0.5
When thickness is 200 mm and radius is 300 t/R
=0.66. This formula is not valid
Let us take S as 1406 E as 1 the P = 1.25 x 1406 x1=
1757 Kg/cm2

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UG 27 c-1

WHEN THICKNESS DOES NOT EXCEED WHEN THICKNESS EXCEEDS ONE

ONE HALF OF INSIDE RADIUS HALF OF INSIDE RADIUS

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Paragraph UG-27: Thickness of shells under internal pressure
The formulae in this section are used to determine the minimum required
thickness of shells when the maximum allowable working pressure is known.
These formulae can be transposed to determine the maximum allowable
working pressure if the minimum required thickness is given.
The symbols used in the formulae are found in paragraph UG-27 (b) and are
defined as follows:
t = minimum required thickness (mm)
P = internal design pressure (MPa) (see UG-21. refers to gauge pressure)
R = inside radius of shell course under consideration (mm)
S = maximum allowable stress value (see UG-23 and the stress limitations
specified in UG-24)
E = joint efficiency for, or the efficiency of, appropriate joint in cylindrical or
spherical shells, or the efficiency of ligaments between openings, whichever is
less (use UW-12 for welded vessels. Use UW- 53 for ligaments between
openings)

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APPENDIX 1-1
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DESIGN DATA REQUIRED

P- DESIGN PRESSURE
R0-OUTSIDE RADIUS OF THE SHELL
S-ALLOWABLE STRESS
E- JOINT EFFICIENCY

CAN YOU RECAST THIS TO FIND OUT S?(SEE WORK SHEET)

THIS WILL BE USED LATER IN STRESS CACLULATIONS DUE TO HYDROTEST

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CONFIGURATION (TYPE)
SERVICE ( LETHAL OR NON LETHAL)
VERTICAL VESSEL
NON – LETHAL (AIR)
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DESIGN AND MANUFACTURING CODE ASME SECTION VIII DIV 1, EDITION 2013
PROCESS DETAILS
INTERNAL DESIGN PRESSURE (INCLUDING STATIC HEAD) 1.2 MPa g
EXTERNAL DESIGN PRESSURE NA MPa g
MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP) 1.2 MPa g
DESIGN TEMPERATURE (MAX) 60 Deg C
DESIGN TEMPERATURE (MIN) 60 Deg C
MINIMUM DESIGN METAL TEMPERATUE (MDMT) 5 Deg C
CORROSION ALLOWANCE 1.6 mm
RADIOGRAPHY RT‐3 AS PER UG‐116 (e)(3)
JOINT EFFICIENCY FOR SHELL (LONG/CIRC) 0.85/ 0.85
JOINT EFFICIENCY FORDISHED END (LONG/CIRC) NA/0.85
LONG SEAM – SPOT AS PER CIRC SEAM ‐ SPOT AS PER
EXTENT OF NDE (FOR COMPLETE VESSEL)
UW‐11(b) UW‐11 (b)
OPERATING PRESSURE (AT TOP) 1.09 MPa g
OPERATING TEMPERATURE (MAX) 50 Deg C
OPERATING TEMPERATURE (MIN) 5 Deg C
PROCESS FLUID AIR
PROCESS FLUID DENSITY (MAX) 1.0 kg/m3
HIGHEST LIQUID LEVEL FROM VESSEL BOTTOM 3000 mm

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HYDROSTATIC TEST PRESSURE(AT TOP) HORIZONTAL
1.56 MPa g
POSITION
HYDROTEST TEMPERATURE (MIN / MAX) 20 / 48 Deg C
PNEUMATIC TEST PRESSURE N.A.
POST WELD HEAT TREATMENT (PWHT) EXEMPTED (AS PER UCS‐56)
IMPACT TEST EXEMPTED (AS PER UG – 20(f), & UCS – 66 (a) & (c) & FIG: UCS ‐ 66)
POST FORMING HEAT TREATMENT EXEMPTED (AS PER UCS – 79 (d) )
RATING OF FLANGES 150#
ASME CODE STAMP MARK WITH ‘U’ DESIGNATION SYMBOL YES
NATIONAL BOARD REGISTRATION YES
OVER PRESSURE PROTECTION IN THE SCOPE OF CLIENT (PROVISION PROVIDED FOR SET UP)

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SR NO APPLICABLE LOADING AS PER UG 22

DESCRIPTION APPLICABLE REMARKS
CLAUSE /NOT

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APPLICABLE
INTERNAL DESIGN PRESSURE APPLICABLE ‐
1 UG – 22(a) NOT
EXTERNAL DESIGN PRESSURE ‐
APPLICABLE
WEIGHT OF THE VESSEL AND NORMAL CONTENTS
UNDER OPERATING OR TEST CONDITIONS (THIS APPLICABLE
2 UG – 22(b) INCLUDES ADDITIONAL PRESSURE DUE TO STATIC
‐
HEAD OF LIQUIDS).
SUPERMIPOSED STATIC REACTIONS FROM WEIGHT NOT
OF ATTACHED EQUIPMENT, SUCH AS MOTORS,
APPLICABLE
3 UG – 22(c) MACHINERY, OTHER VESSELS, PIPING, LININGS,
AND INSULATION. ‐
THE ATTACHMENT OF: ‐
NOT
INTERNALS ‐
APPLICABLE
4 UG – 22(d)
VESSEL SUPPORTS, SUCH AS LUGS, RINGS, SKIRTS,
APPLICABLE LEG SUPPORT
SADDLES, AND LEGS
CYCLIC AND DYNAMIC REACTIONS DUE TO
PRESSURE OR THERMAL VARIATIONS, OR FROM
5 NOT
UG – 22(e) EQUIPMENT MOUNTED ON A VESSEL, AND ‐
APPLICABLE
MECHANICAL LOADINGS
NOT
WIND REACTIONS. ‐
APPLICABLE
NOT
6 SEISMIC REACTIONS. ‐
UG – 22(f) APPLICABLE
NOT
SNOW REACTIONS. ‐
APPLICABLE
IMPACT REACTIONS SUCH AS THOSE DUE TO NOT
7 UG – 22(g) ‐
FLUID SHOCK. APPLICABLE
TEMPERATURE GRADIENTS AND DIFFERENTIAL NOT
8 UG – 22(h)
THERMAL EXPANSION. APPLICABLE ‐
ABNORMAL PRESSURES, SUCH AS THOSE CAUSED NOT
9 UG – 22(i)
BY DEFLAGRATION. APPLICABLE ‐
TEST PRESSURE AND COINCIDENT STATIC HEAD
10 UG – 22(j) APPLICABLE ‐

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M SR. NO.: AIR RECEIVER SHEET NO. : 9 of 35

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EVALUATION OF MATERIALS REV NO. :1

Design Allow Allow Max.

Page No/ Allow Stress
P.No / Temp Stress at Stress Temp. Specified
Sr. Table Line No in @ Test (20° Applicability
Component Material Spec Group Design @ (0°) Limits Cautionary
No No ASME Sec C) temp of Notes
Type No No temp Notes
II ‐ D (MPa)
°C (MPa) (MPa) °C

1. SHELL SA 516 GR 70 1A 1/2 22/06 60.00 138.00 138.00 138.00 538 G10, S1, T2 None

DISHED
2. SA 516 GR 70 1A 1/2 22/06 60.00 138.00 138.00 138.00 538 G10, S1, T2 None
END

NOZZLE 60.00
PIPE
3. SA 106 GR B 1A 1/1 14/19 118.00 118.00 118.00 538 G10, S1, T1 None
(DN 250 &
BELOW)
NOZZLE
4. PIPE(ABOVE SA 516 GR 70 1A 1/2 22/06 60.00 138.00 138.00 138.00 538 G10, S1, T2 None
DN 250)
60.00
NOZZLE
5. SA 105 1A 1/2 18/32 138.00 138.00 138.00 538 G10, S1, T2 None
FLANGES

SA 193 GR B7/ 60.00

STUD /
6. SA 194 GR 2H 3 ‐‐ 352/27 130 130 130 538 ‐‐ None
BOLTS
(t=<64)

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AIR RECEIVER
EVALUATION OF IMPACT TEST
REQUIREMENTS USING UCS‐66 (a) & (c)
FIG UCS‐66
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UG‐20(f) : IMPACT TESTING AS PER UG‐84 IS NOT MANDATORY FOR PRESSURE VESSEL
MATERIALS THAT SATISFY ALL OF THE FOLLOWING:

CONDITION SATISFIED
SR.NO CONDITION (APPLICABLE/NOT

APPLICABLE)

THE MATERIAL SHALL BE LIMITED TO P‐No.1 Gr No 1 OR 2.AND THE

THICKNESS,.AS DEFINED IN UCS‐66(a),SHALL NOT EXCEED THAT GIVEN IN (a)

1 OR (b) BELOW :

(a) 13mm FOR MATERIALS LISTED IN CURVE"A”OF FIG.UCS‐66 APPLICABLE

(b) 25mmFOR MATERIALS LISTED IN CURVE "B”, "C”,OR" D” OF FIG.UCS‐66 APPLICABLE

THE COMPLETED VESSEL SHALL BE HYDROSTATICALLY TESTED AS PER

2 APPLICABLE
UG‐99(b) OR (c ) OR 27 ‐ 4

DESIGN TEMPERATURE IS NO WARMER THAN 345 Deg C NOR COLDER THAN 29

3 DegC. OCCASIONAL OPERATING TEMPERATURE COLDER THAN ‐29 Deg C ARE APPLICABLE

ACCEPTABLE WHEN DUE TO LOWER SEASONAL ATMOSPHERIC TEMPERATURE.

THE THERMAL OR MECHANICAL SHOCK LOADINGS ARE NOT A CONTROLLING

4 APPLICABLE
DESIGN REQUIREMENT.(UG‐22)

5 CYCLICAL LOADING IS NOT A CONTROLLING DESIGN REQUIREMENT.(UG‐22). APPLICABLE

FROM THE ABOVE WE CONCLUDE THAT IMPACT TEST IS EXEMPTED AS PER UCS‐66 (a) & (c), FIG. UCS‐66

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AIR RECEIVER
PWHT REQUIREMENTS –UW‐2, UCS‐56,UCS‐68

POST WELD HEAT TREATMENT IS REQUIRED WHEN ANY OF FOLLOWING CONDITION EXIT:
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APPLICABLE APPLICABLE
SR.No. DESCRIPTION REMARKS
CLAUSE YES / NO

1. UW‐2(a) LETHAL SERVICE NO ‐

UNFIRED STEAM BOILER WITH DESIGN

2. UW‐2(c) NO ‐
PRESSURE EXCEEDING 345 Kpa

IF MDMT IS COLDER THAN ‐48 Deg C

3. UCS‐68 (b) AND THE COINCIDENT RATIO DEFINED NO ‐

IN FIG. UCS‐66.1 IS 0.35 OR GREATER

MATERIAL OVER 32 mm NOMINAL

4. UCS‐56 NO SEE TABLE BELOW
THICKNESS AS DEFINED IN UW‐40 (f)

APPLICABLE THICKNESS MAX. EXEM. THK

DESCRIPTION MATERIAL P NUMBER
CLAUSE mm mm

SHELL SA 516 GR 70 UCS ‐56 1 8 38

DISHED END SA 516 GR 70 UCS ‐56 1 10 38

FORGINGS
(STANDARD
SA 105 UCS ‐56 1 12 38
FLANGES )

PIPES SA 106 GR B UCS ‐56 1 12 38

HENCE, PWHT IS NOT REQUIERED.

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AIR RECEIVER
EVALAUATION OF DESIGN PRSSURE

P’ : INTERNAL DESIGN PRESSURE (AT TOP) (GIVEN BY CLIENT) : 1.2 MPa g

Di : INTERNAL DIAMETER OF SHELL : 600 mm
Ls : T.L TO T.L LENGTH : 2060 mm
ρ : DENSITY OF FLUID : 1.0 kg/m3
TYPE OF DISH END : ELLIPSOIDAL (2:1)
L : INSIDE CROWN RADIUS : 540 mm
r : INSIDEKNUCKLE RADIUS : 102 mm
R : INSIDE HEAD RADIUS : 300 mm
T : DISH END THICKNESS (MINIMUM) : 10
mm S.F : STRAIGHT FACE
LENGTH : 30 mm HLL :
HEIGHEST FLUID LEVEL FROM BOTTOM (GIVEN BY CLIENT) : 2590
mm

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WATER HEAD CALCULATON:

DISH END HEIGHT CALCULATIONS

HEAD HEIGHT = L‐sqrt( (L‐r)^2 ‐(R‐r)^2)+ DISH END THICKNESS + STRAIGHT FACE LENGTH 17
= 540 ‐ sqrt( (540 ‐102 ) ^2 ‐ (300 ‐ 102 ) ^2 ) + 10 + 30
= 189.3083 mm ≈ 189 mm
DESIGN PRESSURE, (MPa g) = 1.2
VESSEL HT. (mm) = TOTAL LENGTH WITH OUT END DISH + 2 x DISH END HT.
= 2000 + 2 * 189
= 2378 mm
STATIC HEAD HEIGHT, H (mm)= VESSEL HT. + BOTTOM DRAIN PROJ.(N5) + TOP PRESSURE
RELIEF VALVE (N3)
= 2378 +60 + 160
= 2598 mm
MAXIMUM POSSIBLE STATIC HEAD, H (mm) =2600mm
(MAX. DISTANCE BETWEEN TOPMOST AND BOTTOM MOST PRESSURE PARTS.)

DESIGN PRESSURE OF AIR RECEIVER

Ph = MAX. POSSIBLE STATIC HEAD (H) x DENSITY OF FLUID (ρ)x9.8067X1E‐6 (MPa g)
= 2600 X 1.0 X 9.8067X1E‐6
Ph = 0.025497MPa g
P= P’+Ph(MPa)
= 1.09+ 0.025497
P = 1.115497MPa g ≈ 1.12MPag (11.42 kg / cm² g)
WHERE,

H : HEIGHT OF FLUID TO BE CONSIDERED FOR STATIC HEAD. Ph

: PRESSURE DUE TO STATIC HEAD OF FLUID.

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AIR RECEIVER SHEET NO. :

HYDROSTATIC TEST PRESSURE –UG‐99(b) REV NO. :
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SHOP TEST PRESSURE DETERMINATION FOR VESSEL BASED ON DESIGN PRESSURE AT TOP OF VESSEL (P) AND DESIGN
TEMPERATURE (T) AS PER CLAUSE NO. UG‐99(b).

P : DESIGN PRESSURE (BOTTOM OF VESSEL) = 1.2 MPa g

MAWP : MAXIMUM ALLOWABLE WORKING PRESSURE = 1.2 MPa g (AS PER UG‐99, FOOT NOTE – 34) Tc : DESIGN
TEMPERATURE = 60 Deg C

SR. NO. COMPONENT TYPE DESIGN PRESSURE P(MPa g) STRESS @ TEST TEMP. Sa (MPa)STRESS @ DESIGN TEMP. S (MPa)
STRESS RATIOSa / S
1 SHELL 1.2 138.00 138.00 1.00
2 DISH END 1.2 138.00 138.00 1.00
3 NOZZLE PIPE 1.2 118.00 118.00 1.00
4 NOZZLE FLANGE 1.2 138.00 138.00 1.00

STRESS RATIO = Sa / S = 118/118 = 1.00 (TAKEN LEAST STRESS RATIO OF SR.NO. 1 to 4)

HYDROSTATIC TEST PRESSURE = 1.3 x P x Sa / S = 1.3 x 1.2 x 1 = 1.56MPa g (15.9073kg / cm² g)

AS PER THE CLIENT REQUIREMENT HYDRO TEST PRESSURE IS TAKEN 1.3 TIMES OF DESIGN PRESSURE.
SO, HYDRO TEST PRESSURE = 1.3 x 1.2
= 1.56MPa g (15.9073kg / cm² g)

1.3 Sb< 90% of Syb YES

AS PER UG‐99, FOOT NOTE – 34 THE MAXIMUM ALLOWABLE WORKING PRESSURE MAY BE ASSUMED TO BE THE SAME
AS THE DESIGN PRESSURE WHEN CALCULATIONS ARE NOT MADE TO DETERMINE THE MAXIMUM ALLOWABLE
WORKING PRESSURE. HENCE, HERE IN THIS CASE DESIGN PRESSURE AND MAWP TAKEN SAME
SRINIVASAN RAMAKRISHNAN

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AIR RECEIVER :
OVER PRESSURE PROTECTION –UG – 125 :
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AS PER UG‐125(a)

(a) OTHER THAN UNFIRED STEAM BOILERS [SEE UG ‐125(b)], ALL PRESSURE VESSELS WITHIN THE SCOPE OF THIS DIVISION,
IRRESPECTIVE OF SIZE OR PRESSURE, SHALL BE PROVIDED WITH OVER PRESSURE PROTECTION IN ACCORDANCE WITH THE
REQUIREMENT Of UG‐125 THROUGH UG‐138 AND/OR OVERPRESSURE PROTECTION BY SYSTEM DESIGN PER UG‐140. IN
ADDITION, THE FOLLOWING SHALL APPLY:
(1) IT IS THE USER’S OR HIS/HER DESIGNATED AGENT’S RESPONSIBILITY TO IDENTIFY ALL POTENTIAL OVERPRESSURE
SCENARIOS AND THE METHOD OF OVERPRESSURE PROTECTION USED TO MITIGATE EACH SCENARIO.
(2) IT IS THE RESPONSIBILITY OF THE USER TO ENSURE THAT THE REQUIRED OVERPRESSURE PROTECTION SYSTEM IS PROPERLY
INSTALLED PRIOR TO INITIAL OPERATION.
(3) IF A PRESSURE RELIEF DEVICE(S) IS TO BE INSTALLED, IT IS THE RESPONSIBILITY OF THE USER OR HIS /HER DESIGNATED
AGENT TO SIZE AND SELECT THE PRESSURE RELIEF DEVICE(S) BASED ON ITS INTENDED SERVICE. INTENDED SERVICE
CONSIDERATION SHALL INCLUDE, BUT NOT NECESSARILY BE LIMITED TO, THE FOLLOWING:
(a) NORMAL OPERATING AND UPSET CONDITIONS. (b) FLUIDS
(c) FLUIDS PHASES
(4) THE OVERPRESSURE PROTECTION SYSTEM NEED NOT BE SUPPLIED BY THE VESSEL MANUFACTURER.
(5) UNLESS OTHERWISE DEFINED IN THIS DIVISION, THE DEFINITION RELATING TO PRESSURE RELIEF DEVICE IN SECTION 2 OF
ASME PTC 25 SHALL APPLY.

AS PER ABOVE THE OVERPRESSURE PROTECTION SYSTEM IS NOT IN THE SCOPE OF THE VESSEL
MANUFACTURER. (NOT REQUIRED FORTHIS VESSEL)

“N3 (DN 50)” AIR VENT OPENING MAY ALSO BE USED AS PROVISION FOR OVER PRESSURE PROTECTION (PRESSURE
RELIEF DEVICE).

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AIR RECEIVER
RADIOGRAPHY & JOINT EFFICIENCY

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UW‐11(a)(1) IS THE VESSEL OR VESSEL SECTIONS USED TO CONTAIN LETHAL SUBSTANCES
NO HENCE NOT APPLICABLE

UW‐11(a)(2) ARE THERE BUTT WELDS IN VESSEL SECTIONS WHERE THE LEAST NOMINAL THICKNESS
EXCEEDS 32 MM (UCS 57)
NO. HENCE NOT APPLICABLE

UW‐11(a)(3) IS THE VESSEL OR VESSEL SECTION AN UNFIRED STEAM BOILER

WITH DEIGN PRESSURE GREATER THAN 0.35 Mpa (50 psi)
NO. HENCE NOT APPLICABLE

UW‐11(a)(5)(a) ARE CATEGORY A & B BUTT WELD JOINT IN VESSEL SECTIONS &
HEADS DESIGNED BASED ON JOINT EFFICIENCY AS PER UW 12 (a) AND ARE OF TYPE NO (1) OR (2)
AS PER TABLE UW ‐12
NO. HENCE NOT APPLICABLE

UW‐11(a)(6) ARE THERE BUTT WELDS JOINED BY ELECTRO SLAG / ELECTRO GAS
WELDING WITH ANY SINGLE PASS GREATER THAN 38 mm
NO HENCE NOT APPLICABLE

FULL RADIOGRAPHY AS PER UW‐11(a) NOT APPLICABLE AS NONE OF PARAMETER MEETS CODE
REQUIREMENT.

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UW‐11(b):
(a) CATEGORY “A” JOINTS SHALL BE RADIOGRAPHED FOR SPOT, AS E=0.85 TAKEN FROM COLUMN (b)
OF TABLE UW‐12

UW‐12: JOINT EFFICIENCY

JOINT JOINT JOINT

SR. NO. DESCRIPTION RT REQ.
CATEGORY TYPE EFFICIENCY

1 A 1 SHELL LONGITUDIANL SEAM SPOT (UW‐11(b)) 0.85

2 B 1 SHELL CIRCUMFERENTIAL SEAM SPOT (UW‐11(b)) 0.85

3 B 2 SHELLTO DISHED END C/S JOINT SPOT (UW‐11(b)) 0.85

4 D 7 NOZZLE NECK TO SHELL JOINT N.A N.A

NOZZLE FLANGES TO NOZZLE NECK
5 C 3 N.A N.A
JOINT (SORF)
NOZZLE NECK LONGITUDINAL
6 A 1 SPOT (UW‐11(b)) 0.85
SEAM

RADIOGRAPHY MARKING:
VESSEL MARKING = RT3 AS PER UG‐116(e)(3)

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AIR RECEIVER
SHELL THICKNESS DUE TO INTERNAL
PRESSURE AS PER UG‐27

SUB CLAUSE PART NUMBER IN DRAWING : 1

UG‐27(b) INTERNAL DESIGN PRESSURE P MPa 1.2
MATERIAL DESIGNATION SA 516 GR 70
UG‐27(b) MAXIMUM ALLOWABLE STRESS (AS PERASME SEC.II PART.D) S MPa
138.00
SHELL INSIDE DIAMETER ( UN CORRODED) mm 600.00
UG‐27(b) INSIDE RADIUS = SHELL ID / 2 = 600.00 / 2 Ruc mm 300.00
UG‐25(b) CORROSION ALLOWANCE CA mm 1.60
INSIDE RADIUS ( CORRODED) = Ruc + CA = 300.000 + 1.60 R mm 301.60
PROVIDED THICKNESS NOMINAL mm 8.00

CIRCUMFERENTIAL STRESS ( LONGITUDINAL JOINTS) [Ref. UG 27 ( c ) ( 1 )]

UW‐12 LONGITUDINAL JOINT TYPE TYPE 1
UW‐12 JOINT EFFICIENCY E ‐ 0.85
FACTOR : 0.385SE = 0.385*138.00*0.85 MPa 41.9934

UG‐27(c)(1) SINCE P<= 0.385SE, UG 27 ( c ) ( 1 ) IS APPLICABLE

MINIMUM REQUIRED THICKNESS
t = P * R / ( S*E ‐ 0.6 * P)
= 1.2*301.60 / (138.00*0.85‐ 0.6*1.2)

t.= 3.1044776MM

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LONGITUDINAL STRESS ( CIRCUMFERENTIAL JOINTS ) [Ref. UG 27 ( c ) ( 2 )] 23

UW‐12 CIRCUMFERENTIAL JOINT TYPE TYPE 1
UW‐12 JOINT EFFICIENCY E ‐ 0.85
FACTOR : 1.25SE = 1.25*138.00*0.85 MPa 146.625
SINCE P<=1.25SE ,UG 27 ( c ) ( 2 ) IS APPLICABLE
MINIMUM REQUIRED THICKNESS
UG‐27(c)(2) t = P * R / (2* S*E + 0.4 * P) t mm 1.539561
= 1.2*301.60/ (2*138.00*0.85+ 0.4* 1.2)

MINIMUM REQUIRED THICKNESS SHALL BE > 2.5 mm ( 3/32 in.) EXCLUDING

UG‐16(b)(4) mm 2.500
CORROSION ALLOWANCE.

MINIMUM THICKNESS REQUIRE AS PER UG‐16(b)(4) + CORROSION

t mm 4.10
ALLOWANCE = 2.50+1.60
GOVERNING THICKNESS GREATER OF UG‐27(c)(1), UG‐27(c)(2) AND
UG‐16(b)(4) t mm 3.1045
= GREATER OF (3.1045, 1.5396, 2.50) =3.1045 mm
GOVERNING THICKNESS + CORROSION ALLOWANCE
t mm 4.7045
= 3.1045 + 1.60
CONCLUSION : REQUIRED THICKNESS = 4.7045 mm < 8.000 mm (PROVIDED) THICKNESS IS OK
NOTE : 1.) REQUIRED THICKNESS = 4.7045 mm
2.) PROVIDE THICKNESS =8.000 mm.
3.) THE PERMISSIBLE UNDER TOLERANCE FOR THE PLATE AS PER UG‐16 ( C ) IS 0.01 Inch ( 0.25mm )
REQUIRED THICKNESS OF SHELL FOR REINFORCEMENT CALCULATIONS AS PER UG‐37(a)

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SAMPLE CALCULATION AS PER APPENDIX 1-4

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DESIGN DATA FOR AIR RECEIVER
Design Internal Pressure -7.7 KG/cm2
Design Internal Temperature 55 °C
Type of Hydrotest Water filled
Hydrotest Position Vertical
Element Outside Diameter 900.00 mm
Shell Thickness 8.0000 mm
Internal Corrosion Allowance 1.5000 mm
Nominal Thickness 8.0000 mm E
External Corrosion Allowance 0.0000 mm
Material Name SA-516 70
Efficiency, Longitudinal Seam 0.85
Efficiency, Circumferential Seam 0.85
Corrosion Allowance 1.5mm
Hydro static test pressure- 1.3 x 7.7 KG=10.01 Kg.cm2

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SHELL THICKNESS CALCULATIONS

Required Thickness due to Internal Pressure

[tr]:
= (P*Ro) / (S*E+0.4*P) per Appendix 1-1 (a)(1)
= (7.700*450.0000)/(1406.14*0.85+0.4*7.700) =
2.8916 + 1.5000 = 4.3916 mm
Max. Allowable Working Pressure at given
Thickness, corroded [MAWP]: =
(S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1)
= (1406.14*0.85*6.5000)/(450.0000-
0.4*6.5000) = 17.365 kgf/cm²
Here given thickness is 8 mm and c = 1.5 mm

WHAT IS 1.5 MM HERE

HOW 6.5 MM IS ARRIVED?

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Maximum Allowable Pressure, New and Cold
[MAPNC]:
= (S*E*t)/(Ro-0.4*t) per Appendix 1-1 (a)(1) =
(1406.14*0.85*8.0000)/(450.0000-0.4*8.0000) =
21.401 kgf/cm²
Actual stress at given pressure and thickness,
corroded [Sact]: = (P*(Ro-0.4*t))/(E*t)
= (7.700*((450.0000-0.4*6.5000))/(0.85*6.5000) =
623.526 kgf/cm²

IS THIS ACCEPTABLE? Yes because it is less than

Allowable stress of 1406

SINCE WE ARE SELECTING A THICKNESS OF 8 MM COMPARED TO REQUIRED THICKNESS O

4.39MM, THE ACTUAL STRESS AT GIVEN PRESSURE WILL BE PROPORTIONALTELY LESS.

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c. 27
NORMALLY IT IS NOT A REQUIREMENT TO
SHOW THIS CALCULATION AS LONG IT IS AS
PER UW99b. HOWEVER THERE MAY BE USER
DEFINED TEST PRESSURE WHICH MAY BE
HIGHER THAN 1.33 TIMES DESIGN PRESSURE .
IN SUCH CASE CALCULTION IS REQUIRED TO
SHOW THAT THE STRESS DUE TO HYDRO TEST IS
WITHIN 90% OF YIELD.

For Hydrostatic Test Pressure

Stress due to Hydrostatic Test Pressure (Past*(R+0.6*t)/(E*t)
Pst= 10.01
R= 450
t= 8 mm
E= 0.85
Calculate stress at Hydrotest.
10.01(450+0.6 x8) /(0.85 x 8)
4552.548/6.8=669.49. This is less than 90% of YS
Case example Riser pipes
When I was inspecting a A 106 Material for Riser pipe, I noticed a special case. The
purchaser included a special condition that the pipes should be hydrotested at 180 bar. This
pipe was offered to me at a ware house and the trader was not aware of this special
condition. At Pipe Mills Pipe was tested to 100 bar so. Trader was shocked. I told him I will
not accept these pipes.
It went back to client and client design engineers told the trader that it requires this high
pressure in design and he has to supply the pipe as per PO.
Finally the trader engaged a contractor and did the hydro test of each pipe and spent lot of
money in that process.
Yes. Some cases, it is user defined Hydro test pressure. It may be higher than the Code
defined Hydro test pressure. Following is an example

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HYDROTEST PRESSURE
CALCULATIONS
WHY HYDRO TEST PRESSURE CALCULATIONS ARE
IMPORTANT?

HYDRO TESTS ARE PERFORMED AT 1,3 TO 1,5

TIMES DESIGN PRESSUE. HENCE IT IS NECESSARY
TO CALCULATE THE STRESSES DUE TO HYDRO TEST
AND ENSURE THAT THEY ARE WITHIN 90% OF
YIELD STRESS. REFER UG 99

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PLEASE NOTE THAT HYDROTEST PRESSURE OF A NEW VESSEL IS 1.3 TIMES MAWP OF SOME
CASES 1.45 TIMES MAWP- (PED)
WHEN USER DEFINED TEST PRESSURES ARE USED, WE NEED TO CALCULATE AND ENSURE THAT
IT IS WITHIN 90% OF THE YIELD
ANOTHER ISSUE IS EFFECT OF TEST TEMPERATURE
CODES ALWAYS SPECIFY TESTING TO DONE AT AMBIENT TEMPERATURE
WHY?

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UG 99b- PRESSURE TEST

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Design Internal Pressure (for Hydrotest) 220.00 bars

Design Internal Temperature 200 °C
Type of Hydrotest Hydrostatic
Hydrotest Position Vertical
Material Name SA-516 70
Allowable Stress, Ambient 174.40 N./mm^2
Allowable Stress, Operating 149.50 N./mm^2
STRESS RATIO- 174,4/149.5 = 1.167
Hydrostatic Test Pressure Results:
Test Pressure at high point in vessel per Equation 8.1 = 1.43 * MAWP
= 1.43 * 220.0000 = 314.600 bars
Test Pressure at high point in vessel per Equation 8.2 = 1.25 * MAWP * ST/S
= 1.25 * 220.0000 * 1.167 = 320.803 bars
HENCE TEST PRESSURE IS 320.803 BARS
NOW THE STRESS DUE TO THIS PRESSURE IS TO BE CALCULATED FOR THE ACTUAL
THICKENSS OF THE VESSEL ;

THE ABOVE EXAMPLE IS FOR AUTO CLAVE DESIGNED TO DIVISION 2.

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WHAT IS STRESS RATIO? WHY IT IS
SPECIFIED?
DESIGN PRESSURE CALCULATIONS ARE AT
DESIGN TEMPERATURES. FOR EXAMPLE 200
DEG.C
HYDRO TEST IS PERFORMED AT ROOM
TEMPERATURE.
HENCE THE ALLOWABLE STRESS AT DESIGN
TEMPERATURE AND AT ROOM TEMPERATURE
MAY BE DIFFERENT.
HENCE THE RATIO OF STRESS AT DESIGN
TEMPERATURE/STRESS AT TEST TEMPERATURE
Test Pressure at high point in vessel =
1.25 * MAWP * ST/S(ALLOWABLE STRESS AT ROOM
TEMPERATURE/ALLOWABLE STRESS AT DESIGN
TEMPERTURE)
= 1.25 * 220.0000 * 1.167 = 320.803 bars
WE NEED TO CALCULATE THAT THE STRESS DUE TO THIS
HYDROSTATIC TEST PRESSURE IS WITHIN 90% OF YS AT
ROOM TEMPERATURE.

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STRESS DUE TO HYDRO

TEST IN SHELL MATERIAL:
EXAMPLE AIR RECEIVER
MAXIMUM PRESSURE DURING HYDRO TEST (VESSEL SIDE) =
1.56 MPa g THICKNESS OF SHELL: 8 mm
INSIDE RADIUS OF SHELL: 301.6 mm
S x E = ((P x R) / t ) + (0.6 x P) =
((1.56 x 301.6) / 8) + (0.6 x 1.56)
S x 0.85 = 59.748 MPa = 59.748/ 0.85 = 70.29 MPa
ALLOWABLE YIELD STRENGTH OF THE MATERIAL AT ITS HYDR
O TEST TEMPERATURE (20 Deg C): 260 MPa FROM ABOVE T
HE ALLOWABLE
YIELD STRENGTH OF SHELL MATERIAL IS GREATER THAN AC
TUAL,
SO SHELL DESIGN UNDER HYDRO TEST CONDITION IS ACCE
PTABLE.

ABOVE EXAMPLE IS A SAMPLE CALCULATION OF STRESS DUE TO HYDRO TEST PRESSURE

THE FORMULA IS SAME AS SHELL THICKNESS CALCULATION USED. BUT HERE IT IS SOLVED FOR
S VALUE.
YOU NEED TO TAKE ACTUAL THICKNESS AND IMPORTANTLY TAKE VALUE OF E. HERE VALUE OF
E IS 0.85.
THIS IS ACTUALLY BACK CALCULATING THE STRESS DUE TO HYDRO STATATIC PRESSURE AND
FINDING THE STRESS VALUE. THIS SHOULD BE BELOW 90% OF THE YIELD STRESS AT ROOM
TEMPERATURE..

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Design Internal Pressure (for test) 199.00 psig
Design Internal Temperature 392 °F
Type of Test UG-99(b
Test Position Vertical
User Defined Test Press. (Used if > 0) 298.50 psig
User defined MAWP 199.00 psig
It is 1.497 x MAWP WHICH IS MORE THAN THE TEST
PRESSURE AS DEFINED IN UG 99.
In such case you need to calculate the stress due to this
higher pressure and record. It should be less than 90% of
yield stress of the material .

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REVIEW
• SHELL CALCULATIONS ARE PERFORMED TO VALIDATE THE DESIGN PARAMETERS
LIKE DEISGN THICKNESS AGAINST THE DESIGN PRESSURE SPECIFIED IN DESIGN
DATA
• FORMULAE USED ARE AS PER UG 27 C AND AS PER APPENDIX 1-1
• REQUIRED THICKNESS IS CALCULATED THICKNESS PLUS CA
• MAWP COLD AND CORRODED IS THE PRESSURE CALCULATED BASED ON
GIVEN THICKNESS MINUS CA
• MAWP NEW AND COLD IS THE PRESSURE CALCULATED BASED ON GIVEN
THICKNESS.
• HYDRO TEST PRESSURE IS 1.3 TIMES MAWP * ST/S UW99b
• USER DEFINED HYDRO TEST PRESSURES CAN BE HIGHER THAN THIS.
• IN THAT CASE WE NEED TO BACK CALCULATE THE STRESS DUE TO HYDRO TEST
AND ENSURE THAT IT IS BELOW 90% OF YIELD STRESS

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