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Project
Pressure/Temperature Definitions for Engineering,
BPVC Technology
Division

1.0 PROBLEM STATEMENT:

1.1 Define important Pressure and Temperature terms related to Boilers and Pressure Vessels.
2.0 PRESSURE TERMS:
2.1 Design Pressure:

2.1.1 The design pressure is the pressure at the most severe coincident pressure and
temperature expected during normal operating condition. It is the highest pressure
difference between inside and outside of the vessel or between two chambers
which the vessel can encounter during testing or normal operation.

[ASME BPVC SEC VIII, DIV 1, UG-21]

2.1.2 The pressure used in the design of a vessel for the purpose of determining the
minimum permissible thickness or physical characteristics of the different parts of
the vessel. When applicable, static head shall be add to the design pressure to
determine the thickness of any specific part of the vessel.

[MFC ENGINEERING SPECIFICATIONS (ES-AD1) THYSSENKRUPP UDHE]

2.1.3 Thickness calculations in UG-27 for ASME BPVC vessels are based on this
Pressure represented by ‘P’. Pressure vessels, especially long towers, containing
liquid in them must be designed considering the hydrostatic pressure exerted by
the length of the liquid above the point to be designed. In such case the design
pressure at the bottom of the tower will be equal to the design pressure at the top
of the tower plus the hydrostatic head.

PB = PT + H

Where, PB = pressure at bottom, PT= Pressure at Top, H= Head of the liquid,

specific Gravity of liquid
Design pressure is selected based on a suitable margin from Maximum operating
pressure. This margin prevent the Safety devices from premature opening due to
temporary pressure surges during startup/shutdown or even normal operation due
to variation in vapor pressure, densities, flow rates etc.

The safety margin is specified by best practices of the manufacturer or Client

Company.

The design pressure is generally specified as greater of (a) 110% of the maximum
operating pressure or (b) The operating pressure plus 25 psi (172kPa)

[EXXON DESIGN PRACTICE]

2.2 Operating Pressure

2.2.1. Pressure at the top of the vessel at which the vessel normally operates. It shall not
exceed the MAWP, and it is usually kept at a certain level below the opening of the
Pressure Relieving devices to prevent their frequent opening.

2.2.2. Operating pressure is specified by chemical or process engineer along with other
operating parameters like temperature, liquid levels, flow rate etc. Based on this
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operating pressure the design engineer selects the optimum design pressure for
the vessel.
2.3 Maximum/Minimum Operating Pressure

2.3.1. While the operating pressure is defined for Steady State, Maximum or minimum
operating pressure will correspond to the variation in the normal Operating
pressure due to change in density, vapor pressure, change in feedstock, changes
in product cut point, static head due to level of liquid or solid, system pressure drop
and pump or compressor shutoff pressure.
[EXXON DESIGN PRACTICE]

2.4 Maximum Allowable Working Pressure

2.4.1. Maximum Allowable Working Pressure (MAWP) is the maximum permissible

pressure at the top of the vessels for normal operating position at designated
coincident operating temperature for that pressure
[REF: ASME BPVC SEC.VIII DIV.1 UG-98]

2.4.2. MAWP is calculated for all the essential parts of the vessel and the least of the
values is used as MAWP for the entire vessel (Strength of the chain is measured
by the strength of the weakest link in the chain).

Calculations based on the designed pressure give required thickness. When the
corrosion allowance is included for the vessel life the new thickness is called
the designed thickness. Based on this designed thickness, next close commercially
available plates are used to fabricate the vessel. This new thickness is
called Nominal thickness. The allowable pressure calculated based on nominal
thickness, excluding the corrosion allowance, is called the MAWP.

Once the MAWP is calculated, it will replace the design pressure. It is the basis for
the pressure setting of the pressure relieving devices protecting the vessel. The
design pressure may be used in all cases in which calculations are not made to
determine the value of the maximum allowable working pressure.

[REF: ASME BPVC SEC.VIII DIV.1 MANDATORY APPENDIX 3].

2.5 Maximum Allowable Pressure (MAP)

2.5.1. The MAP is defined as the highest permissible pressure as determined by the
design formulas for a component using the nominal thickness less corrosion
allowance and the maximum allowable stress value from the Table 1A of Section II,
Part D at the MDMT.

[REF: ASME BPVC SEC.VIII DIV.1, General Notes, page 179 Ed.2004].

2.6 Hydrostatic Test Pressure

2.6.1. 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 pressure33 to be marked on the vessel multiplied by
the lowest ratio (for the materials of which the vessel is constructed) of the stress
value St for the test temperature on the vessel to the stress value Sd for the design
temperature.

1.3 ∗ 𝑀𝐴𝑊𝑃 ∗ 𝑆𝑡
𝑃ℎ =
𝑆𝑑
[REF: ASME BPVC SEC.VIII DIV.1 UG-99]
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2.7 Leak Test Pressure

2.7.1. Leak test is a hydrostatic test performed to check the nozzle reinforcement joints
and tube to tube sheet are leak proof for process fluids. Leak test pressure is kept
below 25% of the design pressure.
[REF: ASME BPVC SEC.V, Article 10]

2.8 Minimum Design Pressure

2.8.1. Minimum design pressure for vessels under BPVC Sec.VIII Div-1 is 15 psig. Vessels
having design pressure less than that does not fall outside the mandatory scope of
ASME code.
[REF: ASME BPVC SEC.VIII DIV.1]

2.8.2. A minimum design pressure of 15 psig is generally used unless there are strong
incentives to do otherwise.
[EXXON DESIGN PRACTICE]

2.9 Pneumatic Test Pressure

2.9.1. Pressure at which Pneumatic test is performed for vessels for which:

 The design or supports are so that the vessel cannot be safely filled with
water.
 Not readily dried or to be used in services where traces of tested liquid are
not tolerated.

2.9.2. For Enameled vessels the pneumatic test should be equal to the design pressure
and for other vessels it should be at least equal to 1.1 times the design pressure
multiplied by the lowest ratio (for the materials of which the vessel is constructed)
of the stress value St for the test temperature on the vessel to the stress value Sd
for the design temperature.

1.1 ∗ 𝑃 ∗ 𝑆𝑡
𝑃𝑛 =
𝑆𝑑
[REF: ASME BPVC SEC.VIII DIV.1 UG-100]

3.0 TEMPERATURE TERMS:

3.1 Design Temperature
3.1.1. Maximum Design temperature shall not be less than the mean metal
temperature (through the thickness) expected under operating conditions for
the part of the vessel considered.
[REF: ASME BPVC SEC.VIII DIV.1 UG-20]

3.1.2. The design metal temperature of vessels without internal insulation with
operating temperatures higher than 0 °C / 32 F shall be at least equal to the
operating temperature plus 10 °C / 86 F min. 65°C/ 149 F.
[MFC ENGINEERING SPECIFICATIONS (ES-AD1) THYSSENKRUPP UDHE]

3.1.3. The minimum metal temperature used in design shall be the lowest expected in
service.
[REF: ASME BPVC SEC.VIII DIV.1 UG-20]
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3.2 Operating Temperature

3.2.1. The temperature that will be maintained in the metal of the part of the vessel
being considered for the specified operation of the vessel

[REF: ASME BPVC SEC.VIII DIV.1 MANDATORY APPENDIX 3]

3.3 Maximum/Minimum Operating Temperature

3.3.1. Maximum or minimum operating temperatures corresponds to the variation in

normal operating temperature of the process fluid due to startup, shutdown, de-
pressuring, alternative operation, control requirement, process flexibility and
process upsets.

[EXXON DESIGN PRACTICE]

3.4 Minimum Design Metal Temperature

3.4.1. The Minimum Design Metal Temperature (MDMT) is the lowest temperature at
which the component is designed to have adequate fracture toughness. It is a
function of the component’s material specification and thickness.

“OVERVIEW OF PRESSURE VESSEL DESIGN” BY VINCENT A. CARUCCI)

3.4.2. MDMT is marked on the name plate of the vessel. While designing the vessel
the thickness and material is selected such that the resulting MDMT is always
above the lowest expected temperature in the operating condition to avoid
Charpy fracture toughness test. Otherwise the material is Charpy tested to
ensure it has the required toughness at the desired temperature.

3.5 Critical Exposure Temperature

3.5.1. The Critical Exposure Temperature (CET) is the minimum metal temperature
that can occur at the same time as a significant membrane stress in the vessel
(e.g., at a pressure that is greater than 25% of the design pressure).

“OVERVIEW OF PRESSURE VESSEL DESIGN” BY VINCENT A. CARUCCI)

3.5.2. The CET is determined by either ambient conditions or process conditions,

whichever results in the lowest metal temperature.

3.6 Minimum Hydrostatic Test Temperature

3.6.1. The hydrostatic test temperature shall be at least 10 °F (6 °C) higher than the
CET in components 2 inch or less in thickness. For components greater than 2
inch in thickness use 30 °F (17 °C) margin from CET.

[EXXON DESIGN PRACTICE]

4.0 REFERENCE DOCUMENTS:

4.1 ASME BPVC Sec VIII, Div 1
4.2 “Overview of Pressure Vessel Design” by Vincent A. Carucci (Carmagen Engineering, Inc.)
4.3 [Exxon Design Practice]

5.0 RECORDS:
5.1 GTEs Training Repository