ASPEK KESELAMATAN DALAM

RANCANGAN VESEL
BERTEKANAN
INTRODUCTION

The Chemical and metallurgical industries are rapidly expanding both in size and diversity of
process.

As a result through attention is given towards safety of the plant design, specially pressure
vessels due to its intrinsic safety requirements due to its high pressure operations. It is not
possible for all safety members to get exposure for P.V. design with respect to safety aspects,
at all execution steps . They normally do regular checking at plant operation and periodic
testing. My sincere effort is to give you exposure on the subject matter based on my
personnel & professional experience in this field, specially on Loss prevention aspects in
process plant design.
1. DESIGN CRITERIA‐ CHECK LIST

The use of Pressure Vessels ( Unfired) is governed by

"THE STATIC & MOBILE PRESSURE VESSELS ( UNFIRED) RULES 1981

The Statutory requirements for the safety pertaining to factory Law, Pollution Board,
Enforced by Central and State Governments for the safety of Pressure vessel and
operation decides applicable Code, standards and recommended practice.

If content of pressure vessel is explosive in nature, we will have to follow Explosive Act.

Design includes drawing, calculations,specifications,model code used for the design, and
all other details necessary for the complete description of the P.V. and its construction
1. DESIGN CRITERIA‐ CHECK LIST

Major points to be checked are:

1) Hazard due to failure of material of construction by corrosion or any unusual condition.
It decides material of construction and corrosion allowance to be considered in design
2) Possibility of runaway, strongly exothermic reactions decides High Pressure trip system. It protects Pressure Vessel against
over pressure and Vacuum
3) Disposal of gas and/or Liquid during reaction , pressure relieving valves, device
4) Gas Explosion hazards, Installation of rupture disc etc.
5) Blow down and depressing system is to be taken care at upper and lower limit alarms
6) Any design constrain due to availability of space decides Vessel Position
7) Process requirements such as mixing intensity, product discharge from reactor by gravity or pump, vessel diameter to
Height/Length ratio etc.
8) Toxicity and flammable properties of material handled, Electrical Area classifications
9) Reliability of available utilities at site and its quality standards suggest
additional Heat Transfer Area requirements at the time of designing pressure vessel
2. SELECTION OF DESIGN CODE & STANDARDS

The design & manufacture of P.V. is always governed by applicable design codes in all countries.
The codes or rules are primarily intended to assure safety in operation and they cover every aspect
of the design criteria with the safety of pressure vessel :

1) Selection of fabrication material & its testing

2) Approval of welder and fabrication work shop
3) Fabrication methodology for the set up, welding and fabrication
4) Testing and quality control through design conventions

They form a basis of agreement between the manufacturer and customer , and the customer’s
insurance company.
Information and guidance on the P.V. codes can be found on the Internet : www.bsi‐global.com

Computer programs to aid in the design of vessels to PD 5500 and the ASME code are available
from commercial organizations and can be found on Internet.
Use of program "PVEllite" is most popular in our country that uses ASME code .
2. SELECTION OF DESIGN CODE & STANDARDS
The codes used in our country for the UFPV ( Unfired Pressure Vessels) are:
2. SELECTION OF DESIGN CODE & STANDARDS

While basic aim of the code is same, there are differences in approach arising out of historical
back ground, Experience, Raw material availability in the country and the design philosophy
adopted in the various countries of origin The choice of code is made by the purchaser and
his process Licensor , guided by their experience on the similar plant and strongly influenced
by the country in which this experience has been gained.

The difference in codes from the point of design, material selection, welding and fabrication
method is dealt with in depth knowledge of design engineering practice. In the United
Kingdom all conventional pressure vessels for use in the chemical and allied industries will
invariably be designed and fabricated according to the British Standard PD 5500 or the
European Standard EN 13445; or an equivalent code such as the American Society of
Mechanical Engineers code Section VIII (the ASME code).

Where national codes are not available, the British, European or American codes would be
used.
3. SELECTION OF MATERIAL

The choice of material is made considering the various factors like :

1) Environmental under which it is intended to give service , Process Requirements

2) The mechanical strength desired
3) The expected life of the equipment
4) Workability and weldability of the metal selected.

The mechanical strength and process requirements plays the greater part while
selecting optimum design criteria

Material stress value is given here under for the majority of material available and in use for
the selection and Fabrication in India :
Material Properties: { ENTER TEMPERATURE }
TO Select Material Properties
3. SELECTION OF MATERIAL
CALCULATE DESIGN PRESSURE
Fluid Properties:
Fluid Specific Gravity (g/cm3)

Water, 1.000
Ethanol, 0.789
Alcohol, 0.789-0.855
Ammonia, .662
Beer, 1.01
Bromine, 2.900
Butane, 0.594
Crude Oil, 0.790-0.843
Gasoline, 0.680-0.740
Glucose, 1.350-1.440
Kerosene, 0.780-0.820
Milk, 1.020-1.050
Sulphuric Acid, 1.814
 4. Design Pressure Vessels ( Brief):

Based on the selection criteria and check list given earlier :

1) Select Metric or British system you want to follow for the design & use units
uniformly over design
2) Select Design Temperature : It is a process requirements
3) Select Design Pressure

A. Design pressure is 10% or 0.69 to 1.7 bar (10 to 25 psi) above the maximum operating
pressure, whichever is greater. The maximum operating pressure is taken as 1.7 bar (25
psi) above the normal operation pressure.
B. For vacuum operations, design pressures are 1 bar(g) (15 psig) to full vacuum
C. Minimum thicknesses for maintaining vessel/tank structure is to be selected as per code
D. ASME Code:P-design [psi] = P+0.433*SG*H ~~ design pressure including static head
Where P = Operating pressure, SG = Sp. Gr. & H = Liquid Height inside vessel
E. For safe Design Practice use 1.1 times operating pressure(min)
4. Design Pressure Vessels ( Brief):

4) Select Corrosion Allowance

The “corrosion allowance” is the additional thickness of metal added to allow for material
lost by corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer.

Corrosion is a complex phenomenon, and it is not possible to give specific rules for the
estimation of the corrosion allowance required for all circumstances.
The allowance should be based on experience with the service conditions to those for the proposed
design.

Guidelines for corrosion allowances are as follows:

1) For carbon and low‐alloy steels, where severe corrosion is not expected,
a minimum allowance of 2.0 mm should be used
2) where more severe conditions are anticipated this should be increased to 4.0 mm.
3) Most design codes and standards specify a minimum allowance of 1.0 mm
4) Select Based on the Service Life predicted by process engineer.
 4. Design Pressure Vessels ( Brief):

5) Select Material Properties : To be selected based on Design Temp. & Press

6) Select Design code

The national codes and standards divide vessel construction into different categories, depending on the
amount of non‐destructive testing required. The higher categories require 100 per cent radiography of
the welds, and allow the use of highest values for the weld joint factors. The lower ‐quality categories
require less radiography, but allow only lower joint ‐efficiency factors, and place restrictions on the
plate thickness and type of materials that can be used. The highest category will invariably be
specified for process‐plant pressure vessels.
The standard specifies three construction categories:

Category 1: the highest class, requires 100 per cent non‐destructive testing (NDT) of the welds; and
allows the use of all materials covered by the standard, with no restriction on the plate thickness.
Category 2: requires less non‐destructive testing but places some limitations on the materials which
can be used and the maximum plate thickness.
 4. Design Pressure Vessels ( Brief):

Category 3: The lowest class, requires only visual inspection of the welds, but is restricted to carbon and
carbon‐manganese steels, and austenitic stainless steel; and limits are placed on the plate thickness and
the nominal design stress. For carbon and carbon manganese steels the plate thickness is restricted to less
than 13 mm and the design stress is about
half that allowed for categories 1 and 2. For stainless steel the thickness is restricted to less than 25 mm
and the allowable design stress is around 80 per cent of that for the other categories.
7) Select Test pressure
Test pressure = Sf*{ Pd*( Fa/Fn) x t/(t‐c) }
Where Pd = design pressure, N/mm2,
fa = design stress at the test temperature, N/mm2,
fn = design stress at the design temperature, N/mm2,
c = corrosion allowance, mm,
t = actual plate thickness, mm.
Sf = Safety factor a) ASME Sec VIII DiV‐1: 1.5 a) ASME Sec VIII DiV‐2: 1.25
2) BS 1515 1.3 3) IS 2825 1.3 4) BS1500, Test Pressure is 1.5 times working pressure
 4. Design Pressure Vessels ( Brief):

8) Select vessel to be Vertical or Horizontal and ratio of Diameter to height

It is a process and lay out requirements

9) Welded joint efficiency

The value of the joint factor used in design will depend on the type of joint and amount of
radiography required by the design code.
Typical values are shown in Table

Taking the factor as 1.0 implies that the joint is equally as strong as the virgin plate; It is achieved by
radiographing the complete weld length, and cutting out/remaking any defects. The use of lower
joint factors in design, though saving costs on radiography, It will result in a thicker, heavier, vessel,
and the designer must balance any cost savings on
inspection and fabrication against the increased cost of materials.
 4. Design Pressure Vessels ( Brief):

10) Select Applicable Design Loads :

Design loads
A Vessel must be designed to resist gross plastic deformation and collapse under all
the conditions of loading. The loads to which a process vessel will be subject in service
are listed below. They can be classified as major loads, that must always be considered in
vessel design, and subsidiary loads. Formal stress analysis to determine the effect of the
subsidiary loads is only required in the codes and standards where it is not possible to
Double welded butt or equivalent Single‐weld butt joint with bonding strips
Type of Joint Degree of radiography Maximum Allowable Joint Efficiency demonstrate the adequacy of
the proposed design by other means; such as by comparison
with the known behavior of existing

Major loads
1. Maximum weight of the vessel and contents, under operating conditions.
2. Maximum weight of the vessel and contents under the hydraulic test conditions
4. Design Pressure Vessels ( Brief):

3. Dynamic Wind loads ( For Tall Vessels):

For a smooth cylindrical column or stack the following semi ‐empirical equation can be
used to estimate the wind pressure:

Pw = 0.05 *u²

where Pw = wind pressure, N/m2,

u = wind speed, km/h.
Note: A wind speed of 160 km/h (100 mph) can be used for preliminary design studies;
equivalent to a wind pressure of 1280 N/m2 (25 lb/ft2).
 4. Design Pressure Vessels ( Brief):

4. Earthquake (seismic) loads.

The movement of the earths surface during an earthquake produces horizontal shear
forces on tall self]supported vessels, the magnitude of which increases from the base
upward. The total shear force on the vessel will be given by:

Fs = a * (W/g)

where "a" is the acceleration of the vessel due to the earthquake,

g = the acceleration due to gravity,
W = total weight of the vessel.
The term (a/g) is called the seismic constant Ce, and is a function of the natural period of
vibration of the vessel and the severity of the earthquake. Values of the seismic constant
have been determined empirically from studies of the damage caused by earthquakes,
& are available for those geographical locations which are subject to earthquake activity.
 4. Design Pressure Vessels ( Brief):

5.Subsidiary loads
1. Local stresses caused by supports, internal structures and connecting pipes.
2. Shock loads caused by water hammer, or by surging of the vessel contents.
3. Bending moments caused by eccentricity of the center of the working pressure
relative to the neutral axis of the vessel.
4. Stresses due to temperature differences and differences in the coefficient expansion
of materials.
5. Loads caused by fluctuations in temperature and pressure.
A vessel will not be subject to all these loads simultaneously. The designer must
determine what combination of possible loads gives the worst situation, and design for
that loading condition.
 4. Design Pressure Vessels ( Brief):
11) THE DESIGN OF VESSELS UNDER INTERNAL PRESSURE
A Design Cylindrical Shell under internal Pressure
The Cylindrical shell thickness based on pressure and radius is given by:

Minimum practical wall thickness There will be a minimum wall thickness required to ensure that
any vessel is sufficiently rigid to withstand its own weight, and any incidental loads. As a general
guide the wall thickness of any vessel should not be less than the values given below; the values
include a corrosion allowance of 2 mm: