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Pressure Vessel
By
- Prakash B Thakur
(Chief Engineer Mechanical, Uhde India Pvt Ltd)
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
1
Uhde India
Qualification
Experience
Have been handling Chemical / Petrochemical project (Ammonia Urea fertilizer, LAB, SB Rubber etc)
and Refinery projects for well known national and international clients in the position of Lead Pressure
Vessel Engineer. Have been deputed to Europe, Middle east region on official assignments several
times.
Contact Detail
Prakash B. Thakur,
Uhde India Pvt. Ltd,
Uhde House, LBS Road, Vikhroli (W), Mumbai -400083
Email: Prakash.Thakur@Thyssenkrupp.com
DID : +91-22-6704 6641
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
2
Uhde India
Todays session?
Pressure Vessels
Basics
Components of Pressure Vessels,
Shell & Dish
Internal & External Pressure
Nozzle, Reinforcement & Manhole
Vessel Supports
Ladders & Platforms
Safety Devices
Vessels Internals
Reactors
Process Column
Heat Exchangers
Day 1
Day 2 Material Strength, Codes, different loads, design and some examples etc.
Day 3 Material Selection, Testing, special requirements, costing etc.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
3
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Drums / Vessels
Heat Exchangers,
Heaters,
Spheres,
Storage Tanks,
Silos etc
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Petrochemical Plant
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The most practical examples of pressure vessels is domestic Pressure cooker. Even a carbonated
soda/soft drink bottle is a pressure vessel.
Industrial examples are KO Drum, Surge Drums, Pots, Separators, Process Columns, Shell & Tube
heat exchangers etc.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
7
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Membrane Stress?
For thin wall vessels, when the thickness is small in
comparison with other dimensions vessel wall is referred
to as membrane and the associated stresses resulting
from the contained pressure are called membrane stress.
A membrane stress implies a stress equal over a surface
resulting from loading. These membrane stresses are
average tension or compression stresses. Often, the
loading that can impose a stress in this manner is a
uniformly distributed load like internal pressure.
These are assumed to be uniform across the vessel wall
and act tangentially to its surface. The membrane or wall
is assumed to offer no resistance to bending.
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Types of Heads
Though spherical shape is most preferred shape due higher holding capacity & minimum
thickness requirement but it is not so common due fabrication difficulty and associated cost.
Spherical vessels are used only in high pressure application (like reactors) or where high volume
is to be stored (spherical tanks).
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half
stresses.
as
much
as
the
circumferential
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Vessel Thickness
Thus we can broadly conclude that the vessel thickness is basically a function of,
Diameter,
Temperature,
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Component - Supports
Support are important component of pressure. Needs to
be selected wisely. Supports are to be design to support
the pressure vessel under different loads conditions.
For tall process column, heavy reactors etc. support
design is next most interesting thing to design after
pressure vessel wall.
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Component - Supports
The main type of supports for Vertical vessels are,
1. Leg Support
2. Bracket / Lug Support,
3. Skirt Support and,
4. Saddle supports are the most common type of support for Horizontal Vessels.
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Reactors
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Reactors
Reactors are nothing but pressure vessels. The process fluid
undergoes a chemical reaction inside a reactor. This reaction
is normally facilitated by the presence of catalyst which is held
in one or more catalyst beds.
Generally, pressure & temperature involved in the reactors
are very high. The presence of high temperature & pressure
results in higher wall thickness (even up to 400mm), very
heavy weight and special fabrication/welding techniques. The
material selection (for high temp, special service) is most
important in Reactors.
Depending on thickness and diameters, reactor shell / dish
can be either rolled plates or forgings.
Internals like pre-distributor, distributor, outlet collectors etc.
are supplied by the highly qualified companies.
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Types of Reactors
Tubular Reactors & Large Heat Exchangers : This Reactor is used in ethylene oxide, methanol and
MTBE production plants. These exchangers containing several thousand tubes, are typically used in
low and medium pressure processes. Tubular Reactors consist of large shell & tube heat exchangers
with very large diameters (up to 8 m) and over 10,000 tubes. Each tube is welded to the tube sheets
with special welding technology for conventional and high alloy materials. Key factors for tubular
reactor manufacturing are tube sheet drilling technology with reduced tolerances and tube to tube
sheet welding operations.
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Specialized welding
Technique used for
Reactor welding
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Process Columns
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Process Columns
Columns or Tower are also pressure vessels in which heat & mass
transfer takes place with help of trays, packing and other internals. Gas
and liquid flows in opposite direction to induce mass &/or heat transfer.
E.g. Distillation, Absorption, Desorption, Splitter column etc.
Due to considerable height of column, ladder and platforms are always
provided on column on regular intervals.
A tower typically contains internal trays &/or packing in the cylindrical shell
section.
These internal trays are needed for flow distribution. Several types of
tower trays are available, such as the bubble -cap, valve, sieve, with
single / double / triple pass and so on. The particular type of tray used
depends on the specific design conditions and process application.
Following internals are generally present in a process column.
Trays & Down comers,
Feed distributors
Packing & support grids, support beams
Seal Pan / Collector tray
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
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Column Size
Process column size is generally large, creates problem of transportation & erection at site.
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Column Size
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Column Size
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Types of Trays
There are many types of tray designs for different
application
based
on
hydraulics
&
performance
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Valve Trays
Valve trays
In valve trays, perforations are covered by liftable
caps. Vapour flows lifts the caps, thus self creating
a flow area for the passage of vapour. The lifting
cap directs the vapour to flow horizontally into the
liquid, thus providing better mixing than is possible
in sieve trays.
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Sieve Trays
Sieve trays
Sieve trays are simply metal plates with holes in
them. Vapor passes straight upward through the
liquid on the plate.
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Process Columns
Cross section
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Packed Column
There is a trend to improve separations by supplementing the use of trays by additions of packings.
Packings are passive devices that are designed to increase the interfacial area for vapor-liquid
contact.
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Packing
Packings impart good vapor-liquid contact when
placed
together
in
numbers,
without
causing
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Column internals are special components of Process column. Whole performance of the
column depends upon correct process design and usage of right internals.
These internals are supplied by reputed vendors after details design & hydraulics of column to
suit the application.
Koch Glitch, Sulzer, Kevin etc are some of the major players in the field of Column internals.
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Heat Exchangers
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Heat Exchangers
In most of the plants fluids are heated or cooled using heat exchangers. A heat exchanger is a
specialized device that assists in the transfer of heat from one fluid to the other. A solid wall may
separate the fluids to prevent them from mixing.
Common appliances containing a heat exchanger include air conditioners, refrigerators and space
heaters.
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Air Cooler
It is quite common, these days, for Air cooled heat exchangers to handle more than half the heat
dissipation load in a refinery or petrochemical plant.
Air is being used as cooling medium which is available freely.
Advantages are,
1. The heat exchangers can be located at any point within a refinery, thus eliminating long
pipe runs for either the process fluid or the cooling water.
2. Scale buildup on the cooling water side of a shell-and-tube heat exchanger is eliminated,
as well as the related shutdowns for cleaning.
3. Cooling tower water treatment and disposal of resulting waste water is eliminated.
4. The overall cost of dissipating heat by this means is generally less than by other methods
for fluid streams above 66C.
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Air Cooler
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Induced Draft
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TEMA Types
TEMA designations for
shell-and-tube heat
exchangers.
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Limitations:
1. Only chemical tube side cleaning is possible.
2. Access to the tubes other that the outside row is
limited.
For the above reason, this type is recommended for clean process fluids and those subject to
chemical cleaning.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
64
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U Bundle
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Limitations:
1. Differential expansion is possible only by
using expansion joint.
2. Tube bundle is not removable.
3. Shell side mechanical cleaning is not possible.
These types are recommended for low and high pressure, but low fouling fluids and where
leakages are to be avoided.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
67
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The above type is recommended for high pressure, non-hazardous process fluids.
Title Basics of Pressure Vessel
Date 21/03/2011 to 23/03/2011
3 Day session on Pressure Vessel at IIT Gandhi Nagar, Gujarat
69
Uhde India
Limitations:
1. Maximum of only two tube side passes is
possible.
2. The shell and tube side leakage is possible.
3. Maximum temperatures of 200 C and
maximum pressure of 20 Kg/cm2g limits the
usage of these units at higher pressure and
temperature.
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Limitations:
1. Hazardous material should not be used on the
shell side because of the possible leakage.
2. Packing will tend to limit shell fluids to
temperatures below 300 F and
pressure below 150 psi.
This types are recommended for low pressure, low temperature non-hazardous fluids.
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Limitations:
1. The seal is not externally visible; therefore
leakage might be undetected for some time.
2. This type will tend to be more expensive than
other types.
This types are recommended for low pressure, low temperature non-hazardous fluids.
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Summary of Features
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Types of Baffle
Tube Pitch
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a)
b)
c)
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Double Pipe
Corrugated Tube
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