Mechanical Design: Skirt Design Saddle Design

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Mechanical Design
Components
Head Types
Skirt Design
Saddle Design
Pipe Connec ons
Internals
Types of Vessels
Separators
Columns
Exchangers
Design Process
Drawing Informa on (datasheet)
ASME Code
Vessel Shell Design Flowchart
Reinforcement Pad
Nozzle Design Flowchart
Design Notes
Typical Vessel Materials
Shell & Head Thickness Calcula ons
Vessel Weight
Design Informa on:

Nominal Pipe Sizes (Imperial & Metric)
Flange Projec on
Skirt Dimensions
Base Ring Dimensions
Saddle Dimensions
Manway Dimensions
Vortex Breaker Design
Head Area and Volume
Example
Pressure Vessel Design:

Introduc on
Pressure vessels are containers designed to perform process func ons like separa ng different fluids, exchanging heat from one fluid stream to another, and
dis lla on. The vessel may operate with an internal pressure up to 20 MPa [ASME Sec on VIII, U-1 (f)] or a perfect vacuum, and they may be opera ng from
cryogenic temperatures to extremely high temperatures. The design, fabrica on and tes ng of pressure vessels must conform to the ASME Boiler & Pressure
Vessel Code - Sec on VIII Division 1: Rules for Construc on of Pressure Vessels.
Interna onal organiza ons that are involved in the design of pressure vessels and piping systems include:
ASME American Society of Mechanical Engineers
AISC American Society of Steel Construction
ANSI American National Standards Institute
API American Petroleum Institute
ASTM American Society of Testing and Materials
Some typical symbols used in the design of pressure vessels are as follows. (Note: these will vary between industries and manufacturers)
ASSY Assembly
BC Bolt Circle
BF Blind Flange
BOM Bill of Materials
BOP Bottom of pipe
BW Butt weld
CA Corrosion Allowance
CO Clean out
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CPLG Coupling
CTR Center
E-E End-to-End
ELB Elbow
F-F Face-to-Face
FF Flat face
FLG Flange
FW Field Weld
HDR Header
IDD Inside depth of dish
INS Insulation
MAWP Maximum Allowable Working Pressure
MH Manhole
RF Raised face
RTJ Ring joint
SCH Schedule
SCRD Screwed
SMLS Seamless
SO Slip-on
STD Standard
SW Socket Weld
SWG Swage
TOC Top of concrete
TOS Top of steel
TYP Typical
WE Welded End
WN Weld neck
WT Weight
XH Extra heavy (pipe)
XXH Double-extra heavy (pipe)
Vessel Components (back to top)

Vessels are made up of a number of standard components, including:
- Shell: made up of a rolled plate and welded together along the longitudinal seam. Note that the longitudinal seams do not line up with the
longitudinal axis (at 0°, 90°, 180°, or 270°). This seam is typically offset 45° to avoid interference between the weld and a achments like nozzles.
- Head: formed from a flat plate and welded to the shell using a circumferen al seam.
- Skirt: on ver cal vessels, designed to support the weight and secure it to a founda on using a base plate.
- Saddles: on horizontal vessels, designed to support the weight and accommodate expansion of the vessel.
Vessel Head-Types (back to top)

There are a number of types of heads used on vessels, including ellipsoidal, hemispherical, and torospherical [ASME VIII, Div. 1, UG-32]. The most commonly
used heads are ellip cal with a 2:1 semi-ellip cal shape (in which the major axis is twice the minor axis). The hemispherical is round, as the name suggests;
and torospherical (or flanged & dished) heads are shallower than semi-ellip cal heads, maintaining a constant radius over a greater por on of the head.
You will no ce on each of the heads a straight length tangent to the shaped head. This ‘straight flange’ (S.F.) is typically 50 mm (2”) in length and is used as the
transi on from the shaped head to the vessel shell. The length of the straight flange can vary between manufacturers and should be confirmed in the design
process. The weld connec ng the straight flange por on of the head and the vessel shell is called the circumferen al seam (or ‘circ seam’).
Vessel A achments (External)

Skirt Design (Ver cal Vessels) (back to top)
Ver cal vessels require a skirt, which is a structural component welded to the vessel to support the weight and secure the vessel to a founda on. It is not a
pressure-bearing component, but must be made of materials that are of weldable quality [ASME Sec on VIII, Div.1, UG-4(b)] and compa ble with the
materials used for the vessel.
The skirt height can be governed by several factors, including:
a) Net posi ve suc on head required (NPSHR) by a downstream pump.

b) Clearance for nozzles and flanges - typically 150mm from Top of Concrete (TOC).
c) Head room for large vessels – minimum skirt height of 2200 mm.
The skirt should have the same outside diameter as the vessel. The base plate is a ring has an inside diameter the same as the skirt minus 4mm to 75mm (as
required for welding); and the outside diameter of the ring is the outside diameter of the skirt plus enough space for the anchor bolts that are used to secure
the vessel to the founda on.
Anchor bolts must be designed for an cipated forces ac ng on the vessel including wind and seismic loadings. Bolt configura ons are applied in mul ples of
four bolts, and should never line up with the vessel centerlines. Large vessels may require double base rings and bol ng chairs (discussed later in design).
The skirt must have an access hole for the inspec on of the vessel head and the pipe a ached to the bo om of the vessel for corrosion and leaks. The access
hole should be a minimum of 75mm in diameter for hand access, but may be as large as 600 mm for manways.
Two vent holes (typically 2” Sch.40 pipe sleeves) are required on the skirt, spaced 180° apart to allow combus ble or toxic gases to escape. They should be
located as close as possible to the vessel, and considera on should be given in the design for the thickness of insula on.
It is not good prac ce to have flanges inside the skirt, due to limited access and leak detec on. The bo om nozzle will include a pipe welded flush to the
inside diameter of the vessel (for complete drainage), an elbow, a straight pipe, and a flange (as shown in the diagram). The nozzle opening should be
reinforced using a larger Sch.40 pipe projec ng 25 mm on each side of the skirt.
Skirt details are illustrated below:
Fire Protec on:

To maintain the structural integrity of a skirt in the event of a fire, the skirt may be protected using fire brick or a cement/sand mixture (gunite) sprayed to the
outside of the skirt.
Saddle Design (Horizontal Vessels) (back to top)

Steel vessels and piping will expand and contract with changes in temperature. The opera ng temperature of a vessel and piping system can vary several
hundred degrees, depending on the process. Horizontal vessel designs should take into considera on this expansion or contrac on by providing slots for the
anchor bolts on the saddles (ver cal vessels are supported only at one end, so only the a achments and piping require expansion considera on).
Saddles for horizontal vessels are placed about 20% of the shell length (L) from each circumferen al seam, as shown. One saddle is fixed to the support
structure and the other has a slo ed anchor to allow for expansion. Choosing which end should be fixed is o en based on the piping entering and leaving the
vessel – if the piping entering or exi ng the vessel is short or very straight from the previous vessel or exchange, this end of the vessel should be fixed; or, in
other words, use a slo ed anchor on the end of the vessel that has the piping with the most flexibility for expansion. If there is a concern about expansion, an
expansion joint or fi ng may be installed in the piping system.
The saddle height is minimized to prevent buckling when the vessel expands on the support. A typical range is 150 to 300 mm below the vessel outside
diameter, to allow access to the bol ng and insula on thickness. The desired vessel height in the layout is ul mately set by the support structure under the
saddles. The contact angle depends on the vessel weight, and may require reinforcing wear pads as well as strengthening ribs to avoid buckling.
Piping Connec ons (back to top)

Connec ons are required on vessels for the inlet and outlet flow of fluids, as well as for instrumenta on and inspec on. Typically, these connec ons are
a ached 90° to the vessel shell or head (concentric nozzle), as opposed to an angle or tangen al to the shell.
It is a typical specifica on to limit connec ons to pressure vessels to flanges. Screwed connec ons have a greater poten al of being damaged during
opera on (i.e., damaged threads) and may require significant repairs to the vessel. Flanged connec ons are more robust, though more expensive. The
minimum flange size is usually 2” NPS (nominal pipe size).
Nozzles must project enough distance for fabrica on, for insula on thickness, and for easy access to studs/nuts. Types of flanges include the raised-face-weld-
neck (RFWN), which is welded to a pipe stub on the vessel. Other flanges include screwed-on and slip-on styles.
Threaded connec ons, if used, are usually 1-1/2” and smaller couplings welded directly to the vessel, as shown.
Nozzles have an internal projec on unless otherwise specified. Reasons for welding a flange or coupling flush to the inside diameter of the vessel is for ven ng
or drainage.
Nozzles should not be welded onto other weld seams (circumferen al or longitudinal), and reinforcing pads may be required to provide strength to the
opening.
Manways are large nozzles located on the side of a ver cal vessel, or the end of a horizontal vessel, for inside access. You may want to access the inside of a
vessel for inspec on or to install and maintain internals like contact trays. Manways are typically 18” (457 mm) to 24” (610 mm) in size, and have a blind flange
a ached to a davit arm for easier access. Manways may also be installed on the top of a vessel (typical of filters) with a davit arm that will swing the blind
flange away from the vessel for access. When designing, special care must be taken to ensure adequate space to swing the davit arm and blind flange.
Nozzle Symbols
On design drawings, nozzles should be labeled. Symbols vary between designers and industries - the following nozzle symbols will be used in this course:
N* Flanged Nozzles
i.e., N1 Inlet Nozzle
C* Coupling Connections
i.e., C1 A/B Level Gauge [there are two connections required for this instrument, A & B]
H* Handhole
V* Vent (usually the skirt)
M* Manway
Nominal Pipe Sizes: (back to top)
Nominal Pipe Sizes
Imperial NPS [inches] Metric [mm]
1/2 21
3/4 27
1 33
1-1/2 48
2 60
3 89
4 114
6 168
8 219
10 273
12 324
14 356
Other External A achments

Ver cal vessels, and occasionally horizontal vessels, require permanent ladders and pla orms to access instrumenta on, valves, and manways (if located 4.5
meters above grade). Ladders are limited to 9 meter eleva on differences at which point a pla orm must be installed. Any ladder exceeding 6 m from grade
requires a cage.
Pipes may require support on the vessel to reduce stresses on the vessel nozzles, and to prevent bending due to expansion and contrac on during opera on.
External insula on rings may be welded to the vessel to a ach insula on to the vessel. These rings are commonly spaced 3600 mm apart.
Finally, protrusions from a vessel may be required for certain func ons. Protrusions on the top may be used to install mist-eliminators (demisters) to reduce
the amount of liquids leaving the vessel as small droplets. Protrusions on the bo om of the vessel are called ‘boots’ and may be used to separate a foreign
fluid from the process. An example might be a boot installed to remove compressor oil from a refrigerant, or glycol from a dehydra on unit.
Vessel A achments (Internal) (back to top)

Baffles
Baffles are used inside a vessel to direct the flow of fluids. They may be located at the inlet, inside the vessel, or at the outlet.
The inlet baffle is used to direct flow along the inside of the vessel in an effort to reduce agita on inside the vessel and erosion of the steel for smaller
diameter vessels.
Baffles may also block of the path of a flowing fluid through a vessel to encourage mixing or increasing the contact me in the vessel or exchanger, preven ng
the short-circui ng of fluids through the vessel.
A baffle installed at the fluid outlet at the bo om of a vessel is called a ‘vortex breaker’ and is designed to inhibit fluid rota on and prevent gas located above
the liquid level from being sucked out with the liquid. You may have no ced this phenomenon when draining a bathtub. Common prac ce uses a vortex
height that is one diameter of the outlet nozzle, and a width that is twice this diameter.
Mist Extractor (Demister)

Demisters are usually pads of steel mesh (not unlike steel wool) that are installed on the gas outlet of a vessel. The purpose of a mist extractor is to provide a
surface area that small droplets of liquid may a ach to form larger droplets that will fall against the upward flow of gas. The demister is bolted to a support
ring welded to the inside of the vessel, and is designed to be removed through the manway during inspec on and maintenance.
Siphon Outlet
If it is necessary to minimize the height of a ver cal vessel skirt, a siphon outlet may be required. The nozzle is projected into the vessel and the entrance is
submerged to prevent gas from escaping through the liquid outlet.
Vapour Outlet
Similar to the siphon outlet, it may be necessary to restrict the height of a vessel or nozzle exi ng the top head of a ver cal vessel.
Tray Systems
Contactor vessels are used for the processing of fluids. In general, the liquid entering the vessel flows downward to each tray, where it collects to the height of
the weir. The liquid overflows the weir and flows to the next tray via the downcomer, which is sealed by the liquid level to prevent gases from travelling up the
downcomer.
On the bo om tray, the liquid is sent to a heat exchanger or boiler where the lighter hydrocarbons are vaporized. From this exchanger, the gas/liquid reenters
the vessel and the liquids fall to the liquid out nozzle at the bo om of the vessel. The vapors travel upward through each tray, which have a number of bubble
caps or valves that allow one-way flow of gases without le ng fluids through. The gas vapor reacts with the liquids, as desired by the process (specific
processes will be discussed later).
If these tray systems are to be removable, they must be bolted to rings welded to the inside of the vessel. Access to the trays is through a manway situated on
both the top and bo om of the vessel (accessed by a ladder/pla orm as required).
Packing Systems
Packing may also be used in contactor vessels to provide surface area and mixing for a reac on to occur. A bo om gra ng is installed within the tower to
support the packing that is placed on top of it. A top gra ng is installed to hold the packing in place and preven ng it from moving upward with the gas.
Handoles or manways are installed on the column for the installa on and replacement of packing, as required.
Packing can come as structured sheetmetal or wire, or it can come loose as pall or saddle rings. You can find some examples from ACS at
h p://www.acssepara ons.com/ .
Types of Vessels:
Separators (back to top)
Separators are designed to separate gas from liquid, two different types of liquid, or all three at once.
The principle of design is to allow droplets to se le at the bo om of the separator, as the gas goes out the top. The droplets can only fall if the velocity of that droplet is
greater than the upward velocity of the gas. If it is otherwise, the liquid droplet will be carried out the top of the separator with the gas and effec ve separa on will not have
occurred.
The velocity of the droplet will depend mainly on the density of the liquid (rela ve to the gas) and the size of the droplet. The mist eliminator described above, helps make
the droplet size bigger to improve the performance of the separator.
The important rela onship in separa on is Stokes Law:
Vs = g (ρs - ρ) d² / 18 μ
Where:
Vs = Settling Velocity
ρs = Density of fluid
ρ = Density of gas
μ = Dynamic viscosity of the fluid
A two-phase separator typically separates a gas from a liquid. The configura on can be horizontal or ver cal.
A three-phase separator will separate two types of liquid from a gas stream.
Exchangers (back to top)
Heat exchangers are designed to exchange heat energy from a hot fluid to a cold fluid. The fluid may be liquid or gas. The purpose of an exchanger is to save
money when you have one fluid that must be cooled and/or another fluid that must be heated. Instead of using energy to cool and heat these fluids, the energy
they contain can be exchanged.
Four common types of heat exchangers are double-pipe exchangers, shell & tube exchangers, U-tube exchangers; and plate exchangers.
The double-pipe exchanger is inexpensive to manufacture and is useful for lower-flowrates. It is commonly a small pipe inserted into a larger pipe - one fluid
flows through the small pipe, and the other fluid flows in the space between the pipe. As they flow, they exchange heat through the pipe wall.
A shell & tube exchanger is similar to the double-pipe exchanger, but instead of there being one pipe inside the outer pipe, there are multiple tubes. These tubes
are held in place by a tubsheet. These exchangers are typical for higher flowrates where more exchange area is required. The group of tubes is called a 'tube
bundle' and can be fixed or removable. It is common to have the dirtier fluid flow through the tubes (tube-side), as they can more easily be exposed for
cleaning. The cleaner fluid is on the 'shell-side' of the exchanger (in the space outside of the tubes).
A U-tube exchanger allows the tube-side fluid to enter and leave the vessel from the same end. The U-tube bundle is typically removable and most commonly
used where the cooling fluid is being boiled (vaporized). The tube-bundle is immersed in the fluid and the kettle-type shell allows space for vapour to separate
and leave the vessel. In cases where not all of the fluid is being vapourized, there is a weir at one end of the exchanger to allow the remaining liquids to exit the
vessel (and the weir will maintain a constant liquid level above the U-tube bundle.
Plate/Plate exchangers are made up of a series of plates between which a fluid can flow. The fluids flow through alternating spaces between the plates. The
advantage of a plate/plate exchanger is high efficiency, which can reduce the size of the exchanger (compared to a shell & tube exchanger, for example). They
are commonly used to exchange heat energy between liquids (with no vapourization of the fluids). Another advantage is that the size of the exchanger can be
adjusted by adding or subtracting the number of plates. The plate pack can be removed for cleaning or servicing. One disadvantage is the higher costs. An
example can be found online at WCR (http://www.wcr-regasketing.com/) or Polaris (http://www.polarisphe.com/).
The Design Process (back to top)

When a facility is being designed, there will be Process Flow Diagram (PFD) with process documenta on that indicates flowrate, opera ng pressure, opera ng
temperature, and fluid proper es at each point in the process (like density and liquid/gas frac ons). Preliminary sizing of the vessels and piping will be based
on the process data. A Process & Instrument Diagram (P&ID) will then be created to show the loca on and types of valves, instrumenta on and controls for
the system. Based on this data, a layout for the facility will be created. Once the P&IDs and Layout has been approved, the vessels and piping will be designed
in detail.
Pressure Vessel Sizing
The size of the vessel (diameter and length) will depend on the process condi ons, including:
- Flowrate of gas and liquid frac ons
- Require gas velocity through the vessel
- Allowable pressure drop through the vessel
- Liquid se ling mes required
- Deten on mes required for level instruments
- Sizes set by tray manufacturer for the process
Pressure Vessel Mechanical Design
The thickness of the shell and head, the type of flanges, and the need for reinforcing pads are determined using the design calcula ons standardized by ASME
Sec on VIII Division 1. Engineering and designers must develop detailed engineering drawings and design calcula ons for each pressure vessel. This
informa on is provided to the Boiler’s Branch for approval, vessel registra on and inspec on in accordance to the Code before the vessel may be put into
opera on.
The mechanical design of a pressure vessel is based upon:
- Materials selec on
- Design pressure and temperature range
- Nozzle orienta ons (from the layout)
- Nozzle reinforcement design
- Welding specifica ons
- Dry and wet weight of the vessel for sta c loading
- Wind and seismic loadings, as required.
Design Terminology
Absolute Pressure Pressure measurements taken rela ve to a perfect vacuum (14.7 psi or 101.3 kPa below atmospheric pressure). Units are in psia
(Imperial) or kPa(a) (metric).
Corrosion Allowance The addi onal thickness added to pressure containing parts of the vessel to provide for the loss of material due to corrosion over the life
cycle of vessel.
Design Pressure The maximum allowable pressure under which the vessel may operate. The minimum design pressure is equal to the opera ng pressure
with an addi on 10% or 25 psi (or 200 kPa), whichever is greater. A vessel may be designed for the maximum pressure for the weakest
member of the vessel a er subtrac ng corrosion allowance from the thickness.
Design Temperature The maximum and minimum working temperatures of the vessel with an addi onal 25°F (or 15°C).
Fabricated Weight The dry weight of the vessel as built by the manufacturer.
Gauge Pressure Pressure measurements taken rela ve to atmospheric pressure. Units are in psig (Imperial) or kPag (metric).
Hydrosta c Test The vessel is filled with a liquid medium and pressurized to 1.5 mes the design pressure to test the integrity of the design and
fabrica on.
Joint Efficiency A factor of safety applied to welded joints to compensate for any lack of soundness in the weld. The joint efficiency is based on the type
of joint and the amount of radiographic inspec on specified.
Opera ng Temperature and Pressure
The an cipated condi ons under which the vessel is expected to operate based on the process.
Opera ng Weight The weight of the vessel in opera on, with the weight of fluids included.
Radiography A process of passing radia on (gamma ray or x-ray) through a vessel to obtain a photographic record of the internal structure of the
materials used to fabricate the vessel. Typically used to iden fy defects in the welded joints.
Safety Factor A factor used in calcula ng allowable stress of the material in the manufacture of pressure vessels. Generally, the allowable stress is 0.25
mes the Ul mate Tensile Strength.
Stress Relieving The vessel is heated to an annealing temperature in order to relieve the stresses caused by the welding process. Other heat treatment
processes like pre-hea ng for welding, and normalizing may be required during the manufacture of the vessel.
Wind Load The addi onal design load required for towers subject to moments caused by wind pressure.
Pressure Vessel Drawings (back to top)

Based on the project specifica ons, the process flow diagram (PFD) and flow data, a datasheet is prepared for each vessel in the process. The datasheet will
indicate:
- Vessel tag number, physical dimensions, type of service, and project references.
- Design data, including design pressure & temperatures, corrosion allowance, and radiographic examina on.
- Outline drawing showing nozzle schedule, including tag number, service, type, size and pressure ra ng. The loca ons of external and internal
a achments are also indicated.
- Addi onal notes and remarks to fully describe the vessel.
The datasheet will then be used to prepare the detailed engineering drawings necessary for the fabrica on of the pressure vessel. Horizontal vessels require
top, front and right side views to fully describe the geometry, while ver cal vessels may require only top and eleva on views. Addi onal sec ons and details
may be required when the tradi onal views are not clear enough.
The usual reference points for pressure vessel design are:
- Tangent line of the head (bo om head for a ver cal vessel) may be used as a reference. This line is indicated by indenta ons punched around the
vessel circumference.
- Seam line is the circumferen al weld holding the head (bo om head for a ver cal vessel) to the shell.
- Datum line is a reference line indicated by indenta ons punched around the vessel circumference at a given distance from the seam line. This
distance is o en 100 mm or 150 mm. The datum line is o en the best reference, so nozzle holes may be cut from the shell before the head is a ached.
The side or eleva on view of a vessel will show the loca on of nozzles and a achments from a given datum. The top or end view will show the nozzle
orienta ons, from 0° at the top and going clockwise around the circumference of the vessel. Projec ons are measured from the vessel centerline.
Separate views and drawings may be required for saddles on horizontal vessels, ladders & pla orms, pipe guides & supports, insula on rings, and internals
like baffles, davit arms, vortex breakers and special welds. Remember, these drawings must be very clear for fabrica on.
Other informa on on the design drawing includes a bill of materials (BOM) including material, size and quan ty of the components; weld details; and a tle
block. The detail block will include:
- Scale of the drawing
- Drawing number
- Engineer, designer, dra sperson, and checker.
- Release date
- Revisions and revision dates.
- Drawing tle
- Vessel tag number
- Vessel size and descrip on
- Customer / owner
- Project number, plant name & loca on
- Approvals & stamps
Design data includes:
- Radiography data
- Post weld heat treatment
- Corrosion allowance
- Opera ng pressure and temperatures
- Design pressure and temperatures
- Hydrosta c test pressure
- Material specifica ons
- Shipping weight
- Cleaning and pain ng specifica ons
- Code used
ASME Boiler & Pressure Vessel Code (Sec on VIII, Division 1) (back to top)
Rules for construc on of pressure vessels: (These notes represent some design highlights as a guideline, and are not meant to be defini ve).
UG-4 General a) Materials subject to stress due to pressure shall conform to one of the specifica ons given in Sec on II, Part D, Subpart 1, Tables 1A, 1B and
3…
b) Materials for nonpressure parts, such as skirts, supports, baffles, lugs, clips, and extended heat transfer surfaces, need not conform to the
specifica on … but if a ached to the vessel by welding shall be of weldable quality …
UG-10 a) Iden fied Material with Complete Cer fica on from the Material Manufacturer … and iden fied to a single produc on lot …
UG-20 Design Temperature: a) Maximum … not less than the mean metal temperature (through the thickness) expected under opera ng condi ons …
b) Minimum … lowest expected in service …
UG-21 Design Pressure: Each element of a pressure vessel shall be designed for at least the most severe condi on of coincident pressure and
temperature expected in normal opera on.
UG-22 Loadings: The loadings to be considered in designing a vessel shall include those from: a) internal or external design pressure … b) weight of
the vessel and normal contents under opera ng or test condi ons … c) superimposed sta c reac ons from weights of a ached equipment,
such as motors, machinery, other vessels, piping, linings, and insula on; d) the a achment of: internals … vessel supports, such as lugs, rings,
skirts, saddles, and legs …
UG-23 Maximum Allowable Stress Values: a) … given in Subpart 1 of Sec on II, PartD. …
UG-25 Corrosion: a) The user or his designated agent (see U-2) shall specify corrosion allowances other than those required by the rules of this
division. … b) Vessels or parts of vessels subject to thinning by corrosion, erosion, or mechanical abrasion shall have provision made for the
desired life of the vessel by a suitable increase in the thickness of the material over that determined by the design formulas, …
UG-27 Thickness of Shells Under Internal Pressure: … c) Cylindrical Shells … (1) Circumferen al Stress (Longitudinal Joints). When the thickness does
not exceed one-half of the inside radius, or P [internal design pressure] does not exceed 0.385 SE [maximum allowable stress x joint efficiency
from UW-12], the following formulas shall apply:
t = PR / (SE – 0.6P)
(2) Longitudinal Stress (Circumferen al Joints). When the thickness does not exceed one-half of the inside radius, or P [internal design pressure]
does not exceed 1.25 SE [maximum allowable stress x joint efficiency from UW-12], the following formulas shall apply:
t = PR / (2SE + 0.4 P)
UG-32 Formed Heads, and Sec ons, Pressure on Concave Side: a) The minimum required thickness at the thinnest point a er forming of … heads
under pressure on the concave side … d) Ellipsoidal Heads With ts/L ≥ 0.002. The required thickness of a dished head of semiellipsoidal form,
in which half the minor axis (inside depth of the head minus the skirt) equals one-forth of the inside diameter of the head skirt, shall be
determined by
t = PD / (2SE – 0.2P)
UG-36 Openings in Pressure Vessels: a) Shape of Opening (1) Openings in cylindrical or conical por ons of vessels, or in formed heads, shall preferably
be circular, ellip cal, or obround. … b) Size of Openings (1) Properly reinforced openings in cylindrical and conical shells are not limited as to
size except with the following provisions for design. The rules in UG-36 through UG-43 apply to openings not exceeding the following: for
vessels 60 in. (1500 mm) inside diameter and less, one-half the vessel diameter, but not to exceed 20 in. (500 mm); for vessels over 60 in.
(1500 mm) inside diameter, one-third of vessel diameter, but not to exceed 40 in. (1000 mm).
UG-37 Reinforcement required for openings and formed heads. (back to top)
A = total cross-sec onal area of reinforcement required.
A1 = area in excess thickness in the vessel wall available for reinforcement.
A2 = area in excess thickness in the nozzle wall available for reinforcement.
A3 = area available for reinforcement when the nozzle extends inside the vessel wall.
A41 & A42 = cross-sec onal area of welds available for reinforcement.
A5 = cross-sec onal area of material added as reinforcement.
c = corrosion allowance.
F = correc on factor for ‘integrally reinforced’ (i.e., no reinforcement pad) rela ve to the plane (longitudinal to circumferen al stresses). A
designer may avoid requiring a reinforcement pad using this correc on. See Figure UG37 for correc ons. F = 1 is conserva ve.
t = Shell thickness – mill tolerance (0.01”) – corrosion allowance

tr = Required thickness of shell
tn = Nominal thickness of pipe – corrosion allowance
trn = Required thickness of nozzle
ti = Nominal thickness of pipe – 2 x corrosion allowance
d = Inside diameter of pipe + 2 x corrosion allowance

fr1 = fr2 = fr3 Ra o of allowable pipe stress to allowable shell stress
fr4 = 1 Ra o of allowable repad stress to allowable shell stress (use same material)
E1 = 1 Joint efficiency of welds
F=1
te = Shell thickness (can vary from 75% to 150% of the nominal shell thickness, mill tolerance is usually ignored)
leg = 1/4" or 3/8" typically (but depends on welding specifica ons and standards)
h = 1" to 2" is common (enough to weld a fillet weld on the inside of the vessel) though it can be 0" for nozzles installed flush with the inside of the vessel (like
liquid outlets or vessels where trays or tube bundles have to be installed).
Required Repad Area
A = d tr F + 2 tn tr F (1- fr1)
Area available in shell (use larger value)
A1 = d (E1 t - F tr) - 2 tn (E1 t - F tr) (1 - fr1)

Or = 2 (t + tn) (E1 t – F tr) - 2 tn (E1 t - F tr) (1 - fr1)
Area available in nozzle projec ng outward (use smaller value)
A2 = 5 (tn - trn) fr2 t

or = 5 (tn - trn) fr2 tn
Area available in nozzle project inward (use smaller value)
A3 = 5 t ti fr2
or = 5 ti ti fr2
or = 5 h ti fr2
Area available from nozzle welds (inward and outward)
A41 = A43 = (leg)² fr2
If A1 + A2 + A3 + A41 + A43 < A
Recalculate A2*:
A2*= 2 (tn – trn) (2.5 tn + te) fr2
A42 = (leg)² fr4
A5 required = A – (A1 + A2*+ A3 + A41 + A43 + A42)

Solve for Dp:
A5 = (Dp - d - 2tn) te fr4
Note: Dp should be a minimum of 4” larger than the nozzle pipe OD.
UG-44 Flanges and Pipe Fi ngs: The following standards covering flanges and pipe fi ngs are acceptable for use under this Division in accordance with the
requirements of UG-11. …
UG-45 Nozzle Neck Thickness: The minimum wall thickness of nozzle necks shall be the larger of (a) or (b) below. Shear stresses caused by UG-22
loadings shall not exceed the allowable shear stress in (c) below. … UG-45(a) The minimum wall thickness of a nozzle neck or other
connec on (including access openings and openings for inspec on) shall not be less than the thickness computed from the applicable
loadings in UG-22 plus the thickness added for allowances for corrosion and threading. ...
UG-46 Inspec on Openings: (a) All pressure vessels for use with compressed air and those subject to internal corrosion or having parts subject to
erosion or mechanical abrasion … shall be provided with suitable manhole, handhole, or other inspec on openings for examina on or
cleaning.
UG-119 Nameplates
[See Figure UG-118 for stamping informa on]
UG-125 Pressure Relief Devices – General: (a) All pressure vessels within the Scope of this Division, irrespec ve of size or pressure, shall be provided
with pressure relief devices in accordance with the requirements of UG-125 through UG-137.
UG-126 Pressure Relief Valves: (a) Safety, safety relief, and relief values shall be of the direct spring loaded type. …
UG-133 Determining of Pressure Relieving Requirements: (a) Except as permi ed in (b) below, the aggregate capacity of the pressure relief devices
connected to any vessel or system of vessels for the release of a liquid, air, steam, or other vapor shall be sufficient to carry off the maximum
quan ty that can be generated or supplied to the a ached equipment without permi ng a rise in pressure within the vessel of more than
16% above the maximum allowable working pressure when the pressure relief devices are blowing. …
UW-12 Joint Efficiencies

Table UW-12 gives the joint efficiencies E to be used in formulas of this Division for joints completed by an arc or gas welding process. Except as
required by UW-11(a)(5), a joint efficiency depends on the type of joint and on the degree of examina on of the joint …
Type of Joint Category Radiography

Full Spot None
Butt joints attained by
A, B, C, D 1.00 0.85 0.70
double-welding
Butt joints attained by
single-welding with A, B, C, D 0.90 0.80 0.65
backing strip
Butt joints attained by A, B, C --- --- 0.60
single-welding without
backing strip
Double full fillet lap
a --- --- 0.55
joint
Note: See Figure UW12 for complete details.
Design Considerations (back to top)

- The head or shell shall be used as the determining component for the allowable working stress for the vessel design, not a minor vessel part.
- The design loadings should consider not only the design pressure, but the weight of the vessel, reaction of supports, wind loading, seismic loadings, and
impact loadings where applicable.
- Corrosion Allowance is 1/16” or 1.60 mm for general service; and 1/8” or 3.20 mm for sour (corrosive) service. The owner may also specify a required
corrosion allowance.
- Under normal conditions, a vessel may not deflect more than 6” (150 mm) over 100’ (30m) or length.
- A plate thickness of 1/4” or 6 mm shall be used as a minimum for vessel heads and shell.
- Longitudinal seams shall not interfere with vessel openings, saddle wear plates, and reinforcing pads.
- Base rings on concrete shall be designed for an allowable stress of 625 psi (3200 kPa). Anchor bolt chairs are to be used for vessels greater than 18
meters in height.
- Skirts on horizontal vessels shall have an OD equal to the vessel it supports, with a minimum thickness of 1/4" or 6 mm. The skirt will have two vent
holes space at 180° located as high as possible without interfering with insulation. Vessels less than 4 feet in diameter (1200 mm) will have one access
port; larger vessels will have two access ports greater than 18” (450 mm) in diameter.
- Openings on vessels 2” NPS or greater will be flanged. Flanges rated from 150# to 600# will be raised face, and flanges rated over 600# will use ring
joints. Connections smaller than 2” NPS will use a 6000# full coupling as a minimum.
- Openings in the vessel used for drainage must have edges rounded to a radius of 1/8” (3.2 mm) or equal to one-half the thickness of the pipe will.
- All openings in the vessel will be designed for reinforcing pads. The pads will be made of the same material as the vessel shell or heads. A minimum
reinforcing pad of 4” (100 mm) plus the outside diameter of the opening is recommended. The reinforcing pad will be provided with a 1/4" (6 mm)
tapped tell-tale hole located 90° off of the longitudinal axis of the vessel.
- All manway blind flanges will have a davit arm for safe removal.
- Vessel drains must be provided. Vessels larger than 760 mm will have a minimum 2” NPS drain, and smaller vessels will have a minimum 1-1/2” NPS
connection.
- Handholes for vessels without a manway will be 6” NPS minimum, with blind flange.
- Tray packages will include detailed drawings and installation instructions. The live loading of the trays must be considered in the design. Two manways
will be provided for tray installation.
- When complete, a vessel name plate shall be welded to the vessel in a designated location.
Vessel Completion:
After heat treating and hydrotesting, the vessel should be prepared for shipping. Flange openings will be protected with steel plating and threaded connections
shall be plugged. A waterproof lubricant should be used to coat all nuts and bolts. Small parts shipped loose from the vessel shall be bagged and clearly marked
with the vessel number and location. Unprotected finished surfaces shall be protected with an anti-rust coating. The vessel will be cleaned and degreased prior
to shipment, and all hydrostatic test fluid will be removed. For winter conditions, antifreeze may be added to prevent residual water in the vessel from freezing.
Final documents will include a manufacturer’s data report with as-built drawings and design calculations; recording charts for the heat treatment; recording
charts for the hydrostatic pressure test; and a rubbing of the name plate.
Material Selec on: (back to top)

The mechanical engineer specifies the materials to be used in the manufacture of the pressure vessel based on the operating and design pressure and temperature and
pressure, and the properties of the the fluid being handled. The American Society for Testing Materials (ASTM) publishes material specifications which are acceptable to the
ASME for pressure vessel design and manufacture.
Each of the SA numbers designates a different steel-making process, or a different steel composition. Each numbered steel designation will have different properties for
pressure over a range of temperatures, or corrosive properties.
The following table shows some examples of different classes of materials used in the fabrication of a pressure vessel.
Part Specification Grade Description
Plate SA-516-70N Intermediate and low temperature service (410°C to -45°C)
Forgings (flanges & fittings) SA-105 Intermediate temperature service (400°C to -29°C)
SA-350 LF2 Low temperature service (-29°C to -45°C)
Pipe SA-106B Intermediate temperature service (400°C to -29°C)

SA-333 Gr.6 Low temperature service (-29°C to -45°C)
Studs/Nuts SA-193B7 / 194-2H Intermediate temperature service (400°C to -29°C)

SA-320L7 / 194-4 Low temperature service (-29°C to -45°C)
Once the above material specifica ons for the vessel have been set the engineer/designer can use the ASME pressure vessel code (i.e.: UCS-23) to determine
the maximum allowable stress to be used in the manufacture of the pressure vessel.
Material Stress Values: (back to top)
Properties of Materials for Carbon & Low Alloy Steel
Maximum Allowable Stress Values in Tension [x1000 psi]
Material Spec. Maximum Design Temperatures [°F]
Number Grade -20 700 750 800 850 900 950 1050 1100 1150
to
650
SA-283 C 12.6 - - - - - - - - -
SA-285 C 13.7 13.2 12.0 10.2 8.3 6.5 - - - -
SA-515 55 13.7 13.2 12.0 10.2 8.3 6.5 4.5 2.5 - -
SA-515 60 15.0 14.3 12.9 10.8 8.6 6.5 4.5 2.5 - -
SA-515 65 16.2 15.5 13.8 11.4 8.9 6.5 4.5 2.5 - -
SA-515 70 17.5 16.6 14.7 12.0 9.2 6.5 4.5 2.5 - -
SA-516 55 13.7 13.2 12.0 10.2 8.3 6.5 4.5 2.5 - -
SA-516 60 15.0 14.3 12.9 10.8 8.6 6.5 4.5 2.5 - -
SA-516 65 16.2 15.5 13.8 11.4 8.9 6.5 4.5 2.5 - -
SA-516 70 17.5 16.6 14.7 12.0 9.2 6.5 4.5 2.5 - -
SA-105 17.5 16.6 14.7 12.0 9.2 6.5 4.5 2.5 - -
SA-181 I 15.0 14.3 12.9 10.8 8.6 6.5 4.5 2.5 - -
SA-350 LF1 15.0 - - - - - - - - -
SA-350 LF2 17.5 - - - - - - - - -
SA-53 B 15.0 14.3 12.9 10.8 8.6 6.5 - - - -
SA-106 B 15.0 14.3 12.9 10.8 8.6 6.5 4.5 2.5 - -
SA-333 Gr.6
SA-193 B7< 25.0 25.0 23.6 21.0 17.0 12.5 8.5 4.5 - -
2 1/2"
SA-194 2H - - - - - - - - -
Steel Plate Nominal Thickness and Weight: (back to top)

Note: Density of steel = 490 lb/ ³
Conversion 1 lb/ ² = 4.88 kg/m² for weight/area below
1 lb/ ³ = 16.0185 kg/m³
Weight [lb/ft²]
Nominal Size [inches]
1/4 10.20
5/16 12.75
3/8 15.30
7/16 17.85
1/2 20.40
9/16 22.95
5/8 25.50
11/16 28.05
3/4 30.60
13/16 33.15
7/8 35.70
1 40.80
1-1/8 45.90
1-1/4 51.00
1-3/8 56.10
1-1/2 61.20
1-5/8 66.30
1-3/4 71.40
1-7/8 76.50
2 81.60
2-1/8 86.70
2-1/4 91.80
2-1/2 102.00
2-3/4 112.20
3 122.40
3-1/4 132.60
3-1/2 142.80
3-3/4 15.00
4 163.20
4-1/4 173.40
4-1/2 183.40
4-3/4 183.60
Joint Efficiencies: (back to top)
JOINT EFFICIENCY RATINGS FOR WELDED JOINTS

JOINT EFFICIENCY, “E”
a. b. c.
TYPES OF JOINTS CODE per UW-12 Fully Radio- Spot Not
graphed Examined Examined
Bu joints as a ained by
double welding or by other
means will obtain the same 1.00 0.85 0.70
quality of deposited weld
metal on the inside and the
outside weld surface.
Backing strips if used shall
be removed a er welding.
Single welded bu joint 0.90 0.80 0.65

with backing strip which
remains in place a er
welding.
Single welded bu joint - - 0.60

without the use of a
backing strip.
Double full fillet lap joint - - 0.55
Single full fillet lap joint - - 0.50

without plug welds
Single full fillet lap joint - - 0.45

without plug welds.
Shell and Head Design Parameters: (back to top)

The formulae for pressure vessel shell and head thickness calcula ons is found in sec on UG-27 and UG-32 when the vessel is subjected to internal pressure.
This informa on is provided by the process engineering group. By using the corrosion allowance added to the inside diameter of the vessel a factor of safety
is added to the vessel design, for details see Figure 6-1.
Terminology
R = Inside radius in corroded condi on
Ro = Outside radius (1/2 of the outside diameter of the shell)

C.A. = Corrosion allowance
t = Shell thickness + C.A.
If a shell is fabricated from manufactured pipe the inside radius is not altered to reflect the mill tolerance of the pipe.
Thickness Defini ons

It is essen al that the designer understand the various terms used to define what exactly is meant by wall thickness.
1. The nominal thickness is the thickness of material that is commercially available to the pressure vessel manufacturer. In a sense, it is the thickness not
including mill tolerances from manufacturing.
2. Required thickness is the thickness calculated by formulae from the pressure vessel design code, before the corrosion allowance is added.
3. Design thickness is the sum of the calculated thickness plus the corrosion allowance.
If the pressure vessel is made from pipe, a -12.5% mill tolerance (variance in the manufacture of the pipe) must be taken into account when selec ng the final
wall thickness that exceeds the design thickness.
Internal Pressure Vessel Pressures:
1. The Limit of Hydrotes ng is equal to 1.75 mes the Maximum Allowable Working Pressure (MAWP), or 90% of yield strength.
2. Standard Hydrosta c Tes ng is 1.5 mes the new and cold MAWP.
3. Maximum Allowable Pressure (New & Cold) is calculated in the uncorroded condi on at ambient (surrounding) temperature.
4. Maximum Allowable Working Pressure (Hot & Corroded) is the maximum allowable pressure at the top of the vessel in its normal opera ng posi on at
the design temperature. It is the smallest value calculated for essen al parts in the vessel corrected for sta c head or any combina on of loadings listed
in UG-22. This pressure is stamped onto the nameplate and is used to set pressure-relieving devices (otherwise the design pressure is used as the set
point).
5. Design Pressure corresponds to the most severe condi on of coincident pressure and temperature for normal opera on. It is usually taken as the larger
value of 10% or 25 psi (200 KPa) above the maximum opera ng pressure.
6. Maximum Relieving Pressure is 10% above MAWP (hot & corroded) for build-up during relief.
7. Design Temperature is the temperature that corresponds to the design pressure. The Minimum Design Metal Temperature (MDMT) is the lowest
temperature expected in service or the lowest allowable temperature for individual parts.
8. Normal Opera ng Pressure is the average expected pressure during normal opera on measured at the top of the vessel.
External Pressure Vessel Pressures:
1. Full vacuum is 15 psig, or 100 KPa.

2. Pressure Induced by Jacke ng Fluid
Pressure Vessel Tes ng Prac ces:

Tes ng a pressure vessel consists of pressurizing it to a hydrosta c pressure of 150% of its maximum design pressure.
The vessel tes ng is performed under new and cold condi ons at ambient temperature. In order to sufficiently stress the vessel material, the Maximum
Allowable Working Pressure (New and Cold) can be used. Since design formulae for the head and the shell may result in different pressures the minimum
pressure value is used.
Different Pressure Vessel Weights: (back to top)
Es mates of pressure vessel weights are made for the following reasons:
1. To provide the design informa on used to confirm the vessel structural strength.
2. Informa on provided for designing support structures and founda ons.
3. For informa on regarding rigging and loading requirements.
4. For es ma ng manufacturing and shipping costs.
Four Different Weights
1. Fabricated Weight – WF
2. Empty Weight – WE
3. Opera ng Weight – WO
4. Test Weight – WT
1. Fabricated Weight (WF) is inclusive of everything the pressure vessel manufacturer supplies or installs in the vessels manufacture. The fabricated
weight can be transformed to shipping weight by including such items as: shipping saddles, extraneous materials shipped with the vessel, and e
downs.
2. Empty Weight (WE) is similar to dry weight or li weight and is calculated by adding the following items: internal trays, refractory, ladders and
pla orms, fireproofing, insula on, external piping, inert packing materials, and a ached reboilers.
3. Opera ng Weight (WO) is the weight calculated by adding the following items to the empty weight: desiccant, catalyst, molecular sieve material, clay or
similar packing materials, opera ng liquid in the vessel, on trays, and in piping and reboilers.
4. Test Weight (WT) is calculated by adding the weight of the test fluid (typically water) to the empty weight in the vessel piping and reboilers. This weight
is the field test weight and should not be confused with the manufacturers shop test weight (which is the weight of the test fluid added to the
fabricated weight).
The calculated weight values should be in pounds or kilograms rounded to three decimal places, as more significant decimal places result in calcula on
inaccuracies.
Weld Neck Projec on Matrix: (back to top)

To use the “Weld Neck Projec on Matrix” determine the size and flange ra ng of the nozzle required for the pressure vessel being deigned. From the matrix
marked “O.D. PIPE SIZE”, select the pipe size, and then select the column with the appropriate nozzle ra ng. Where this row and column intersect on the
matrix the correct nozzle projec on will be found.
These projec ons assume that there is no insula on. For insulated vessels, simply add the insula on thickness to the projec on.
Weld Neck Flange Projec on [mm]

PIPE SIZE A.N.S.I. WELD NECK FLANGE Ra ng
[mm OD] DIMENSIONS IN mm
150# 300# 600# 900# 1500# 2500#
60.3mm 180 180 180 200 200 210
88.9mm 180 180 200 200 200 250
114.3mm 180 200 200 200 250 300
168.3mm 200 200 200 250 250 400
219.1mm 200 200 250 250 300 500
273.1mm 210 210 250 300 350 550
323.9mm 210 250 250 300 400
355.6mm 250 250 250 350 400
406.4mm 250 250 300 350 400
457mm 250 250 300 400 450
508mm 250 250 300 400 450
610mm 250 300 300 400 500
Pressure Vessel Skir ng Matrix (back to top)
Skirt Dimensions
VESSEL DIAMETER METRIC UNITS
IMPERIAL METRIC
UNITS UNITS A B C D
24” 610mm 610 380 60.3 219.1
30” 765mm 685 380 60.3 219.1
36” 915mm 765 410 60.3 273.1
42” 1070mm 840 460 88.9 323.9
48” 1220mm 915 460 88.9 323.9
54” 1370mm 990 510 88.9 355.6
60” 1525mm 1070 510 114.3 355.6
66” 1675mm 1120 510 114.3 406.4
72” 1830mm 1145 510 114.3 406.4
78” 1980mm 1195 510 114.3 406.4
84” 2135mm 1220 510 114.3 406.4
Where:
A is the average skirt height from the circumferen al seam of the vessel.
B is the inspec on port opening, and may have to be increased of a double base ring is required.
C represents the skir ng vent port opening, and should be located as close to the vessel head as possible. However, allowances must be made to make
sure the vent port clears any vessel insula on. The vents must have 180 degrees of separa on from each other.
D is the skirt inspec on port opening. The reinforcing pipe sleeve welded into the port opening must project at least 50mm outside of the skirt (or by the
thickness of any skir ng fire protec on). A minimum interior sleeve projec on of 25mm must be maintained. All pipe sleeves must be schedule 40
pipe unless otherwise specified for vessel loading requirements.
Note:
- Pipe access openings must be 50mm or one pipe size larger than the pipe exi ng the skirt.
- All nozzle flanges on the bo om of the vessel must clear the top of concrete founda ons by at least 6” or 150mm.
Base Ring Design Parameters: (back to top)
The above table illustrates the height / diameter ra o to empty vessel weight. If the ra o vs. weight falls into the small box labeled “Single Plate Base Ring”
then go to the Single Plate Base Ring Detail drawing and chart to size the base ring.
If the ra o vs. weight falls into the large box labeled “Double Plate Base Ring” then go to the Double Plate Base Ring and Chairs drawing and chart to size the
base ring.
Single Plate Base Ring Detail
SINGLE PLATE BASE RING
BOLT SIZE
Dimension [mm]
IMPERIAL METRIC
UNITS UNITS A B C D E F
3/4” 19mm 65 38 27 25 16 100

7/8” 22mm 70 41 29 28 19 100
1” 25mm 75 45 30 32 22 115
1 1/8” 29mm 85 48 37 35 25 130
1 1/4” 32mm 95 50 45 38 32 140
1 1/2” 38mm 115 57 58 45 38 165
Double Base Ring Plate and Chairs
Double Plate Ring & Chair
BOLT SIZE
Dimensions [mm]
Imperial Metric
A B C D E F G H J K SLEEVE SIZE
Units Units
1” 25mm 90 45 45 44 10 65 16 150 12.7 130 42.2 mm - Sch. 40

1 1/8” 29mm 100 50 50 50 10 65 19 180 16 135 48.3 mm - Sch. 80
1 1/4” 30mm 100 50 50 50 12.7 85 19 200 16 140 48.3 mm - Sch. 40
1 1/2” 38mm 120 60 60 60 12.7 100 25 230 19 165 60.3 mm - Sch. 80
1 3/4” 45mm 130 65 65 60 12.7 100 25 250 22 180 60.3 mm - Sch. 40
2” 51mm 130 70 70 75 16 115 32 250 22 190 73.0 mm - Sch. 80
2 1/4” 57mm 130 70 80 75 16 115 32 280 25 200 73.0 mm - Sch. 40
2 1/2” 64mm 160 75 85 90 16 140 38 280 25 210 88.9 mm - Sch. 80
2 3/4” 70mm 165 75 90 90 16 140 40 280 25 230 88.9 mm - Sch. 40
3” 76mm 180 85 95 115 16 150 40 300 32 240 114.3 mm - Sch. 40
Large Tower Access Opening
The size of the opening allows easy access by field personnel to the bo om of the vessel and its cons tuent hardware. Reinforcing is required around the
opening to s ffen the skir ng where the opening is cut into the vessel skirt. Note: the base ring is not cut out but s ll goes the en re way around the vessel
and is bolted to the concrete founda on.
Saddle Design (back to top)
Saddle Layout
Dimensions [mm]
Vessel Anchor
# Rib
Outside Diameter A B C D E F G H J Bolt K
Ribs Thk
Size
24” 610mm 500 100 150 12.7 10 10 8 45 - - - 1” 300
30” 762mm 650 100 150 12.7 10 10 10 45 - - - 1” 350
36” 915mm 850 150 200 12.7 10 10 10 45 - - - 1” 550
42” 1070mm 1000 150 200 12.7 10 10 10 45 - 1 10 1” 700
48” 1220mm 1050 175 225 12.7 12.7 12.7 10 45 - 1 12.7 1” 750
54” 1370mm 1150 175 225 12.7 12.7 12.7 10 45 - 1 12.7 1” 850
60” 1520mm 1300 175 225 12.7 12.7 12.7 12.7 45 230 2 12.7 1” 1000
66” 1680mm 1400 200 225 12.7 12.7 12.7 12.7 45 250 2 12.7 1” 1100
72” 1830mm 1550 200 250 16 12.7 12.7 12.7 50 250 3 12.7 1” 1250
78” 1980mm 1750 200 250 16 12.7 12.7 12.7 50 450 3 12.7 1” 1450
84” 2130mm 1850 200 250 16 12.7 12.7 12.7 50 450 3 12.7 1” 1550
90” 2290mm 2000 200 250 16 16 16 12.7 50 500 3 12.7 1” 1700
96” 2440mm 2150 200 250 16 16 16 12.7 50 530 3 12.7 1 -1/4” 1850
102” 2590mm 2250 200 250 16 16 16 12.7 50 560 3 12.7 1 -1/4” 1950
108” 2740mm 2400 200 250 19 16 16 16 50 610 3 16 1 -1/4” 2100
114” 2900mm 2500 200 250 19 16 16 16 50 630 3 16 1- 1/4” 2200
120” 3050mm 2650 250 250 19 16 16 16 50 690 3 16 1- 1/4” 2350
126” 3200mm 2800 250 300 19 16 16 16 75 710 3 16 1 -1/4” 2500
132” 3350mm 2900 250 300 19 19 19 16 75 740 3 16 1- 1/4” 2600
138” 3500mm 3050 250 300 19 19 19 16 75 760 3 16 1 -1/4” 2750
144” 3660mm 3200 250 300 19 19 19 16 75 810 3 16 1 -1/4” 2900
150” 3810mm 3350 300 300 19 19 19 16 75 810 3 16 1 1/4” 3050
156” 3960mm 3500 300 350 25 25 25 19 100 580 5 16 1 1/4” 3200
162” 4110mm 3650 300 350 25 25 25 19 100 610 5 16 1 1/4” 3350
168” 4270mm 3800 300 350 25 25 25 19 100 630 5 16 1 1/4” 3500
174” 4420mm 3950 300 350 25 25 25 19 100 660 5 16 1 1/4” 3650
Slo ed Hole Detail
Saddle Slo ed Hole (For Expansion & Contrac on)
Distance Dimensions [mm]

Between PRESSURE VESSEL OPERATING TEMPERATURE [°C]
Saddles
-50 50 100 150 200 250 300 350 400 450
[m]
A A A A A A A A A A
3 0 0 0 10 10 10 13 16 22 22
6 0 0 6 10 16 20 25 28 31 35
10 6 3 10 16 20 28 35 41 41 50
13 6 3 10 20 28 38 47 53 60 63
16 10 6 13 25 35 41 56 66 75 85
20 10 6 16 31 41 53 70 78 91 103
23 13 6 20 35 47 63 78 91 106 116
26 16 10 22 41 56 70 97 110 128 145
30 16 10 25 47 66 91 113 128 150 166
Ver cal Manway Design (back to top)
DESIGN NOTES:
1. All dimensions are in millimeters
2. All welds are to be a minimum of 10mm.
3. Center stud on plate is to be 25mm dia.
4. The sleeve is to be 73.0mm dia. std. pipe.
5. The top plate handle is to 20mm dia. round steel bar stock.
6. The design limit on the davit arm shown above is 640 KG in weight.
7. The davit arm is to be constructed from 60.3 XXH pipe.
8. For stud bolt sizes see pages 41-42 in the text “Pipe Dra ing” by Hartman, Williams
Horizontal Manway Design
DESIGN NOTES:
1. All dimensions are in millimeters

2. All welds are to be a minimum of 10mm.
3. Center stud on plate is to be 25mm dia.
4. The sleeve is to be 73.0mm dia. std. pipe.
5. The top plate handle is to 20mm dia. round steel bar stock.
6. The design limit on the davit arm shown above is 640 KG in weight.
7. The davit arm is to be constructed from 60.3 XXH pipe.
8. For stud bolt sizes see pages 41-42 in the text “Pipe Dra ing” by Hartman, Williams
Vortex Breaker Design (back to top)
DESIGN NOTES:
1. All vortex material is to be 6mm mild steel plate unless otherwise specified.
2. Weld sizes are to be 6mm unless otherwise specified.
3. Contour the bo om of the vortex breaker the match the inside contour of the pressure vessel.
4. Dimension “D” is equal to the O.D. of the nozzle pipe. If the pipe is an odd number of millimeters round it up to the next largest mul ple of 10mm.
Pressure Vessel Head - Volume Table (back to top)
Volumes listed are approximate volumes of dished por on of head. Straight flanges are not included.
[Note: I.D. in feet, Volume in USgallons]
Imperial Metric
Surface Area
[ID in feet, [ID in meters
[D in meters, Area in square meters]
Volume in USGallons] Volume in cubic meters]
V [m³] = 0.124 (I.D.

2:1 Ellipsoid Volume = 0.954 (I.D.)³
[m])³ A [m²] = 1.084 D²
V [m³] = 0.255 (I.D.

Hemispherical Volume = 1.958 (I.D.)³
[m])³ A [m²] = Π D² / 2
V [m³] = 0.076 (I.D.

Torospherical Volume = 0.582 (I.D.)³
[m])³ A [m²] = 0.9286 D²
Full Volumes of Vessel Heads
Torospherical Head 2:1 Ellipsoidal Head Hemispherical Head

Inside Volume Inside Volume Inside Volume
Diameter Gallons Diameter Gallons Diameter Gallons
Inches Inches Inches
12” 0.58 12” 0.95 12” 1.95
18” 1.96 18” 3.2 18” 6.6
24” 4.65 24” 7.6 24” 15.6
30” 9.2 30” 15 30” 30.5
36” 15.7 36” 26 36” 53
42” 25 42” 41 42” 84
48” 37 48” 61 48” 125
54” 53 54” 87 54” 178
60” 73 60” 119 60” 245
66” 97 66” 159 66” 326
72” 126 72” 206 72” 423
78” 160 78” 262 78” 638
84” 200 84” 327 84” 672
90” 246 90” 403 90” 826
96” 298 96” 489 96” 1003
102” 357 102” 586 102” 1203
108” 424 108” 696 108” 1428
114” 499 114” 818 114” 1679
120” 582 120” 954 120” 1958
126” 674 126” 1110 126” 2267
132” 775 132” 1270 132” 2606
138” 885 138” 1452 138” 2978
144” 1006 144” 1649 144” 3384
Flange Ra ng: (back to top)
Using the maximum design temperature of the vessel, select the column with a pressure ra ng that is higher than the vessel design pressure. That column will
represent the flange ra ng.
For example, if the design temperature was 300°F and design pressure was 1200 psig: Select 300°F from the le -hand column and move across to 1315 psig
(the first value higher than 1200 psig). The top of that column will show the 600# flange ra ng required for this vessel.
PRESSURE – TEMPERATURE RATINGS

AMERICAN STANDARD CARBON STEEL PIPE FLANGES
Flange Ra ng: 150 # 300 # 400 # 600 # 900 # 1500 # 2500 #
Service
Temperature MAXIMUM ALLOWABLE NON-SHOCK PRESSURE [psig].
[° F]
-2O TO 100 285 740 990 1480 2220 3705 6170
200 F 260 675 900 1350 2025 3375 5625
300 F 230 655 875 1315 1970 3280 5470
400 F 200 635 845 1270 1900 3170 5280
500 F 170 600 800 1200 1795 2995 4990
600 F 140 550 730 1095 1640 2735 4560
650 F 125 535 715 1075 1610 2685 4475
700 F 110 535 710 1065 1600 2665 4440
750 F 95 505 670 1010 1510 2520 4200
800 F 80 410 550 825 1235 2060 3430
850 F 65 270 355 535 805 1340 2230
900 F 50 170 230 345 515 860 1430
950 F 35 105 140 205 310 515 860
1000 F 20 50 70 105 155 260 430
Example: Pressure Vessel Design Calcula ons for Pressure Vessels under Internal Pressure (back to top)
The following formulae are taken from sec ons UG-27 and UG-31 of the Pressure Vessel Design Code for the calcula on of shell and head thicknesses exposed
to internal pressure. For a more in-depth study of pressure vessel structural design, the student should refer to the latest edi on of the ASME Boiler &
Pressure Vessel Design Code.
The pressure vessel design calcula ons will use with the outside radius or diameter of the vessel under design.
Vessel Shell & Head Thickness Design

Defini on of Design Formulae Constants and Variables
D = Inside diameter of vessel in the corroded condi on

Do = Outside diameter of vessel
E = Joint efficiency of welds
L = Inside crown radius in inches corroded condi on
Lo = Outside crown radius in inches
R = Inside radius in inches corroded condi on
Ro = Outside radius in inches
S = Stress value of material in psi
t = Wall thickness in inches
tn = Nozzle wall thickness less the mill tolerance.
P = Design pressure or max. allowable pressure in psig
tr = required thickness of seamless shell or head due to pressure
trn = required thickness if seamless nozzle
Inside Diameter 72”

Vessel Material SA-516, Grade 70 (17500 psig @ 450°F)
Design Temperature 450 deg. F
Design pressure 500 psig
Longitudinal seam single-welded bu joint no backing, not examined
Corrosion allowance 0.125”
1. Pressure Vessel Design “Cylindrical Shell” Thickness & Pressure Formulae
a) Thickness of Shells Under Internal Pressure [ASME Sec on VIII, Div 1, UG-27, UG-32]
Longitudinal Stress t= P R / (2SE + 0.4P)

Circumferen al Stress t= P R / (SE – 0.6 P)
Ellipsoidal Head t= P D / (2SE – 0.2 P)
Longitudinal tr = (500 psig) x (72” / 2) / (2 x 17500 psig x 0.6 + 0.4 x 500 psig)
= 0.849”
Circumferen al tr = (500 psig) x (72”/2) / (17500 psig x 0.6 – 0.6 x 500 psig)
= 1.765”
2:1 Ellipsoidal Head
tr = (500 psig) x (72”) / (2 x 17500 psig x 0.6 – 0.2 x 500 psig)
= 1.723”
Using the maximum thickness plus a corrosion allowance and mill tolerance.
t = 1.765 + 0.125 [C.A.] + 0.01" [mill tol.] = 1.900” (a 2” plate would be used).
b) Maximum Working Pressure (MWP, N&C) = pressure based on 2” – 0.01” (mill tol.).
Rearranging the formulae for circumferen al stress:
P = SEt / (R + 0.6t)
= (17500 psig) (0.6) (1.99”) / [(72”/2) + 0.6 (1.99”)]
= 561.8 psig
c) Test Pressure = MAWP(N&C) x 1.5
Test Pressure = 1.5 x 561.8 psig

= 842.7 psig
d) Maximum Allowable Working Pressure (hot & corroded)
t = 2”plate – 0.125” – 0.01” mill tol. = 1.865”
P = (17500 psig) (0.6) (1.865”) / [(72”/2) + 0.6 (1.865”)]
= 527.6 psig
Nozzle Wall Thickness Design:

Nozzle: 4” NPS (4.5” OD)
Shell Diameter: 72” ID
Vessel Material SA-516, Grade 70 (17500 psig @ 450°F)
Pipe Material SA-106B (15000 @ 450°F)
Design Temperature 450 deg. F
Design pressure 500 psig
Corrosion allowance 0.125”
Full Radiography UW11(a)
1. Determine the require pressure.

trn(nozzle) = PRo / (SE + 0.4P)
= (500 psig)(4.5”/2) / [(15000)(1.0) + (0.4 x 500 psig)]

= 0.074”
2. Determine the shell thickness:
tr(shell) = PRi / (SE - 0.6P)
= (500 psig)(72”/2) / [(17500)(1.0) - (0.6 x 500 psig)]

= 1.047”
3. Determine Standard wall thickness:
t = STD wall thickness
= 0.237”
Choose the greater of 1 and (the smaller of 2 and 3).
The smaller of 2 and 3 is 0.237”. The large of this number or #1 is 0.237”. Choose a wall thickness greater than 0.237” + 0.125” (C.A.). A 4” Sch.160 pipe has a
thickness of 0.531” (Sch.80 pipe was 0.337” and not adequate for this design). The mill tolerance of the pipe wall should be considered.
Reinforcing Pad Design:

- ASME Sec on VIII Div 1, UG - 37 shows the requirements for reinforcing.
- When nozzles are a ached to the pressure vessels a certain amount of material is removed from the vessel. This weakens the vessel and, as a result,
addi onal steel may be added to the vessel in the form of a reinforcing pad.
- The most common method for determining the size of a reinforcing pad (repad) is the Area Replacement Method, in which the area removed from the
vessel shell may be replaced by: extra shell thickness, extra nozzle thickness, internal projec on of the nozzle inside the vessel, extra welds, and/or a
reinforcing pad.
- It is advisable to use the same material as the vessel shell for the reinforcement pad. The pad thickness should be not less than75% and no more than
150% of the part it is being a ached to (shell or head). It is common to use the same thickness as the vessel as it may be rolled to the contour of the
vessel during forming, or the nozzle reinforcing pad can be created from scrap le over from manufacturing.
- Tell-tale holes should be provided with a 1/4” tapped hole at least 45° off the longitudinal center line and given an air-soap test [UW-15(d)].
- The minimum fillet weld size which may be used to weld a pad to a shell is to be 6mm (1/4”). This, in turn, limits the pad thickness to a minimum of
6mm (1/4”).
- Some pressure vessel manufacturers specify that the minimum reinforcing pad diameter used is to be 100mm (4”) greater than the nozzle outside
diameter.
- If the nozzle neck is made from pipe it is easiest to use the outside radius equa ons for calcula on of required thickness since the outside pipe
dimensions are closely controlled and monitored during the manufacturing process.
Example:
A aching a 4” sch.80 nozzle with 300#RF flange onto a vessel with a thickness of 2”, CA=0.125”:
Nozzle OD = 4.5” Sch.160
t = 2” – 0.01” – 0.125 = 1.865” fr1 = 15,000/17,500 = 0.8571
tr = 1.765” fr1 =fr2 = fr3
trn = 0.074” fr4 = 1 (repad material same as shell)
tn = 0.531” – 0.125” C.A. = 0.406” E1 = 1
= 0.531 – 2 (0.125”) = 0.281” F=1
d = 3.438” + 2(.125) = 3.688”
Area Required
A = d tr F + 2 tn tr F (1- fr1)
= (3.688”) (1.765”) (1) + 2(0.406)(1.765)(1-.8571)

A = 6.714 in²
Area available in shell (use larger value)
A1 = d (E1 t - F tr) - 2 tn (E1 t - F tr) (1 - fr1)
or = 2 (t + tn) (E1 t – F tr) - 2 tn (E1 t - F tr) (1 - fr1)
A1
= (3.688”) [(1)(1.865”) – (1)(1.765)] – 2(0.406)[(1)(1.865)- (1)(1.765)](1-0.8571) = 0.357 in²
or
= 2 (1.865” + 0.406”) [(1)(1.865”) – (1)(1.765)] – 2(0.406)[(1)(1.865)- (1)(1.765)](1-0.8571) = 0.441 in²
Area available in nozzle projec ng outward (use smaller value)

A2 = 5 (tn - trn) fr2 t
or = 5 (tn - trn) fr2 tn
A2 = 5 (0.406”- 0.074”) (0.8571) (1.865”) = 2.654 in²

= 5 (0.406” - 0.074”) (0.8571) (0.406”) = 0.578 in²
Area available in nozzle project inward (use smaller value)

A3 = 5 t ti fr2
or = 5 ti ti fr2
or = 5 h ti fr2
Assume an internal projec on of 3.0”
A3 = 5 (1.865”) (0.281”) (0.8571) = 2.246 in²

or = 5 (0.281”)² (0.8571) = 0.338 in²
or = 5 (3.0” – 0.125”) (0.281”) (0.8571) = 3.46 in²
Area available from nozzle welds (inward and outward)

A4 = (leg)² fr2
Assuming a 1/4" fillet weld, each leg is 0.25”
A41 = (0.25)² (0.8571) = 0.054 in²

A43 = (0.25)² (0.8571) = 0.054 in²
A1 + A2 + A3 + A41 + A43 = 0.441 + 0.578 + 0.338 + 0.054 + 0.054 = 1.47 in²

Since 1.47 in² < 6.714 in² the opening is not adequately reinforced. A reinforcing pad is required.
Assume a reinforcing pad the same thickness of the wall.
For a reinforced nozzle: A, A1, A3, A41 and A43 are the same. A2 may be recalculated; A42 is added for the weld on the reinforcing pad; and the area of the
reinforcing element must be added.
Area required in the reinforcing element

Recalculate A2:
A2 = 2 (tn – trn) (2.5 tn + te) fr2
= 2 (0.406 – 0.074) [2.5 (0.406) + 2”] (0.8751) = 1.752 in²

A5 = 6.714” - (0.441 + 1.752 + 0.338 + 0.054 + 0.054+ 0.063*) = 4.0121 in²
*the repad weld (A42) uses (leg)² fr4 where fr4 = 1
A5 = (Dp - d - 2tn) te fr4
4.0121 in² = [Dp – (3.688”) - 2 (0.406”)] (2”) (1)
Dp = 6.51” (One might default to a diameter of 8.5”, which is 4” larger than the pipe OD)
(back to top)

Mechanical Design: Skirt Design Saddle Design

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Design Informa on:

Pressure Vessel Design:

ASME American Society of Mechanical Engineers

AISC American Society of Steel Construction

ANSI American National Standards Institute

API American Petroleum Institute

ASTM American Society of Testing and Materials

BOM Bill of Materials

BOP Bottom of pipe

IDD Inside depth of dish

MAWP Maximum Allowable Working Pressure

RTJ Ring joint

TOC Top of concrete

TOS Top of steel

XH Extra heavy (pipe)

XXH Double-extra heavy (pipe)

Vessel Components (back to top)

Vessel Head-Types (back to top)

Vessel A achments (External)

a) Net posi ve suc on head required (NPSHR) by a downstream pump.

Skirt details are illustrated below:

Fire Protec on:

Saddle Design (Horizontal Vessels) (back to top)

Piping Connec ons (back to top)

Nominal Pipe Sizes: (back to top)

Nominal Pipe Sizes

Imperial NPS [inches] Metric [mm]

Other External A achments

Vessel A achments (Internal) (back to top)

Mist Extractor (Demister)

Exchangers (back to top)

The Design Process (back to top)

Pressure Vessel Drawings (back to top)

t = Shell thickness – mill tolerance (0.01”) – corrosion allowance

tn = Nominal thickness of pipe – corrosion allowance

trn = Required thickness of nozzle

ti = Nominal thickness of pipe – 2 x corrosion allowance

d = Inside diameter of pipe + 2 x corrosion allowance

E1 = 1 Joint eﬃciency of welds

Area available in shell (use larger value)

A1 = d (E1 t - F tr) - 2 tn (E1 t - F tr) (1 - fr1)

Area available in nozzle projec ng outward (use smaller value)

A2 = 5 (tn - trn) fr2 t

Area available in nozzle project inward (use smaller value)

Area available from nozzle welds (inward and outward)

A41 = A43 = (leg)² fr2

A42 = (leg)² fr4

A5 required = A – (A1 + A2*+ A3 + A41 + A43 + A42)

Note: Dp should be a minimum of 4” larger than the nozzle pipe OD.

UW-12 Joint Eﬃciencies

Type of Joint Category Radiography

Note: See Figure UW12 for complete details.

Design Considerations (back to top)

Material Selec on: (back to top)

Part Specification Grade Description

Plate SA-516-70N Intermediate and low temperature service (410°C to -45°C)

Pipe SA-106B Intermediate temperature service (400°C to -29°C)

Studs/Nuts SA-193B7 / 194-2H Intermediate temperature service (400°C to -29°C)

Material Spec. Maximum Design Temperatures [°F]

Steel Plate Nominal Thickness and Weight: (back to top)

Joint Eﬃciencies: (back to top)

JOINT EFFICIENCY RATINGS FOR WELDED JOINTS