DESIGN of PRESSURE VESSEL Disusun oleh : Agus Suwarno PUSPETINDO - GRESIK

Pressure vessels are used in many industries (e.g., hydrocarbon processing, chem ical, power, pharmaceutical, food and beverage). The mechanical design of most p ressure vessels is done in accordance with the requirements contained in the ASM E Boiler and Pressure Vessel Code, Section VIII.

Main Pressure Vessel Components - Shell - Head - Nozzle - Support

SHELL The shell is the primary component that contains the pressure. Pressure vessel s hells are welded together to form a structure that has a common rotational axis. Most pressure vessel shells are either cylindrical, spherical, or conical in sh ape.

HEAD Head is part/component to close at both end of shell. Heads are typically curved rather than flat. Curved configurations are stronger and allow the heads to be thinner, lighter, and less expensive than flat heads. Heads can also be used ins ide a vessel.

NOZZLES A nozzle is a cylindrical component that penetrates the shell or heads of a pres sure vessel. The nozzle ends are usually flanged to allow for the necessary conn ections and to permit easy disassembly for maintenance or access.

 Nozzles are applications: used for the following Attach piping for flow into or out of the vessel. Attach instrument connections, (e.g., level gauges, thermowells,or pressure gauges) Provide access to the vess el interior at manways. Provide for direct attachment of other equipment items, (e.g., aheat exchanger or mixer).

SUPPORT The type of support that is used depends primarily on the size and orientation o f the pressure vessel. In all cases, the pressure vessel support must be adequat e for the applied weight, wind, and earthquake loads. The design pressure of the vessel is not a consideration in the design of the support since the support is not pressurized. Temperature may be a consideration in support design from the standpoint of material selection and provision for differential thermal expansio n.

Material Selection Factors The main factors that influence material selection are: Strength Corrosion Resis tance Resistance to Hydrogen Attack Fracture Toughness Fabricability

Strength Strength is a material's ability to withstand an imposed force or stress. Streng th is a significant factor in the material selection for a particular applicatio n. Strength determines how thick a component must be to withstand the imposed lo ads

Corrosion Resistance Corrosion is the deterioration of metals by chemical action. A material's resist ance to corrosion is probably the most important factor that influences its sele ction for a specific application. The most common method that is used to address corrosion in pressure vessels is to specify a corrosion allowance. A corrosion allowance is supplemental metal thickness that is added to the minimum thickness that is required to resist the applied loads.

Resistance to Hydrogen Attack If this hydrogen diffusion continues, pressure can build to high levels within t he steel, and the steel can crack. At elevated temperatures, over approximately 600F (315,5C), monatomic hydrogen not only causes cracks to form but also attacks the steel. Hydrogen attack differs from corrosion in that damage occurs through out the thickness of the component, rather than just at its surface, and occurs without any metal loss. In addition, once hydrogen attack has occurred, the meta l cannot be repaired and must be replaced. Instead, materials are selected such that they are resistant to hydrogen attack at the specified design conditions.

Fracture Toughness Fracture toughness refers to the ability of a material to withstand conditions t hat could cause a brittle fracture. The fracture toughness of a material can be determined by the magnitude of the impact energy that is required to fracture a specimen using Charpy V-notch test. Generally , the fracture toughness of a mate rial decreases as the temperature decreases. The fracture toughness at a given t emperature varies with different steels and with different manufacturing and fab rication processes.

Fabricability Fabricability refers to the ease of construction and to any special fabrication practices that are required to use the material. Pressure vessels commonly use w elded construction. The materials used must be weldable so that individual compo nents can be assembled into the completed vessel.

DESIGN Design Conditions and Loadings All pressure vessels must be designed for the mos t severe conditions of coincident pressure and temperature that are expected dur ing normal service. Normal service includes conditions that are associated with: Start up. Normal operation. Deviations from normal operation that can be anticip ated (e.g., catalyst regeneration or process upsets). Shutdown.

DESIGN PRESSURE Generally, design pressure is the maximum internal pressure, that is used in the mechanical design of a pressure vessel. For full or partial vacuum conditions, the design pressure is applied externally and is the maximum pressure difference that can occur between the atmosphere and the inside of the pressure vessel. So me pressure vessels may experience both internal and external pressure condition s at different times during their operation. The mechanical design of the pressu re vessel in this case is based on which of these is the more severe design cond ition. (see UG-21)

Operating Pressure Operating pressure is is the pressure to be used in operating condition. The ope rating pressure must be set based on the maximum internal or external pressure t hat the pressure vessel may encounter.

 The following factors must be considered: Ambient temperature effects. Normal op erational variations. Pressure variations due to changes in the vapor pressure o f the contained fluid. Pump or compressor shut-off pressure. Static head due to the liquid level in the vessel. System pressure drop. Normal pre-startup activit ies or other operating conditions that may occur (e.g., vacuum), that should be considered in the design.

Design Temperature The design temperature of a pressure vessel is the maximum fluid temperature tha t occurs under normal operating conditions, plus an allowance for variations tha t occur during operation. The maximum temperature used in design shall be not le ss than the mean metal temperature (through the thickness) expected under operat ing conditions for the part considered (see 3-2). The minimum metal temperature used in design shall be the lowest expected in service.

Operating Temperature The Operating temperature is fluid temperature that occurs under normal operatin g conditions. The operating temperature must be set based on the maximum and min imum metal temperatures that the pressure vessel may encounter.

Other Loadings The loadings that must be considered to determine the minimum required thickness es for the various vessel components are as follows: Internal or external design pressure. Weight of the vessel and its normal contents under operating or test conditions. Superimposed static reactions from the weight of attached equipment (e.g., motors, machinery, other vessels, piping, linings, insulation). Loads at attached of internal components or vessel supports.

 Wind, snow, and seismic reactions. Cyclic and dynamic reactions that are caused by pressure or thermal variations, or by equipment that is mounted on a vessel, and mechanical loadings. Test pressure combined with hydrostatic weight. Impact reactions such as those that are caused by fluid shock. Temperature gradients wi thin a vessel component and differential thermal expansion between vessel compon ents.

MAXIMUM ALLOWABLE STRESS VALUE The maximum allowable stress value is the maximum unit stress permitted in a giv en material used in a vessel constructed under these rules. The maximum allowabl e tensile stress values permitted for different materials are given in Subpart 1 of Section II, Part D.(see UG-23).

MAXIMUM ALLOWABLE WORKING PRESSURE The maximum allowable working pressure for a vessel is the maximum pressure perm issible at the top of the vessel in its normal operating position at the designa ted coincident temperature specified for that pressure. It is the least of the v alues found for maximum allowable working pressure for any of the essential part s of the vessel and adjusted for any difference in static head that may exist be tween the part considered and the top of the vessel.(see UG-98)

CORROSION The user or his designated agent shall specify corrosion allowances other than t hose required by the rules of this Division. Where corrosion allowances are not provided, this fact shall be indicated on the Data Report. Vessels or parts of v essels subject to thinning by corrosion, erosion, or mechanical abrasion shall h ave 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, or by using some other suitable method of protection. (see UG-25)

THICKNESS SHELL UNDER INTERNAL PRESSURE (CYLINDRICAL SHELL) See UG-27

CIRCUM STRESS (LONGITUDINAL JOINT) t = minimum required thickness P = internal design pressure R = inside radius of the shell course under consideration, (pertimbangkan C.A.) S = maximum allowabl e stress value (see UG-23 and the stress limitations specified in UG-24) E = joi nt efficiency for, or the efficiency of, appropriate joint in cylindrical or sph erical shells, or the efficiency of ligaments between openings, which ever is le ss. OR

LONGITUDINAL STRESS (CIRCUM JOINT) OR

CONTOH Thickness for Internal Pressure Inside Diameter - 10 - 6 Design Pressure - 650 psi g Design Temperature - 750F Shell & Head Material - SA-516 Gr. 70 Corrosion Allow ance - 0.125 in. 2:1 Semi-Elliptical heads, seamless 100% radiography Vessel in vapor service

 The minimum thickness or maximum allowable working pressure of cylindrical shell s shall be the greater thickness or lesser pressure as given by formula Circumfe rential Stress (Longitudinal Joints) or Longitudinal Stress (Circumferential Joi nts)

SPHERICAL SHELL

THICKNESS OF SHELL AND TUBES UNDER EXTERNAL PRESSURE

SYMBOL DEFINED A = factor determined from Fig. G in Subpart 3 of Section II, Part D. Cylinders having Do /t values less than 10, see UG-28(c)(2). B = p factor determined from the applicable material chart or table in Subpart 3 of Section II, Part D for ma ximum design metal temperature Do = outside diameter of cylindrical shell course or tube E = modulus of elasticity of material at design temperature. Taken from the applicable chart in Subpart 3 of Section II, Part D. L = total length, in. (mm), of a tube between tube sheets, or design length of a vessel section betwee n lines of support.

 P = external design pressure. Pa = calculated value of maximum allowable externa l working pressure for the assumed value of t Ro = outside radius of spherical s hell. t = minimum required thickness of cylindrical shell or tube, or spherical shell, in. (mm) ts = nominal thickness of cylindrical shell or tube, in. (mm)

CYLINDRICAL SHELL AND TUBES Hitung nilai dari Do/t. A. Bila nilai Do/t 10, ikuti step berikut: Step 1, Asumsikan nilai tebal t, dan hitung rasio L/Do dan Do /t. Step 2, Lihat Fig. G pada Subpart 3 of Section II, Part D. Pakai nilai L/Do sesuai perhitungan yang didapat pada step 1: Bila nilai L/Do >50, maka L/Donya=50. Jika nilai L/Do < 0.05, maka L/Do nya = 0. 05.

 Step 3, Tarik garis dari L/Do ke kurva Do/t sehingga ada titik potongan. Dari ti tik tersebut ditarik garis lagi ke area factor A untuk memperoleh nilai factor A . Step 4, Cari nilai B, dengan memasukkan nilai factor A yang diperoleh ke grafi k/chart tabular sesuai material yang dipakai, di subpart 3 ASME II D.(contoh fig -CS1untuk carbon steel and low alloy steel). Tentukan kurva material/temperature disain yang akan dipakai.

Contoh grafik untuk mencari nilai B

 Step 5, Tarik garis dari nilai A ke kurva material/temperature yang dimaksud. Pa da perpotongan garis tsb, tarik garis ke arah area B untuk memperoleh nilai B. S tep 6, hitung maksimum allowable external pressure (Pa) dengan menggunakan nilai B yang didapat dari step 5 dengan rumus:

 Step 7, Jika nilai A terletak pada sebelah kiri kurva material/temperature, perh itungan Pa menggunakan rumus: Step 8, Bandingkan nilai Pa yang didapat dari perhitungan di step 6 dan 7 dengan design pressure P. Jika Pa<P, lakukan penghitungan kembali dengan menggunakan t yang lebih tebal, sampai diperoleh PaP

 Bila Do/t < 10. Step1, langkah kerja sama seperti step 1s/d 5 untuk Do/t10 untuk memperoleh nilai B: Jika Do/t < 4, nilai factor A bisa dihitung dengan rumusan: untuk nilai A ketemu>0.10, ditetapkan A=0,10

 Step 2, Bila nilai B sudah didapat, hitung maksimum allowable external pressure (Pa1) dengan rumusan: Step 3, hitung Pa2 dengan rumusan:

 Step 4, Bandingkan nilai Pa1 dan Pa2, yang lebih kecil diambil sebagai Pa. Bandi ngkan Pa dengan P, jika Pa<P, hitung kembali dengan menggunakan material yang le bih tebal dengan langkah yang sama sampai diperoleh PaP

EXTERNAL PRESSURE PADA SPHERICAL SHELL Step 1, buat asumsi tebal material yang dipakai, t, dan hitung nilai faktor A de ngan rumusan: Step 2, Masukkan nilai A yang didapat ke chart yang sesuai pada ASME II D. Tarik garis ke arah kurva material/temperature hingga ketemu titik perpotongan. Bila nilai A berada di sebelah kiri kurva, perhitungan Pa mengikuti step 5.

 Step 3, cari nilai B dengan menarik perpotongan ke area B. Step 4, hitung nilai Pa,dengan rumus: Step 5, Hitung nilai Pa dengan rumus berikut, bila nilai A berada disebelah kiri grafik seperti step 2:

 Step 6, bandingkan Pa terhadap P, bila: Pa<P, pakai material yang lebih tebal da n hitung kembali sampai diperoleh PaP

BUKAAN NOZZLE

 A = total cross-sectional area of reinforcement required in the plane under cons ideration (see Fig. UG-37.1) (includes consideration of nozzle area through shel l if Sn /Sv<1.0) A1 = area in excess thickness in the vessel wall available for reinforcement (see Fig. UG-37.1)includes consideration of nozzle area through sh ell if Sn /Sv<1.0) A2 = area in excess thickness in the nozzle wall available fo r reinforcement (see Fig.UG-37.1) A3 = area available for reinforcement when the nozzle extends inside the vessel wall (see Fig. UG-37.1)

 t t e

A41, A42, A43 = cross-sectional area of various welds available for reinforcemen (see Fig. UG-37.1) A5 = cross-sectional area of material added as reinforcemen (see Fig.UG-37.1) c = corrosion allowance D = inside shell diameter Dp =outsid diameter of reinforcing element (actual size of reinforcing element may exceed the limits of reinforcement establish ed by UG-40; however, credit cannot be ta ken for any material outside these limits).

 d = finished diameter of circular opening or finished dimension (chord length at mid surface of thickness excluding excess thick ness available for reinforcemen t) of non radial opening in the plane under consider ation, in.(mm) [see Figs. U G-37.1 and UG-40] E = 1 (see definitions for tr and trn) E1 = 1 when an opening is in the solid plate or in Category B butt joint; or = joint efficiency obtaine d from Table UW-12 when any part of the opening passes through any other welded joint

 F = correction factor which compensates for the varia tion in internal pressure stresses on different planes with respect to the axis of a vessel. A value of 1. 00 shall be used for all configu rations except that Fig. UG-37 may be used for integrally reinforced openings in cylindrical shells and cones. [See UW16(c)(1). ] h = distance nozzle projects beyond the inner surface of the vessel wall. (Ext ension of the nozzle beyond the inside surface of the vessel wall is not limited ; however, for reinforcement calculations, credit shall not be taken for materia l outside the limits of reinforcement established by UG-40.)

 K1 = spherical radius factor (see definition of tr and Table UG-37). L = length of projection defining the thickened portion of integral reinforcement of a nozz le neck beyond the outside surface of the vessel wall [see Fig. UG-40 sketch (e) ] P = internal design pressure (see UG-21), psi (MPa) R = inside radius of the s hell course under consideration Rn = inside radius of the nozzle under considera tion S = allowable stress value in tension (see UG23), psi (MPa)

Sn = allowable stress in nozzle, psi (MPa) (see S, above) Sv = allowable stress in vessel, psi (MPa) (see S, above) Sp = allowable stress in reinforcing element (plate), psi (MPa) (see S, above). fr = strength reduction factor, not greater than1.0 [see UG-41(a)] fr1 = Sn /Sv for nozzle wall inserted through the vessel wall. fr1 = 1.0 for nozzle wall abutting the vessel wall and for nozzles shown i n Fig. UG-40, sketch (j), (k), (n) and (o). fr 2 = Sn /Sv fr3 = (lesser of Sn or Sp) /Sv fr4 = Sp /Sv

 t = specified vessel wall thickness,24 (not including forming allowances). For p ipe it is the nominal thickness less manufacturing under tolerance allowed in th e pipe specification. te = thickness or height of reinforcing element (see Fig. UG-40) ti = nominal thickness of internal projection of nozzle wall tr = require d thickness of a seamless shell based on the circum ferential stress, or of a fo rmed head, computed by the rules of this Division for the designated pressure. t n = nozzle wall thickness.24 Except for pipe, this is the wall thickness not inc luding forming allowances. For pipe, use the nominal thickness [see UG-16(d)]. t rn = required thickness of a seamless nozzle wall W = total load to be carried b y attachment welds (see UG-41)

 Design for Internal Pressure. The total cross-sectional area of reinforcement A required under internal pressure shall be not less than A = dtrF + 2tn trF(1 fr1 ) Design for External Pressure The reinforcement required for openings in singl e-walled vessels subject to external pressure need be only 50% of that required in formula above.

MODEL SAMBUNGAN NOLLZE YANG DITERIMA SESUAI UW 16.