Unit II
Pressure Vessel
Pressure vessels are the container for the containment of pressure, either internal or external.
Dr. Renuka Garg, Ph.D, Postdoc
Definition:
Pressure vessels are closed containers (such as cylinders, tanks, or boilers) designed to hold fluids (liquids or
gases) at a pressure substantially different from the ambient pressure.
•Importance:
• They are widely used in industries such as power plants, chemical processing, petroleum refineries,
and food industry.
• A failure or rupture can lead to explosions, loss of life, and severe property damage.
• Hence, they must be designed with great care, following strict codes and standards.
Classification of Pressure Vessels
According to the Dimensions
a) Thin b) Thick shell
According to the end construction
a) Open b) Closed end
According to the Geometrical Shapes
a) Cylindrical pressure vessel b) Conical pressure vessel c) Spherical pressure vessel
According to the Position Arrangement
a) Horizontal pressure vessel b) Vertical pressure vessel
According to the Materials
The pressure vessels, according to the materials used, are classified as:
a) Brittle material pressure vessels b) Ductile material pressure vessels
According to the Direction of Force Acting on the Wall of Vessels
a) Subjected to internal pressure b) Subjected to external pressure
Pressure vessels types
Storage Vessels
Heat Exchangers
Process vessel
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Storage vessels
Butane storage tank LPG storage tank
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Heat exchangers
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Process vessels
Distillation column Reactor
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Typical ethylene plant
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Pressure vessel code
❖ The purpose of using design codes is to standardize requirements and to minimize risk
for designers, manufacturers, and those working with pressure vessels. As such, codes have been
developed over the years using industry experience and best practices.
❖ In most countries the National codes have the force of law and strict adherence to their rules is
required. It is therefore desirable that any design, regardless of the method adopted, should be
checked with the standard code.
❖ The Indian Standards Institute has prepared a similar code IS-2825-1969.
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ASME BPVC is a globally recognized
standard for the design and construction of
boilers and pressure vessels.
Section VIII specifically deals with pressure
vessels, and Division 1 focuses on design by
rules (vs. design by analysis in Div. 2).This
code ensures safety, quality, and compliance in
pressure vessel fabrication.
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ASME Boiler & Pressure vessel code
FRP- Fiberglass Reinforced Plastic, NDE- Non-destructive examination 16
ASME Boiler & Pressure vessel code
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ASME section VIII, Division 1
U stamp certifies that a manufacturer meets the quality control system requirements laid out
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ASME Code structure
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What is the significance of ASME Section VIII – Division 1, and why is it
important in industry?
Section VIII – Division 1 provides rules for design, fabrication, inspection, testing,
and certification of pressure vessels. It is the most commonly used division due to its
straightforward "design-by-rule" approach. Its importance lies in ensuring safe operation
under pressure, and compliance with this code is often a legal requirement and necessary
for U-stamp certification and international trade.
Introduction
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Subsection A-General requirement
U- is for unfired. G- general guidelines 23
Subsection A-General requirement
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Subsection B- Methods of fabrication
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Subsection C- Classes of materials
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ASME Section V- NDE Examination
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ASME Section IX- Welding
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Chart for determining wall thickness
of tubes under external pressure
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Selection of the Type of Vessel
The selection of a pressure vessel depends on its function, location, nature of fluid, operating
temperature and pressure, required volume, and regulatory codes. Vessels are generally classified by
geometry into four main types:
•Open Vessels – Simple, low-cost tanks or ponds for low-value, non-hazardous liquids (e.g., brine,
settling tanks, reservoirs). Not suitable for toxic or pressurized fluids.
•Flat-Bottomed, Vertical Cylindrical Tanks – Common for large-volume storage at atmospheric or
low pressure; often with conical or spherical roofs.
•Cylindrical Vessels with Formed Ends (Vertical or Horizontal) – Most widely used in processing
and pressure service. Heads may be hemispherical, torispherical, or ellipsoidal; applications include
reactors, heat exchangers, autoclaves, and air receivers.
•Spherical or Modified Spherical Vessels – Best for high-pressure gases (LPG, LNG, ammonia).
Offer uniform stress distribution and material efficiency but are costly and complex to fabricate.
Orientation:
•Vertical vessels save floor space and are preferred for mixing, reactors, and separators.
•Horizontal vessels ease cleaning and access, used in heat exchangers, surge drums, and settling
tanks.
General Rule:
•Open vessels → low-value/non-hazardous fluids.
•Cylindrical vessels → standard choice for most processing under pressure.
•Spherical vessels → specialized for high-pressure gas storage.
Selection must balance safety, performance, fabrication, material availability, and cost-
effectiveness.
Factors to Consider in Selecting Pressure Vessel Materials
Strength & Pressure Requirements: Must withstand internal/external pressures, stresses, cyclic loading,
and fatigue. Check yield strength, tensile strength, and fracture toughness.
Corrosion Resistance: Crucial in harsh environments. Prevent pitting, crevice, and stress corrosion with
resistant alloys or protective liners.
Cost & ROI: Evaluate lifecycle cost, procurement, fabrication, maintenance, inspections, downtime
while balancing safety and durability.
Fabrication & Maintenance: Ensure good weldability, machinability, and compatibility with NDT.
Materials should allow reliable fabrication and easy long-term inspection.
Availability & Standards: Use standardized, certified materials (ASME, API etc.,) with local availability
to cut lead time and ensure compliance.
Temperature & Environment: Assess performance at high/low or cryogenic temperatures, considering
creep, embrittlement, and environmental/safety compliance.
Materials Used for Pressure Vessels
When designing pressure vessels, the choice of material is critical because it affects strength,
corrosion resistance, cost, and lifespan. Let’s discuss the main materials used:
1. Carbon Steel
•Contains up to 2.5% carbon → gives high tensile strength.
•Advantages:
• Widely available and low cost.
• Suitable for high-pressure applications.
• Common in refineries, water treatment, compressed air systems.
•Limitations:
• Poor corrosion resistance → prone to rust/oxidation in wet or chemical environments.
• Requires protective coatings or linings to last longer.
Stainless Steel
•Contains 10.5–30% chromium + nickel → forms a protective oxide layer.
•Advantages:
• Excellent corrosion and chemical resistance.
• Ideal for food, pharma, and corrosive fluids.
• Good ductility, weldability, and high strength-to-weight ratio.
•Limitations:
• More expensive than carbon steel.
• But lower maintenance and longer service life often make it more economical in the
long run.
Hastelloy (Nickel-Chromium-Molybdenum Alloy)
•Developed by Haynes International.
•Advantages:
• Exceptional resistance to corrosion, oxidation, and stress cracking.
• Performs well at high temperature + aggressive chemicals.
• Common in petrochemical, nuclear, and energy sectors.
• Good weldability and durability.
•Applications: Reactors, heat exchangers, containment systems.
Nickel Alloys (e.g., Inconel, Monel)
•Advantages:
• Strong resistance to corrosion, oxidation, and extreme temperatures.
• Maintain strength and ductility from cryogenic to very high temperatures.
• Used in cryogenic tanks, offshore oil & gas, chemical processing.
•Limitations:
• Costly and difficult to fabricate.
• Require precise alloy composition for performance.
Pressure vessel design procedure
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Operational Requirements
The first step in this design procedure is to set down the operational requirements. These are imposed on
the vessel as part of the overall plant and include the following:
a. Operating pressure. normal steady operating pressure, the maximum maintained pressure needs to be
defined. Regulations and/or standards will define how this maximum pressure is translated into vessel
design pressure.
b. Fluid conditions. Maximum and minimum fluid temperatures will need to be specified and translated
into metal design temperatures. Fluid physical and chemical properties will influence material choice and
specific gravity will effect support design.
c. External loads. Loads to be considered include wind, snow, and local loads such as piping reactions and
dead weight of equipment supported from the vessel.
d. Transient conditions. Some vessels may require an assessment of cyclic loads resulting from
operational pressure, temperature, structural and accoustic vibration loading.
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Functional Requirements
It covers geometrical parameters. Some of these parameters are again defined by the plant design team
whilst some are left to the discretion of the pressure vessel designer. The functional requirements
include the following:
a. Size and shape of the vessel.
b. Method of vessel support.
c. Location and size of attachments and nozzles.
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Materials
Some national standards list acceptable materials with acceptable temperature ranges and design
stresses. Design stresses are set using safety factors applied to material properties, which include:
a. Yield strength at design temperature.
b. Ultimate tensile strength at room temperature.
c. Creep strength at design temperature.
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Materials
The standard will have selected the materials based upon the above material properties together with
knowledge of the following properties that influence fabrication and operation:
a. Elongation and reduction of area at fracture
b. Toughness.
c. Ageing and embrittlement under operating conditions
d. Fatigue strength
e. Availability.
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Materials
The range of materials used for pressure vessels is wide and includes, but is not limited to, the following:
a. Carbon manganese steel (giving higher strength than carbon steel).
b. Carbon steel (with less than 0.30% carbon).
c. Low alloy steels.
d. High alloy steels.
e. Austenitic stainless steels.
f. Non-ferrous materials (aluminium, copper, nickel and alloys).
g. High duty bolting materials.
Clad materials are accepted by national standards but often only the base material thickness can be used in design
calculations.
Proprietary materials are used for special applications by agreement between the designer and purchaser although
standard bodies will require evidence of previous successful applications before accepting as a material to be listed in
the standard.
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Design Rules
Before construction starts, the manufacturer is often required to submit fully dimensioned drawings of the
main pressure vessel shell and components for approval by the purchaser and inspecting authority. In
addition to showing dimensions and thicknesses, these drawings include the following information:
a. Design conditions.
b. Welding procedures to be applied .
c. Key weld details.
d. Heat treatment procedures to be applied.
e. Non-destructive test requirements.
f. Test pressures.
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Inspection and Testing
Each pressure vessel is inspected by the inspecting authority during construction. The standard specifies
the stages from material reception through to completed vessel at which inspection by this authority is
mandatory. The purchaser may require additional inspection, for example, to check internals.
The national standard defines the level of non-destructive testing that is applied during the construction.
This non-destructive testing is usually one or more of the following:
a. Magnetic particle or dye penetrant (for weld surface flaws).
b. Radiography (for weld internal flaws).
c. Ultrasonic (for weld internal flaws).
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Thin Cylindrical Shell due to an Internal Pressure
Change in Dimensions of a Thin Cylindrical Shell due to an Internal Pressure
The Trans-Alaska Pipeline carries crude oil 1, 284
kilometres through Alaska. The pipeline is 1.2
metres in diameter and can transport 318 million
litres of crude oil a day.