Department of Mechanical Engineering

CHAPTER 5
Code design Pressure vessel

Introduction
Pressure vessels are an integral part of many manufacturing facilities and processing plants,
enabling the safe storage of pressurized liquids and gases. From industrial boilers to gasoline
tankers, pressure vessels operate in a wide array of potentially hazardous environments.
However, if not properly designed, constructed and maintained, pressure vessels can be
extremely dangerous.
Historically, numerous fatal accidents have occurred due to flawed pressure vessels. As such,
pressure vessel design, manufacturing and operation are regulated by engineering authorities like
ASME (American Society of Mechanical Engineers).
Although it is possible to construct a pressure vessel of any shape and size, sections of cylinder,
sphere and cone are usually preferred. A more common pressure vessel design consists of a
cylinder closed with end caps, known as heads, that are usually hemispherical.
Spherical pressure vessel design is typically stronger than a cylindrical shape with the same wall
thickness. However, spherical pressure vessels are difficult and costly to manufacture, which
makes cylindrical shape pressure vessels with semi-elliptical heads preferred in many cases.
Sizing a pressure vessel
A design engineer usually requires the following basic data to size a pressure vessel:
 Vessel function
 Process materials and services (corrosion, deposits, etc.)
 Operating conditions (temperature and pressure)
 Materials of construction
 Dimensions and orientation
 Type of vessel heads to be used
 Openings and connections required
 Heating/cooling requirements
 Agitation requirements
 Specification of internal fittings
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Once the preliminary data is obtained, the pressure vessel design can be initiated following the
standard procedures outlines in BPVC Section VIII. This section is further subdivided into
subsections and appendices, guiding the engineer to determine general design requirements,
fabrication requirements and material requirements to effectively size the pressure vessel.

ASME Code Pressure Vessel Design (ASME BPVC)

The ASME Boiler and Pressure Vessel Codes are used throughout the world, (less common in
the UK and the EU). If you want to design vessels for the European market then you have to
comply with the European Pressure Equipment Directive (PED). The design code that conforms
to the PED is BS EN 13445 part1 - 5 Unfired pressure vessels. ASME codes are used for
pressurized equipment – vessels, piping and fittings in many countries. ASME codes cover the
design, construction, maintenance and alteration of pressurized equipment. The American
Society of Mechanical Engineers (ASME) is a professional association and leading international
developer of codes and standards associated with the art, science, and practice of mechanical
engineering.
The ASME BPVC is structured into the 13 sections, with Section XIII being added in 2021
including rules for overpressure protection.
These are design by rules codes which provide formula methods that work if the design falls
clearly within the scope of the code.
For more complex or unusual designs, ASME VIII-2 rules based on design by analysis is used in
conjunction with Finite Element Analysis (FEA) tools.
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Code Sections
The following is the structure of the BPV Code:
ASME BPVC Section I - Rules for Construction of Power Boilers
ASME BPVC Section II - Materials
Part A - Ferrous Material Specifications
Part B - Nonferrous Material Specifications
Part C - Specifications for Welding Rods, Electrodes, and Filler Metals
Part D - Properties (Customary)
Part D - Properties (Metric)
ASME BPVC Section III - Rules for Construction of Nuclear Facility Components
ASME BPVC Section IV - Rules for Construction of Heating Boilers
ASME BPVC Section V - Nondestructive Examination
ASME BPVC Section VI - Recommended Rules for the Care and Operation of Heating Boilers
ASME BPVC Section VII - Recommended Guidelines for the Care of Power Boilers
ASME BPVC Section VIII - Rules for Construction of Pressure Vessels
Division 1 - Rules for Construction of Pressure Vessels
Division 2 - Alternative Rules
Division 3 - Alternative Rules for Construction of High Pressure Vessels
ASME BPVC Section IX - Qualification Standard for Welding, Brazing, and Fusing Procedures;
Welders; Brazers; and Welding, Brazing, and Fusing Operators
ASME BPVC Section X - Fiber-Reinforced Plastic Pressure Vessels
ASME BPVC Section XI - Rules for In-service Inspection of Nuclear Power Plant Components
Division 1 - Rules for Inspection and Testing of Components of Light-Water-Cooled Plants
Division 2 - Requirements for Reliability and Integrity Management (RIM) Programs for
Nuclear Power Plants
ASME BPVC Section XII - Rules for the Construction and Continued Service of Transport
Tanks
ASME BPVC Section XIII - Rules for Overpressure Protection
ASME BPVC Code Cases - Boilers and Pressure Vessels
Code Cases provide rules that permit the use of materials and alternative methods of
construction that are not covered by existing BPVC rules. For those Cases that have been
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adopted will appear in the appropriate Code Cases book: "Boilers and Pressure Vessels"
and "Nuclear Components."
NB: Codes Cases are usually intended to be incorporated in the Code in a later edition. When it
is used, the Code Case specifies mandatory requirements which must be met as it would be with
the Code.
Summary of ASME BPVC Section VIII Div 1 (Part 1)
ASME Section VIII in itself consists of three divisions, where;
Division 1 is focused on a design-by-rule approach and; pressure range15 PSI to 3000 psi (1psi=
6894.76 Pa)
Division 2 on design-by-analysis approach; pressure range 3000 psi to 10,000 psi
Division 3 is meant for designing pressure vessels that require internal or external operating at a
pressure above 10,000 psi.
ASME Section VIII, Division 1’s design-by-rule approach is most commonly utilized by
engineers to size the pressure vessel according to the application requirements. It is quite a
conservative approach.
The empirical relations and other mandatory and non-mandatory design criteria often result in an
expensive pressure vessel design.
ASME Section VIII, Division 2’s design-by-analysis approach requires more detailed
calculations than Division 1. This may increase the cost of pressure vessel design but allows
pressure vessels to withstand higher stresses.
ASME Section VIII, Division 2 is intended for purpose-specific vessels with a defined fixed
location. Another major difference between the Division 1 and Division 2 lies in failure theory.

 Division 1 is based on normal stress theory;

 Division 2 is based on maximum distortion energy (Von Mises).

This Code contains compulsory requirements, specific prohibitions, and non-mandatory

guidance for pressure vessel materials, design, fabrication, examination, inspection, testing, and
certification, and pressure relief.
This code is not a handbook and cannot replace education, experience, and use of engineering
judgment.
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The use of engineering judgment should not be used to overrule the mandatory requirements of
this code. The Code is published every two years.
ASME VIII Div I
Subsection A:
General Requirements for All Methods of Construction and All Materials
Subsection B:
Requirements pertaining to the Methods of Fabrication of Pressure Vessels
Part UW: Requirements for Pressure Vessels Fabricated by Welding
Part UF: Requirements for Pressure Vessels Fabricated by Forging
Part UB: Requirements for Pressure Vessels Fabricated by Brazing
Subsection C
Requirements Pertaining to the Classes of Materials
Part UCS: Requirements of Pressure Vessels Constructed of Carbon and Low alloy Steel
Part UNF: Requirements of Pressure Vessels Constructed of Non Ferrous Materials
Part UHA: Requirements of Pressure Vessels Constructed of High Alloy Steel
Part UCI: Requirements of Pressure Vessels Constructed of Cast Iron
Part UCL: Requirements for Welded Pressure Vessels Constructed of Material with
Corrosion Resistance Integral Cladding, Weld Metal Overlay Cladding, or Applied
Linings
Part UCD: Requirements of Pressure Vessels of Cast Ductile Iron
Part UHT: Requirements of Pressure Vessels of Ferritic Steels with Tensile Properties
Enhanced by Heat Treatment
Part ULW: Requirements of Pressure Vessels Fabricated by Layered Construction
Part ULT: Alternate rules for Pressure Vessels Constructed of Materials having Higher
Allowable Stresses at Low Temperature.
Part UHX: Rules for Shell and Tube Heat Exchangers
Part UIG: Requirements of Pressure Vessels Constructed of Impregnated Graphite
Part UCD: Requirements of Pressure Vessels of Cast Ductile Iron

Examples showing the application of the design rules of this Division are contained in ASME
PTB-4, ASME Section VIII, Division 1, and Example Problem Manual.
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Design Considerations
Below are design aspects to consider when building a pressure vessel:
1. Pressure
Calculation of vessel specifications occurs around the design pressure, a value obtained from the
maximum operating pressure expected during startups, emergency shutdowns, process
abnormalities, and other upset conditions. Design pressure should be 5-10% above the maximum
operating pressure. If the vessel has the likelihood of experiencing vacuum pressure, the design
pressure must be a value that resists a full vacuum (-14.7 PSIG).
2. Temperature
The maximum allowable pressure depends on the temperature because material strength may be
lower with increasing temperature, and material toughness may be lower in low temperatures.
Pressure vessels should not operate at a temperature above the evaluated maximum allowable
stress value. Therefore, the design temperature is always less than the minimum temperature and
greater than the maximum operating temperature.
3. Corrosion allowance
Corrosion allowance requirements may vary by manufacturer. Heat exchanger equipment
specifically requires a small corrosion allowance because wall thickness affects the heat transfer
rate.
4. Allowable stress
The maximum allowable stress of a pressure vessel is determined by ASME Section II part D.
The stress values in ASME Section II part D account for potential deviations from the ideal
construction and operation of the pressure vessel.
5. Joint efficiency
Joint efficiency refers to the ratio of the strength of the welded plate to that of the un-welded
plate. Joint efficiencies are determined by the ASME BPV Code Sec. VIII D.1.
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Procedure
Design of Cylindrical Shell subjected to internal pressure

Design Procedure
NB: The design pressure used to establish the wall thickness must be adjusted for the liquid head
in accordance with paragraph UG
UG-21.
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A. Determine ID
Determine the inside radius and adjust for corrosion allowance.
Using Section VIII, Division 1
Refer to: UG-27 Thickness
hickness of shells under internal pressure
(c) Cylindrical Shells
B. For Circumferential
cumferential Stress
Evaluate per UG-27(c) (1)
1)

E = joint efficiency for, or the efficiency of, appropriate joint in cylindrical

or spherical
rical shells
P = internal design pressure (see UG
UG-21)
R = inside diameter of shell
S = maximum allowable stress value (see UG
UG-23 and the stress limitations
specified in UG
UG-24)
t = minimum required thickness of shell
Using above equations calculate the shell thickness and add corrosion allowance
C. For Longitudinal Stress
Evaluate per UG-27(c)(2).
).

D. Tank heads
Heads with pressure on the concave side are designed in accordance with UG-32
UG and
UG-34.
34. The formula, UG 32 (d), ((e), (f)
Hemispherical heads evaluate
valuate per UG-32 Formed heads, and sections, pressure on
concave side
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You must be able to calculate head depth for standard ellipsoidal and hemispherical
heads. This may be needed for static head or external pressure calculations.
 2:11 elliptical head h = 1/4 D
 Hemispherical head h= I = Inside radius

When t < 0.356R or P < 0.665SE - (Thin Spherical or Hemispherical Heads):

Symbols
E = lowest efficiency of any joint in the head
L = inside spherical radius
P = internal design pressure ((see UG-21)
S = maximum allowable stress value in tension
t = minimum required thickness of head after forming
Worked example
Determine the wall thickness for the pressure vessel shown in fi
figure
ure below using ASME bpvc.
bpvc
Also determine
etermine the required thickness for a hemispherical head
heads at the ends of the vessel if the
heads are made of the same material as the vessel
vessel.
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Material SA 516 Gr 70
Internal pressure 2MPa
Temperature 100 ⁰C
Inside diameter 2000mm
Max allowable stress 138MPa
Tan to tan length 4000mm
Joint efficiency 1
Corrosion allowance 4mm

 Determine the inside radius and adjust for corrosion al

allowance.
D=2000=2(corrosion allowance)
nce) = 2000+
2000+2(4)
=2008mm
R =D/2 =1004mm
 Thickness calculation for circumferential stress UG-27(c) (1)

Add corrosion allowance

Required shell thickness = 20mm

 Check for conditions specified in UG-27(c) (1)
𝑡 ≤ 0.5𝑅
𝑃 ≤ 0.385𝑆𝐸

Both conditions are valid

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 Thickness calculation for longitudinal stress UG-27(c)(2).

Add corrosion allowance

Minimum design thickness =12mm

 Check for conditions specified in UG-27(c)(2).

Both conditions are valid

 Determine the thickness of the hemispherical heads UG-32(e)
L= inside radius + corrosion allowance

Adding corrosion allowance

Minimum design thickness = 12mm

 Check for conditions specified in UG-32(e)
t < 0.356R or P < 0.665SE

Both conditions are satisfied