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    Process Equipment Design

    Uploaded by

    Vivek Nair
    The document discusses process equipment design and outlines various types of process equipment and standards used for their design. It covers static equipment, machinery, piping, storage tanks, heat exchangers, fired heaters, boilers, pressure vessels, stacks, and design considerations like material selection, thickness calculations, and codes & standards used for equipment design and fabrication. Key aspects discussed include determining design loads, allowable stresses, minimum required thickness, and joint efficiency calculations as per ASME codes.

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    © All Rights Reserved
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    Process Equipment Design

    Uploaded by

    Vivek Nair
    171 views27 pages
    The document discusses process equipment design and outlines various types of process equipment and standards used for their design. It covers static equipment, machinery, piping, storage tanks, heat exchangers, fired heaters, boilers, pressure vessels, stacks, and design considerations like material selection, thickness calculations, and codes & standards used for equipment design and fabrication. Key aspects discussed include determining design loads, allowable stresses, minimum required thickness, and joint efficiency calculations as per ASME codes.

    Original Description:

    Process Equipment (Static/Pressure Vessels) Design - Presentation on the basics of PV design

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    The document discusses process equipment design and outlines various types of process equipment and standards used for their design. It covers static equipment, machinery, piping, storage tanks, heat exchangers, fired heaters, boilers, pressure vessels, stacks, and design considerations like material selection, thickness calculations, and codes & standards used for equipment design and fabrication. Key aspects discussed include determining design loads, allowable stresses, minimum required thickness, and joint efficiency calculations as per ASME codes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    171 views27 pages

    Process Equipment Design

    Uploaded by

    Vivek Nair
    The document discusses process equipment design and outlines various types of process equipment and standards used for their design. It covers static equipment, machinery, piping, storage tanks, heat exchangers, fired heaters, boilers, pressure vessels, stacks, and design considerations like material selection, thickness calculations, and codes & standards used for equipment design and fabrication. Key aspects discussed include determining design loads, allowable stresses, minimum required thickness, and joint efficiency calculations as per ASME codes.

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    1.

    STATIC EQUIPMENT
    2. MACHINERY & MATERIAL
    HANDLING

    3. PIPING
    Process Equipment Design

    BASED ON SERVICE & DESIGN PHILOSOPHY

    1. STORAGE TANKS
    2. HEAT TRANSFER EQUIPMENTS
    3. FIRED HEATERS & BOILERS
    4. COLUMNS, REACTORS, DRUMS, ETC.
    5. STACKS & CHIMNEYS
    Process Equipment Design

    1. ATMOSPHERIC STORAGE TANKS


    a. OPEN TOP TANKS
    b. FIXED ROOF :SELF-SUPPORTED / SUPPORTED
    CONE / DOME / UMBRELLA

    c. FLOATING ROOF :EXTERNAL / INTERNAL


    SINGLE DECK / DOUBLE DECK

    2. LOW PRESSURE STORAGE TANKS

    LOW TEMPERATURE / CRYOGENIC


    SINGLE WALL / DOUBLE WALL / DOUBLE INTEGRITY
    Process Equipment Design

    HEATERS, EVAPORATORS, CONDENSERS,


    COOLERS, WASTE HEAT BOILERS (WHB) /
    STEAM GENERATORS
    1. SHELL & TUBE HEAT EXCHANGERS (STHE)
    2. PLATE HEAT EXCHANGERS (PHE)
    3. SPIRAL HEAT EXCHANGERS (SHE)
    4. DOUBLE PIPE HEAT EXCHANGERS
    Process Equipment Design

    A. FIRED HEATERS :1. PRIMARY REFORMERS / CATALYTIC


    CRACKERS
    2. PROCESS HEATERS
    3. THERMAL OIL HEATERS

    B. STEAM GENERATING BOILERS :1. POWER BOILERS


    2. HEATING BOILERS
    Process Equipment Design

    PRESSURE VESSELS
    1. PACKED COLUMNS & TOWERS :

    ABSORBTION / REGENERATION COLUMNS

    2. DISTILLATION COLUMNS (WITH TRAYS)


    3. REACTORS, SEPERATORS, K.O DRUMS,
    SEAL POTS, ETC.
    Process Equipment Design

    1. FLARE STACKS

    2. FLUE GAS STACKS / CHIMNEYS :

    SELF-SUPPORTED/ GUYED/DERRICK

    Process Equipment Design

    1. BASIC EQUIPMENT DATA SHEET


    a. SERVICE CONDITIONS SERVICE FLUID,
    DESIGN/OPERATING PRESSURE & TEMPERATURE
    b. OVERALL DIMENSIONS (O.D/I.D, HEIGHT/LENGTH, ETC)
    c. GENERIC MATERIAL SPECIFICATION
    d. CORROSION ALLOWANCE
    e. INSULATION/REFRACTORY/LINING
    f. NOZZLES / APPURTENANCES

    2. DETAILED MECHANICAL DESIGN

    a. SPECIFIC MATERIAL SELECTION / WELD JOINT EFFICIENCY


    b. CODE/STANDARD BASED DESIGN FOR MINIMUM / DESIGN
    / NOMINAL THICKNESS.
    c. DESIGN BASED ON FIRST PRINCIPLES/GOOD ENGINEERING
    PRACTICES FOR COMPONENTS NOT ADDRESSED BY CODES
    d. DETAILED FABRICATION DRAWINGS
    Process Equipment Design

    CODES :

    LEGAL DOCUMENT / STATUTE WHICH IS MANDATORY


    INTENTS TO PREVENT / MITIGATE FATALITIES, DISABILITIES,
    ENVIRONMENTAL POLLUTION & LOSS OF PROPERTY

    STANDARDS :

    TECHNICAL SPECIFICATIONS / PRECISE CRITERIA TO BE USED


    CONSISTENTLY AS RULE, GUIDELINES OR DEFINITIONS OF
    CHARECTERISTICS TO ENSURE THAT MATERIALS, PRODUCTS,
    PROCESSES, AND SERVICES ARE FIT FOR THEIR PURPOSE.
    NOT LEGALLY BINDING AND MAY BE FOLLOWED
    VOLUNTARILY UNLESS REFERENCED BY CODES IN WHICH
    CASE; IT BECOMES MANDATORY.
    Process Equipment Design

    DERIVED FROM COLLECTIVE KNOWLEDGE &


    EXPERIENCE

    STANDARDIZATION

    SAFETY

    CERDIBILITY / RELIABILITY

    Process Equipment Design

    IBR INDIAN BOILER REGULATIONS


    PESO - PETROLEUM & EXPLOSIVES SAFETY ORGANISATION
    OSHA OCCUPATIONAL SAFETY & HEALTH ADMINISTRATION
    EPA ENVIRONMETAL PROTECTION AGENCY
    DOT - DEPARTMENT OF TRANSPORTATION
    ANSI - AMERICAN NATIONAL STANDARDS INSTITUTE
    ASME - AMERICAN SOCIETY OF MECHANICAL ENGINEERS
    API AMERICAN PETROLEUM INSTITUTE
    NACE - NATIONAL ASSOCIATION OF CORROSION ENGINEERS
    TEMA TUBULAR EXCHANGER MANUFACTURERS ASSOCIATION
    Process Equipment Design

    INDIAN BOILER REGULATIONS (IBR)

    STATIC & MOBILE PRESSURE VESSELS (SMPV)

    COMPRESSED GAS CYLINDER RULES

    IS 2825, IS 875 & IS 1893

    ASME SECTION VIII, Div. 1 (DBF), 2 (DBA) & 3

    TEMA

    PD 5500

    API 650 & API 620

    API 530 & API 560


    Process Equipment Design

    ASME SECTION II Part A, B, C & D

    ASTM STANDARDS

    ANSI B 16.5, B 16.9, 16.11

    ASME SECTION V (NDT)

    NACE STANDARDS & RECOMMENDED


    PRACTICES
    INDIAN STANDARDS (IS)
    Process Equipment Design

    SECTION I POWER BOILERS


    SECTION II MATERIAL SPECIFICATIONS
    PART A
    PART B
    PART C
    PART D

    :
    :
    :
    :

    FERROUS MATERIALS
    NON FERROUS MATERIALS
    WELDING RODS, ELECTRODES, FILLER MATERIAL
    MATERAL PROPERTIES

    SECTION III NUCLEAR POWER PLANT CONPONENTS


    SECTION IV HEATING BOILERS
    SECTION V NON DESTRUCTIVE TESTING
    SECTION VI CARE & OPERATION OF HEATING BBOILERS
    SECTION VII CARE & OPERATION OF POWER BOILERS
    SECTION VIII :

    DIVISION 1 : PRESSURE VESSELS


    DIVISION 2 : ALTERNATE RULE S (PRESSURE VESSELS)
    DIVISION 3 : RULES FOR CONSTRUCTION OF HIGH PRESSURE VESSELS

    SECTION IX WELDING & BRAZING QUALIFICATIONS


    SETION X FIBRE REINFORCED PLASTIC PRESSURE VESSELS
    SECTION XI RULES FOR IN-SERVICE INSPECTION OF NUCLEAR PLANT
    COMPONENTS
    SECTION XII TRANSPORT TANKS

    Process Equipment Design

    PRESSURE VESSELS WITHIN SCOPE

    VESSELS DESIGNED FOR PRESSURE ABOVE 15 PSIG AND


    NOT EXCEEDING 3000 PSIG.
    VESSELS HAVING INSIDE DIAMETER ABOVE 6 IN.
    UNFIRED STEAM BOILERS, EVAPORATORS, HEAT
    EXCHANGERS

    PRESSURE VESSELS EXCLUDED FROM SCOPE


    VESSELS COVERED BY OTHER SECTIONS.
    PRESSURE CONTAINERS WHICH ARE INTEGRAL PART OF
    ROTATING MACHINERY.
    PIPING SYSTEM & COMPONENTS.
    VESSELS FOR HUMAN OCCUPANCY.
    Process Equipment Design

    DETERMINATION OF LOADS :

    PRESSURE / VACUUM INDUCED LOADS AT COINCIDENT TEMPERATURE


    LOADS INDUCED DUE TO WIND / SEISMIC / DEAD WEIGHT
    LOCAL LOADS PIPING INDUCED / LIFTING LUGS
    THERMAL LOADS

    COMPUTE STRESSES INDUCED DUE TO COMBINED LOADINGS ON


    EACH COMPONENT.

    DETERMINATION OF CODE ALLOWABLE STRESSESES FOR EACH


    COMPONENT AT DESIGN TEMPERATURE.

    COMPUTATION OF MINIMUM REQUIRED THICKNESS FOR WORST

    DESIGN THICKNESS, d

    tr
    = tr. + C.A + F.A.

    NOMINAL THICKNESS,

    = PROVIDED THK. (>

    CASE OF LOADING

    tnom

    Process Equipment Design

    td )

    Maximum allowable stress is the maximum


    stress that may be safely applied to a pressure
    vessel component. The maximum allowable
    stress includes a safety margin between the
    stress level in a component due to the applied
    loads and the stress level that could cause a
    failure.
    Tables in the ASME Code Section II, Part D
    contain the maximum allowable tensile stresses
    of materials that are acceptable for use in
    ASME Code Sections. The maximum allowable
    stress varies with temperature.
    Process Equipment Design

    18

    Process Equipment Design

    19

    Process Equipment Design

    20

    Process Equipment Design

    21

    Category A: Longitudinal welded joints within

    the main shell, communicating chambers and


    nozzles, circumferential joints connecting end
    closure to main shell, any welded joint in sphere or
    formed head.
    Category B: Circumferential welded joints in main
    shell, communicating chambers or nozzles.

    Category C: Welded joints connecting flanges and

    Category D : Welded joints connecting

    flat heads to main shell.

    communicating chambers and nozzles with the


    main shell.
    Process Equipment Design

    CYLINDRICAL SHELLS
    The
    minimum thickness or maximum
    allowable working pressure of cylindrical
    shells shall be the greater thickness or lesser
    pressure as given by (1) or (2) below.
    (1) Circumferential Stress (Longitudinal Joints)
    When the thickness does not exceed one-half of
    the inside radius, or P does not exceed 0.385SE,
    the following formulae shall apply:

    Process Equipment Design

    23

    (2)Longitudinal Stress (Circumferential Joints)


    When the thickness does not exceed one-half of the
    inside radius, or P does not exceed 1.25SE, the
    following formulae shall apply:

    SPHERICAL SHELLS
    When the thickness of the shell of a wholly spherical
    vessel does not exceed 0.356R, or P does not exceed
    0.665SE, the following formulae shall apply:

    Process Equipment Design

    24

    t =
    P
    R
    S
    E

    =
    =
    =
    =

    minimum required thickness of shell,


    in (mm)
    internal design pressure, psi
    inside radius of shell in (mm)
    maximum allowable stress value, psi
    joint efficiency

    Process Equipment Design

    25

    Process Equipment Design

    26

    27

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