4/8/2017 Pressure 

vessel design by analysis versus design by rule

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TANKS AND VESSELS

PRESSURE VESSEL DESIGN BY ANALYSIS VERSUS

DESIGN BY RULE
Considering the design of ASME-certi꺛�ed pressure vessels

KASHYAP VYAS — APRIL 5, 2017 SHARE ON:     

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4/8/2017 Pressure vessel design by analysis versus design by rule

 A mechanical pressure vessel design     

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 ��awed pressure vessels. As such, pressure vessel
design, manufacturing and operation are regulated by engineering authorities like ASME (American Society of
Mechanical Engineers). Industry standards outline critical design parameters such as maximum safe operating
pressure, temperature, safety factor, corrosion allowance, and failure modes.

History of pressure vessel design

The earliest documented design speci⦈�cations for pressure vessels date back to 1495 in the book Codex Madrid
I, by none other than Leonardo da Vinci. Da Vinci, which theorized the use of containers carrying pressurized air
to lift weights underwater.

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But, it wasn’t until the 1800s that the practical use of pressure vessels was demonstrated to store pressurized
steam generated from a boiler. However, a general lack of knowledge on the design, operation and
maintenance of pressure vessels led to a series of fatal accidents, killing dozens of people in some instances.

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4/8/2017 Pressure vessel design by analysis versus design by rule

Such disasters provoked the development of the ⦈�rst standard pressure vessel code in 1911, which was
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ultimately published in 1915. This standard, known as Boiler and Pressure Vessel Code (BPVC), was later
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incorporated into the laws of most U.S. states and territories and Canadian provinces. Today, BPVC is widely
utilized all over the globe to design safe pressure vessels for a wide range of industrial applications. The ASME
Boiler and Pressure Vessel Code has mandated the use of standard design codes and procedure for developing
pressure vessels exceeding the pressure value of 15 PSI.

A simulation showing pressure vessel testing. (Image courtesy of Hi-Tech CADD

Services)

Pressure vessel construction and key features

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.

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Spherical pressure vessel design is typically stronger than a cylindrical shape with the same wall thickness.
However, spherical pressure vessels are di�cult and costly to manufacture, which makes cylindrical shape
pressure vessels with semi-elliptical heads preferred in many cases.

Typically, pressure vessels are made of steel, but there are some that employ composite materials, such as
carbon ⦈�ber, ceramics and polymers like PET (polyethylene terephthalate).

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4/8/2017 Pressure vessel design by analysis versus design by rule

While ASME Section VIII, Division 1’s design­by­rule 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 non­mandatory design criteria often
result in an expensive pressure vessel design.

Modern pressure vessels include safety features such as relief valves to relieve excessive pressure from the
container and ensure safe operation. And most pressure vessels today are designed with a leak-before-burst
feature, which enables the vessel to relieve pressure by leaking the contained ��uid, rather than by means of an
immediate and potentially explosive fracture.

In cases where leak before burst design is not possible, pressure vessels are required to be designed with more
stringent requirements for fatigue and fracture failure modes.

ASME Boiler Pressure Vessel Code, Section VIII (Rules for construction of
pressure vessels)
Most pressure vessels employed in industries today are designed according to the ASME BPVC Section VIII,
which consists of standard codes and rules that a manufacturer is required to follow. More than 60 nations
generally recognize and apply the BPVC for pressure vessel design. BPVC Section VIII is speci⦈�cally meant to
guide mechanical engineers in designing, constructing and maintaining PVs operating at either internal or
external pressure exceeding 15 PSIG.

ASME Section VIII in itself consists of three divisions,

where Division 1 is focused on a design-by-rule approach
and Division 2 on design-by-analysis approach. Division 3
is meant for designing pressure vessels that require
internal or external operating at a pressure above 10,000
PSI.

While 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. Although this may increase the cost of
pressure vessel design, it allows pressure vessels to
withstand higher stresses.

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4/8/2017 Pressure vessel design by analysis versus design by rule

ASME Section VIII, Division 2 is intended for purpose-

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speci⦈�c vessels with a de⦈�ned ⦈�xed location. Another
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major di낋�erence between the Division 1 and Division 2

lies in failure theory. While Division 1 is based on normal How to size a pressure vessel
stress theory, Division 2 is based on maximum distortion
energy (Von Mises). A design engineer usually requires the
following basic data to size a pressure vessel:
The codes mentioned under Section VIII for both divisions
also include appendices. These appendices are Vessel function
alternative or supplementary rules that serve as Process materials and services
guidelines, since they are less frequently employed than (corrosion, deposits, etc.)
the main body codes. However, the appendices Operating conditions (temperature and
themselves contain both mandatory and non-mandatory pressure)
sections. Materials of construction
Dimensions and orientation
The mandatory appendices are as important as the code Type of vessel heads to be used
itself and provide alternative rules to the main codes Openings and connections required
included in the body. At present, there are 40 mandatory Heating/cooling requirements
appendices included in ASME Section VIII. Non- Agitation requirements
mandatory appendices are not a requirement for ASME Speci⦈�cation of internal ⦈�ttings
certi⦈�cation. However, it is good practice to keep them in
mind as they can be particularly helpful in design Once the preliminary data is obtained, the
veri⦈�cation and testing. pressure vessel design can be initiated
following the standard procedures outlines in
A new edition of the ASME BPVC codes is issued every BPVC Section VIII. This section is further
two years, including revisions in interpretations and code subdivided into subsections and appendices,
cases. A code case is an urgent revision of the ASME code guiding the engineer to determine general
to be included in the current running editions. Currently, design requirements, fabrication requirements
the 2015 edition is in practice, while the 2017 edition will and material requirements to e낋�ectively size
be made available to the public by July 2017. the pressure vessel.

With each new edition, the codes are re⦈�ned to help

pressure vessel manufacturers comply with the
applicable regulations and gain operational, cost and safety bene⦈�ts. In the future, the codes are likely to be
developed considering advances in technologies and the use of advanced materials. For example, future codes
will include detailed recommendations in stress analysis methods, component modeling, and result validation.

Pressure vessel design software

In recent years, there has been a signi⦈�cant move towards utilizing design by analysis approach for pressure
vessel design, due to the ability to consider higher allowable stresses and get more real, economic and reliable
results. The recent development in computational technologies has further permitted engineers to develop
cost-e낋�ective pressure vessels using the design-by-analysis approach.

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4/8/2017 Pressure vessel design by analysis versus design by rule

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Fatigue analysis on pressure vessel as per ASME BPVC Section VIII, Div.2.
(Courtesy of Hi-Tech CADD Services)

Finite Element Analysis (FEA) enables pressure vessel designers to study stresses over the entire geometry and
optimize material usage. Further, FEA is a tool that helps design engineers to size pressure vessels at much
reduced cost and time.

Kashyap Vyas is an engineer at Hi-Tech iSolutions LLP. He has a master’s degree in

Thermal Engineering with several research papers to his credit. He specializes in CAD
and CAE for engineering applications. His contributions are primarily focused on
encouraging manufacturers and suppliers to adopt virtual product development tools
to build e�cient products with reduced time-to-market. He can be reached at
kashyap.vyas@hitechexport.com.

Hi-Tech iSolutions LLP

TAGS:
EQUIPMENT AND SYSTEM DESIGN MARCH 2016 FEATURES MARCH 2016

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