Pressure Vessels

What is a pressure Vessel???

 DEFINITIONS
Pressure Vessels are defined in ASME Section VIII, Div 1:

“Pressure Vessels are containers for the containment of

pressure either external or internal. The pressure may be
obtained from an external source, or by the application
of heat from a direct or indirect source, or any
combination thereof.”

A pressure vessel is usually defined as a vessel designed

to safely withstand an internal pressure in excess of 15
psig.”
 USE OF PRESSURE VESSELS
 Used as a surge drum for storing liquids
(volatile or dangerous)
 Used as a thermal reactor or a catalytic reactor
 Used as a fractionators
 Used as a separator
 Used as a regenerator
 Used as an exchanger
TYPES OF PRESSURE VESSELS

 Trayed columns

 Reactors/Process Vessels

 Packed Columns

 Drums & MISC. Vessels

 Storage vessels like bullets & spheres

TYPES OF PRESSURE VESSELS

SHAPES OF PRESSURE VESSELS

 CYLINDRICAL HAVING
 Flat, Conical, Toriconical, Torispherical, Semi-ellipsoidal Or
Hemispherical Heads

 SPHERICAL

SUPPORTS OF PRESSURE VESSELS

Cylindrical vessels may be horizontal or vertical. They are supported by

skirts or steel columns attached to the shell.
Spherical vessels are usually supported by steel columns attached to
the shell.
TYPES OF PRESSURE VESSELS
HORIZONTAL PRESSURE VESSEL
TYPES OF PRESSURE VESSELS
VERTICAL PRESSURE VESSEL

 The max. Shell length to

diameter ratio for a small
vertical drum is about 5 : 1
TYPES OF PRESSURE VESSELS
TALL VERTICAL TOWER

 Constructed in a wider range

of shell diameter and height.
 They can be relatively small
in dia. and very large (e.g. 4 ft
dia. And 200 ft tall distillation
column.
 They can be very large in dia.
and moderately tall (e.g. 3 ft
dia. And 150 ft tall tower).
 Internal trays are needed for
flow distribution.
TYPES OF PRESSURE VESSELS
VERTICAL REACTOR

 Figure shows a typical

reactor vessel with a
cylindrical shell.
 The process fluid undergoes
a chemical reaction inside a
reactor.
 This reaction is normally
facilitated by the presence
of a catalyst which is held in
one or more catalyst beds.
TYPES OF PRESSURE VESSELS
SPHERICAL PRESSURIZED STORAGE VESSEL
 Development of Pressure vessel Construction
codes
 Numerous boiler explosions took place through the late 1800s and early
1900s
 ASME issued its first standard, Code for the Conduct of Trials of Steam
Boilers, in 1884. This paper evolved into Rules for the Construction of
Stationary Boilers and for Allowable Working Pressure.
 The first edition of ASME’s now-legendary Boiler and Pressure Vessel Code
(BPVC)—issued in 1914 and published in 1915. This document was
referred to a theoretical factor of safety of 5 (The petroleum industry did
not consider it to be adequate for their purposes and also desired better
utilization of available materials.)
 In 1924, a joint API–ASME Committee published the First edition of an
unfired pressure vessel code specifically for the petroleum industry.
Development of Pressure vessel Construction
codes

 In 1952 these two separate codes merged into a single code – the
ASME Unfired Pressure Vessel Code, Section VIII.
 The ASME Pressure Vessel Code, Section VIII Division 2: ‘‘Alternative
Rules for Pressure Vessels,’’ was published in 1968 and the original
code became Section VIII Division 1: ‘‘Pressure Vessels.’’
 By 1960 the need for a code for pressure vessels for commercial
nuclear plants became imperative. This resulted in publication of the
1963 Edition, Section III: ‘‘Nuclear Pressure Vessels.’’ This was a
design by analysis code with a theoretical safety factor of 3.
 In 1997, ASME published Pressure Vessel code specially for very high
pressure operating pressure vessel Section VIII Division 3: Alternative
Rules for Construction of High Press.ure Vessels
Development of Pressure vessel Construction codes

Brief History of ASME

 1911 – ASME set up the B&PV Committee – to formulate std rules for c construction
of boilers and pressure vessels
 1915 – first Code issued – ASME 1 – Power Boilers
 1923 – Heating Boilers – Section IV 1924 – Materials – Section II
 1925 – Pressure Vessels – Section VIII Div 1
 1941 – Welding & Brazing – Section IX
 1963 - Nuclear Codes – Section III
 1968 – Pressure Vessels – Section VIII Div 2
 1971 - NDE – Section V
 1997 - Pressure Vessels – Section VIII Div 3
APPLICABLE CODES & STANDARDS

 ASME BPVC, SECTION VIII DIV.1 - Rules for

construction of pressure vessels
 BS 5500 – Specification for unfired pressure vessels
 API 510 –Pressure vessel inspection code:
maintenance inspection, rating, repair & alteration.
 API RP 572 – INSPECTION OF PRESSURE VESSELS
METHODS OF CONSTRUCTION

 Most pressure vessels constructed with welded joints

having longitudinal seam.

 Shell rings made by rolling plates and welding of ends done

to form a cylinder.

 Hot forging for high-pr, heavy wall vessels used for

hydrocracker reactors. no longitudinal seam.

 Multilayer method
MATERIALS OF CONSTRUCTION

Carbon steel
Ferritic or austenitic alloy steel
Metallic liners for corrosion / erosion resistance
(Austenitic / Ferritic SS, Monel, Lead)
Non-metallic liners (concrete, acid brick, refractory
material, rubber, plastic)
 ALLOY GRADES / DESIGNATIONS

CS - Carbon steel
KCS - Killed Carbon steel
P11 - 1.25% Chromium and 0.5 Molybdenum
P22 - 2.25% Chromium and 1.0 Molybdenum
P5 - 5%Chromium and 1.0 Molybdenum 9% Chromium
P9 - and 1.0 Molybdenum
SS410 - 11% - 13% Chromium
SS304 - 0.08% C, 18% Cr and 8% Ni.
SS316 - 0.08% C, 16% Cr 10% Ni and 2% Mo.
SS321 - SS304 with Titanium stabilization SS304 with
SS347- Columbium stabilization

All alloy designation should be preceded by relevant ASTM/ BS /

IS standard number
Pressure Equipment Categories
TYPICAL COMPONENTS OF PV

1. Cylindrical or
Spherical Shell
2. Formed Heads
3. Blind Flanges,
Cover Plates,
Flanges
4. Openings And
Nozzles
5. Supports
NECESSITY OF INSPECTION

Why Inspection is required in Pressure Vessels???

NECESSITY OF INSPECTION

To determine the physical condition of the vessel. systematic & periodic

inspection will also reveal the following:
 Corrosion rate & remaining corrosion allowance
 Forecasting future repairs & replacement
 Minimizing probability of instantaneous failures
 Causes of deterioration and taking remedial measures
 Statutory requirement

TYPES OF INSPECTION
 External inspection
 Internal inspection
 When to inspect?
 The frequency of inspection depends broadly on the
following factors.
 Operating conditions
 Physiochemical characteristics of process streams and
operating environment
 Process licensor’s recommendation
 Manufacturer’s recommendation
 Statutory requirements
 Recommendations of various codes and standards like API,
OISD etc which are applicable to our types of refinery.
 Past practices in similar types of operation in other
refineries / plants for
 History of operation of the equipment.
 Risk based Inspection criteria
CAUSES OF DETERIORATION

• Erosion – Impingement of solid particles or liquid drops on the

surface.
• Due to restrictions in flow, change in direction or high
fluid velocities.
• Found in inlet / outlet nozzles, vessel walls opposite
inlet nozzles, baffles etc.
• Metallurgical & physical changes – Due to exposure to service
conditions.
• Affects the mech. properties.
• GRAPHITIZATION, HTHA, CARBIDE PRECIPITATION, IGC –
MICROSTRUCTURAL CHANGES
CAUSES OF DETERIORATION

• Corrosion – Common corrodents are sulfur & chloride

compounds. caustics, inorganic acids, water (low ph)
etc. are other corrodents.
• MECHANICAL FORCES- Thermal Shock, Vibration,
Excessive Pr. Surge& External Loads.
• FAULTY MATERIAL – Laminations In Plate, Casting
Defects.
• FAULTY FABRICATION – Poor Welding, Improper Heat
Treatment Etc.
Comparison of ASME Sec VIII Div. 1, 2 & 3
Div. 1 ( Unfired Pressure Div. 2 ( Alternative Div. 3 ( Alternative
Vessels) Rules) Rules for High Pressure)
Published < 1940 1968 1997
Pressure Normally Up to 3000 psig No limit either way, No limit, normally from
Limits ( i.e. ~211 Kg/cm2(g)) usually 600+ psig ( i.e. 42 10000 psig ( i.e. 703
Kg/cm2(g)) kg/cm2(g))
Design Design Factor 3.5 on tensile Design Factor of 3 on Yield based with reduction
Factor (4 used tensile factor for
previously) and other yield (lower factor under yield to tensile ratio less
and reviewed) and other than 0.7
temperature considerations yield and temperature
considerations
Design Membrane - Maximum Shell of Revolution - Max. Maximum shear stress
Rules stress shear stress
Generally Elastic analysis Generally Elastic analysis Elastic/Plastic Analyses and
more. Some design rules
Very detailed design rules Membrane + Bending. provided; Fatigue
with Quality Fairly detailed analysis required; Fracture
(joint efficiency) Factors. design rules. mechanics
evaluation required
Comparison of ASME Sec VIII Div. 1, 2 & 3

Div. 1 ( Unfired Div. 2 ( Alternative Div. 3 ( Alternative

Pressure Vessels) Rules) Rules for High
Pressure)

Code Stamp U Stamp U2 Stamp U3 Stamp

and
Marking

Hydrostatic 1.3 (Was 1.5 before 1.25 1.25 (may be

Test the use of the 3.5 exempted for
Design Factor in the Auto-frettaged
1999 Addenda) vessels)
 DIFFERENT STAMPING OF PRESSURE
VESSELS
Stamp Used for As per ASME Code
“U” Designator Pressure Vessels
“UM” Designator Miniature Pressure Vessels
ASME Sec VIII Div. 1
“UV” Designator Pressure Vessels Pressure Relief Valves
“UD” Designator Pressure Vessel Rupture Disk Devices
R” Designator For repair& alteration of Pressure Vessels ASME Sec VIII Div. 1
“U2” Designator Pressure Vessels (Alternative Rules for ASME Sec VIII Div. 2
Pressure Vessels)
“U3” Designator High Pressure Vessels
“UV3” Designator High Pressure Vessel Pressure Relief Valves ASME Sec VIII Div. 3

“UD3” Designator High Pressure Vessel Rupture Disk Devices

OISD Guideline for inspection of
Pressure Vessels (OISD-128)
 Stages of Pressure Vessel Inspection
1. Inspection during pre-commissioning
- To ensure that all examinations and tests during fabrication, erection and hydro-
testing have been carried out in line with the design standard/ approved
procedure
2. In-service (External) Inspection
- External visual inspection including aided visual inspection techniques such as
thermography, X-ray profiling.
- Inspection for corrosion under insulation
- Internally lined pressure vessels operating at high temperatures shall be checked
for external hot spots to assess lining condition
- Special attention shall be given to pressure vessels in humid area, areas near to
cooling tower and in areas where corrosive chemical vapours are present
OISD Guideline for inspection of
Pressure Vessels (OISD-128)
 Frequency of Inspection
1. In-service (External) Inspection
- Each above ground vessel shall be externally visually inspected, once
in two years. Insulated vessels operating between -4 deg C & 120
deg C shall also be externally inspected by removing insulation
pockets at select locations.
2. Out of Service Inspection
- The frequency of out of service inspection shall be determined
based on history, corrosiveness of the fluid handled and operating
conditions.
- The periods between these inspections shall not exceed one half of
estimated remaining life of the vessel based on corrosion rate.
- However, the interval of out of service inspections shall not exceed
five years
OISD Guideline for inspection of
Pressure Vessels (OISD-128)

In-service (External) Inspection.

-FOUNDATION & SUPPORTS

 Steel reinforced concrete / steel fireproofed with concrete to be

checked for spalling, cracking & settling.
 Steel skirts to be checked for corrosion, distortion & cracking.

-FOUNDATION / ANCHOR BOLTS

 Should be checked for corrosion & damage

 Nuts to be checked for proper tightness.

-LADDERS, STAIRWAYS, PLATFORMS

 Check for external corrosion, cracks, paint failure etc.

OISD Guideline for inspection of
Pressure Vessels (OISD-128)
In-service (External) Inspection Contd.
- NOZZLES
 Check for distortion & cracking.
 Visual inspection & thickness survey.
 Hammer testing (out of service)
 Checking of flange gasket faces for corrosion.
 Tell-tale holes of lined nozzles should be checked for leakage. Pressure
testing to be done.
- EXTERNAL METAL SURFACES
 Shell to be checked for buckles or bulges
 Checking for hot spots due to failure of internal lining
 Skirt to shell weld joint to be checked for cracks.
 Thickness survey of vessels walls & heads
OISD Guideline for inspection of
Pressure Vessels (OISD-128)
Stages of Pressure Vessel Inspection
Out of Service (Comprehensive) Inspection
- To assess the integrity of the equipment, condition of internals and to
determine the corrosion rate to estimate the remaining life.
- The thickness for all major components (shells, heads, and cone sections)
and a representative sample of vessel nozzles shall be measured,
remaining life and next inspection interval shall be calculated for the
limiting component
- Hydrostatic pressure testing shall be carried out for pressure vessels as per
statutory requirements and also under the following conditions;
a) After any major alteration / re- rating / replacement/ exposure
to fire
b) After chemical cleaning involving metal loss
c) Out of service for more than 6 months
OISD Guideline for inspection of
Pressure Vessels (OISD-128)
Out of Service (Comprehensive) Inspection Contd.
Allparts of vessels internals should be inspected for corrosion, erosion,
hydrogen blistering, cracking & lamination.
Thickness measurements to be taken on heads, shell, nozzles to know the
extent of deterioration.
Top dome & shell to be checked for pitting. depth of pits / grooves
measured by pit depth gauge.
Hammer testing done for shells & nozzles to identify thin spots by
resulting sound.
For wet H2S , Amine or Caustic service, Magnetic particle testing
(WFMPT) done in welded seams to detect surface cracks.
Connected nozzles should be checked for internal corrosion.
OISD Guideline for inspection of
Pressure Vessels (OISD-128)

Out of Service (Comprehensive) Inspection Contd.

Supports for internals like trays, baffles, screens, grids, piping etc.
should be visually checked.
General condition of internals like trays, packing m/l should be
checked for corrosion.
The flash (feed) zone should be thoroughly checked for erosion /
corrosion of impingement plate attached with the shell.
Bottom dome & shell near the draw-off nozzle are critically
inspected for pitting corrosion.
Shellopposite to steam injection nozzle should be checked for
impingement.
OISD Guideline for inspection of
Pressure Vessels (OISD-128)
Special Inspection
1. Pressure Vessel Inspection in New Plants
- Pressure vessels installed in new process plants shall be inspected
based on licensor recommendations or within first 2 years of
operation to assess the internal conditions at select locations.
2. Inspection of Reactors and Catalyst filled Vessels
- The internal inspection of reactors and catalyst filled pressure
vessels shall be carried out as and when the catalyst is dumped/
replaced. However, it is recommended that in-situ metallography be
carried out at the time of replacement of catalyst, if necessary.
- The reactors and catalyst filled pressure vessels shall be inspected
externally every two years and the internal inspection shall be
carried out within 10 years.
OISD Guideline for inspection of
Pressure Vessels (OISD-128)

Special Inspection
Pressure Vessel of small sizes (man entry not possible)
- For pressure vessels where size and configuration or
lack of access makes vessel entry for internal
inspection physically or operationally impossible,
hydrotest and external inspection shall be carried
out.
CORROSION PRONE AREAS IN COLUMNS /
REACTORS / VESSELS
 Bottom head & shell of fractionators processing high `s’
crude oils are susceptible to sulphide corrosion.
 Top heads & upper shell of distillation columns are
prone to chloride attack in the form of pitting corrosion.
 Fractionation & distillation column, knockout drums &
reflux drums in the presence of wet h2s or cyanides are
prone to cracks in welds & their HAZ.
 Corrosion & erosion will take place in shell directly
opposite to steam inlet & inlet streams.
 Corrosion occurs where two dissimilar metals are in
close contact (cladded / uncladded zone)
HYDROSTATIC TESTING

 After partial replacement of shell / domes, the column /

vessel is hydrostatically tested.
 Hyd. Test pressure: –
 1.5 x ( MAX. ALLOWABLE OPR. PR.) x STRESS AT TEST TEMP.
 STRESS AT DES. TEMP.
 The pressure should be held for min. 30 minutes duration
and pr. gauge installed at the highest point.
 Area of repair should be thoroughly checked for leaks.
 Austenitic stainless steel pr.vessels should be hydro-tested
with dm water.
INTERNAL INSPECTION OF PRESSURE VESSELS
(PERMIT SYSTEM)
 In IOCL, for Internal inspection of any Pressure Vessel permit
system is in place which is called “Vessel Entry / Confined
Space Entry Permit”.
 Before entering inside any confined space or inside any
pressure vessel, Permit shall be taken from the Operating
personal (Production / P&U department) followed by
registration of same at F&S department.
 After issuance of permit, clearance shall be taken shift wise
before going inside the vessel.
 The permit system specifies that at least one person in
addition to the person going inside the vessel shall be
stationed outside the vessel ( near manhole / entry location)
FREQUENCY OF INSPECTION DEPENDS ON

 Rate of deterioration.
 Remaining corrosion allowance.
 On the basis of service history, inspection interval set in accordance with API
510.
 Statutory requirements (SMPV rules – all vessels to be hydro-tested every 5
years).
 ACCORDING TO API 510 (Pressure Vessel Inspection Code)
 Period between internal inspections shall not exceed one half the estimated
remaining life or 10 years, whichever is less.
 External inspection should be conducted at least every 5 years or at the same
interval as internal inspection, whichever is less.
REMAINING LIFE (YEARS) = T(ACTUAL) – T (MIN.)
CORROSION RATE
SMPV (Static and Mobile Pressure Vessels)

 Applicable in our case to Spheres, Nitrogen

storage vessels and the relief devices installed.
 Mobile vehicles carrying hazardous goods.

 Inspection of spheres and Nitrogen vessels:

Frequency 05 years. Inspection Frequency of
Relief devices is one year.
HORTON SPHERE
 IBR (Indian Boiler Regulation)
 “Boiler” means any closed vessel exceeding 22.75 liters in capacity used
expressly for generating steam under pressure.
 “Steam pipe” any pipe through which steam passes at pressures greater
than 3 bars or having dia. greater than 10”.
 All steam generators shall be inspected by the competent persons
appointed by IBR once in 12 months.
 In case of process unfired boilers (waster heat boilers) exemption may be
granted for inspection of the boilers by the competent persons once in 24
months.
 Once in 10 years, bare inspection
 Visual inspection and Hydro test
Requirement of Factories Act for Pressure Vessels

 New Pressure vessel / plant or Pressure vessel / plant

remained isolated or idle for more than 2 months, shall be
hydrostatically tested and examined externally and internally.

 Every pressure vessel or plant in service to be thoroughly

examined
 Externally Once in six months
 Internally Once in 12 months
 Hydrostatically tested Once in every four years
TOOLS FOR PRESSURE VESSEL INSPECTION
INSPECTION TOOLS
 DOCUMENTATION

Observations & repairs carried out after each inspection should be

properly recorded in history cards.
The following documents are used for pressure vessels:

1. VESSEL DATA CARD

2. ULTRASONIC THICKNESS MEASUREMENT RECORD
3. HISTORY CARD
4. FILED INSPECTION CHECKLIST
5. DEVELOPMENT SKETCH
6. CONSTRUCTION DRAWINGS
CHECKLISTS
CHECKLISTS
 SAFETY REQUIREMENTS

 Have a proper/valid confined space entry

permit issued by operations. Confined space
entry typically has to be issued every 24 hrs.
 Check whether there are additional openings
in the vessel that provides a natural
circulation of air.
 Minimum oxygen percentage required is
20%.
 Ensure that manhole has standby person to
act in case of emergency.
 Know about the contents of the vessel during
operation.