Vessel Design Guide

Kinetic Systems, Inc.
Seven Penn Center, 1635 Market Street, Suite 1500 Philadelphia, PA 19103 USA Telephone 215.656.2500 Facsimile 215.656.4444 www.kineticsgroup.com
VESSEL DESIGN GUIDE
Revision 0 Issued: 19-Jul-02

Form A-002-T3_2
1
1.01
GENERAL
VESSEL GEOMETRY (VERTICAL VESSELS) A. Definitions 1. 2. 3. Total Volume Volume of vessel including top and bottom heads Maximum Capacity Volume to top tangent line Working Volume Operating maximum volume (Working volume is the volume that is indicated on the P&IDs, equipment lists, and data sheets. When referring to a 1,000 liter vessel we are indicating a 1,000 liter working volume vessel) (Working volume includes the volume in the bottom head). Working volumes are typically rounded up. For example, if the process requires a working volume of 2,350 liters, we would make the vessels volume either, 2,400, 2,500 or even 3,000 liters. Minimum Volume Minimum mixing volume. This can vary depending on the process requirement, type of agitator used and headroom needed above or below the vessel for removing the impeller/shaft assembly. The following can be used as a guide, if it meets the process requirements and the available headrooms; a. For top mounted agitators, the typical minimum mixing volume is approximately 25 to 35% of the working volume. For higher accuracy, the minimum mixing level is typically 1D for fixed speed agitators (one times the diameter of the agitator impeller) above the impeller. For example, the minimum mixing volume of a 8 diameter fixed speed impeller is 8 above the impeller. If an agitator is variable speed the height of liquid can be reduced to 0.25D to 0.5D.
4.
Vessel Design Guide Page 2

Form A-002-T3_2
b.
For magnetic drive impellers, since the impeller lies close to the bottom of the vessel, the minimum volume is lower than the top mounted as described above. As an estimate, the minimum agitation level is the volume of the bottom head. Refer to the chart below for the volumes of bottom heads based on ASME flanged and dished heads; Vessel Diameter 1'-6" 2'-0" 2'-6" 3'-0" 3'-6" 4'-0" 4'-6" 5'-0" 5'-6" 6'-0" 6'-6" 7'-0" 7'-6" 8'-0" Volume 8 liters 18 liters 39 liters 63 liters 104 liters 150 liters 220 liters 290 liters 390 liters 510 liters 635 liters 825 liters 990 liters 1230 liters
B.
Typical Sizes 1. Heads of vessels are fabricated in increments of 6 diameters due to head rolling machines. Therefore, when specifying vessels, use diameters such as 12, 18, 24, etc. Do not use 34.5 or 40. The height of a vessel can be fabricated in any length. Vessel fabricators first cut sheets of stainless steel to the specified length, and then they are rolled. Increments of 6 are not necessary when specifying the tangent to tangent length. The typical L/D (length over diameter, also known as aspect ratio) is between 1.0 to 1.2. This is a guide as there may be times when, due to process or layout concerns, an aspect ratio of 0.8 or 1.4 (or even lower or higher) can also be used. (This is typical for process vessels. Utility vessels do not have limitations.) When specifying a tan-tan length, the percentage above the working volume, known as freeboard, should be at least 10% so the sprayballs are a few inches above the working volume. The freeboard may be higher due to process concerns such as excessive foaming.
2.
3.
4.

Form A-002-T3_2
5.
Refer to the attached chart for sample sizes of vessels.
Working Volume (liters) 50 100 125 150 200 250 300 350 500 600 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 4000 4500 5000 7500 10000 12500 15000 20000 25000
6. 7.
Maximum Capacity (liters) 55 110 140 170 220 280 330 390 550 660 830 1100 1400 1700 2000 2200 2500 2800 3000 3300 4400 5000 5500 8300 11000 14000 17000 22000 28000
Diameter
Tan-Tan Length 1'-6" 2'-0" 2'-6" 1'-9" 2'-3" 3'-0" 3'-6" 2'-9" 3'-9" 3'-0" 3'-9" 3'-9" 4'-9" 4'-3" 5'-0" 5'-9" 5'-0" 5'-6" 6'-3" 5'-6" 6'-0" 6'-9" 6'-3" 8'-0" 8'-3" 9'-0" 9'-6" 10'-0" 11'-6'
1'-3" 1'-6" 1'-6" 2'-0" 2'-0" 2'-0" 2'-0" 2'-6" 2'-6" 3'-0" 3'-0" 3'-6" 3'-6" 4'-0" 4'-0" 4'-0" 4'-6" 4'-6" 4'-6" 5'-0" 5'-6" 5'-6" 6'-0" 6'-6" 7'-0" 8'-0" 8'-6" 9'-6" 10'-0"
For sizing assistance, the Intranet has a calculation sheet titled Tank Sizing for determining vessels dimensions. An alternate method to size a vessel is to specify the working volume and the diameter and state in the data sheet the vendor is to provide the tan-tan length. The vendor will need to ensure the bottom of the sprayball is located several inches above the working volume of the vessel.

Form A-002-T3_2
1.02
PRESSURE/TEMPERATURE RATING A. B. Most pressure vessels are rated at 45 psig and full vacuum. The jackets are rated at 90 psig and full vacuum. (Some applications require higher pressure ratings) The vessels and jackets are required to be ASME stamped if the vessels diameter is greater than 6 and its design pressure is 15 psig or higher per ASME Boiler and Pressure Vessel Code, Section VIII, Division I. When a vessel is stamped, the vessel is provided with the Usymbol stamp, ASME nameplate, and is assigned a National Board Registration Number. (Refer to the ASME Code for additional information is required) Vessels and jacket design temperature shall be 177 deg C. This design temperature will allow for steam in place capabilities, if so required. Since the vessel can be large and heavy, a seismic zone code is required for the project location.
C. D.
1.03
MATERIAL OF CONSTRUCTIONS/SURFACE FINISH A. The material of construction for the product contact surfaces is usually 316L SS. Other materials such as AL6XN can be used where 316L SS is not adequate. Non-product contact surfaces, such as lugs, lugs, supports, etc. can be 304L SS. Interior Surface Finish 1. As a rule of thumb the interior surface finish of the vessel should be the same as the piping. Use Ra as the units, never use grit. Ra means roughness average and is the arithmetic average of the measured profile height deviation. The units are typically microinches. More on the subject can be found in ANSI/ASME B46.1 SURFACE TEXTURE (Surface Roughness, Waviness, and Lay) If a finish is not known a default value can be 15 Ra, then electropolish. If a vessel is required to be electropolished, the vessel will be mechanically polished to the specified level and then electropolished. As an example, if the requirement for the vessels interior surface finish is 15 Ra and electropolished, the vessel is mechanically polished to 15 Ra,, then electropolished. A profilometer (instrument used to measure surface finish) is then used to ensure the surface finish is equal to or less than 15 Ra. The welds are required to be ground flush for sanitary vessels (ground flush indicates the weld is flush with the parent material and weld discoloration is gone). If the vessel is located in a manufacturing or clean area, the exposed exterior finish (not the area under the heat transfer jacket and/or the thermal insulation) should be mechanically polished to 35 Ra and the welds should be ground flush. If the vessel is located in a mechanical area, the finish can be mill (mill means as it leaves the steel mill) with the welds ground smooth (ground smooth indicates the weld crown is present and discoloration is completely gone). (Note: mill is acceptable for a mechanical area but beware it is not pretty) Sand or glass blasting is another method of polishing the exposed exterior of the vessel. Small glass beads or sand are blasted against the vessel making a uniform finish. Glass beads make a smoother finish than sand because the glass, upon hitting the vessel, tend to explode whereas the sand does so but to a lesser extent. After glassblasting the surface finish is 100 Ra and after sandblasting the finish is 120 Ra. It is not recommended
B.
2. 3.
4. C.
Exterior Surface Finish 1.
2.

Form A-002-T3_2
to use sand or glassblasting because it shows grease and handprints and if scratched in the field it is very difficult to repair (you cant sand or glassblast in the field). D. Electropolishing 1. Electropolishing is a process of smoothing, polishing and deburring metal surfaces in an electrolytic bath. The process removes high points on the vessel surface while producing a uniform luster on the vessel surface. During electropolishing, the tank is manipulated to control the amount of metal removed so that polishing is accomplished and dimensional tolerances are maintained. To achieve electropolishing, the vessel is immersed in a liquid media and subjected to a direct current. The vessel is made anodic (+) and a metal, usually copper, is made cathodic (-). The direct current flows from the anode to the cathode removing metal ions at a controlled rate. The amount of metal removed is dependent on the bath media, temperature and time. See picture below for a detail on electropolishing.
2.
E.
Passivation 1. Passivation is the means of obtaining the electrochemical condition of Passivity: through stabilization of the passive layer due to the formation of a surface film which acts as a barrier to further corrosion. This is generally accomplished through the utilization of mixed chelant solutions. These are nontoxic organic acids or viable salt forms applied together with equally nontoxic synergizing agents. A simpler definition of passivation found in MILS-5002C as follows A process designed to remove foreign metals from the surface of stainless and corrosion resistant steel and to promote natural tendency of surface to oxidize. Does not change the appearance of the base metal. Process purifies surfaces and therefore improves corrosion resistance. The film primarily contains chromium and iron oxides with only trace quantities of other elements found in the 316L SS vessel wall. All process vessels are required to be passivated. Passivation of vessels is done in the factory by the vessel vendor.
2. 3.

Form A-002-T3_2
1.04
NOZZLES/MANWAYS A. There are typically four nozzles we use for vessels which are; 1. Tri-clamp the minimum size for a connection on the top of a vessel is 1 for vessels which are to be cleaned in place. Any smaller and they are difficult to clean from the sprayballs. (USP or WFI storage tanks may have nozzles smaller than 1 . This type of tank we are concerned with wetting the inside of the tank, not cleaning)
2.
Ingold size is 25 millimeters and are used for instrument connections.
Ingold Fitting 3.
Ingold Plug
Sanitary Flange used for nozzles with larger weights, torques and bending moments. Typically used for top mounted agitators. Size of the flange will be determined by the agitator vendor. Flange used for jacket connections (chilled water, glycol and plant steam).
4.

Form A-002-T3_2
B.
Refer to the lead sheets for nozzle designations. Do not show connections as 1.5 but as 1 . Do not show a nozzle tags as P1 unless there is a P2. The following chart is Kinetics standard for nozzle designations.
C.
The following can be used for a guide for sizing nozzles. They may change depending on project requirements: 1. 2. 3. 4. Vent 1 tri-clamp (no smaller than 1 due to cleaning concerns) Pressure Indicator 1 tri-clamp Pressure Transmitter 2 tri-clamp Sight Glass 3 tri-clamp
Light Glass (Canty)

Form A-002-T3_2
5.
Light Glass 2 tri-clamp
Sight Glass (Canty) 6. 7. 8. Spare 2 tri-clamp (provide with clamp) Spare 25 mm Ingold (provide with plug) Sprayball 3 tri-clamp on the vessel with a 1 process connection. Number of sprayballs are estimated as follows (actual number to be determine by vessel fabricator); a. b. c. d. Under 1,000 liters one sprayball 1,000 liters up to less than 5,000 liters two sprayballs 5,000 liters up to less than 10,000 liters three sprayballs 10,000 liters and above four sprayballs
Sample Sprayballs 9. Removable Heads a. b. Vessels whose diameter is 30 and below have removable heads. Smaller heads have less real estate on the top head, so be careful not to put too many nozzles on the top head

Form A-002-T3_2
10. Manways a. b. c. Vessels with 3-0 to 3-6 diameters have 18 manways. All other vessels 4-0 diameters and above have 20 manways. Manways are heavy and can be provided with lift assist devices to help opening the vessel. Some devices can be expensive so they may only be necessary for manways which will be opened frequently.
Manway 11. Rupture Disks a.
Manway Lift Assist
Pressure rated sanitary vessels require rupture disks to protect the vessel in case of excessive pressure.
Rupture Disk (BS & B) b. The following can be used when estimating the size of a rupture disk; 1) 2) 3) a. Vessels 1,500 liters and less 1 rupture disk Vessels above 1,500 liters up to 5,000 liters 2 rupture disk Vessel above 5,000 liters up to 20,000 liters 3
12. Jacket Connections The process will determine the size of the connections. If the process is not known, the following can be used as an estimate; 1) 2) 3) Vessels 500 liters and less 1 flange Vessels above 500 liters up to 1,000 liters 1 flange Vessels greater than 1,000 liters 2 flange

Form A-002-T3_2
b.
Chilled water or glycol supply is to the lower jacket connection and return is out the top connection. This will allow any air bubbles to float to the top and travel out the top nozzle. Steam enters the top jacket nozzle, condenses and condensate exits out the bottom nozzle. Usually jacketing is required only on the side of the vessels and not on the bottom head. Bottom head jacketing may be necessary if the process requires a large surface area for heating or cooling or the vessel will operate at low volumes where the side jacket does not reach low enough.
c. d.
13. Diptubes are commonly used when there is a concern with splashing and foaming. The following vessel nozzle sizes should be used for diptubes: a. b. c. d. a. For a process line the tank connection is 2 For a to 1 process line the tank connection is 3 For a 2 process line the tank connection is 4 For a 3 to 4 process line the tank connection is 6 Drains on the bottom of the tank are typically flush mounted or tri-clamp. Flush mounted are typically used when the deadlegs are to be kept to a minimum.
14. Drains
Bottom Outlet Valve (NovAspetic) b. Vortex breakers are advisable for vessels which are to be CIPed or will be storing and pumping out hot fluids. The use of vortex breakers will inhibit the formation of vortices, which allow air to be carried with the water down the drain. Drain valves 1 and below should not be used on vessels. The 1 and below valves will hold up CIP solutions when draining due to the small cross sectional area.
c.
15. Sample Valves- There are many different types of sample valves. The following are examples of several which can be used on projects. a. b. Tri-clamp with diaphragm valve not recommended due to the large dead leg as well as cleaning difficulties. ASEPCO sample valve must be welded in the side of the tank. Does not allow for future changes. Clean steam is added through the top port for an aseptic sample.

Form A-002-T3_2
c.
Keofitt sample valve Clean steam is added through the top port for an aseptic sample.
Keofitt Sample Valve
Sampling
Steaming
d.
Novaseptum uses a needle which is inserted in a diaphragm. Fluid then flows through the needle and into a sample bags. Bags can get expensive. Does not require steaming for aseptic sampling. Requires a NAConnect port.
Novaseptum Connection D.
NA Connect
Nozzle schedule for the data sheets shall be as follows: 1. 2. 3. Nozzle Designation shall match exactly as on the P&IDs. These shall also match the P&ID lead sheet. Size Use 1 , not 1.5. Remember to use 25 mm for Ingold fittings. Also indicate the tank connection, not the process connection. Type of Connection The following are acceptable terms to be used for the type of connection. a. b. c. d. e. f. g. Tri-clamp Sanitary (for manway) Weld plate (for bottom outlet valves, sample valves and agitators) Thermowell Ingold NA Connect Tank Spud (for differential pressures on the bottom head)

Form A-002-T3_2
4.
Location Use the following for location. a. b. c. Top head Bottom head Side Relief Feed (for all incoming lines) Vent Spare Sight glass Light glass Sprayball Manway Pressure (for PIs and PITs) Level Agitator Outlet Sample Jacket Conductivity, pH, dO (for analytical probes) removable sprayball with 1 process connection weld plate supplied by agitator vendor ASEPCO bottom outlet valve model number XXXX provide diptube with 1 process connection sanitary tank spud Rosemount model XXXX. instrument provided by others sample device provided by tank vendor sample device provided by others
5.
Service Use the following for service. a. b. c. d. e. f. g. h. i. j. k. l. n. o. p.
m. Temperaure
6.
Remarks add items which will further define the connection. For example; a. b. c. d. e. f. g. h.
1.05
JACKETS A. There are two different types of jackets which are used, dimple and half pipe. The following is a short explanation of the differences of the jacket types: 1. Dimple jacket is a 304L SS gauge sheet wrapped around the vessel. The spacing between the vessel outer wall and the jacket is . Dimples are pressed into the jacket to promote even distribution of the chilled water. The dimples are spaced about 2 to 3 apart from one another.

Form A-002-T3_2
Dimple Jacket (before welded onto tank)
2.
Half pipe jacket looks like a pipe is cut in half and welded around the vessel. Each pipe is between 2 to 3 wide. The material of construction is typically 304L SS.
Half Pipe Jacket 3. The following are differences between the two types of jackets; a. b. c. d. 4. A dimple jacket is less expensive than a half pipe jacket. A half pipe jacket has a more uniform heat transfer distribution than the dimple jacket. The pressure drop of a half pipe jacket is higher than a dimple jacket. Half pipe jackets are difficult to fit around nozzles.
Examples of calculations for pressure drop can be found in Precision Stainless Vessel Design Manual

Form A-002-T3_2
1.06
INSULATION/SHEATHING A. Insulation 1. 2. For most applications 2 thick insulation is adequate. The insulation specified should have minimum amounts of chloride ions. Chloride ions cause corrosion when moisture is present and temperatures are above 140 deg F. Insulation containing less than 1 part per million is considered safe. As an extra precaution the stainless steel which is in contact with insulation is coated with Thurmalox. If the contents of the vessel are cold, the side and bottom head should be insulated to prevent condensation. If the vessel is subjected to hot temperatures during cleaning, steaming or the process, the bottom and side areas of the vessel should be insulated for personnel protection. The outer sheathing is a protective coating for the heat transfer jacket and insulation. It acts as a barrier for the insulation and allows the vessel to be cleaned on the outside with greater ease. The outer sheathing is typically 12 gauge 304L and covers all areas which are insulated. It is not necessary or cost effective to cover the top head due to the number of fittings. The outer surface of the sheathing is polished to the required level as the exterior of the vessel.
3. 4.
B.
Sheathing 1.
2. 3.
1.07
CLEANING IN PLACE A. B. C. The purpose of sprayballs is to ensure the vessel is 100% covered of all the wetted surfaces. This is required to ensure the vessel will be properly cleaned in place. Refer to specification 22000 titled Sanitary Stainless Steel Vessels for details pertaining to CIP testing. The maximum pressure drop through a sprayball is usually 20 psig. The maximum allowable flowrate is determined from the following formula;
Vessel Diameter (ft)*2.5*3.14 *3.8= flow (lpm)

1.08 SUPPORTS A. B. Legs are required for vessels which rest on the floor. Lugs are required for vessels who are supported from structural steel. The vessels can be provided with either three or four supports. The following are issues to evaluate when determining the number of supports: 1. If the tank is provided on load cells it is recommended to have three supports. Only three load cells are required for three supports (do not have to pay for the fourth load cell). Also, it is easier to install the three load cell than four due to unequal weights (similar to a chair with one leg shorter than the other three) If a tank is large the vessel vendor may recommend a four legs due to structural concerns. If lugs are used, a vessel with four lugs may be easier to install due to the structural layout. Structural beams in facilities are laid out perpendicular to one another and it is very easy to
2. 3.

Form A-002-T3_2
mount a vessel with four legs. If three lugs are used, the structural steel will be needed to be installed in a non-perpendicular layout. 1.09 SAMPLE DRAWING A. Refer to the following drawing for suggested vessel P&ID details.

Form A-002-T3_2
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Kinetic Systems, Inc.