STATIC EQUIPMENT

BY:
K. SANKARANAND
 INTRODUCTION

•WHAT IS STATIC EQUIPMENT

???....
In Mechanical Engineering the word “Static Equipment” is
given to any equipment which is in Static mode of motion or
does not have rotating part. Application of Static Equipment
is broadly used in Process Industry which cover, Refinery,
Chemical & Fertilizer Plant.
The purpose of Static Equipment is to hold the fluid generally
at a pressure in an enclosed container, for storage or for any
reaction/process to take place in the container. Large volume
of liquid at atmospheric pressure is store in “Tank”.
ARE THERE ANY CLASSIFICATIONS ???...
STATIC EQUIPMENT ARE CLASSIFIED IN
DIFFERENT WAYS:
1. Based on Container shape
 Spherical Vessel, also known as Horton Sphere
 Cylindrical Vessel
 Rectangular vessel

2. Based on Application
 Pressure Vessel - for storage or for some process operation
 Heat Exchanger – for transfer of heat
Distillation Column – for heat and mass transfer
Reactor – for any kind of thermal and/or chemical reaction.
 INTRODUCTION TO PRESSURE VESSEL
• A pressure vessel is a container designed to hold gases or liquids at
a pressure substantially different from the ambient pressure.
• ASME BPV Code is the legally required standard for pressure vessel design,
fabrication, inspection and testing.

S. No. ITEM INTERNATIONAL CODES AND

STANDARDS
A Design, fabrication and inspection ASME Sec. 1
ASME Sec. VIII Div. 1 or Div. 2
B Material ASTM / ASME Sec. II
C Non – Destructive Examination ASME Sec. V
D Flanges ASME B 16.5 / 16.47 Series B
E Piping ASME 31.3
PRESSURE VESSEL DESIGN PROCEDURE:
 ASME SECTION VIII - RULES FOR
CONSTRUCTING PRESSURE VESSELS
• The section of the ASME BPVC consists of 3 divisions.

• Division 1:
• This division covers the mandatory requirements, specific prohibitions and
non-mandatory guidance for materials, design, fabrication, inspection and
testing, markings and reports, overpressure protection and certification of
pressure vessels having an internal or external pressure which does not
exceed 15 psi (100 kPa).

• The requirements of national or local codes applying to pressure vessels at

the job site shall be taken into account.
• Division 2 - Alternative Rules:

• It covers the mandatory requirements which exceeds 15 psi (103 kPa).

• Generally the Division 2 rules are more onerous than in Division 1 with respect
to materials, design and nondestructive examinations but higher design
stress intensity values are allowed.

• Division 2 has also provisions for the use of finite element analysis to
determine expected stress in pressure equipment, in addition to the
traditional approach of design by formula.

• Division 3 - Alternative Rules for Construction of High Pressure Vessels:

• It covers the mandatory requirements which exceeds 10,000 psi (70,000 kPa).
 GENERAL SPECIFICATION:
1. The chosen construction code is ASME Section VIII Div. 1, the manufacturer
need not possess an ASME approval stamp (unless specifically required).

2. Manufacturers of vessels in accordance with ASME Section VIII Div. 2 shall possess
appropriate, valid ASME approval stamps.

3. The requirements of national or local codes applying to pressure vessels at the job
site shall be taken into account.

4. i) Hydrogen Service :
Materials for vessels in hydrogen service at elevated temperatures shall be
chosen on the basis of the Nelson curves and other data contained in API code 941.
ii) Caustic Service :
For EQUIPMENT exposed to caustic soda solution, the necessity
of post weld heat treatment shall be determined by Fig. below, independently of
equipment wall thickness.

iii) Hydrogen Sulfide Service :

For EQUIPMENT of carbon steel exposed to wet hydrogen sulfide service, if its
hardness is over HB (Brinell Hardness Number) = 200 after manufacturing, post weld
heat treatment shall be required. The cold formed heads or hot formed heads, of
which final forming temperature is 700 Υ or below, shall be stress relieved after forming,
unless otherwise specified.

NOTE :
• NELSON CURVE :
Nelson curves are commonly used to select the various grades of steels and the safe
operating limits of temperature and hydrogen partial pressure.
WHY DO WE CONSIDER NELSON CURVE????......
• We are taking Nelson curve into consideration because of High-temperature
Hydrogen Attack also known as Decarburization.
• It refers to the loss of strength and ductility of steel by high-temperature
reaction of absorbed hydrogen with carbides in the steel, resulting in
decarburization and internal fissuring.
• It occurs in carbon and low-alloyed steels exposed for an extended period
to hydrogen under high pressure and at high temperature.
• Atomic hydrogen diffuses into steel. the atomic hydrogen reacts with the
dissolved carbon or with the metal carbides, forming methane:
8H+C+Fe3C =2CH4+3Fe
• the decarburization process leads to the loss of carbon in the steel and
hence a reduction in tensile strength and an increase in ductility and creep
rate.
 MATERIAL OF CONSTRUCTION :
• Selection Criteria For Carbon Steel :
• In view of material forms, applicable thickness limitation and temperature
ranges applied carbon steel specification shall be selected.
• For design temperatures of 16º C and above, the following carbon steel shall
be selected to provide the most economical construction based on the
guidelines as shown below
• For design temperature of 15º C to - 29º C, materials shall be selected based
on the guidelines shown below
• MATERIAL SELECTION FOR ALLOY STEEL AND STAINLESS STEEL ARE GIVEN
BELOW :
 DESIGNING OF PRESSURE VESSEL :
Design pressure :
• The maximum operating pressure of a vessel is the maximum gauge pressure which
is expected to occur at the top of the vessel in its operating condition.

• In vessels, which contain a static head of liquid during operation, the design pressure
for any affected portion of the vessel shall be increased by an amount
corresponding to the liquid head.

• Vessels in which a vacuum may be expected to occur (due to condensation of a

vapor, emptying of a liquid or any other reason) shall be designed to withstand such
a vacuum.
DESIGN TEMPERATURE :
• For vessels in which the pressure is governed by the vapor pressure of
saturated steam (steam drums, condensate separators, etc.), the maximum
design temperature shall be equal to the saturation temperature of steam at
the design pressure.

• The minimum design temperature shall be the lowest metal temperature,

which can occur at full operation or design pressure.

• In cases where the lowest operation temperature is above the lowest

ambient temperature, the minimum design temperature shall be -10ºC.
 SHELLS AND HEADS :
• Actual wall thicknesses (including corrosion allowance) shall not be less than
those shown below:
• Formed heads shall preferably be ellipsoidal 2:1 (i.e. the inside radius shall be
twice the inside minor semi-axis) or of hemispherical shape. For low-pressure
service, torispherical heads with crown radius R equal to nominal diameter D
may be used.

• Where a formed head is furnished with a cylindrical skirt, the thickness of the
cylindrical portion shall not be less than the shell thickness, and the length
not less than 3 x the head thickness.

• Where shell diameters are 600 mm or below, pipe material is preferred.

• Shell plates of different thicknesses shall be aligned along the inner surface of
the vessel, unless otherwise specified.
• All items, whether internal or external, which are welded directly to a shell or
head, shall be of the same material category as the shell or head. This shall
apply to all nozzles, brackets, pads and the upper portion of skirts for vertical
vessels.

• A reinforcing pad which is welded to a shell or head with a continuous weld

shall be provided with a vent hole.

• If the attachment weld is to be leak-tested, the hole shall be ¼" NPT tapped.
•
If no leak-test is required, the hole shall be 5 mm dia. plain.

• Before dispatch of the vessel, the vent holes shall be filled with non-
hardening mastic to prevent ingress of water. Threaded metallic plugs shall
not be used.
 WIND AND SEISMIC LOADING :
• The effects on vessels of wind and seismic loads shall be calculated in
accordance with the codes and conditions prevailing at the job site and as
described in the purchaser's project documents.
• All freestanding vertical vessels shall be self-supporting. Guy ropes and other
forms of external bracing are forbidden, unless expressly permitted in the
project documents.
• The maximum permissible deflection at the top of any tall, unlined vessel
when subjected to design wind loading = 0.005 x vessel height, unless
otherwise stated.
• Vertical vessels with height/diameter ratio equal to or larger than 6 shall be
analyzed for vibration due to Vortex shedding.
• If the calculated critical wind speed is more than 30 m/s, dynamic loads
from vibration need not be considered.
• NOTE :
• vortex shedding is an oscillating flow that takes place when a fluid such as
air or water flows past a bluff (as opposed to streamlined) body at certain
velocities, depending on the size and shape of the body.
• Cylinders and spheres are considered bluff bodies because at large
Reynolds numbers the drag is dominated by the pressure losses in the wake.
• Wake is the region where decelerated fluid that arises behind the body
around which the fluid flows and extends for some distance.
 MANHOLES, HANDHOLES AND
INSPECTION OPENING :
• Manholes shall not normally be smaller than 20" nom. dia.

• Oval, flued-type manholes are not allowed, unless expressly required in the
construction code.

• Bolt holes shall straddle the main axes.

• Manhole covers shall be furnished with 2 jack screws 3/4" UNC, diametrically
opposed on the flange bolt pitch circle and midway between flange bolts.
• jack screw is used to facilitate separating the flanges for inspection or replacement
of the gaskets.
• To assist entry and exit through a horizontal manhole, horizontal and vertical
grip shall be welded to the inside of the shell.

• Handholes, which are provided for removal of catalyst or packings, shall be

minimum 16" nom. dia. (vessel dia. permitting). For very large vessels
manholes are recommended instead of handholes. Handholes (or manholes
in a catalyst or packing bed) shall be provided with a retaining plate.
 NOZZLES :
• Minimum nozzle dia. = 1½ inches nom.

• Nozzles < or = 10 inches nom. dia. shall be seamless, whereas nozzles > 10 inches
nom. dia. may be seam-welded with full penetration welds.

• Nozzle reinforcement shall, where possible, be integral with the nozzle.

• Beveling on welding end nozzles shall be shop prepared and dished end caps for
hydraulic test and transportation shall be fillet welded to outside nozzle on a special
recess and cut off after erection. This arrangement shall be indicated on
manufacturer's drawing.
• Vent nozzles shall be provided at the high points of vessels, and drain nozzles at low
points.

• Flanges for external nozzles shall normally be of welding-neck type. The neck
thickness of the flange shall correspond to the wall thickness of the nozzle at the
weld.

• Slip-on and socket-weld type flanges are not permitted for vessels in hydrogen
service or corrosive service.

• NOTE : socket welded systems promotes corrosion and make them less suitable for
corrosive or radioactive applications where solids buildup at the joints may cause
operating or maintenance problems.

• Flanges ”rating Class 600 shall have raised face. Above rating Class 600, ring joint
facings are preferred.

• Flange bolts shall be stud bolts threaded over the whole length.

• Bolt holes shall straddle the main axes.

 SUPPORTS FOR HORIZONTAL
VESSELS :
• Supports for horizontal vessels shall be in the form of saddles, as shown below
• Where the operating load on the sliding saddle is less than 2500 kg, the
sliding saddle shall rest directly upon the supporting steel or foundation plate
and shall be guided by slotted holes in the sliding saddle base plate.

• Where the operating load is above or equal to 2500 kg, the sliding saddle
shall rest on a low-friction pad or rollers. The manufacturer's drawing shall
show this pad included in the saddle height. No slotted holes are required in
the base plate but the saddle shall be guided and prevented from lifting.

• When rollers are used, these shall be prevented from running out.

• The rollers can, for example, be 40 mm nom. dia. carbon steel bars linked
together in parallel at 60 mm spacing. They shall extend to the outer vertical
webs of the saddle, but shall not be attached either to the saddle or to the
supporting steel.
• When low friction pads are used, counterpart shall be polished SS plate and
be designed so that low friction pads are entirely covered by the SS plate
under all operating conditions.

• When deciding which saddle should be chosen as fixed, the permissible

deflection of any large-bore pipes attached to the vessel shall be taken into
consideration.

• The height of saddles shall be decided for each individual vessel.

• Saddles shall not be higher than absolutely necessary; however, the

underside of the saddle base plates shall be at least 50 mm below the lowest
point of any nozzle on the vessel to minimize the danger of damage to the
nozzles during transport.
 SUPPORTS FOR VERTICAL VESSELS :
• Free-standing vertical vessels with shell dia. above 1000 mm shall be supported on
skirts.

• Vessels which are surrounded by a steel structure may, if required, be supported

from the structure by means of brackets welded to the shell.

• Skirts for vessels shall normally be cylindrical.

• In certain cases vessel skirts may be conical in order to provide an adequate bolt
area at the base ring.
• Where skirts are used as vessel supports, they shall normally be provided with
access holes. Access holes are mandatory in all cases where the bottom
head is insulated or where valves or flanged connections are located inside
the skirt.

• Where skirts are used as vessel supports, they shall normally be provided with
access holes. Access holes are mandatory in all cases where the bottom
head is insulated or where valves or flanged connections are located inside
the skirt.

• Where such access is necessary the vessels shall be supported on legs.

 CORROSION ALLOWANCE :
• Corrosion allowances shall be as stated in purchaser's project documents.

• Minimum internal corrosion allowance for carbon and low-alloy steel shall be
1 mm.

• No allowance is made for atmospheric corrosion unless specifically stated in

the project documents.

• No allowance shall be considered for corrosion of high-alloy steel or non-

ferrous materials.

• Where corrosion protection is achieved by lining or cladding, the thickness of

such lining or cladding shall be minimum 3 mm.
 FABRICATION :
Shells and heads :
• Shell plates shall be dimensioned and arranged to give a minimum of weld
seams.
• Weld seams in shells and heads shall not conflict with nozzle openings, nozzle
reinforcement pads, saddle pads etc., or with welds for internal fixtures.
• Longitudinal weld seams shall be staggered by a distance corresponding to
minimum 4 x shell thickness, though at least 100 mm.
• All butt-welds shall be full penetration. The use of suitable consumable inserts
is permitted, whereas permanent backing strips are forbidden, where not
specifically permitted.
• Formed heads shall preferably be monolithic. Where this is not possible,
crown and petal construction is permitted.
 INSPECTION AND TESTING :
• Inspection and testing shall be carried out in accordance with the
requirements of the construction code.

• Hydrostatic pressure tests shall, wherever possible, be carried out with the
vessel in the operating position.

• When tall vertical vessels are hydro-tested in the horizontal position they shall
be supported on saddles at suitable intervals to avoid excessive bending
stresses.
Hydrostatic test pressure shall take liquid head into account; however, no
part of a vessel shall be subjected to a stress greater than 0.9 x yield stress at
test temperature.
• Test water for austenitic stainless steel vessels shall not contain more than 50
ppm chlorides.

• Test water for carbon steel and low-alloy steel vessels shall contain a rust
inhibitor, e.g. 0.2% sodium nitrite.

• The temperature of test water shall comply with the construction code, but
shall never be lower than 7ºC.
THANK YOU