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

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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:

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(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

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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

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