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PIP VESBI002
Design and Specification of
Vessels for Bulk Solids
This Practice is subject to revision at any time by the responsible Function Team and
will be reviewed every 5 years. This Practice will be revised, reaffirmed, or withdrawn.
Information on whether this Practice has been revised may be found at www.pip.org.
PIP will consider requests for interpretations (inquiries) for this Practice. Instructions for
preparing inquiries are available on the PIP website at www.pip.org.
July 2001
PIP VESBI002
Design and Specification of
Vessels for Bulk Solids
Table of Contents
1. Introduction .................................. 3
2. References ................................... 4
2.1
2.2
2.3
2.4
2.5
3. Definitions .................................... 7
4. General ......................................... 8
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
6. Design ........................................ 24
6.1 Geometric Configurations................ 24
6.2 Design Pressure and Temperature . 24
6.3 MAWP and Coincident Maximum
Temperature .................................... 25
6.4 Minimum Design Metal Temperature
(MDMT) and Coincident Pressure ... 26
6.5 Venting and Relief Protection .......... 26
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
7. Materials......................................44
7.1
7.2
7.3
7.4
7.5
July 2001
8. Fabrication..................................45
8.1
8.2
8.3
8.4
8.5
8.6
General.............................................45
Welding ............................................45
Flanges.............................................46
Prohibited Construction ....................47
Tolerances .......................................47
Linings ..............................................47
10. Shipping....................................51
10.1 General.............................................51
10.2 Cleaning and Painting ......................52
10.3 Preparation for Shipment .................52
11. Instrumentation.........................53
11.1 General.............................................53
11.2 Side-Entry Instrumentation...............53
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
1.
Introduction
1.1
Purpose
This Practice describes the materials, design, fabrication, inspection, testing, and
documentation requirements for the construction of atmospheric and low-pressure,
welded, shop- and field-fabricated dry bulk solids bins, hoppers, silos, and gravity
blenders for various chemical facilities. These bulk solids bins, hoppers, silos, and
blenders generally meet the philosophy and requirements of Section VIII, Division 1,
of the ASME Boiler and Pressure Vessel Code, henceforth referred to as the Code;
however, Code inspection and stamping are not required.
1.2
Scope
In addition to any limitations stated in this Practice, the provisions of this Practice do
not address the following:
1.2.1
1.2.2
For bulk solids vessels having internal and/or external pressures exceeding
the 15-psig limit, use this Practice for solids-handling issues, and use
PIP VECV1001, PIP VESV1002, and PIP VEDV1003 for pressure vessel
issues.
1.2.3
1.2.4
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
1.3
2.
References
The documents listed in this section are only those specifically referenced in this Practice.
Laws or regulations issued by any applicable local, county, state, or federal authorities
covering low-pressure vessels shall be reviewed before the initiation of design work, because
the requirements may be different or more restrictive than the requirements covered in this
Practice.
2.1
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Design and Specification of Vessels for Bulk Solids
July 2001
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Design and Specification of Vessels for Bulk Solids
July 2001
Other Codes
Requirements for solids vessels, constructed in accordance with rules other than
those specified in the ASME Pressure Vessel Code in Section 2, shall be by written
agreement between Purchaser and Supplier(s).
2.4
Other References
ANSI/AIIM, Microrecording of Engineering Source Documents on 35-mm
Microfilm, M32
ASCE Task Committee on Wind-Induced Forces, Wind Loads and Anchor
Bolt Design for Petrochemical Facilities [ISBN-0-7844-0262-0]
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Buzek, J. R., Useful Information on the Design of Steel Bins and Silos,
American Iron and Steel Institute and Steel Plate Fabricators Association, Inc.,
1989
Galletly, G. D., Design Equations for Preventing Buckling in Fabricated
Torispherical Shells Subjected to Internal Pressure, Proceedings, Institution of
Mechanical Engineers, London, Vol. 200, No A2, pp. 127-139, 1986
Process Equipment Design, Brownell and Young, Wiley and Sons Publishers,
1959
Jenike, A. W., Johanson, J. R., and Carson, J. W., Journal of Engineering for
Industry, Transaction ASME, Series B Vol. 95, No. 1, Feb. 1973, pp. 1-16
Vellozzi, Joseph, Dynamic Response to Wind Loading, U.S. Dept. of Standards
2.5
Government Regulations
U.S. Environmental Protection Agency (EPA)
Clean Air Act Amendments of 1990
U.S. Department of Labor, Occupational Safety and Health Administration
(OSHA)
OSHA 29 CFR 1910.106(b)(5)(ii) - Flammable and Combustible Liquids
OSHA 29 CFR 1910.119 - Process Safety Management of Highly Hazardous
Chemicals
OSHA 29 CFR 1910.146, (K)(3)(ii) - Permit-Required Confined Spaces for
General Industry
3.
Definitions
For the purposes of this Practice, the following definitions apply:
Angle of Repose (Poured): The slope of the surface of bulk solids when formed as a pile by
pouring solids onto a horizontal plane. The angle is measured from the horizontal plane. This
angle is not a flow property.
Angle of Repose (Drained): The slope of the top surface of bulk solids when formed by
discharging a container that holds the bulk solid. This angle is not a flow property.
Arching: A no-flow condition in which the bulk solid forms a stable arch across a vessel.
Typically, this arch forms at the bottom outlet opening, but may form at a higher location in
the hopper or bin. At a sufficiently large discharge opening, a stable arch cannot be
sustained. The terms bridge and dome are also used to describe this condition.
Bulk Density: Weight per unit volume of a material including voids within the particle
structure and also including voids between individual particle masses. The bulk density of a
material can vary, depending on over-pressurization, vibration, time consolidation, etc.
Code: The ASME Boiler and Pressure Vessel Code, Section VIII, Division 1
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Design and Specification of Vessels for Bulk Solids
July 2001
4.
General
4.1
4.2
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Exemptions
4.2.1
4.2.2
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
4.3
4.4
Jurisdictional Compliance
4.3.1
All aspects of the work shall comply with any applicable local, county, state,
and federal rules and regulations, including but not limited to the rules and
standards established by EPA and OSHA, if applicable.
4.3.2
Site-specific laws, rules, and regulations shall be considered for all criteria
and shall be noted on data sheets, in engineering notes, or in specific site
specifications.
4.3.3
Units of Measurement
U.S. customary (English) units shall be regarded as standard; metric (SI units) may
be included for reference only and shall not be interpreted as a precise conversion.
4.5
Language
All documents shall either be in English or shall show the English translation.
4.6
Purchasers Responsibilities
The Purchaser shall furnish a User Specification, which shall set forth the intended
operating conditions of the vessel to provide a basis for design and fabrication. The
User Specification shall also identify the external environment to which the vessel is
exposed, the intended function of the vessel, the mechanical loads imposed on the
vessel, the specific installation requirements, and the specific codes and laws
applicable where the vessel will be installed.
4.7
4.6.1
The Purchaser shall provide the minimum and maximum bulk densities of
the product. The values of the minimum and maximum bulk densities shall
be shown on data sheets, sketches, or drawings that are part of the User
Specification.
4.6.2
The strength and flow properties of the contained product shall be provided
by the Purchaser and shall be determined by testing a representative sample
of the product.
Suppliers Responsibilities
4.7.1
The Supplier is responsible for the construction of all bins, hoppers, and
silos and associated chutes; supports; and internal/external assemblies as
identified in or required by this Practice and the documents referenced
herein. Review by the Purchaser or User of documentation provided (e.g.,
fabrication drawings or weld procedures) does not alter this responsibility.
4.7.1.1 Supports (design, fabrication, and installation) for attaching
platforms, ladders, railings, and/or fire protection supports shall be
provided if indicated on the data sheet(s). Platform details shall be
provided to the Supplier.
4.7.1.2 The Supplier shall provide and install grounding clip(s) in
accordance with PIP VEFV1103.
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4.8
4.9
July 2001
4.7.2
The Supplier shall guarantee that the equipment supplied, when operated
under the conditions specified by this Practice and the documents referenced
herein, shall maintain structural integrity and meet all operating and
structural requirements outlined in these documents and in the purchase
order.
4.7.3
Bins, hoppers, and silos and associated chutes, supports, and internal
assemblies shall be identified and labeled in accordance with the Purchasers
designations.
4.7.4
Any alternative design(s) shall not be used unless approved in writing by the
Purchaser.
4.7.5
Disclaimers
4.8.1
4.8.2
4.8.3
Conflicts
If a conflict is identified between this Specification, the design drawings, or data
sheet, referenced codes and standards, or any supplementary specification, the party
having identified the conflict shall obtain written clarification from the Purchaser
before proceeding with any work.
4.10
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Design and Specification of Vessels for Bulk Solids
July 2001
4.11
Support(s)
Nozzle load(s) analysis for local and gross effect, when required
4.11.8 Fabrication data package shall include the documents listed in Appendices A
and B and shall be provided to the Purchaser in accordance with quantities
and dates indicated on the Documentation Schedule in Appendix B. The
final fabrication data package shall be printed on 8-1/2-inch x 11-inch paper
(or folded to 8-1/2 inches x 11 inches) and bound in data books.
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
5.
Mass flow critical wall angle (Wall Friction Test, ASTM D6128)
Independent laboratories may perform these tests, or the test equipment may
be purchased and the tests performed by the Purchaser or Supplier.
Certain material and/or environmental conditions may affect results from the
above-listed tests. It is important that the following parameters are
considered and that tests are run over the complete range of parameter values
that are expected in the solids-handling process:
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Temperature
Pressure
Mechanical overpressure
Moisture
Particle size
Particle shape
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
5.2
Flow Regimes
Graphical representations of the four major symmetrical flow regimes are shown in
Figure1. Descriptions of each of these flow regimes follow. Symmetrical flow
describes the flow pattern achieved from a center-discharge nozzle where no
obstructions exist that might cause preferential flow from one side of the outlet or
from one side of the vessel. This Practice covers only symmetrical flow from vessels
for solids.
Off-center or side-discharge outlets will cause eccentric flow patterns. Eccentric
flow patterns can also be caused by improper discharge methods. For example,
eccentric flow patterns may be induced by improperly designed discharge
equipment, such as non-mass flow screw feeders, and by partly opened discharge
valves. The effects of eccentric flow patterns on structural loads necessitate
implementation of proper discharge practices to ensure symmetric flow. If eccentric
flow is required, it is important to perform proper analysis to verify that the vessel
design can accommodate loads created by eccentric flow.
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Design and Specification of Vessels for Bulk Solids
July 2001
Type 1
Mass Flow
Type 2
Funnel Flow
Flow Zone
Primary Flow
Zone
Type 4
Expanded Flow
Flow Region
Secondary Flow
Zones
Stagnant Regions
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Design and Specification of Vessels for Bulk Solids
July 2001
5.2.1
5.2.2
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
material (thus the name rathole) from the discharge up to the top of the
vessel through which new material placed in the vessel may flow. The
stagnant material may significantly reduce the effective inventory of a
vessel. Ratholes may be avoided by designing the vessel outlet large enough
to overcome the internal strength of the product being stored.
5.2.4
5.3
5.4
Conical Center-Discharge
A conical hopper with a center discharge is a standard, single outlet, cone
hopper design to which many types of feeders are easily adapted. Conical
hoppers may also be designed with dual angles (angle from the hopper outlet
to inlet varies) and with eccentric outlets. Design to achieve mass flow
includes the following:
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The hopper angle(s) must be steeper than the critical hopper angle for
mass flow for a given application.
Discharge from the outlet must be uniform across the width of the
outlet.
The outlet diameter must be larger than the minimum arching diameter
for a given application.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
5.4.2
Flat Bottom
Flat bottoms are generally a good choice for configurations in which fully
fluidized blending and/or discharging will be used and for large-quantity
storage vessels where complete emptying is not required. The use of a flat
bottom vessel for mass flow applications is often not practical because of the
size of the feeder required. Design to achieve mass flow includes the
following:
5.4.3
Discharge from the outlet must be uniform across the width of the
outlet.
The outlet diameter (and thus the cylinder shell diameter) must be
larger than the minimum arching diameter for a given application.
Chisel (Wedge)
A chisel hopper has a slotted discharge outlet with a length equal to the
diameter of the cylindrical shell. The slotted outlet is suitable for use with,
for example, auger, screw, and belt feeders. Wedge shape (and transition
hoppers as described below) may be advantageous to the standard conical
hopper for the following reasons:
Less steep hopper angles (10 to 12 less steep than cylindrical cones
and still have mass flow, which is more forgiving)
The design of a wedge hopper may require more in-depth load analysis than
does the standard cone design. Design to achieve mass flow includes the
following:
The hopper angle must be steeper than the critical cone hopper angle
for mass flow for a given application.
Discharge from the outlet must be uniform across the width of the
outlet (care must be taken to design a proper feeder to achieve this).
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
5.4.4
July 2001
The outlet width must be larger than the minimum arching width for a
given application.
The length of the discharge opening must be at least three times the
width of the discharge opening.
Transition Hoppers
A transition hopper is used for the change from a cylindrical shell to a
slotted discharge outlet. The slotted outlet is suitable for use with auger,
screw, and belt feeders as examples. (See above comparison of wedge and
transition hoppers to conical hoppers.) The design may require more indepth load analysis than does the standard cone design. Design to achieve
mass flow includes the following:
5.4.5
The hopper end-wall angle must be steeper than the critical cone
hopper angle for mass flow for a given application.
The hopper side-wall angle must be steeper then the wedge (chisel)
angle for mass flow for a given application.
The discharge outlet width must be greater than the minimum arching
width.
The discharge outlet length must be three times greater than the
discharge outlet width.
Discharge from the outlet must be uniform across the width of the
outlet.
Multiple Dischargers
Hoppers with more than one outlet may be designed in various fashions
depending on the particular need. Design to achieve mass flow includes the
following:
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The discharge outlet width must be greater than the minimum arching
width.
The hopper end-wall angle must be steeper than the critical cone
hopper angle for mass flow for a given application.
The hopper side-wall angle must be steeper then the wedge (chisel)
angle for mass flow for a given application.
For chisel discharge outlets, the width must be greater than the
minimum arching width.
For chisel discharge outlets, length must be three times greater than
the discharge outlet width.
For conical discharge outlets, the outlet diameter must be greater than
the minimum arching diameter.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
5.5
Discharge from the outlets must be uniform across the width of chisel
outlets, and material must be drawn from all outlets simultaneously.
Discharge Aids
Discharge aids are used to promote flow of bulk solids from vessels that have design
characteristics such that none of the bulk solid flows from the vessel or such that the
bulk solids flows at rates less than required. The following describes such aids:
5.5.1
Fluidization and aeration devices - These devices are used for bulk solids
where gas easily permeates interstitial spaces in the bulk solid, thus reducing
internal cohesive forces and wall friction forces and aiding flow.
Fluidization is effective in promoting flow and in increasing flow rates from
a vessel holding fluidizable material. Fluidization devices can be designed
into a vessel or can often be retrofit into an existing vessel. Fluidization or
aeration may be introduced through nozzles or pads in the vessel or through
internal fluidizing media (for example, perforated or sintered metal).
5.5.2
5.5.3
Compressed gas devices (air cannons or air blasters) - Compressed gas (air
or nitrogen) is often used as a means to create a shock wave in a vessel. The
shock wave acts over a localized area and is intended to overcome the
stresses that enable a stable arch or rathole to form. Limited effectiveness
may be seen when using air cannons on ratholes or caked material because
only localized areas can be cleared. Best results will be achieved when the
size, number, and placement of air cannons are properly determined. When
using these devices, consideration must be given to the reaction forces and
localized pressure zones created in the vessel wall as the device discharges
compressed gas. Consideration must also be given to fatigue effects in the
vessel wall, especially with aluminum vessels.
5.5.4
Sonic horn - Similar to compressed gas devices, sonic horns use sound
waves to promote material movement.
5.5.5
Vibration devices - Air-driven or electric-driven vibrators use highamplitude, low-frequency vibrations or low-amplitude, high-frequency
vibrations to promote flow. Externally mounted vibrators are generally easy
to retrofit by means of a mounting bracket that should be full-penetration
welded onto a vessel. Because of maintenance and contamination concerns,
internal vibration devices should be used only after careful consideration and
then only according to strict adherence to the Suppliers recommendations.
Consideration should be given to fatigue effects, use with pressure-sensitive
materials, and the number and location of vibrators used.
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Design and Specification of Vessels for Bulk Solids
5.6
July 2001
5.5.6
5.5.7
5.5.8
Flexible wall - Flexible walls in a hopper allow for the stresses to be relieved
in a material that would normally build, thus promoting flow. Flexible walls
can be used in conjunction with external mechanical devices that massage
the flexible wall, thus agitating the material. In this mode of operation, care
must be taken not to overly compact the material. In general, maintaining a
flexible wall hopper is of concern because of the wear on the liner and the
inaccessibility of the liner if it fails while in use.
5.5.9
Fluidized Material
In designing for fluidization in general, the following items shall be considered:
5.7
Stresses on the bin from both fluidized and non-fluidized material being held
and discharged from the bin
Design of the vessel and/or its relief devices to meet available maximum
pressure from the gas header
Design of the vessel and/or its discharge devices and/or its relief devices to
meet required gas flow and its discharge from the vessel
Bin Inserts
Flow, mass flow, or blending of certain products may require internal cones or other
internal flow aids.
5.7.1
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Bin inserts are generally used to expand the flow channel in a funnel flow
bin or to convert a funnel flow bin to mass flow. These types of inserts are
typically inverted cones or pyramids or hopper(s) inside a hopper designs.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
5.8
5.7.2
The design of the bin insert must account for the stresses created by the
product that the insert will experience in both static and discharging modes.
5.7.3
Bin inserts must be designed to avoid ledges or other obstructions that might
hinder or block product flow.
5.7.4
All parts on the insert that come in contact with the product must be
compatible with the product.
5.7.5
The design of the vessel and connection members to the insert (bolts,
flanges, welds, etc.) must account for the dead load of the bin insert as well
as any live loads or fatigue loads created by use of the insert (e.g., vibrating
bottoms).
Blender Selection
Many types of blenders are available for various applications, from large-scale,
continuous blending to small-scale, batch blending. This Practice focuses on
blending applications that utilize vessels in the blending process.
5.8.1
5.8.2
Gravity tube blend vessels are generally good for granular and
pelletized materials.
Ensure that the vessel wall thickness and blend tube piping and
supports are adequate for the eccentric loads created by discharging
material into the blend tubes.
5.8.3
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Design and Specification of Vessels for Bulk Solids
July 2001
and fluidized blenders. This Practice does not cover blending design
considerations related to these types of blenders and mixers.
5.9
5.10
Lateral forces produced from product flow within a vessel area caused
by the presence of a gravity blend tube system. These lateral forces
impact both the system and the system-to-shell/cone intersection.
Consideration shall be given to provide additional reinforcement at the
tube-to-wall intersection and blend tube support areas.
5.9.2
5.9.3
5.9.4
5.9.5
5.9.6
Support Selection
5.10.1 Smaller vessels (less than 200,000 lbs. operating weight) can be supported
from three or four support points.
5.10.2 Supporting larger vessels (more than 200,000 lbs. operating weight) may be
impractical from three to four support points. Multiple support points, skirts,
or double rings may be required.
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Design and Specification of Vessels for Bulk Solids
July 2001
5.11
5.12
Materials
The Designer shall select materials, coatings, liners, and surface finishes that shall be
tested with the contained product to determine which is most favorable for the
product and shall identify these choices in data sheets, drawings, or other documents.
5.13
Gas introduced into a vessel by gas cannons, aeration pads, aeration cones, bin
vents, fluidization media, gas purges, etc.
Gas introduced and gas displaced when pneumatically conveying material into
a vessel
Gas flow induced by temperature changes inside the vessel (can be induced by
temperature changes outside the vessel)
For more information on venting for deflagrations (relief devices) and for explosion
prevention systems, refer to NFPA 68 and NFPA 69, respectively.
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Design and Specification of Vessels for Bulk Solids
6.
July 2001
Design
6.1
6.2
Geometric Configurations
6.1.1
The design volume and equipment dimensions shall be based on the design
storage capacity and the minimum bulk density of the contained product.
6.1.2
When the geometric configuration and critical dimensions are not provided
by the Purchaser, the Designer shall ascertain the relevant strength and flow
properties of the bulk solid to be contained by the bin, hopper, or silo. These
shall be the properties at the worst-case conditions that are likely to occur in
practice. This shall include factors such as the minimum particle size,
highest moisture content, temperature range, and maximum storage time at
rest.
6.1.3
Where the contained product is a well-known commodity, having wellknown flow characteristics, the User may choose to select the geometric
configuration and critical dimensions on the basis of previous experience
with that product.
6.1.4
Where the discharge opening must be much larger (to avoid an arching or
ratholing) than is required to attain the desired discharge rate, the use of a
feeder to control flow without affecting the desired flow pattern is indicated.
The Designer shall select a hopper configuration and corresponding
discharge shape and dimensions in conjunction with a practical discharge
device, subject to the Users approval.
6.1.5
When the geometric configuration and critical dimensions to assure flow are
provided by the User, the Designer shall assure that the structural design will
sustain the loads caused by internal and external factors without deformation
of the bin, hopper, or silo walls.
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Initial startup
Normal operations
Temporary operations
Emergency shutdown
Emergency operations
Normal shutdown
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
6.2.2
6.3
Upset conditions
6.3.2
6.3.3
6.3.4
The MAWP for internal pressure shall not exceed 15 psig at the top of the
vessel.
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Design and Specification of Vessels for Bulk Solids
6.3.5
6.4
6.5
6.6
July 2001
6.4.2
The MAWP shall be based on the maximum design temperature and shall
not be limited by the MDMT. The MAWP shall be marked on the vessel
nameplate and vessel drawing(s).
Vessel vent systems shall be sized such that the MAWP, both internal and
vacuum (external pressure), and the relief protection pressure setting are not
exceeded.
6.5.2
All vessels shall be provided with relief protection for both internal pressure
and vacuum.
6.5.3
Actions of the relief device shall not exceed the MAWP (internal pressure
and vacuum) rating of the vessel.
6.5.4
6.5.5
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6.6.2
6.6.3
6.6.4
6.6.5
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July 2001
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PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Cf
0.5
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The governing equation for horizontal seismic base shear of groundsupported equipment is V = CsW, where
Cs = 1.2AvS/0.66RT.
However, CS (seismic design coefficient) need not be greater than
5.5Aa/R. (Av, Aa, S, and R are site-specific values. T is the first
natural period of the equipment to be calculated.)
W is the operating weight of the equipment.
The lateral horizontal seismic forces induced at the levels or mass
points of the equipment and in the direction causing the highest
stresses shall be determined from the rules in ASCE 7.
6.6.6.2 Seismic Loads for Structure-Mounted Equipment
The Designer shall specify requirements for seismic design and the
site-specific design values on data sheet PIP VEDBI003. When
specified, the vessel and vessel supports shall be designed for
seismic effects, and evidence shall be provided to document that the
vessel and vessel supports satisfy applicable seismic requirements.
Satisfactory evidence shall be design calculations or other
documented proof of compliance. Seismic design criteria and factors
shall be included on Suppliers drawing. Analysis of additional shear
and bending moments imposed by the seismic loading along with the
operating conditions shall not lead to over stressing of foundation
supports.
6.6.7
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Design and Specification of Vessels for Bulk Solids
July 2001
6.6.8
6.6.9
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Design and Specification of Vessels for Bulk Solids
July 2001
2. L1+L2+L3+L4+L5+L8+L9
3. L1+L2+L3+L4+L6+L8+L9
5. Lift Condition
6.7
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The type of vessel support (skirt, legs, lugs, rings) shall be as specified on
the data sheets, sketches, and/or drawings by the User.
6.7.2
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
6.7.3
6.7.4
Stresses resulting from direct bending in support and support ring base plates
shall not exceed 1.5 times the Code-allowable tensile values. Compressive
stresses in support rings and lug gussets and other compression members
shall not exceed 1.25 times the Code-allowable tensile stress values.
6.7.5
Support skirts attached to the bottom head shall have the skirt butted to the
outer portion of the head such that the outer diameter (OD) of the shell and
the OD of the skirt coincide. The attachment shall be by a continuous weld,
sized to accommodate the maximum imposed loads and in accordance with
PIP VEFV1128.
6.7.6
Support skirts created by extending the shell below the bottom head to shell
weld joint shall be in accordance with PIP VEFV1128.
6.7.7
6.7.8
6.7.9
Leg supports shall be limited to vessels that meet the following criteria:
Page 35 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Page 36 of 71
Top Head
6.8.1
6.8.2
Head designs other than those identified within the scope of API 650 and
that exceed 2.5 psig pressure rating shall be in accordance with the Code and
its allowable stress values.
6.8.3
Roofs without operator platforms shall be designed for a minimum live load
of 25 pounds per square foot.
6.8.4
The product being handled can exert upward forces on the top head of the
vessel if overfilled and (1) the material is fluidized or (2) the top head has an
angle with the horizontal plane that is greater than the minimum angle of
repose for the product. Depending on the situation, the problem may be
avoided by the following actions:
Designing the top head to withstand the forces exerted by the product
(see Australian Code for force calculations)
6.8.5
6.8.6
The inside crown radius is not greater than the outside diameter of the
straight flange.
The inside knuckle radius is not less than three times the minimum
specified head thickness after forming.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
6.8.7
6.9
Shell
6.9.1
Straight side heights-to-diameter ratios of 2:1 for silos and of 3.5:1 for
blenders are to be used for preliminary design layouts. Suppliers have the
option to vary slightly the diameter and straight side dimensions to better
utilize plate dimensions and available head diameters to provide more
economical fabrication.
6.9.2
Shell design shall include the wall pressure induced by mass flow or funnel
flow of solids on the basis of the flow test data in the Data Sheet. Shell
design shall also consider forces that may result from eccentric flow patterns
created by flow through blend tubes, side discharge nozzles, etc. The method
used to determine bulk loads for the purpose of vessel design shall be agreed
upon by the Supplier and Purchaser.
6.9.3
The equipment shall sustain the axial load on the shell and hopper walls
developed from vertical friction caused by the contained product. This
internal dead load is additive to other dead loads, such as the weight of the
containing walls and roof above the support point, and to external live loads,
such as wind and seismic load.
6.9.4
The total axial load shall be used to compute the tensile stress and buckling
resistance of the shell at the point of support and at other critical points such
as the bottom cone-shell intersection and all other discontinuities.
6.9.5
When designing for mass flow, the internal weld surfaces shall be specified
as follows:
6.9.5.1 All longitudinal weld surfaces shall be provided with a ground
smooth finish, and all circumferential weld surfaces shall be
provided with a ground smooth finish having a maximum crown
height the lesser of 1/8 inch or 25% of the wall thickness.
6.9.5.2 Weld surface finishes (i.e., ground smooth) shall be in accordance
with Appendix C of NACE RP0178.
6.9.6
6.10
Bottom
6.10.1 Conical and toriconical head design shall be in accordance with the Code
and its allowable stress values.
6.10.2 Flat, chisel, and double cone bottoms, along with geometric transition
pieces, require special consideration in design. Accordingly, finite element
Page 37 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
6.12
Vessel Connections
6.12.1 Flanges for nozzle and body sizes NPS 24 and smaller shall be in accordance
with ASME B16.5. If required, blind covers shall be in accordance with
ASME B16.5 or designed per the Code, paragraph UG-34. Gaskets shall be
in accordance with ASME B16.21. Flanges designed in accordance with the
Code, Appendix 2, are also acceptable if the bolting dimensions and pattern
are in accordance with ASME B16.5.
6.12.2 Flanges for nozzle and body sizes larger than NPS 24 shall be designed in
accordance with the Code, Appendix 2, with bolting dimensions and pattern
in accordance with ASME B16.47, Series B flanges. Minimum design
pressure for these flanges shall be 50 psig.
6.12.3 Flanged joints for stainless steel and nonferrous components may be of the
lap joint type with carbon or low-alloy steel flanges. Lap joint flanges
NPS 24 and smaller shall be furnished in strict accordance with
ASME B16.5. The nominal outside diameter of laps shall be the same as the
raised face diameter in ASME B16.5 standard flanges.
6.12.4 Flanges for manways shall be designed in accordance with the Code,
Appendix 2. Manway covers shall be blinds designed in accordance with the
Code, paragraph UG-34. Minimum design pressure for manway flanges and
covers shall be 50 psig. Side-entry manways shall be provided with flushed
plugs in accordance with Figure F-2 in Appendix F.
6.12.5 Minimum manway size shall be a nominal 24 inches, with a finished inside
diameter not less than 23 inches. Larger diameter manways should be used
to satisfy additional needs such as, but not limited to, installation of internal
parts, maintenance requirements, etc.
Page 38 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Note: 1-inch and larger bolts shall have 8 threads per inch.
Note: Bolts shall have rolled threads.
Note: The arc length between bolt centers on the bolt circle shall not
exceed inches for bolts 1-inch diameter and smaller. Total number of
bolts shall be divisible by 4 and shall straddle centerlines. Purchaser
approval shall be obtained to deviate from this requirement. See
Appendix E for the method usually employed for considering significant
mechanical loads other than pressure.
6.12.9 Minimum radial distance for wrench clearance for custom design flanges
shall be as follows:
6.12.10 Carbon or low-alloy steel lap joint-type flanges are acceptable for flanged
joints of stainless steel and nonferrous components. The nominal outside
diameter of laps shall be the same as the raised face diameter given in
ASME B16.5 for nozzle and body sizes NPS 24 and smaller. Minimum
finished thickness of custom-designed lap joint welding ring for flanged
connections shall not be less than the following:
6.12.10.1 The T dimension shall be as defined in ASME B16.9 for cylinder
sizes less than NPS 24.
6.12.10.2 The nominal thickness of the cylinder wall (to which it is attached)
shall be greater than 3/16 inch for cylinders NPS 24 and larger.
This thickness will allow possible future re-machining of the lap
Page 39 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Page 40 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
6.12.19 Static nozzle loads, other than agitators, shall be evaluated per
WRC Bulletin 107. Special nozzle loads such as dynamic and thermal
(identified by the Purchaser) will require a higher level of analysis. Such
analysis is subject to Purchaser approval.
6.12.20 The minimum size connection shall be 1-1/2 inch.
6.12.21 Nozzle and manway openings shall not be made in weld seams.
6.12.22 The Designer shall determine the need for reinforcement for all openings
larger than 2 inches, in accordance with the Code (paragraph UG-37).
6.13
Gaskets
6.13.1 The dimensional requirements of ASME B16.21 shall be considered standard
gaskets. Any deviation from these standard gaskets by the Supplier shall be
submitted for Purchaser approval. The data sheet will indicate the number of
spare gaskets to be furnished by the Supplier.
Exceptions to the standard dimensions of ASME B16.21 require User and/or
Purchaser approval.
6.13.2 Gasket type(s) and rating(s) shall be specified on the data sheet. Purchaserspecified gasket m and y design factors will be supplied on the data
sheet.
6.13.3 Minimum gasket width for custom sheet gaskets shall be as follows:
Nmin = (Ab)(Sb)/2(y)(G)
where
Ab = sum of cross sectional areas of basic minimum minor diameter of bolts,
inch2
Sb = bolt allowable stress, Psi
y = ASME Code y factor, Psi
G = mean diameter of gasket, inch
Note: Under no circumstance shall the actual custom gasket-seating width
used be less than the following:
6.13.4 Gaskets shall be seamless, except metal gaskets made integral by welding
and non-metallic (e.g., Grafoil tape) gaskets with abutting ends suitably
joined are acceptable. Means shall be provided for positioning (centering)
the gasket during joint make-up.
6.13.5 No joint-sealing compound or lubricant shall be used unless specified by
Purchaser. A light dusting of 3-M 77 or equivalent spray adhesive may be
used if required to hold gasket in place during assembly.
Page 41 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
6.14
July 2001
Internal Components
6.14.1 Internal piping, attachments (blend tubes, well pipes, flow baffles, etc.), and
cones shall be adequately supported. Purchaser review and approval of
support bracket/attachment calculations is required.
6.14.2 Design of internal components shall consider forces resulting from eccentric
flow patterns that may be caused by discharge through blend tubes, side
discharge nozzles, etc.
6.15
Corrosion Allowance
The Designer shall evaluate the requirement for a corrosion allowance to be added to
all parts of the bin or hopper contacting the contained product. Unless otherwise
specified, the minimum nominal corrosion allowance for components in contact with
the service product shall be as follows:
6.16
Compartment Vessels
Common component(s) of vessels having more than one compartment, shall be
designed for the most severe combinations of pressure, vacuum, temperature, and
other loads that may occur during operation and test conditions. Design on the basis
of simultaneous loading of internal pressure in adjacent compartments is not
acceptable.
6.17
Minimum Thickness
6.17.1 The minimum nominal material thickness exclusive of corrosion/erosion
allowance for pressure-retaining non-piping, non-tubing components shall be
as follows:
Aluminum - Schedule 10
6.17.3 The minimum nominal thickness for nozzle necks shall be per Code
paragraph UG-45, except in no case shall the nominal thickness selected for
NPS 3 and smaller be thinner than the following:
Page 42 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
Aluminum - Schedule 80
6.17.4 The minimum nominal thickness for all flanges is1/2 inch.
6.17.5 For tubular products, minimum thickness shall be 16 gauge, exclusive of
corrosion/erosion allowance.
6.18
Anchor Bolting
6.18.1 Design stresses - Anchor bolts shall not be smaller than 3/4 inch. Allowable
design tensile stresses for carbon steel anchor bolts, as calculated using the
tensile stress area of the threaded portion, shall be 20,000 psi.
6.18.2 Carbon steel anchor bolts shall have a 1/8-inch corrosion allowance,
minimum.
6.18.3 Spacing and location - Anchor bolts for vertical vessels shall be selected in
multiples of four bolts. Purchaser shall furnish orientation.
6.19
Lifting Lugs
6.19.1 Lifting lugs shall be installed as a permanent component of all vessels and
shall be capable of lifting and supporting the entire vessel and its
appurtenances. See data sheet(s) for lifting lug requirements. Lifting lugs for
vertical vessels shall be located near the top of the vessel and capable of
lifting and erecting the vessel from a horizontal position into the vertical
position. Tailing lugs are required for positioning the vessel unless otherwise
approved by the Purchaser. Lifting lug design calculations shall be provided
to the Purchaser for review.
6.19.1.1
6.19.1.2
Two ear-type lugs spaced 180 degrees apart and welded to the
straight portion of the top of the shell and/or head are acceptable.
6.19.1.3
6.19.1.4
6.19.2 Removable vessel covers and manway covers shall be provided with suitable
lifting lugs. Davit requirements shall be specified on the Purchasers data
sheets, sketches, and/or drawings. See PIP VEFV1117 and PIP VEFV1118
for davit applications.
Page 43 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
6.20
July 2001
Structural
6.20.1 Roof platforms and platform framing and supports shall be designed
according to PIP STF05535.
6.20.2 Horizontal external stiffener members shall be oriented so as to minimize
build-up of material on the stiffeners. Channels and angles shall have
downward-turned flanges/legs, and beams, stiffeners, and tees shall have
drain holes.
6.20.3 All inside edges of nozzles, manways, and other connections shall be
rounded to a minimum 1/4-inch radius.
7.
Materials
All materials shall be in accordance with the Code.
7.1
7.2
Carbon Steel
Where carbon steel is the selected material, the following grades shall be used:
7.3
7.2.1
Flanges for aluminum lap joint stub ends shall be galvanized carbon steel.
7.2.2
Stainless Steel
When specified in the vessel specifications, all formed heads fabricated from
austenitic (type 304 and type 316 only, including low-carbon and stabilized grades)
or duplex stainless steel shall be solution annealed after forming in accordance with
ASME SA-480.
7.4
Page 44 of 71
Clad Material
7.4.1
7.4.2
Integrally clad plates for vessels designed for vacuum service and for vessels
for which design calculations include the cladding shall be examined per
ASME SA-578 Acceptance Standard - Level 1 and Supplementary
Requirement S6.
7.4.3
Sleeve liners shall not be used in lieu of providing clad or weld overlay.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
7.5
Prohibited Materials
The following materials are prohibited:
8.
Mercury-containing products
Cadmium-plated products
Fabrication
8.1
8.2
General
8.1.1
8.1.2
8.1.3
Any temporary internal fixtures (e.g., bracing, lifting lugs, clips, brackets,
etc.) required for fabrication, erection, and fit-up purposes shall be removed,
and the affected area shall be ground smooth. If the affected area is in the
cone of a mass flow silo, the area shall be ground smooth and flush (see
NACE RP0178 for definitions).
8.1.4
Nozzles intended for use with a safety relief device and nozzles serving as
vessel discharges shall be trimmed flush inside the vessel wall.
8.1.5
Welding
8.2.1
8.2.2
Vessel shall be all-welded construction, except for cast or forged vessel parts
attached by bolting. Unless otherwise specified, all welding shall be full
penetration, double- or single-welded butt joint design, void of pit and
fissures. Lap joint seam welds are acceptable only for segmented domed top
heads and conical heads and shall have a combination of both inner and
outer continuous fillet welds. A combination of both inner and outer
continuous fillet welds is acceptable only for the following:
Page 45 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
8.2.3
8.2.4
8.2.5
8.2.6
When connecting tubing to form blend tubes for a gravity tube blender, the
diameter of the lower section of tubing in a joint shall have a larger diameter
than that of the upper section of tubing in the joint. This design prevents
material from collecting on the ledges in the joint.
8.2.7
8.2.8
Deposited weld metal shall be essentially of the same ductility and chemical
composition as the material joined.
8.2.9
8.2.10 The minimum distance from the toe of fillet welds attaching supports, or
wear plates, to the centerline of either a longitudinal or circumferential shell
seam shall be Rt where R = shell inside radius and t = shell thickness, in
inches, exclusive of corrosion allowance.
8.3
Page 46 of 71
Flanges
8.3.1
Bolt holes in all fixed flanges and studding outlets shall straddle the natural
centerlines.
8.3.2
8.3.3
Bolt holes in flanges shall be 1/8 inch larger than the diameter of the bolts.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
8.4
Prohibited Construction
The following are prohibited:
8.5
8.6
Single butt welds with backing material (strips, rings, etc.) that remain in place
Single inner or outer fillet welds for any welded joint of pressure-retaining
components
Pinch rings (outer flange face rings) in flanged connections, unless specified
by Purchaser
Nozzles attached per the Code, Figures UW-16.1 (a), (a-1), (a-2), (a-3) and (b).
Exceptions to these requirements shall be defined in the quotation by the
Supplier and shall require Purchaser approval.
Tolerances
8.5.1
8.5.2
Linings
This section covers the additional requirements necessary for vessels that are to be
lined with an elastomeric, thermoplastic, reinforced thermoset plastic, phenolic, or
cured polymer system. These requirements are the responsibility of the vessel
Supplier to complete before the lining contractor installs the lining in the vessel. The
requirements for the lining system shall be given in a separate overlay specification
to this Practice.
Information in this section takes precedence over information elsewhere in this
document when a liner is applied.
Page 47 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
8.6.1
July 2001
General
8.6.1.1 Equipment shall be fabricated in accordance with this Practice and
shall meet the special requirements for surface quality of this
section.
8.6.1.2 All vessels with non-metallic linings shall have the following notice
painted on two sides of the shell and insulation covering, if present,
(and/or channel) in 3-inch-high letters visible in the shipping
position from grade:
LINED VESSEL - DO NOT BURN OR WELD
8.6.2
8.6.3
Page 48 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
9.
Inspection
9.1.1
9.1.2
The Purchaser shall be allowed to make dye penetrant or other tests at any
location selected by the Purchaser to determine that all specifications,
welding procedures, and welding performance requirements have been
satisfied.
9.1.3
All work found not in conformance with this Practice and attachments made
a part of this Practice shall be re-worked to the satisfaction of the Purchaser,
at the Suppliers expense.
Page 49 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
9.2
Page 50 of 71
July 2001
9.1.4
9.1.5
All shell and head butt welds shall be inspected with a minimum spot
radiography in accordance with Code paragraph UW-52.
9.1.6
9.1.7
Formed heads shall be seamless, or, if welded, the flat plate from which a
head is to be made shall be radiographed per Code paragraph UW-51 in the
knuckle region of the head, including the straight flange and 2 inches into
the spherical portion, before forming.
Testing, General
9.2.1
All vessels shall be neither painted nor shot-peened before the pressure test.
9.2.2
For atmospheric vessels with a total volume <500 ft3 and an h/D ratio <3.0,
the vessel shall be filled with water while in the operating position by the
Supplier in the Suppliers shop. Test water level shall be no higher than the
top head to shell joint. Exceptions to the type of test and/or test location
shall be by agreement between the Supplier and the Purchaser.
9.2.3
For vessels with a total volume 500 ft3, with an h/D ratio 3.0, and
constructed for pressures exceeding atmospheric and 15 PSIG, a
combination air-over-water pressure test shall be performed on the vessel in
the operating position by the Supplier in the Suppliers shop. The test
pressure shall be equal to and not exceeding the MAWP for the vessel. Test
water level shall be no higher than the top head to shell joint. Exceptions to
the type of test or test location shall be by agreement between the Supplier
and the Purchaser.
9.2.4
For vessels with a total volume > 500 ft3 or with an h/D ratio > 3.0 and
constructed for pressures 15 PSIG, a combination air-over-water pressure
test shall be performed on the vessel in the operating position by the
Supplier at the Suppliers shop or the Users operating site. This pressure
test shall be performed at a pressure equal to and not exceeding the MAWP
of the vessel. The weight of the water used during testing shall not exceed
the expected operating weight of the solids in the vessel. The level of water
shall not exceed the top head to shell joint. This pressure test is intended to
represent as closely as practical the operating static loads experienced by the
vessel and the vessel support system without exceeding the allowable
stresses for the shell, bottom head, and related joints and connections. The
Purchaser shall provide guidelines for the test procedure and/or approve test
procedures proposed by the Supplier. Exceptions to the type of test or test
location shall be by agreement between the Supplier and the Purchaser.
9.2.5
Gas leak test pressures shall not exceed the MAWP of the vessel and shall be
performed before any hydrotest.
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
9.2.6
9.2.7
9.2.8
When testing vessels with water, the test water shall be clean and free of
debris. Only potable water with a chlorine ion concentration not exceeding
50 ppm shall be used when testing stainless steel vessels.
9.2.9
Vessels shall be field tested for leaks after installation. Supplier(s) shall be
responsible for repairs to vessels if leaks are detected. Tests will be by air
pressure.
9.2.10 The vessel metal temperature, for the entire duration of the test, shall not be
colder than 30F above the minimum design metal temperature (MDMT, see
Section 6.4) and not hotter than 120F.
9.2.11 The Supplier(s) shall furnish all blind flanges, gaskets, and bolting (or other
types of blanking covers as may be required) necessary for testing. For
connections not specified to be furnished with blind flanges, the blind
flanges and bolting (or other type covers) may be removed after testing and
remain the property of the Supplier.
9.2.12 Test gaskets - Any flanged joint for which the Supplier is to furnish the
service gasket and for which disassembly will not occur after testing shall be
tested with the specified service gasket identified in the data sheets. If the
joint is to be disassembled after testing and employs flanges per
ASME B16.5, the Supplier may select the test gasket subject to any
limitations identified in the purchase requisition. The Purchaser must
approve the test gasket to be used if the joint is to be disassembled after test,
employs non-standard flanges (other than ASME B16.5), and/or the service
gasket is not specified.
9.2.13 Repairs to eliminate imperfections revealed during testing, which resulted in
test failure, shall be tested at the Suppliers expense by reapplying the
original test(s).
9.2.14 Body flanges, manways, and nozzles specified to be furnished with blind
flanges shall be left undisturbed and assembled after testing if practical.
10.
Shipping
10.1
General
10.1.1 The Purchaser shall be notified if the completely assembled and insulated
vessel sections, including attachments, exceed 20,000 pounds, are greater
than 60 feet in overall length, are wider than 12 feet, or are taller than 13 feet
6 inches projected diameter.
Page 51 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
10.3
Page 52 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
11.
Instrumentation
11.1
General
The Designer shall evaluate the need for instrumentation, such as pressure,
temperature, level, and weight indicators.
11.2
Side-Entry Instrumentation
Level indicators shall be installed in accordance with manufacturers instructions
and detail drawings provided with the instrumentation. A protective covering (pup
tent) shall be provided by the vessel Supplier in accordance with the
instrumentation manufacturers instructions as required for specific mounting
configurations.
12.
Nameplates
The Supplier shall be responsible for assuring installation of a nameplate that
provides the as-built fabrication and construction conditions as follows:
12.2
The nameplate shall be made either of a 300 series stainless steel or of a nickel
alloy or equivalent and shall be attached securely on a support bracket.
Stampings
The following information shall be stamped on the nameplate in addition to
information that may be required elsewhere in this Practice or the purchase order:
Page 53 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
Page 54 of 71
Vessel weight
July 2001
July 2001
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
APPENDIX A
Quality Overview Plan for
Vessels for Solids
Page 55 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX A
Quality Overview Plan for
Vessels for Solids
Equip. No. ______________________ P. O. No.
Equip. Description
Project Engineer
Inspection Contact
S. O. No.
Phone No.
Phone No.
Activities checked apply to the above item (see Quality Overview Notes). In most cases, the User/Purchaser representative will require
five (5) days notification to make arrangements for hold point inspections.
References are either to Division 1 Code paragraphs
or to applicable referenced standards. All additional
requirements covered by the purchase specifications
also apply.
No.
1.
2.
WITNESS
INSPECT
Yes
Yes
Yes
No
No
No
HOLD POINT
Yes
No
REQUIRED
Yes
No
3.
4.
5.
6.
7.
8.
Weld Map
9.
10.
11.
12.
13.
14.
15.
16.
Page 56 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
No.
17.
18.
Other NDE
19.
20.
21.
Out-of-Roundness (UG-80)
22.
23.
24.
Dimensional Check
25.
Installation of Internals
26.
27.
PWHT (UW-40)
28.
29.
30.
31.
Nameplate Bracket
32.
33.
34.
35.
36.
Coating/Lining Inspection
37.
38.
Description of Nonconformance(s)
39.
WITNESS
INSPECT
Yes
Yes
Yes
No
No
No
HOLD POINT
Yes
No
REQUIRED
Yes
No
40.
41.
42.
43.
Page 57 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
1. The Purchaser will provide the Supplier with a completed Quality Overview Plan.
2. The Supplier shall provide the Purchaser with the documents for review, witness/hold
point activity notification, and inspection opportunity as indicated by the Purchaser on
the Plan, as follows:
2.1 Review: Supplier shall provide documentation, the review of which will allow
the Purchaser to verify that the referenced construction activity has been
performed as specified. Other construction requirements may be verified/audited.
2.2 Witness: Supplier shall notify Purchaser not later than five (5) days before
performing the referenced construction activity so that the Purchaser may
exercise the option to observe. Other construction requirements may be
verified/audited.
2.3 Inspect: Supplier shall provide Purchaser access to physically conduct
internal/external inspection of the referenced item. Other construction
requirements may be verified/audited.
2.4 Hold Point: Supplier must notify Purchaser not later than five (5) days before
performing the referenced construction activity and must receive authorization
from the Purchaser before performing the activity. Other construction
requirements may be verified/audited.
3. Some of the items in this Quality Overview Plan for Vessels for Solids are covered
elsewhere in this Practice.
4. If a work item is not checked, then documentation or notification to the Purchaser is not
required. However, the work item itself is still required to be performed if specified
elsewhere in this Practice, the data sheet, the purchase order, the Code, etc.
Page 58 of 71
July 2001
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
APPENDIX B
Documentation Schedule and
Suppliers Data Package
Page 59 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX B
Documentation Schedule
Equip. No. _________________________ P.O. No. ________________________ S.O. No. ________________________________
Equip. Description _________________________________________________________________________________________________
Project Engineer __________________________________________ Phone No. ________________________________________
WKS
P
T
ITEM
FOR
APPROVAL
WKS
FROM
PO
FINAL (2)
CERTIFIED
WKS
FROM
PO
DATA (3)
BOOKS
WKS
FROM
PO
WITH
EQUIP
ALLOW FOR
USER
APPROVAL
WEEKS FROM
DATE OF DATA
RECEIPT
Page 60 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
1. Final certified fabrication drawings per PIP VESBI002, as shown on the following sheets
2. Suppliers design calculations
3. Cast and plate material (mill) test reports and/or certificates of compliance (provide index
when appropriate) for all materials in pressure-containing parts of the vessel. Use a liquid
penetrant test to obtain 90% quality factor for castings.
4. Impact test values including production weld test results
5. Heat treatment charts (time/temperature record)
6. Pressure test charts (time/pressure/water temperature record)
7. Nondestructive examination records and reports (PT, MT, RT, BHN, PMI chemistry)
8. Nameplate facsimile
9. If requested, welding procedures and qualifications in accordance with Section IX of the
ASME Code, and welding maps.
10. Description of non-conformities accepted by the User, if any
11. Required bolted joint assembly procedures including bolt preload for custom flanges
12. Any other documentation required on Appendix A
13. Operating instructions, performance data, and parts list (when applicable)
Page 61 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX C
Flanged Pressure Boundary Joint Assembly
Page 62 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX C
Flanged Pressure Boundary Joint Assembly
For blinding before hydrotest or for final joint assembly, all bolted joints shall be assembled and
tightened in accordance with the following:
1. All working surfaces must be cleaned and inspected before assembly is started.
a. Clean gasket-seating surfaces to remove all grease and dirt. Gasket-seating
surfaces shall be free from any scratches, nicks, burrs, weld spatter, or similar
defects.
b. External and internal threaded surfaces shall be inspected for damage. Replace
questionable parts.
c. Inspect nut-bearing surfaces for scores, burrs, etc. Remove protrusions; spot face
if required.
2. Install new gasket.
a. Handle gaskets carefully to avoid damage. Do not remove any gasketshipping/handling protector until ready to use the gasket.
b. Examine gasket for defects or damage.
c. Place new gasket in position. Make sure that the gasket is in proper alignment
with the gasket surfaces on the flanges or lap-joint stub ends.
d. Use a light dusting of 3M 77, or equivalent, spray adhesive if required to hold
gasket in place during assembly.
3. Liberally coat all external and internal threaded surfaces of fasteners (bolts, nuts, and
threaded holes, as applicable) with the lubricant specified on the vessel data sheet,
PIP VEDBI003. Lubrication is not required for new PTFE-coated bolts. If the lubricant is
not specified on the vessel data sheet, the lubricant shall be approved by Purchaser.
4. Align flange or stub end faces carefully before bolting up. Fasteners shall fit loosely in
bolt holes. Do not use fasteners to spring flanges for alignment.
5. Install fasteners with nuts hand tightened, then snug up at 10 to 20 ft-lbs.
6. Tighten bolts carefully to specified torque level using a cross-bolting technique and stepwise tightening to increase loading about 1/4 to 1/3 of total preload per step.
Page 63 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX D
Suppliers Drawing Information
Page 64 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX D
Suppliers Drawing Information
Supplier shall provide certified, as-built assembly and working drawings for all vessels for bulk
solids. These drawings shall incorporate the drawing requirements specified throughout this Practice.
In addition, these drawings shall be complete and shall include, but not necessarily be limited to, the
following information:
1. Maximum allowable working pressure (MAWP) and coincident maximum design
temperature (see Section 6.3) (internal and external if applicable)
2. Minimum design metal temperature and coincident maximum allowable working
pressure (see Section 6.4)
3. Design bulk density (minimum and maximum), maximum fill level, and other operating
loads
4. Reference to all applicable codes, standards, practices, and specifications, including date
of issue. References shall include any applicable Supplier standards. When reference is
made to Suppliers own standards, copies of such standards shall be included with the
submitted working drawings.
5. Special service notes, e.g., for cyclic service followed by a description of the cyclic
loads and number of cycles used in the design
6. Applicable Code paragraphs for impact test exemption, e.g., UG-20(f), UCS-66(a),
UCS-66(b), UCS-66(c), or for impact test requirements, e.g., UHA-51 or UHT-6
7. ASME material specifications for all pressure-resisting components and all attachments
to pressure-resisting components; full identification of all other materials
8. Wind/seismic design criteria
9. Corrosion allowance
10. Weld details. All welds shall be either detailed or identified by use of the standard
welding symbols of ANS/AWS A2.4.
11. Nondestructive examination requirements of welded pressure joints
13. Nondestructive examination of non-pressure-resisting welds
14. Postweld heat treatment requirements
15. Test pressures, as applicable:
a. Shop test in operating position (referenced to top of vessel)
b. Field test in operating position (referenced to top of vessel) (in the corroded
condition for vessels having a corrosion allowance)
16. Minimum permissible metal temperature during hydrostatic testing
17. Gas leak tests, if any
18. Minimum thickness required and nominal thickness used of all components (minimum
thickness required after forming [includes corrosion allowance] for formed heads)
Page 65 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
19. Datum line information for all pertinent dimensions shall be used, including location of
primary weld seams, location, and projection of nozzles, location of vessel and insulation
supports, and any other information necessary for a complete description of the vessel.
The datum line used shall be clearly identified. Normal vessel centerlines may be used as
the datum line to locate projections of nozzles, supports, etc.
20. Suppliers drawings shall have the same designation for nozzles, manways, and skirt
openings as shown on Purchasers drawings.
21. Complete description of all vessel flanges (including both standard and custom design),
bolting, bolt torques, and gaskets
23. Vessel support details
24. Surface preparation and painting or other protective coating specifications
25. Weight of vessel: empty, operating, full of solids, and shipping
26. Capacity of vessel (or each compartment), in cubic feet
27. Facsimiles of Suppliers nameplate with as-built information
28 Purchasers vessel identification number(s) and purchase order number
29 Information on any installed accessories (include Supplier, model number, etc.)
SPECIAL NOTES
Page 66 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX E
Equivalent Pressure Formulas for
Bending Moment and Axial Tensile Load
Page 67 of 71
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
July 2001
APPENDIX E
Equivalent Pressure Formulas for Bending Moment and Axial Tensile Load
When sustained bending moments or axial thrust loads are applied to the flanged joint during
operation in sufficient magnitude to warrant consideration in the flange design. The design pressure,
P, used in the calculation of total hydrostatic end load, H, in the flange design calculations shall be
replaced by the following design pressure:
PFLG = P + PEQ
16M
4F
G2
where
M = Sustained bending moment applied across full section at flange during the design
condition, inch-lb
F = Sustained axial tensile force applied at flange, lb
G = Diameter at location of gasket load reaction, inch (See Appendix 2 of the Code for full
definition.)
Note: Experience has shown that axial tensile forces resulting from a properly designed piping
system have no significant effect on the flange design and hence are typically not included in the
PEQ determination.
Therefore, the hydrostatic end load, H, used in the flange calculations is determined as follows:
2
H = 0.785 G PFLG
8M
G3
where
M = Bending moment, as defined above, but including dynamic bending moment (e.g., seismic
moment) applied across full section at flange during the design condition, inch-lb
Other terms = Same as above
Page 68 of 71
July 2001
PIP VESBI002
Design and Specification of Vessels for Bulk Solids
APPENDIX F
Standard Details
Page 69 of 71