HEDCO

Spring 2009

DESIGN BY ANALYSIS
A GENERAL GUIDELINE
G. Ghanbari
Overall Design Procedure of Pressure Vessel
ASME Sec VIII Div. 1
Input Data
(Mechanical and Process
Data Sheets)

Material Selection for Vessel Components

1. Service
2. Design Temperature (UG-23 and ASME Sec. II Tables)
3. MDMT and Impact Test (UCS-66, 67, UHA-51, UG-20 (f), UG-84)

Shell Design (Thickness of Shell) under Shell Design (Thickness of Shell) under
External Pressure (UG-16, 28, 31) Internal Pressure (UG-16, 27, 31)

YES Is External
Cylindrical Shell pressure applied
NO

NO
YES
Head Design (Thickness of Formed Head)
Calculation of Stiffening Rings
under Internal Pressure
(UG-29, 30)
(UG-16,32, 34)

Head Design (Thickness of Formed Head) Is External pressure

YES
under External Pressure (UG-33, 34) applied

NO
Nozzle / Opening and Reinforcement Design
Calculation of Nozzle Load and
(UG-36, 37, 38, 39, 40, 41, 42, 43, 44, 45,
Strength (WRC-107, 297)
UW-15, 16)

Wind and Seismic Calculations for Welding Design (UW-9, 12, 13)
Support Design Skirt, Leg, etc.
Vessel and Anchoring Design Definition of PWHT (UW-40, UCS-56, UHA-32)
(Standard Drawings)
(Appendix L, UBC, ASCI-112) Requirement for Examinations (UG-99, UW-11, 52)
Design of External Attachments and Transportation
Tolerances (specification,
Weight Calculations Components lifting lug, Tailing lug, Piping clip (Standard
UG-80,81)
Drawings)

Design Review (QA procedure, Vortex shedding, vibration analysis

Relevant Paragraphs) (Specification)
 Pressure Scope
Div. 3
Div. 2
Div. 1

0.00E+00 2.00E+07 4.00E+07 6.00E+07 8.00E+07 1.00E+08 1.20E+08 1.40E+08 1.60E+08

Not Recommended Recommended Allowed

3.5
t P
t/Ri Div 1 =
Ri SE − 0.6 P
3.0
t  P 
t/Ri Div 2 = exp  −1
Ri  SE 
Thickness / Inner Radius

2.5
t  3P 
t/Ri Div 3 = exp  −1
Ri  2S 
2.0  y 

t/Ri Div 1 considering allowable stress of Div 2

1.5

1.0

0.5

0.0
0.00E+00 2.00E+07 4.00E+07 6.00E+07 8.00E+07 1.00E+08 1.20E+08 1.40E+08 1.60E+08
Pressure, Pa
Introduction to DBA

The “design by analysis” procedures are intended to guard against eight possible pressure
vessel failure modes by performing a detailed stress analysis of the vessel with the sufficient
design factors. The failure modes are:

1. excessive elastic deformation, including elastic instability,

2. excessive plastic deformation,
3. brittle fracture,
4. stress rupture/creep deformation (inelastic),
5. plastic instability - incremental collapse,
6. high strain - low cycle fatigue,
7. stress corrosion, and
8. corrosion fatigue

Most of the “design by analysis” procedures that are given in ASME BPVC relate to designs
based on “elastic analysis.”
Introduction to DBA
The design-by-analysis requirements are organized based on protection against the failure modes listed
below. The component shall be evaluated for each applicable failure mode. If multiple assessment
procedures are provided for a failure mode, only one of these procedures must be satisfied to qualify the
design of a component.

a) All pressure vessels within the scope of this Division, irrespective of size or pressure, shall be provided
with protection against overpressure in accordance with the requirements of this Part.
b) Protection Against Plastic Collapse – these requirements apply to all components where the thickness
and configuration of the component is established using design-by-analysis rules.
c) Protection Against Local Failure – these requirements apply to all components where the thickness
and configuration of the component is established using design-by-analysis rules. It is not necessary
to evaluate the local strain limit criterion if the component design is in accordance with Part 4 (i.e.
component wall thickness and weld detail per paragraph 4.2).
d) Protection Against Collapse From Buckling – these requirements apply to all components where the
thickness and configuration of the component is established using design-by-analysis rules and the
applied loads result in a compressive stress field.
e) Protection Against Failure From Cyclic Loading – these requirements apply to all components where
the thickness and configuration of the component is established using design-by-analysis rules and
the applied loads are cyclic. In addition, these requirements can also be used to qualify a component
for cyclic loading where the thickness and size of the component are established using the design-by-
rule requirements of Part 4.
Overall Design Procedure of Pressure Vessel
ASME Sec VIII Div. 2 Vessel Design Data
(Generally extracted from UDS)

1-Engineering judgment
Div 1 2-Client’s Specification NO P>3000 psi
3-Economics
YES

Div 2

Vessel Design
Is the DBR enough?
calculation
Design By Rule (1-Engineering judgment YES
Report
2-Client’s Specification)

Tentative
Geometry for NO
Analysis

Determine of
Load Parameters
Table 5.2

Definition of Loading
1-Modify the configurations Conditions Table 5.1
2-Reduce applied Loads

Stress
Elastic Plastic (R/t)>4 Elastic
Analysis Method

Material Properties: E, ν, App. 3.D
Material Model: Actual, Associated
Plasticity, von Misses
Formulation: Large Displacement
Updated Lagrangian
Establishing Design Load
Combinations and Load Factors
Table 5.5
Limit Load
Material Properties: E, ν, Sy Material Properties: E, ν
Material Model: Elastic perfectly Plastic Material Model: Linear Elastic
Formulation: Small Displacement Formulation: Small
Total Lagrangian Displacement
Load-Control Loads
Establishing Design Load
Displacement-Control Loads
Combinations and Load Factors
Establishing Design Load
Table 5.4
Combinations Table 5.3

Post-processing and
Does the problem Does the problem
Classification of Stresses Table
converge? NO converge?
NO 5.6 Appendix 5.A

YES Limit Check

NO
Fig 5.1
Specifying
Vessel Areas to
YES YES
be Locally
Evaluated
Overall Design Procedure of Pressure Vessel
ASME Sec VIII Div. 2 (Con.)

Elastic-Plastic Fabrication
Non-Standard Standard Elastic Analysis
Analysis Detail

1-Modify the configurations

εpeq+εcf≤εL NO
2-Reduce applied Loads NO σ1+σ2+σ3≤4S

YES Buckling Analysis YES

Explicit Analysis Type Bifercation

Determination of Capacity
Reduction Factor, βcr

1-Modify the configurations Determination of Minimum

Load Factors of Table 5.5
2-Reduce applied Loads Design Factor, ФB

Does the problem Probable Buckling Modes occur at loads

NO NO
converge? greater than design Loads multiplied by ФB

Cyclic Analysis
YES YES
Requirement Check
Table 5.1 – Loads and Load Cases To Be Considered in a Design
Loading Condition Design Loads

Pressure Testing
Normal Operation
Normal Operation plus
Occasional (note: occasional
loads are usually governed by
wind and earthquake;
however, other load types
such as snow and ice loads
may govern, see ASCE-7)
1. Dead load of component plus insulation, fireproofing, installed internals, platforms and other
equipment supported from the component in the installed position.
2. Piping loads including pressure thrust
3. Applicable live loads excluding vibration and maintenance live loads.
4. Pressure and fluid loads (water) for testing and flushing equipment and piping unless a pneumatic test
is specified. 5. Wind loads
1. Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
platforms and other equipment supported from the component in the installed position.
2. Piping loads including pressure thrust
3. Applicable live loads.
4. Pressure and fluid loading during normal operation. 5. Thermal loads.
1. Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
platforms and other equipment supported from the component in the installed position.
2. Piping loads including pressure thrust
3. Applicable live loads.
4. Pressure and fluid loading during normal operation.
5. Thermal loads.
6. Wind, earthquake or other occasional loads, whichever is greater.
7. Loads due to wave action

Abnormal or Start-up
1. Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
Operation plus Occasional
platforms and other equipment supported from the component in the installed position.
(see note above)
2. Piping loads including pressure thrust
3. Applicable live loads.
4. Pressure and fluid loading associated with the abnormal or start-up conditions.
5. Thermal loads.
6. Wind loads.
Table 5.2 – Load Descriptions
Design Load Description
Parameter
P Internal and external maximum allowable working pressure
Ps Static head from liquid or bulk materials (e.g. catalyst)
D Dead weight of the vessel, contents, and appurtenances at the location of interest, including
the following:
• Weight of vessel including internals, supports (e.g. skirts, lugs, saddles, and legs), and
appurtenances (e.g. platforms, ladders, etc.)
• Weight of vessel contents under operating and test conditions
• Refractory linings, insulation
• Static reactions from the weight of attached equipment, such as motors, machinery, other
vessels, and piping
L • Appurtenance Live loading
• Effects of fluid momentum, steady state and transient
E Earthquake loads (see ASCE 7 for the specific definition of the earthquake
load, as applicable)
W Wind Loads
Wpt Is the pressure test wind load case. The design wind speed for this case shall be specified by
the Owner-User.
Ss Snow Loads
T Is the self-restraining load case (i.e. thermal loads, applied displacements). This load case
does not typically affect the collapse load, but should be considered in cases where elastic
follow-up causes stresses that do not relax sufficiently to redistribute the load without
excessive deformation.
Table 5.3 – Load Case Combinations and Allowable Membrane Stresses for an
Elastic Analysis
Design Load Combination Allowable General Primary
Membrane Stress (1),(2),(3)
1) P +Ps +D S
2) P + Ps + D + L S

3) P + Ps+ D + Ss S
4) 0.6D + (W or 0.7E) (4) S
5) 0.9P + Ps + D+ (W or 0.7E ) S
6) 0.9P + Ps + D + 0.75L + 0.75 Ss S
7) 0.9P + Ps + D + 0.75(W or 0.7E) + 0.75L + 0.75Ss S
Notes
1) The parameters used in the Design Load Combination column are defined in Table 5.2.
2) The term 0.9P is considered an operating pressure.
3) S is the allowable stress for the load case combination. This value represents the general primary
membrane stress limit for “load-controlled” loads. Stress limits for local membrane and
bending stresses from “load-controlled” or “strain-controlled” loads are provided in paragraph
5.2.2.4.
4) This load combination addresses an overturning condition. If anchorage is included in the
design, consideration of this load combination is not required.
Table 5.4 – Load Case Combinations and Load Factors for a Limit Load Analysis

Design Conditions
Criteria Required Factored Load Combinations
1) 1.5 (P+ Ps+ D)
2) 1.3 (P+ Ps+ D+ T ) + 1.7L + 0.54 Ss
Global Criteria 3) 1.3 (P+ D) + 1.7Ss + max[1.1L , 0.86W]
4) 1.3 (P + D) + 1.7W + 1.1L + 0.54Ss
5) 1.3 (P + D) + 1.1E + 1.1L + 0.21Ss
Local Criteria Per Table 5.5
Serviceability Criteria Per User’s Design Specification, if applicable, see Table 5.5
Hydrostatic Test Conditions
Global Criteria {max[1.43, 1.25 (ST/S)]}.(P + Ps + D) + 2.6 Wpt
Serviceability Criteria Per User’s Design Specification, if applicable.
Pneumatic Test Conditions
Global Criteria 1.15 (ST/S).(P + Ps + D) + 2.6 Wpt
Serviceability Criteria Per User’s Design Specification, if applicable.
Notes:
1) The parameters used in the Design Load Combination column are defined in Table 5.2.
2) See paragraph 5.2.3.4 for descriptions of global and serviceability criteria.
3) S is the allowable membrane stress at the design temperature.
4) ST is the allowable membrane stress at the pressure test temperature.
Table 5.5 – Load Case Combinations and Load Factors for an Elastic-Plastic
Analysis
Design Conditions
Criteria Required Factored Load Combinations
1) 2.4 (P+ Ps+ D)
2) 2.1 (P+ Ps+ D+ T ) + 2.6L + 0.86 Ss
Global Criteria 3) 2.1 (P+ D) + 2.6Ss + max[1.7L , 1.4W]
4) 2.4 (P + D) + 2.6W + 1.7L + 0.86Ss
5) 2.4 (P + D) + 1.7E + 1.7L + 0.34Ss
Local Criteria 1.7 (P+ Ps+ D)
Serviceability Criteria Per User’s Design Specification, if applicable, see paragraph 5.2.4.3.b.
Hydrostatic Test Conditions
Global Criteria {max[2.3, 2.0 (ST/S)]}.(P + Ps + D) + Wpt
Serviceability Criteria Per User’s Design Specification, if applicable.
Pneumatic Test Conditions
Global Criteria 1.8 (ST/S).(P + Ps + D) + Wpt
Serviceability Criteria Per User’s Design Specification, if applicable.
Notes:
1) The parameters used in the Design Load Combination column are defined in Table 5.2.
2) See paragraph 5.2.4.3 for descriptions of global and serviceability criteria.
3) S is the allowable membrane stress at the design temperature.
4) ST is the allowable membrane stress at the pressure test temperature.
 Table 5.6 – Examples Of Stress Classification
Vessel
Location Origin of Stress Type of Stress Classification
Component
General membrane Pm
Shell plate remote Internal pressure
Gradient through plate thickness Q
from
Membrane Q
discontinuities Axial thermal gradient
Any shell Bending Q
including Net-section axial force and/or bending Local membrane PL
Near nozzle or
cylinders, moment applied to the nozzle, and/or Bending Q
other opening
cones, internal pressure Peak (fillet or corner) F
spheres and Temperature difference between shell Membrane Q
Any location
formed and head Bending Q
heads Shell distortions Membrane Pm
such as out-of- Bending Q
Internal pressure
roundness and
dents
Net-section axial force, bending Membrane stress averaged through the Pm
Any section across
moment applied to the cylinder or thickness, remote from discontinuities; stress
entire vessel
cone, and/or internal pressure component perpendicular to cross section
Cylindrical or
Bending stress through the thickness; stress Pb
conical shell
component perpendicular to cross section
Junction with head Membrane PL
Internal pressure
or flange Bending Q
Membrane Pm
Dished head Crown Internal pressure
Bending Pb
or conical
Knuckle or Membrane PL [note (1)]
head Internal pressure
junction to shell Bending Q
Membrane Pm
Center region Internal pressure
Bending Pb
Flat head
Membrane PL
Junction to shell Internal pressure
 Table 5.6 – Examples Of Stress Classification (Con.)
Vessel
Location Origin of Stress Type of Stress Classification
Component
Membrane (averaged through cross section) Pm
Typical ligament in Bending (averaged through width of ligament., but Pb
Pressure
a uniform pattern gradient through plate)
Perforated
Peak F
head or shell
Membrane Q
Isolated or atypical
Pressure Bending F
ligament
Peak F
Within the limits of Pressure and external loads and Pm
General membrane
reinforcement moments including those attributable to Pm
Bending (other than gross structural discontinuity
given by paragraph restrained free end displacements of
stresses) averaged through nozzle thickness
4.5 attached piping
Outside the limits Pressure and external axial, shear, and General Membrane Pm
of reinforcement torsional loads including those
given by paragraph attributable to restrained free end
4.5 displacements of attached piping
Nozzle (see
Pressure and external loads and Membrane PL
paragraph
moments, excluding those attributable Bending Pb
5.6)
to restrained free end displacements of
attached piping
Membrane PL
Pressure and all external loads and
Bending Q
moments
Peak F
Membrane PL
Nozzle wall Gross structural discontinuities Bending Q
Peak F
Membrane Q
Differential expansion Bending Q
Peak F
 Table 5.6 – Examples Of Stress Classification (Con.)
Vessel
Location Origin of Stress Type of Stress Classification
Component
Membrane F
Cladding Any Differential expansion
Bending F
Radial temperature distribution [note Equivalent linear stress [note (4)] Q
Any Any
(3)] Nonlinear portion of stress distribution F
Any Any Any Stress concentration (notch effect) F
Notes:
1. Consideration shall be given to the possibility of wrinkling and excessive deformation in vessels with large diameter-to-thickness ratio.
2. If the bending moment at the edge is required to maintain the bending stress in the center region within acceptable limits, the edge bending is
classified as Pb ; otherwise, it is classified as Q .
3. Consider possibility of thermal stress ratchet.
4. Equivalent linear stress is defined as the linear stress distribution that has the same net bending moment as the actual stress distribution.
Figure 5.1 – Stress Categories and Limits of Equivalent Stress
Stress Primary Secondary Membrane plus Peak
Category General Membrane Local Membrane Bending Bending
Description Average primary Average equivalent Component of Self-equilibrating equivalent 1.Increment added
(For equivalent stress stress across any solid primary equivalent stress necessary to primary or
examples, across solid section. section. stress proportional to to satisfy continuity of structure. secondary
see Table Excludes Considers distance from Occurs at structural equivalent stress
5.6) discontinuities and discontinuities but not centroid of solid discontinuities. by a concentration
concentrations. concentrations. section. Excludes Can be caused by mechanical load (notch).
Produced only by Produced only by discontinuities and or by differential thermal 2.Certain thermal
mechanical loads. mechanical loads. concentrations. expansion. stresses which may
Produced only by Excludes local stress cause fatigue but
mechanical loads. concentrations. not distortion of
vessel shape.
Symbol Pm PL Pb Q F

Pm S 1.5S SPS
PL PL+Pb+Q

Δ(PL+Pb+Q+F) 2Sa
Design Load PL+Pb 1.5S

Operating Load

SPS=max[3S, 2SY]
 6.E+08

5.E+08 Primary plus Secondary Stress Limit

4.E+08
Stress, Pa

100% Primary
Stress
3.E+08 Mixed Responce
Primary Stress Limit Linear Elastic
2.E+08 100% Secondary

1.E+08

0.E+00
0 0.02 0.04 0.06 0.08 0.1 0.12
Strain
Displacement-Control Mixed Loading Load-Control Original

σ=Kδ/A σ=W/(2A) σ=W/(2A)

+Kδ/A

δ
Stress Classification
THANKS FOR YOUR ATTENTION