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2nd January
Asset Integrity
2017 Section owner.
Azlan Azahar ©Petroliam Nasional Berhad (PETRONAS) 2014 1
Objective

1. To understand various pressure terminology used in pressure vessel design

& fabrication:
 Operating pressure (OP)
 Maximum operating pressure (MOP)
 Design pressure (DP)
 Maximum allowable working pressure (MAWP)
 Maximum allowable pressure (MAP)
 Hydrostatic test pressure (HTP)
 Static head pressure (SHP)
2. Concept of static head pressure
3. Understanding the differences between pressure & non-pressure loadings
Aim

At the end of this training, you should be able to fill up below table:

Design Pressure Int Pressure + Minimum

Component MAWP MAP
(bar) Static Head Thickness + CA
Ch Head 58
Ch Barrel 58
Sh Barrel 9
Sh Head 9
References

 PTS 12.20.01 – Pressure Vessels

 PTS 16.50.01 - Design Conditions : Temperature, Pressure & Toxicity
 ASME Section VIII Division 1
 Pressure Vessel Design Manual, Dennis Moss
 API 510
ASME Section VIII Division 1 Related Clauses

UG-21 – Design Pressure

UG-22 – Loadings
UG-27 - Thickness of shells under internal pressure
UG-28 - Thickness of shells and tubes under external pressure
UG-98 – MAWP
UG-99 – Standard hydrostatic Test
Operating Pressure (OP)

 Gauge pressure exists inside equipment and piping during any

intended operation.
 At the top of a vessel at which it normally operates.
 Determined by process engineer.

Operating pressure
Maximum Operating Pressure (MOP)

 The highest gauge pressure that provides control flexibility of the

intended operation.
 Determined by the process engineer in consultation with the process
control engineer.
 Typically set at 105% of OP or minimum of 1.0barg higher than OP.
 At the top of a vessel at which it normally operates.
Maximum operating
pressure
Design Pressure (DP)

 DP is selected to provide a suitable margin above the most severe pressure

expected during normal operation at a coincident temperature.
 At the top of a vessel at which it normally operates.
 The pressure used in the design of a vessel component (i.e. determining the
minimum required thickness excluding any metal thickness specified as
corrosion allowance) together with the coincident design metal temperature.
 Static head pressure in the operating position is be added to the design
pressure to determine the thickness of any specific zone of the vessel.
 DP is determined by the Process Engineer and finalized by the Mechanical
Design Engineer.
 Generally it shall be with a margin of 10% above the Maximum Operating
Pressure.
Design Pressure (DP)

Design pressure of a vessel

𝑃𝑅
𝑡=
𝑆𝐸 − 0.6𝑃

where P is the Design Pressure plus the static head

pressure
Static Head Pressure

 Pressure resulting from liquid height 1000kg 9.81N

𝑃𝑆𝐻 = x x 1m
 𝑃 = 𝜌𝑔ℎ 𝑚3 kg
 Water density = 1000kg/m3 = 62.4lbs/ft3 9810𝑁
𝑃𝑆𝐻 = = 0.0981𝑏𝑎𝑟𝑔
 Gravity = 9.81N/kg = 1 lbf/lbs 𝑚2

62.4𝑙𝑏𝑠 1lbf
12” 𝑃𝑆𝐻 = x x 1ft
𝑓𝑡 3 lbs
62.4𝑙𝑏𝑓
𝑃𝑆𝐻 = = 0.433𝑝𝑠𝑖
12” 𝑓𝑡 2
12”

 How much force (weight) is on the bottom of this container? 62.4lbs

 How much pressure is on each square inch of the box’s bottom? 0.433psi/ft height
(0.0981bar/m height)

This is a static head pressure!

𝑃𝑆𝐻 = 0.433𝑝𝑠𝑖 𝑥 𝐿𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 (𝑓𝑡)
𝑃𝑆𝐻 = 0.0981𝑏𝑎𝑟 𝑥 𝐿𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑖𝑔ℎ𝑡 (𝑚)
Design Pressure (DP)

Design pressure of a vessel

Design pressure + static head for vessel top head

 to be used in calculation to determine
its minimum required thickness

Design pressure + static head for vessel shell

 to be used in calculation to determine its
minimum required thickness

Design pressure + static head for vessel bottom head

 to be used in calculation to determine its
minimum required thickness
Exercise

1) A vertical pressure vessel with 50’ height is designed at 100psi, what is the total pressure at
the bottom head?
𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 𝑃𝐷 + 𝑃𝑆𝐻

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 100𝑝𝑠𝑖 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 50𝑓𝑡)

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 100𝑝𝑠𝑖 + 21.65𝑝𝑠𝑖 = 121.65𝑝𝑠𝑖

2) A 60’ vessel is filled with water. The pressure at the bottom is 210psi. What is the pressure
at the top?
𝑃𝐷 = 𝑃𝑏𝑜𝑡𝑡𝑜𝑚 − 𝑃𝑆𝐻

𝑃𝐷 = 210𝑝𝑠𝑖 − (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 60𝑓𝑡)

𝑃𝐷 = 210𝑝𝑠𝑖 − 25.98𝑝𝑠𝑖 = 184.02𝑝𝑠𝑖

3) A vessel with 50’ height is to be hydrotested at test pressure of 100psi, what is the total
pressure at the bottom?
𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 𝑃𝐷 + 𝑃𝑆𝐻

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 100𝑝𝑠𝑖 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 50𝑓𝑡)

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 = 100𝑝𝑠𝑖 + 21.65𝑝𝑠𝑖 = 121.65𝑝𝑠𝑖

Exercise

1) A 50’ high vessel has a design pressure of 100psig. The elevations are shown on the sketch
below:
a) The shell should be designed for
b) The top head should be designed for
c) The bottom head should be designed for

0’ 100 psig 𝑃𝑠ℎ𝑒𝑙𝑙 = 100𝑝𝑠𝑖𝑔 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 48𝑓𝑡)

2’ ?? psig 𝑃𝑠ℎ𝑒𝑙𝑙 = 120.78

𝑃𝑡𝑜𝑝 ℎ𝑒𝑎𝑑 = 100𝑝𝑠𝑖𝑔 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 2𝑓𝑡)

𝑃𝑡𝑜𝑝 ℎ𝑒𝑎𝑑 = 100.87

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 ℎ𝑒𝑎𝑑 = 100𝑝𝑠𝑖𝑔 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 50𝑓𝑡)

𝑃𝑏𝑜𝑡𝑡𝑜𝑚 ℎ𝑒𝑎𝑑 = 121.65
48’ ?? psig
50’ ?? psig
Exercise

A horizontal pressure vessel, 60” inside diameter is to be fabricated from SA-516 Grade 70
normalized material. S = 19,400psi. The design pressure at the top of the vessel is 600psi at
600oF. All joints shall be Type 1 and spot radiographed in accordance with UW-52. The vessel
operated full of liquid. The density of the liquid is 62.4lb/ft3 and the distance from the
centerline to the upper most part of the vessel is 4 feet. Determine the required thickness away
from vessel support.

𝑃𝑠ℎ𝑒𝑙𝑙 = 600𝑝𝑠𝑖𝑔 + (0.433𝑝𝑠𝑖/𝑓𝑡 𝑥 6.5𝑓𝑡)

𝑃𝑠ℎ𝑒𝑙𝑙 = 602.8𝑝𝑠𝑖
4’
𝑃𝑅
60” 𝑡=
𝑆𝐸 − 0.6𝑃
602.8 𝑥 30"
𝑡=
(19400 𝑥 0.85) − (0.6 𝑥 602.8)

𝑡 = 1.121" 𝑈𝑠𝑒 1 − 1/4 𝑖𝑛𝑐ℎ 𝑝𝑙𝑎𝑡𝑒

Exercise (LD1-11-E104)

1) Use the drawing and design data, calculate what is the minimum required thickness for
shell? Note: Please use E=1 throughout the calculation. Shell material: SA-516 Gr. 70

𝑃𝑠ℎ𝑒𝑙𝑙 = 9𝑏𝑎𝑟𝑔 + (0.0981𝑏𝑎𝑟𝑔/𝑚 𝑥 0.7366𝑚)

𝑃𝑠ℎ𝑒𝑙𝑙 = 9.072𝑏𝑎𝑟𝑔
Remember, Design
736.6𝑚𝑚
𝑅= + 3𝑚𝑚 = 371.3𝑚𝑚 Pressure is determined
2 in corroded condition

𝑆 = 20𝑘𝑠𝑖 = 1378.95𝑏𝑎𝑟𝑔

9.072 𝑥 371.3
𝑡𝑟𝑒𝑞 =
1378.95 𝑥 1.00 − (0.6 𝑥 9.072)

𝑡𝑟𝑒𝑞 = 2.452𝑚𝑚

𝑡𝑟𝑒𝑞 + 𝐶𝐴 = 2.452𝑚𝑚 + 3𝑚𝑚 = 5.452𝑚𝑚

Maximum Allowable Working Pressure (MAWP)

 The maximum gauge pressure permitted at the top of a pressure vessel in its operating
position for a designated temperature, together with the effect of any combination of
non-pressure loadings listed in UG-22 that is likely to occur.

 Excluding any metal thickness specified as corrosion allowance.

 Calculated using nominal thicknesses exclusive of allowances for corrosion

 Basis for the pressure setting of the pressure relieving devices protecting the vessel, as
well as determining the hydrostatic pressure test according to ASME & API.

 The MAWP for the vessel will be governed by the MAWP of the weakest part

 The design pressure may be used in all cases in which calculations are not made to
determine the value of the MAWP (ASME Section VIII, MA3)
 UG-22 – Loadings

The loadings to be considered in designing a vessel shall include those from:

Pressure Loadings Non-Pressure Loadings

Internal design pressure Superimposed static weight of attached equipment, such as

(UG-27) motors, machinery, other vessels, piping, linings, and insulation

External design pressure Weight of attachment:

(UG-28)  internals such as trays, tray support ring, etc.
 vessel supports such as lugs, rings, skirts, saddles, and legs

Static head for normal contents under cyclic and dynamic reactions due to pressure, thermal variations,
operating or test conditions. or mechanical loadings;

Wind, snow, and seismic

Impact reactions such as those due to fluid shock

Temperature gradients and differential thermal expansion

Abnormal pressures, such as those caused by deflagration

MAWP Formula for Cylindrical Shell

 Vessel part MAWP is determined from the design formulas in the Code.

𝑆𝐸𝑡
𝑃=
𝑅 + 0.6𝑡

𝑆 = 𝐴𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑑𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙, 𝑐𝑜𝑟𝑟𝑜𝑑𝑒𝑑

𝑅 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑐𝑜𝑟𝑟𝑜𝑑𝑒𝑑

 This “P” is the maximum pressure allowed on this shell

 The shell doesn’t care about the source of the pressure. It can be static head, non-pressure
loads, or process or both. It only cares about the maximum pressure.
Exercise (LD1-11-E104)

1) Use the drawing and design data, calculate the MAWP for shell.
Note: Please use E=1 throughout the calculation. Shell material: SA-516 Gr. 70
MAWP
𝑆𝐸𝑡
𝑃=
𝑅 + 0.6𝑡
1378.95 𝑥 1.00 𝑥 7
𝑃=
371.3 + (0.6 𝑥 7)

𝑃 = 25.706 − 0.072 (𝑆𝐻)

𝑃 = 25.633𝑏𝑎𝑟𝑔
Maximum Allowable Pressure (MAP)

 Maximum permissible pressure based on the weakest part as determined by

the design equations for a component using the nominal thickness.

 New (un-corroded) and cold condition.

𝑆𝐸𝑡
𝑃=
𝑅 + 0.6𝑡

𝑆 = 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑠𝑡𝑟𝑒𝑠𝑠 𝑎𝑡 𝑎𝑚𝑏𝑖𝑒𝑛𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝑡 = 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑠ℎ𝑒𝑙𝑙, 𝑛𝑒𝑤

𝑅 = 𝑖𝑛𝑠𝑖𝑑𝑒 𝑟𝑎𝑑𝑖𝑢𝑠, 𝑛𝑒𝑤

Exercise (LD1-11-E104)

1) Use the drawing and design data, calculate the MAP for shell.
Note: Please use E=1 throughout the calculation. Shell material: SA-516 Gr. 70

𝑆𝐸𝑡
𝑃=
𝑅 + 0.6𝑡
1378.95 𝑥 1.00 𝑥 10
𝑃=
368.3 + (0.6 𝑥 10)

𝑃 = 36.84𝑏𝑎𝑟𝑔
PV Elite Calculation Summary
Hydrostatic Test Pressure

 ASME Section VIII UG-99(b): Vessels designed for internal pressure shall be
subjected to a hydrostatic test pressure that at every point in the vessel is at
least equal to 1.3 times the maximum allowable working pressure36 multiplied
by the lowest stress ratio (LSR) for the materials of which the vessel is
constructed.
a) 1.3 x DP x LSR (Most of the time)
b) 1.3 x MAWP x LSR (ASME & API)
c) 1.3 x MAP x LSR (PTS 12.20.01)

UG-99 Endnotes 36: The maximum allowable working pressure may be assumed to be
the same as the design pressure when calculations are not made to determine the
maximum allowable working pressure
Recap…

1. Which pressure is used to determine the minimum required thickness?

Answer: Design pressure

2. Which pressure is calculated using the nominal thickness exclusive of CA?

Answer: MAWP

3. What is the value of static head pressure?

Answer: 𝑃𝑆𝐻 = 0.433𝑝𝑠𝑖/ft or 0.0981𝑏𝑎𝑟/m

4. Which pressure is calculated when the plate is in new condition?

Answer: MAP

5. Which pressure must be determined by the Process Engineer?

Answer: OP, MOP, and DP
  New & cold condition
 Calculated using the nominal thickness MAP
 Highest permissible pressure
 Determine by Mechanical Design Engineer
 Hot and corroded condition
 Include static head and non-pressure loads per UG22
 Usually = DP when MAWP calculations are not made MAWP
 Usually calculated using nominal thickness less CA
 Determine by Mechanical Design Engineer
 + 10% of MOP
 Hot and corroded condition
 Exclude non-pressure loads per UG22 Design Pressure (DP)
 Static head is included when determining the treq per UG-27
 Determined by PE and finalized by Mechanical Design Eng.

 105% of OP or minimum of 1barg higher than OP

 Determined by the Process Engineer in consultation
Maximum Operating Pressure
with the process control engineer. (MOP)

 The pressure at the top of a vessel at which it

normally operates Operating Pressure (OP)
 Determined by Process Engineer (PE)

Vessel’s External

Manufacturer’s tolerance MAWP

Nominal

MAP
thickness
DP

Minimum required thickness

Corrosion allowance
Vessel’s Internal
Things to Ponder

Determining the minimum required thickness

 In the absence of original design calculation, MCI engineer sometimes manually calculate the
treq based on the available information from drawings.

 But have we consider the static head pressure, as well as the “corroded” condition?

Hydrostatic test pressure

 PTS 12.20.01 para. 6.8.2(iii) says “Unless otherwise agreed by Owner, the test pressure shall be
determined in accordance with the construction code. The test pressure shall be based on MAP in
lieu of MAWP”.

 Has anyone of us really practicing this?

Things to Ponder

Pressure to be stamped on the name plate

 PTS 12.20.01 para. 2.6.2 says “The MAWP shall be calculated for all pressure vessels and it shall
also be indicated in the vessel’s name plate”.

 Then how about P&ID? What is the SOL value?

Thank you