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
External Pressure (UG-16, 28, 31)

Shell Design (Thickness of Shell) under

Internal Pressure (UG-16, 27, 31)

Is External
pressure applied

YES

Cylindrical Shell

NO

NO

YES
Calculation of Stiffening Rings
(UG-29, 30)

Head Design (Thickness of Formed Head)

under External Pressure (UG-33, 34)

Head Design (Thickness of Formed Head)

under Internal Pressure
(UG-16,32, 34)

YES

Is External pressure
applied
NO

Nozzle / Opening and Reinforcement Design

(UG-36, 37, 38, 39, 40, 41, 42, 43, 44, 45,
UW-15, 16)
Support Design Skirt, Leg, etc.
(Standard Drawings)

Weight Calculations

Wind and Seismic Calculations for

Vessel and Anchoring Design
(Appendix L, UBC, ASCI-112)

Calculation of Nozzle Load and

Strength (WRC-107, 297)

Welding Design (UW-9, 12, 13)

Definition of PWHT (UW-40, UCS-56, UHA-32)
Requirement for Examinations (UG-99, UW-11, 52)

Design of External Attachments and Transportation

Components lifting lug, Tailing lug, Piping clip (Standard
Drawings)
Design Review (QA procedure,
Relevant Paragraphs)

Tolerances (specification,
UG-80,81)
Vortex shedding, vibration analysis
(Specification)

Pressure Scope
Div. 3
Div. 2
Div. 1
0.00E+00

2.00E+07

4.00E+07

6.00E+07

8.00E+07

Not Recommended

1.00E+08

Recommended

1.20E+08

1.40E+08

1.60E+08

1.40E+08

1.60E+08

Allowed

3.5

t/Ri Div 1

t
P
=
Ri SE 0.6 P

t/Ri Div 2

t
P
= exp
1
Ri
SE

t/Ri Div 3

3P
t
1
= exp
2S
Ri
y

Thickness / Inner Radius

3.0

2.5

2.0

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

Pressure, Pa

1.00E+08

1.20E+08

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-byrule 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
2-Clients Specification
3-Economics

Div 1

NO

P>3000 psi
YES
Div 2

Design By Rule

Tentative
Geometry for
Analysis

Is the DBR enough?

(1-Engineering judgment
2-Clients Specification)

YES

NO

Determine of
Load Parameters
Table 5.2

Definition of Loading
Conditions Table 5.1

1-Modify the configurations

2-Reduce applied Loads

Stress
Analysis Method

Elastic Plastic

(R/t)>4 Elastic

Limit Load
Material Properties: E, , App. 3.D
Material Model: Actual, Associated
Plasticity, von Misses
Formulation: Large Displacement
Updated Lagrangian

Material Properties: E, , Sy
Material Model: Elastic perfectly Plastic
Formulation: Small Displacement
Total Lagrangian

Material Properties: E,
Material Model: Linear Elastic
Formulation: Small
Displacement

Establishing Design Load

Combinations and Load Factors
Table 5.5

Establishing Design Load

Combinations and Load Factors
Table 5.4

Load-Control Loads
Displacement-Control Loads
Establishing Design Load
Combinations Table 5.3

Does the problem

converge?

Does the problem

converge?

NO

NO

YES

YES

Specifying
Vessel Areas to
be Locally
Evaluated

Post-processing and
Classification of Stresses Table
5.6 Appendix 5.A

Limit Check
Fig 5.1

NO

YES

Vessel Design
calculation
Report

Overall Design Procedure of Pressure Vessel

ASME Sec VIII Div. 2 (Con.)

Elastic-Plastic
Analysis

Fabrication
Detail

Standard

Elastic Analysis

1-Modify the configurations

2-Reduce applied Loads

NO

1+2+34S

Non-Standard

peq+cfL

NO

YES

Explicit

Buckling Analysis

YES

Analysis Type

Bifercation

Determination of Capacity
Reduction Factor, cr

Load Factors of Table 5.5

Does the problem

converge?

YES

1-Modify the configurations

2-Reduce applied Loads

NO

NO

Cyclic Analysis
Requirement Check

Determination of Minimum
Design Factor, B

Probable Buckling Modes occur at loads

greater than design Loads multiplied by B

YES

Table 5.1 Loads and Load Cases To Be Considered in a Design

Loading Condition

Design Loads

Pressure Testing

1.
2.
3.
4.

Normal Operation

1.
2.
3.
4.

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)

Abnormal or Start-up
Operation plus Occasional
(see note above)

1.
2.
3.
4.
5.
6.
7.
1.
2.
3.
4.
5.
6.

Dead load of component plus insulation, fireproofing, installed internals, platforms and other
equipment supported from the component in the installed position.
Piping loads including pressure thrust
Applicable live loads excluding vibration and maintenance live loads.
Pressure and fluid loads (water) for testing and flushing equipment and piping unless a pneumatic test
is specified. 5. Wind loads
Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
platforms and other equipment supported from the component in the installed position.
Piping loads including pressure thrust
Applicable live loads.
Pressure and fluid loading during normal operation. 5. Thermal loads.
Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
platforms and other equipment supported from the component in the installed position.
Piping loads including pressure thrust
Applicable live loads.
Pressure and fluid loading during normal operation.
Thermal loads.
Wind, earthquake or other occasional loads, whichever is greater.
Loads due to wave action
Dead load of component plus insulation, refractory, fireproofing, installed internals, catalyst, packing,
platforms and other equipment supported from the component in the installed position.
Piping loads including pressure thrust
Applicable live loads.
Pressure and fluid loading associated with the abnormal or start-up conditions.
Thermal loads.
Wind loads.

Table 5.2 Load Descriptions

Design Load
Parameter

Description

Internal and external maximum allowable working pressure

Ps

Static head from liquid or bulk materials (e.g. catalyst)

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
Appurtenance Live loading
Effects of fluid momentum, steady state and transient
Earthquake loads (see ASCE 7 for the specific definition of the earthquake
load, as applicable)

L
E
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

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

1) P +Ps +D

Allowable General Primary

Membrane Stress (1),(2),(3)
S

2) P + Ps + D + L

3) P + Ps+ D + Ss

4) 0.6D + (W or 0.7E) (4)

5) 0.9P + Ps + D+ (W or 0.7E )

6) 0.9P + Ps + D + 0.75L + 0.75 Ss

7) 0.9P + Ps + D + 0.75(W or 0.7E) + 0.75L + 0.75Ss

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
3) 1.3 (P+ D) + 1.7Ss + max[1.1L , 0.86W]
Global Criteria
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 Users Design Specification, if applicable, see Table 5.5
Hydrostatic Test Conditions
{max[1.43, 1.25 (ST/S)]}.(P + Ps + D) + 2.6 Wpt
Global Criteria
Serviceability Criteria
Per Users Design Specification, if applicable.
Pneumatic Test Conditions
1.15 (ST/S).(P + Ps + D) + 2.6 Wpt
Global Criteria
Serviceability Criteria
Per Users 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
3) 2.1 (P+ D) + 2.6Ss + max[1.7L , 1.4W]
Global Criteria
4) 2.4 (P + D) + 2.6W + 1.7L + 0.86Ss
5) 2.4 (P + D) + 1.7E + 1.7L + 0.34Ss
1.7 (P+ Ps+ D)
Local Criteria
Serviceability Criteria
Per Users Design Specification, if applicable, see paragraph 5.2.4.3.b.
Hydrostatic Test Conditions
{max[2.3, 2.0 (ST/S)]}.(P + Ps + D) + Wpt
Global Criteria

Serviceability Criteria
Per Users Design Specification, if applicable.
Pneumatic Test Conditions
1.8 (ST/S).(P + Ps + D) + Wpt
Global Criteria
Serviceability Criteria
Per Users 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
Component

Origin of Stress

Type of Stress

General membrane
Gradient through plate thickness
Membrane
Bending
Net-section axial force and/or bending Local membrane
moment applied to the nozzle, and/or Bending
internal pressure
Peak (fillet or corner)
Temperature difference between shell Membrane
and head
Bending
Membrane
Bending
Internal pressure

Shell plate remote Internal pressure

from
discontinuities
Axial thermal gradient

Any shell
including
Near nozzle or
cylinders,
other opening
cones,
spheres and
Any location
formed
heads
Shell distortions
such as out-ofroundness and
dents

Cylindrical or
conical shell

Net-section axial force, bending

Any section across
moment applied to the cylinder or
entire vessel
cone, and/or internal pressure

Junction with head

Internal pressure
or flange
Dished head Crown
or conical
Knuckle or
head
junction to shell

Internal pressure
Internal pressure

Center region

Internal pressure

Junction to shell

Internal pressure

Flat head

Membrane stress averaged through the

thickness, remote from discontinuities; stress
component perpendicular to cross section
Bending stress through the thickness; stress
component perpendicular to cross section
Membrane
Bending
Membrane
Bending
Membrane
Bending
Membrane
Bending
Membrane

Classification
Pm
Q
Q
Q
PL
Q
F
Q
Q
Pm
Q

Pm

Pb
PL
Q
Pm
Pb
PL [note (1)]
Q
Pm
Pb
PL

Table 5.6 Examples Of Stress Classification (Con.)

Vessel
Component

Perforated
head or shell

Location

Origin of Stress

Typical ligament in
Pressure
a uniform pattern
Isolated or atypical
Pressure
ligament

Nozzle (see
paragraph
5.6)

Within the limits of

reinforcement
given by paragraph
4.5
Outside the limits
of reinforcement
given by paragraph
4.5

Nozzle wall

Type of Stress

Classification

Membrane (averaged through cross section)

Bending (averaged through width of ligament., but
gradient through plate)
Peak
Membrane
Bending
Peak

Pm
Pb

Pressure and external loads and

General membrane
moments including those attributable to
Bending (other than gross structural discontinuity
restrained free end displacements of
stresses) averaged through nozzle thickness
attached piping
Pressure and external axial, shear, and General Membrane
torsional loads including those
attributable to restrained free end
displacements of attached piping
Pressure and external loads and
Membrane
moments, excluding those attributable Bending
to restrained free end displacements of
attached piping
Membrane
Pressure and all external loads and
Bending
moments
Peak
Membrane
Gross structural discontinuities
Bending
Peak
Membrane
Differential expansion
Bending
Peak

F
Q
F
F
Pm
Pm

Pm

PL
Pb

PL
Q
F
PL
Q
F
Q
Q
F

Table 5.6 Examples Of Stress Classification (Con.)

Vessel
Component

Location

Origin of Stress

Type of Stress

Classification

Cladding

Any

Differential expansion

Any

Any

Membrane
Bending
Equivalent linear stress [note (4)]
Nonlinear portion of stress distribution
Stress concentration (notch effect)

F
F
Q
F
F

Radial temperature distribution [note

(3)]
Any

Any
Any
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
Category
Description
(For
examples,
see Table
5.6)

Symbol

Primary
Local Membrane

General Membrane
Average primary
equivalent stress
across solid section.
Excludes
discontinuities and
concentrations.
Produced only by
mechanical loads.

Average equivalent
stress across any solid
section.
Considers
discontinuities but not
concentrations.
Produced only by
mechanical loads.

Pm

Pm

Bending
Component of
primary equivalent
stress proportional to
distance from
centroid of solid
section. Excludes
discontinuities and
concentrations.
Produced only by
mechanical loads.

PL

Design Load
Operating Load
SPS=max[3S, 2SY]

PL

Secondary Membrane plus

Bending

Peak

Self-equilibrating equivalent
stress necessary
to satisfy continuity of structure.
Occurs at structural
discontinuities.
Can be caused by mechanical load
or by differential thermal
expansion.
Excludes local stress
concentrations.

1.Increment added
to primary or
secondary
equivalent stress
by a concentration
(notch).
2.Certain thermal
stresses which may
cause fatigue but
not distortion of
vessel shape.

Pb

1.5S

PL+Pb

PL+Pb+Q

1.5S

SPS
(PL+Pb+Q+F)

2Sa

6.E+08
Primary plus Secondary Stress Limit

5.E+08

Stress, Pa

4.E+08
100% Primary

3.E+08

Stress

Mixed Responce
Primary Stress Limit
100% Secondary

2.E+08

Linear Elastic

1.E+08
0.E+00
0

0.02

0.04
Mixed Loading

Displacement-Control

=K/A

0.06

Strain

=W/(2A)
+K/A

0.08
Load-Control

=W/(2A)

0.1

0.12
Original

Stress Classification

THANKS FOR YOUR ATTENTION