DOWNCOMER
A
B
A
C
C
C
C
D
E
F
G
H
J
K
L
M
J
N
O
P
Q
H
WIDTH SUPPORT
INTERNAL PIPE DISTRIBUTORS ndash FEED OPTIONS ndash ELEVATIONS
1-PASS OPTIONS 2-PASS OPTIONS
358 Pressure Vessel Design Manual
4 INCH MINIMUM
ALTERNATELOCATION
ALTERNATELOCATION
1 4
5
6
7
8
2
1
2
3
Vessel Internals 359
360 Pressure Vessel Design Manual
DOWNCOMER
SPARGER DETAILS
DETAIL 1
DETAIL 3
DETAIL 5 DETAIL 6
DETAIL 4
DETAIL 2
NO
HO
LES
SLO
TSIN
TH
IS A
REA
BLANK OFF ENDSOF HEADER
frac14 DRAIN HOLEAT BOTTOM OF PIPE
frac14 VENT HOLE ATTOP OF PIPE(EACH END)
INSULATING BAFFLESPARGER
SPARGER
SPARGER
SUPT CLIPS
INLET WEIR
5 NPS
SAME AS DOWNCOMER SPACING
5 N
PS +
10
15 NPS
2 N
PS
NPS + 1
15 NPS + 1
INLET BAFFLE
INLET WEIR
SAME ASDOWNCOMER SPACING
5 N
PS
5 NPS
t
t = 025 INCHES + 2 Ca MINIMUM
15
NPS
2 NPS
CL SLOTS OR HOLES
NPS + 2 INCHES
α
α = 30ndash45deg
2
Vessel Internals 361
362 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
4 INCH MINIMUM
ALTERNATELOCATION
ALTERNATELOCATION
1 4
5
6
7
8
2
1
2
3
Vessel Internals 359
360 Pressure Vessel Design Manual
DOWNCOMER
SPARGER DETAILS
DETAIL 1
DETAIL 3
DETAIL 5 DETAIL 6
DETAIL 4
DETAIL 2
NO
HO
LES
SLO
TSIN
TH
IS A
REA
BLANK OFF ENDSOF HEADER
frac14 DRAIN HOLEAT BOTTOM OF PIPE
frac14 VENT HOLE ATTOP OF PIPE(EACH END)
INSULATING BAFFLESPARGER
SPARGER
SPARGER
SUPT CLIPS
INLET WEIR
5 NPS
SAME AS DOWNCOMER SPACING
5 N
PS +
10
15 NPS
2 N
PS
NPS + 1
15 NPS + 1
INLET BAFFLE
INLET WEIR
SAME ASDOWNCOMER SPACING
5 N
PS
5 NPS
t
t = 025 INCHES + 2 Ca MINIMUM
15
NPS
2 NPS
CL SLOTS OR HOLES
NPS + 2 INCHES
α
α = 30ndash45deg
2
Vessel Internals 361
362 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
360 Pressure Vessel Design Manual
DOWNCOMER
SPARGER DETAILS
DETAIL 1
DETAIL 3
DETAIL 5 DETAIL 6
DETAIL 4
DETAIL 2
NO
HO
LES
SLO
TSIN
TH
IS A
REA
BLANK OFF ENDSOF HEADER
frac14 DRAIN HOLEAT BOTTOM OF PIPE
frac14 VENT HOLE ATTOP OF PIPE(EACH END)
INSULATING BAFFLESPARGER
SPARGER
SPARGER
SUPT CLIPS
INLET WEIR
5 NPS
SAME AS DOWNCOMER SPACING
5 N
PS +
10
15 NPS
2 N
PS
NPS + 1
15 NPS + 1
INLET BAFFLE
INLET WEIR
SAME ASDOWNCOMER SPACING
5 N
PS
5 NPS
t
t = 025 INCHES + 2 Ca MINIMUM
15
NPS
2 NPS
CL SLOTS OR HOLES
NPS + 2 INCHES
α
α = 30ndash45deg
2
Vessel Internals 361
362 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
DOWNCOMER
SPARGER DETAILS
DETAIL 1
DETAIL 3
DETAIL 5 DETAIL 6
DETAIL 4
DETAIL 2
NO
HO
LES
SLO
TSIN
TH
IS A
REA
BLANK OFF ENDSOF HEADER
frac14 DRAIN HOLEAT BOTTOM OF PIPE
frac14 VENT HOLE ATTOP OF PIPE(EACH END)
INSULATING BAFFLESPARGER
SPARGER
SPARGER
SUPT CLIPS
INLET WEIR
5 NPS
SAME AS DOWNCOMER SPACING
5 N
PS +
10
15 NPS
2 N
PS
NPS + 1
15 NPS + 1
INLET BAFFLE
INLET WEIR
SAME ASDOWNCOMER SPACING
5 N
PS
5 NPS
t
t = 025 INCHES + 2 Ca MINIMUM
15
NPS
2 NPS
CL SLOTS OR HOLES
NPS + 2 INCHES
α
α = 30ndash45deg
2
Vessel Internals 361
362 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
362 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Table 5-15Cross sectional area of pipe Ap in
2
Pipe Size
Schedule
10 40 80 160
1 0945 0864 0719 0522
125 1633 1496 1283 1057
15 2222 2036 1767 1404
2 3654 3356 2953 224
25 545 479 424 355
3 835 739 66 541
4 1425 1273 115 928
6 317 289 261 211
8 545 50 457 365
10 853 789 718 567
12 1206 1119 1016 805
14 1431 1353 1227 983
16 1887 1767 1609 129
18 2405 2237 2042 1637
20 2986 278 2527 2027
Table 5-16Size (ID) of equalizing branches inches
Size of Main Pipe Area Ap in2 (2)
Quantity of Branches (3)
2 4 6 8 10 12
2 3356 1461 103
3 739 217 153 125
4 1273 285 201 164 142
6 289 429 303 248 214 192
8 50 564 399 326 282 252
10 789 708 5 409 354 317 289
12 1119 844 597 487 422 377 345
14 1353 928 656 536 464 415 379
16 1767 106 75 612 53 474 433
18 2237 1193 843 688 597 533 487
20 278 133 94 768 711 595 543
Notes
1 The table lists the exact ID required such that the cross sectional area of the main line and the sum of the cross sectional area of the branches is
equal
2 Assumes that main line is Sch 40
3 Quantity of branches shown is total Assume equal quantity for each side
Vessel Internals 363
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
364 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
27637125
23625
6
DEAD LEG
THIS ENDONLY
BEAMS NOT SHOWN IN ELEVATION FOR CLARITY
361
25
22
185
2244
44
44
195
plusmn0
63
plusmn06
331
75
44
44
44
37125
14oslash
14oslash
24625 2462538125 38125
283
75
38125 38125
R1
R1
DEAD LEG
BEAM NOT SHOWN IN ELEVATION FOR CLARITY
SPRAY HEADERS - EXAMPLES
plusmn07
1
10oslash
6
324375
51 5133625 33625521875 521875 521875
370
TOP OF PACKING
521875
30
30
265
571
457
496
25
602
5
602
560
25
603
75
602
5
388
75
602
5
A2
10oslashA2
Vessel Internals 365
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Procedure 5-9 Design of Trays
Typical Tower Dimensions and Nomenclature
1
2
5
4
11
2115
12
29
13
8 10
6
7
322
19
31
2
9
25
24
2318
17
20
22
1413
16
24
30
36 35
27
28
28 26
28
2 PASS
1 PASS
C
E
F
G
A34
4rdquo MIN
33
26 2827
H
2
31
32
C
KL J
N
MP
Q
E
TL
TL
366 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Tray Types
1 Valve2 Bubble Cap3 Sieve4 Tunnel5 Chimney6 Ripple7 Shower8 Shed Rows9 Disc amp Donut10 Cartridge11 Jet12 Kittle13 Turbogrid14 Dual Flow15 Slotted16 Venturi17 Cascade18 Accumulator
Tray Nomenclature
1 InletFeedReflux2 Inlet Weir3 Inlet Baffle4 Downcomer Clearance5 Weir Height6 Anti-Jump Baffle7 Seal Pan8 Straight Downcomer9 Sloped Downcomer10 Side Downcomer11 Center Downcomer12 Insulating Baffle13 Draw (Off) Nozzle14 Draw (Off) Pan15 Pass Transition16 Total Draw Chimney Tray
17 Chimney18 Chimney Hat19 Return Nozzle20 Sump21 Intermediate Feed Nozzle22 Partial Drawoff Nozzle23 Partition24 Vapor Inlet25 Vapor Inlet Baffle26 Feed Area27 Active Tray Area28 Dowcomer Area (Inactive Tray Area)29 Vapor Outlet30 Baffle31 Internal Pipe32 Support Clips33 Internal Flanges34 End Plate35 Product Outlet Nozzle36 Reboiler Draw Nozzle
Dimensions
A frac14 Short frac14 5 NPSthorn 4 in
Long frac14 5 NPSthorn 10 in
B frac14 Same as middle downcomer
C frac14 5 NPS
D frac14 Same as weir height
E frac14 NPSthorn 6 in
F frac14 NPSthorn 1 in
G frac14 15 NPSthorn 1 in
H frac14 5 NPSthorn 15 in
J frac14 15 NPS
Vessel Internals 367
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
K frac14 NPS
L frac14 2 NPS
M frac14 Minimum with 21 SE head frac1425 Dthorn tH thorn 15 NPSthorn 2 in
Minimum with hemi head frac14M frac14 5 Dthorn tH thorn 15 NPSthorn 2 in
N frac14 Minimum distance from tangent line to nozzlecenterline See Table 519
P frac14 Minimum skirt height for 21 SE Head SeeTable 5-20
Q frac14 Minimum seal pan depth frac14 tray spacing thorn 6 inR frac14 Downcomer width
Table 5-18Minimum Distance From Tangent Line ldquoNrdquo
Noz Size N Noz Size N
lt2 in 5 12 in 16
3 in 7 14 in 18
4 in 8 16 in 20
6 in 10 18 in 24
8 in 12 20 in 27
10 in 14 24 in 30
Table 5-19Minimum Skirt Height ldquoPrdquo
Dia P Dia P
lt24 in 2 ft e 6 in 114e120 5 ft e 6 in
30e36 3 ft e 0 in 126e132 6 ft e 0 in
48e54 3 ft e 6 in 138e144 6 ft e 6 in
54e60 3 ft e 6 in 150e156 7 ft e 0 in
66e72 4 ft e 0 in 162e168 8 ft e 0 in
78e84 4 ft e 6 in 174e180 8 ft e 6 in
90e106 5 ft e 0 in
368 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
A1 A1
A1
A1 A1
A1 A1
A1 A2
A2A1
A1A1
A1
A1
A1
A1
A2 A2
A2
A2A1
AS AS
AS
AS
AC
AC AC
AQ
D
SIDE DOWNCOMER
CENTERDOWNCOMER
TRAYS
1-PASS TRAY 2-PASS TRAY 3-PASS TRAY 4-PASS TRAY
Vessel Internals 369
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
TYPICAL TRAY ASSEMBLY
Hex Head Bolt
Manway Lock Clamps
Manway Lock StudsManway Clamps
Seal Plate
Tray Floor (Active)
Tray Floor (Active)Outlet Weir
Downcomer Truss
Standard WasherHex NutFrictional Washer
Downcomer Panel
Downcomer Bolting Bar
Bottom Tray ClampHex Head Bolt DowncomerTruss
Hex NutFrictional Washer
DOWNCOMER BOLTING BAR
Hex Nut
Hex Nut
Hex Nut
Hex Head Bolt
Hex Head Bolt
Frictional Washer
Bottom Tray Clamp
Tray Floor (Inlet Panel)
TRAY FLOOR
(INLET PANEL)
TRAY SUPPORT RING
Tray Support Ring
Manway (Active)
ONE PASS TRAY SHOWN
370 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Design of Tray Plates
Stress and DeflectionCase 1 Perforated Plate
Reference Roark 5th Edition Table 26 Case 1A
bull Rectangular platebull Uniformly loadedbull All edges simply supported
DATA
a b g frac14 Coefficients from Table 5-21E frac14 Modulus of elasticity at design temperature PSI
t frac14 Corroded thickness of tray inCa frac14 Corrosion allowance inn frac14 Hole efficiencyd frac14 Deflection at center inp frac14 Uniform load PSIs frac14 Bending stress PSI
FORMULAS
bull Stress s
s frac14 b p b4
n t2
BUBBLE-CAPTRAY
VALVELIQUID FLOW
WEIRDOWNCOMER
VAPOR
VAPORVAPOR
VAPOR
VAPOR
TYPES OF TRAYS
CHIMNEY CHIMNEY HAT
SUMPTRUSS
CHIMNEYACCUMULATOR TRAYS
LIQUID
LIQUID
LIQUID
SIEVE TRAY
VALVE TRAY
BUBBLE - CAP TRAY
USUALLY2rsquondash0rdquo
18rdquo MINIMUM
Vessel Internals 371
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
bull Deflection d
d frac14 a p b4
E n t3
bull Efficiency of holes for perforated plate n
n frac14 1 25 p d2
e C
DIMENSIONAL DATA
a frac14b frac14t frac14a=b frac14b frac14a frac14p frac14d frac14e frac14C frac14E frac14
Tray DesignCase 2 Standard tray plates
LOADS
A DL frac14 Dead load weight of trays and beams
B LL frac14 Live load dynamic load DP
C LL frac14 Liquid load weight of liquid supported
bull Total area AT
AT frac14 p D2=4 frac14 7854 D2
bull Total load PT
PT frac14 DLthorn LLthorn LL
bull Uniform load p
p frac14 PT=AT
LONG EDGE
SHORTEDGEBEAMS (TYP)
c = PITCH60deg
a
b
e
d
Table 5-20Coefficients
ab b a g
10 2874 044 420
12 3762 0616 455
14 4530 0770 478
16 5172 0906 491
18 5688 1017 499
20 6102 1110 503
30 7134 1335 505
40 7410 1400 502
50 7476 1417 501
N 7500 1421 500
372 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
PROPERTIES OF SECTIONS
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
CALCULATIONS
bull Determine panel area AP
AP frac14 Ln dnbull Load on panel FP
FP frac14 AP p
Uniform Load
bull Uniform load on beam w
w frac14 FP=Ln
bull Moment M
M frac14 w L2
n
8
bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 5 w L4
n
384 E I
Concentrated Load
bull Moment M
M frac14 ethP LnTHORN=4bull Bending stress fb
fb frac14 M=Z
bull Deflection d
d frac14 P L3
n
48 E I
TYPE 1
1
2
XX
h
dn
t
PART A Y AY AY2 I12sum
C frac14 SAY=SA
I frac14 SAY2 thorn SI C SAY
Z frac14 I=C
TYPE 2
1
32
XX
h
dn
do
t
PART A Y AY AY2 I123sum
L1
DC
DIMENSIONS OF TRAY PANELS
d1 d2 d3 d4
Vessel Internals 373
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
NOTES1 Design Loads Trays pans drawoff boxes or
similar intemals shall be designed using a corrodedthickness to support their own weight plus thefollowing live loadsa Fractionation trays Design live load shall be the
greater of 20 PSF (98 KgSq meter) or the weightof water 2 (50 mm) over the highest weirsetting
b Areas under downcomers Design live load shallbe the greater of 64 PSF (314 Kg Sq meter) ora head of water one half the height of thedowncomer
c Pans (accumulator and drawoff pans) Designlive load shall be the greater of 1 PSI (700 Kg Sqmeter) or the weight of water at the maximumoperating level of the pan
d Baffles With no operating liquid level shall usea design live load of 1 PSI (700 KgSq meter) onthe projected horizontal area or actual impulseforce whichever is greater
2 Maintenance Loads Tray support members (allbeams support clips etc) shall be designed fora concentrated load of 300 Lbs (135 Kg) at any pointon the installed assembly The design shall be basedon the corroded thicknesses and an allowable stressof 9 Fy For maintenance loads stresses in the trayplates need not be considered
3 Uplift resistance Typical design of uplift for traysand packing is 25 PSI (17 Millibar) For serviceswhere excessive uplift can occur a higher upliftresistance may be used Examples of higher upliftfactors are as follows
a Crude and FCC side strippers 1 PSI (70 millibar)b Vacuum tower stripping trays overflash
collector wash trays or beds 2 PSI (140Millibar)
c Collectiors and packed beds above the washsection of a vacuum Tower 1 PSI (70 Millibar)
4 Failure sequence Tray assemblies wheneverpossible shall be designed so that failure will occurin the following ordera Tray manwaysb Tray deck active areasc Minor beams and downcomersd Major beams (defined as beams 10ft (3 Meters)
or longer or beams which extend across a vesselwithout interruption regardless of length)
5 Allowable stresses Allowable unit stress shall bebased on yield strength Fy at design temperaturewith AISC factors for tension bearing shear etc
6 Allowable Deflection The calculated combineddeflection of trays and support beams due to oper-ating loads shall not exceed the lesser of 1900 of thevessel diameter (in inches) or 316 (5 mm)
RECOMMENDED TRAY SPACING amp MANWAY SIZE
COLUMN DIA
(FT)
TRAY SPACING
(IN)
MANWAY
SPACING
MIN MANWAY
SIZE
25 to 16 24 Every 10 trays 18 in
16 to 24 30 Every 8 trays 20 in
24 to 32 36 Every 6 trays 24 in
32 and larger 42 Every 4 trays 30 in
374 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Procedure 5-10 Flow Over Weirs
Notation
b frac14 width ftH frac14 static head of liquid ftQ frac14 discharge rate cu ftsecV frac14 velocity of approach ftsecH0 frac14 head correction per Table 5-22
Calculations
Discharge Q
bull For a full-length weir (Case 1)
Q frac14 333beth15 HTHORNbull For a contracted weir (Case 2)
Q frac14 333beth15 HTHORNbull For a V-notch weir (Case 3)
Q frac14 633 H
bull For a Cippoletti weir (Case 4)
Q frac14 3367beth15 HTHORN
Notes
1 Assumes troughs are level
Case 1 Full-Width Weir
V frac14 1ndash2 ftsec at 4 H upstream
Case 2 Contracted Weir
V frac14 1ndash2 ftsec at 3 H upstream
Case 3 V-Notch Weir
V frac14 5 ftsec at 5 H upstream
Case 4 Cippoletti Weir
V frac14 1ndash2 ftsec at 4 H upstream
Table 5-21Head correction for velocity of approach
V 04 06 08 10 12 14 16 18 20
Hrsquo 0002 0005 001 0015 0023 003 004 005 0062
V 22 24 26 28 30 32 34 36 38
Hrsquo 0075 0089 0105 0122 014 015 0179 0201 0213
Vessel Internals 375
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Procedure 5-11 Design of Demisters
Demister pads or mist eliminators are important inter-nals in process vessels Anytime there is a continuous twophase flow vapor and liquid there is the possibility forliquid entrainment If it is desirable to separate the liquidand vapor or prevent liquid carryover in the vapor streamthe velocity must be kept sufficiently low to allow the liquiddroplets to fall out of the vapor stream Demister pads areeffective entrainment separators which allow operation atvapor velocities that would otherwise be excessive
ldquoVapor disengagementrdquo can be accomplished withouta demister but the vessel must be made much larger toaccomplish the same degree of separation This is knownas gravity separation
Demister pads are used in a wide variety of processvessels Good performance can be achieved at velocitiesof 30 to 110 of optimum
Demister pads can be used in vertical or horizontalvessels The mesh pad orientation can be either vertical orhorizontal in a vertical or horizontal vessel
A wire mesh demister consists of a knitted wire matmounted on a light weight support grid The mesh is madeby weaving small diameter metal wire into a mesh Padsmay be made out of metal or plastics Metal type includecarbon steel stainless steel monel and others Plasticmaterials include PTFE HDPE and PP
Pressure drop is usually extremely low in the range of1 inch of water column maximum The pressure drop isnormally so low that it is ignored in design
Vapor disengagement is dependent on the velocity ofthe stream The most common equation for determining theallowable vapor velocity for two phase flows is as follows
Va frac14 K frac12ethrL rVTHORN=rV1=2
Where
Va frac14 Allowable vapor velocity FtSecK frac14 Constant or coefficientrL frac14 Density of liquid PCFrV frac14 Density of vapor PCF
Notes
1 The mesh pad shall be in one piece or sectional asrequired for insertion through the vessel manwayEach pad section shall be removable through thevessel manhole
2 Layers shall not be more than 6 inches thick3 Where more than one layer is required all joints
shall be staggered
4 One piece circular pads may be spiral in form5 Each section of mesh shall include a grid on one or
both sides The grid wire andor fastening deviceshall be the same material as the mesh pad Top andbottom grids shall be constructed of frac14 inch diam-eter rods welded to ⅛ inch by 1 inch bars Themaximum gap between mesh pad and grids shall befrac12 inch for diameters less than 84 inches and 1 inchfor larger diameters
6 Estimate grid weights as 3 PSF7 Tie down wires shall be 1=16 inch diameter wire thru
frac14 inch diameter holes on 4 inch centers Tie wiresshould not be pushed through the pad as this couldcause leak paths
8 Pressure drop across mist eliminator shall beassumed as 02 PSI for support design
9 Unless otherwise specified support rings shall be2 inches wide for pads 84 inches in diameter andless and 3 inches wide for larger diameters
10 The mist eliminator shall be a tight fit against theshell or enclosure as well as between sections Meshpads shall be⅜ inches oversize all around for a forcefit against the enclosure No gaps are allowed
11 Vessel fabricator shall provide the mesh and gridsas well as any stiffeners required
12 The Mist eliminator shall be specified as either topor bottom removable
13 ldquoKrdquo is a constant or coefficient that is a functionof the efficiency of the separation K-values rangefrom 04 to 43 but are generally in the 15 to 35range The K-value is affected by pressure type ofpad size of wire type of vessel and disengagingheight For pressure applications the K-valueshould be decreased by 01 for every 100 PSI ofpressure after 100 PSI
14 Wire diameter for the mesh pad itself vary from0003 to 0016 inches
15 The free volume of demisters range from 92 to994
16 The density of the pads ranges from 3 to 33 PCF17 The NSA (nominal surface area) is the surface area
to volume ratio Ft2 Ft3 and is an important indi-cator of performance Ratios range from 50 to 600
18 To obtain higher separation efficiencies the wirediameter is decreased and the density and thicknessare increased
19 Typical width of sections for multi-section pads is12 inches (300 mm) but may vary by manufacturer
376 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
A Horizontal element B Vertical elements
Vertical vessels
Manway
Plate-Pakunit
Meshpad
Drain tubewith seal trap
END VIEW
END VIEW
SIDE VIEW
SIDE VIEW
C Vertical element
Horizontal vessels
D Horizontal element
Figure 5-15 Typical demister configurations in vessels
Vessel Internals 377
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
d
E Axial entrance
H gt (23) D ndash d
H gt D2 + d(minimum 24rdquo)
H gt D2 ndash d2
H gt D2 + d
H gt D2 ndash d2
h gt d
D
D Side entrance
d
D
B Axial exit
d
D
Φ lt 45ordm
Φ lt 45ordm
C Reverse axial exit
d
A Side exit
D
Figure 5-16 Guidelines for maintaining even flow distribution in vessels with axial flow
378 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
wire mesh
Top grid
Bottom grid
Vertical 14rdquo rodsspaced 12rdquo to 18rdquocenter to center
12rdquo to 18rdquosegmentwidth
18rdquo x 1rdquo flat bars14rdquo rodsspaced 6rdquocenterto center
Manway
Support ring
Support beam
Tie wires
Figure 5-17 Typical mesh pad construction and installation
Vessel Internals 379
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Table 5-22Properties of demister pads
Type NSA (1) Ft2 Ft3 Density Pcf Wire Dia in Free Area York Style No Remarks
A 48 5 0011 99 931 High Throughput
B 65 7 0011 986 531 Economy Performance
C 85 9 0011 982 431 Standard - Good All
Around
D 110 108 0011 977 421 Heavy Duty
E 140 8 0006 984 326 Super High Efficiency -
Fine Mist
F 163 0006 94 371 Liquid - Liquid Coalescer
G 450 20 00045 959
H 600 27 00045 945
Notes
1 NSA frac14 Nominal Surface Area
Table 5-23Values of K (Note 13)
Based on Pressure
Pressure (PSIa) Vacuum (In Hg)
Pressure (PSIa) K Vacuum (In Hg) K
15 035 30 035
50 034 20 032
100 032 10 028
200 031 5 023
300 03 1 017
500 028 lt1 017
1000 027
gt1000 027
Based on Disengaging Height
Disengaging Height in K Disengaging Height in K
3 012 9 032
4 015 10 035
5 019 11 038
6 022 12 04
7 025 13 042
8 029 14 043
Based on Application
Vertical Vessels Horizontal Vessels
Type K Type K
General 035 General 035
Compressor Suction Drums 025 Steam Drums 025
Steam Drums 015
380 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Procedure 5-12 Design of Baffles [10]
Baffles are frequently used in pressure vessels eithervertical or horizontal to divide the interior volume intodifferent compartments These compartments may beused to segregate liquids or provide overflow weirs forthe separation of liquids Baffles may be stiffened orunstiffened When welded across the entire cross sectionof the vessel they must be checked that they are notunduly restricting the diametral expansion of the vesselIf the unrestrained radial expansion of the vessel exceedsthat of the baffle by more than 1=16 in (⅛ in on thediameter) then a ldquoflexiblerdquo type of connection betweenthe vessel shell and the baffle should be utilized Variousflexible attachment designs are shown within theprocedure
Baffles should always be designed in the corrodedcondition It is typical for welded baffles to be designedwith a full corrosion allowance on both sides If the baffleis bolted in then one-half the full corrosion allowancemay be applied to each side the logic being that a boltedbaffle is removable and therefore replaceable
The majority of baffles are flat and as a result are veryinefficient from a strength standpoint Deflection is thegoverning case for flat plates loaded on one side Thepreference is to have unstiffened baffles and they shouldalways be the first choice This will be acceptable forsmall baffles However for larger baffles as the bafflethickness becomes excessive stiffeners offer a moreeconomical design Therefore stiffeners are frequentlyused to stiffen the baffle to prevent the thickness of thebaffle from becoming excessive The number size andspacing of stiffeners are dependent on the baffle thicknessselected There is a continual trade-off between bafflethickness and stiffener parameters
The design of a baffle with stiffeners is an iterativeprocess The procedure for the design of the stiffeners isfirst to divide the baffle into ldquopanelrdquo sections that are rigidenough to withstand the pressure applied on one sideEach individual panel is checked as a flat plate of thedimensions of the panel The stiffeners are assumed to bestrong enough to provide the necessary edge support forthe panel
The stiffeners themselves are designed next A sectionof the baffle is assumed as acting with the stiffener and ascontributing to the overall stiffness This combinedsection is known as the composite stiffener Thecomposite section is checked for stress and deflectionBoth vertical and horizontal stiffeners can be added asrequired
If required an alternate design is assumed based ona thicker or thinner baffle and checked until a satisfactorydesign is found There is no ldquorightrdquo answer however itshould be noted that the thinner the baffle the greater thenumber of stiffeners The lightest overall weight isprobably the ldquobestrdquo design but may not be the leastexpensive due to the welding costs in attaching thestiffeners
One alternative to a flat baffle with stiffeners is to go toa curved baffle A curved baffle works best as a verticalbaffle in a vertical vessel The curved baffle takes pressurefrom either side wall If the pressure is on the concave sidethe baffle is in tension If the pressure is on the convexside the baffle is in compression
There are various tables given in this procedure for flatplate coefficients Flat plate coefficients are utilized todetermine the baffle thickness or a panel thickness Eachtable is specific for a given condition and loading
Vessel Internals 381
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Notation
Ap frac14 area of baffle working with stiffener in2
As frac14 area of stiffener in2
Cp frac14 distance from centroid of composite section topanel in
Cs frac14 distance from centroid of composite section tostiffener in
E frac14 modulus of elasticity psiFb frac14 allowable bending stress psiI frac14 moment of inertia composite in4
Is frac14 moment of inertia stiffener in4
l frac14 length of baffle that works with the stiffener inM frac14 moment in-lbn frac14 number of welds attaching stiffenerP frac14 vessel internal pressure psigp frac14 maximum uniform pressure psipn frac14 uniform pressure at any elevation an psiRm frac14 vessel mean radius inSg frac14 specific gravity of contentst frac14 thickness shell intb frac14 thickness baffle ints frac14 thickness stiffener inV frac14 shear load lbw frac14 required fillet weld size ina frac14 thermal coefficient of expansion ininF
bg frac14 flat plate coefficientsDT frac14 differential temperature (design temperature
minus 70F) Fsb frac14 bending stress in baffle psiss frac14 bending stress in stiffener psi
6n frac14 radial expansion ind frac14 deflection inda frac14 maximum allowable deflection in
Baffle Dimensions
382 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Table 5-24Flat plate coefficients
Vessel Internals 383
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Unstiffened Baffle Check
bull Find load p
p frac14 624aSg144
bull Find baffle thickness tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
s
bull Find baffle deflection d
d frac14 pg1b4
Et3b
Limit deflection to the smaller of tb2 or b360 Ifdeflection is excessive then
a Increase the baffle thicknessb Add stiffenersc Go to curved baffle design
If stiffeners are added the first step is to find themaximum ldquoardquo and ldquobrdquo dimensions that will meet theallowable deflection for a given panel size This willestablish the stiffener spacing for both horizontal andvertical stiffeners The ultimate design is a balancebetween baffle thickness stiffener spacing and stiffenersize
Thermal Check of Baffle
bull Vessel radial expansion due to pressure
D1 frac14 085PRm
tE
bull Vessel radial expansion due to temperature
D2 frac14 Rma DT
bull Thermal expansion of baffle
D3 frac14 05ba DT
bull Differential expansion
D4 frac14 D1 thorn D2 D3
Stiffener Design
Divide baffle into panels to limit deflection to the lesserof tb2 or b360 Deflection is calculated based on theappropriate Cases 1 through 3
bull Check baffle for panel size a0 b0bull Check stiffener for length a or b
Recommendations for attaching stiffeners
Benefits Provides added stiffness and no corrosiontrap
Figure 5-18 Example of stiffener layout
384 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
As frac14 tsh
Ap frac14 tbl
IS frac14 tsh3
12
Cp frac14 AsyAs thorn Ap
thorn tb2
Cs frac14 ethhthorn tbTHORN Cp
I frac14 IS thorn Apt2b12
thorn AsApy2
As thorn Ap
lsquo frac14 lesser of 32tb or stiffener spacing
Stresses in BaffleStiffener
sp frac14 MCp
I
ss frac14 MCs
I
Size Welds Attaching Stiffeners
For E70XX Welds
w frac14 Vdy11 200In
Table 5-25Intermittent Welds
Percent of
Continuous Weld
Length of Intermittent Welds
and Distance Between Centers
75 3e4
66 4e6
60 3e5
57 4e7
50 2e4 3e6 4e8
44 4e9
43 3e7
40 2e5 4e10
37 3e8
33 2e6 3e9 4e12
Reprinted by permission of the James F Lincoln Arc Welding
Foundation
Vessel Internals 385
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
For E60XX Welds
w frac14 Vdy9600In
Sample Problem
bull Given Horizontal vessel with a vertical baffle
P frac14 250 psig
DT frac14 500F
Material frac14 SA-516-70
Ca frac14 0125 in
JE frac14 10
E frac14 273 106 psi
a frac14 7124 10-6 in=in=FFy frac14 308 ksi
D frac14 240 in
Fb frac14 066 Fy frac14 2033 ksi
Rm frac14 120938
ts frac14 175 in
Sg frac14 08
a frac14 15 ft
DT frac14 500 70 frac14 430F
bull Find baffle thickness without stiffener
p frac14 624aSg144
frac14 52 psi
a
bratio frac14 15=20 frac14 075
from Table 5-25 Case 1
b1 frac14 016 g1 frac14 0033
bull Thickness of baffle tb
tb frac14ffiffiffiffiffiffiffiffiffiffiffiffib1pb
2
Fb
sfrac14
ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi016eth52THORN2402
20 330
s
tb frac14 153thorn 025 frac14 178
No good Use stiffeners
bull Assume a suitable baffle thickness and determinemaximum panel size
tb frac14 075 in corroded
maximum panel size frac14 4ft 4ft
bull Maximum pressure p
p frac14 13eth624THORN08144
frac14 45 psi
a
bfrac14 4
4frac14 1
See Table 5-25 Case 3
b3 frac14 0287 g3 frac14 00443
sb frac14 b3pb2n
t2
frac14 0287eth45THORN4820752
frac14 5290 psi lt 20 333 psiFigure 5-19 Sample problem
386 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
d frac14 g3
pE
b4nt3
frac14 00443
45
273 106
484
0753
frac14 0092 in lt 0375 in
Balance OK by inspection
bull Assume a layout where the maximum stiffenerspacing is 4 ft
(4) horizontal stiffeners(4) vertical stiffeners(18) panels
bull Check horizontal stiffeners
Dimensions
a1 frac14 3 ft b1 frac14 4 ft
a2 frac14 4 ft b2 frac14 4 ft
a3 frac14 4 ft b3 frac14 12 ft
a4 frac14 4 ft b4 frac14 196 ft
a5 frac14 13 ft
a6 frac14 148ft
bull Assume stiffener size 1 in 4 in
y frac14 2375 in
As frac14 tsh frac14 1eth4THORN frac14 4 in2
l frac14 32tb frac14 32eth075THORN frac14 24 in lt 48 in
AP frac14 tbl frac14 07524 frac14 18 in2
Is frac14 bh3
12frac14 1
43
12frac14 533 in4
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 533thorn 0633thorn 1846 frac14 2442 in4
Cp frac14 AsyAs thorn Ap
thorn tb2
frac14 4eth2375THORN22
thorn 0752
frac14 0807 in
Cs frac14 hthorn tb
Cp
frac14 4thorn 075 0807 frac14 3943
Check deflections
Deflections exceed allowable No good
bull Assume a larger stiffener size WT9 593
tf frac14 106 025 frac14 081
tw frac14 0625 025 frac14 0375
bull Check corroded thickness to find properties ofcorroded section This section would be equivalent toa WT9 30 Properties are
As frac14 882 in2
Is frac14 647 in4
Cs frac14 216 in
H frac14 9 in
Cp frac14 hthorn tb Cs
frac14 9thorn 075 216 frac14 759 in
Figure 5-20 Battle layout for sample problem
Item bn pn d
1 2352 104 149
2 2352 243 349
3 144 381 0767
Vessel Internals 387
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
y frac14 Cp tb2
frac14 7215 in
I frac14 Is thorn Apt2b12
thorn AsApy2
As thorn Ap
frac14 647thorn 0844thorn 30814 frac14 3737 in4
bull Check stresses and deflections See results in Table5-27
bull Stresses and deflections are acceptablebull Check welds
d frac14 ts thorn 2tw frac14 0375thorn 2eth0323THORN frac14 102
y frac14 7215 in
I frac14 3737 in4
n frac14 2
w frac14 Vdy11 200In
frac14 6681eth102THORN721511 200eth3737THORN2
frac14 0005thorn 0125 frac14 013 in
bull Check thermal expansion of baffle
D1 frac14 085PRm
tEfrac14 085eth250THORN120938
175eth273 106THORNfrac14 000054 in
D2 frac14 Rma DT frac14 1209387124 106430
frac14 0370 in
D3 frac14 05ba DT frac14 05240
7124 106430
frac14 0367 in
D4 frac14 D1 thorn D2 D3 frac14 000054thorn 0370 0367
frac14 00035 lt 006 in
Table 5-26Summary of Results for Stress and Deflection in Composite Stiffeners for Sample Problem
Item Orientation an bn pn M d V sp ss
1 Horiz 2352 d 104 172595 009 2690 3504 997
2 Horiz 2352 d 243 403275 021 6287 8186 2330
3 Horiz 144 d 381 237012 0045 6035 4811 1370
4 Vert d 156 450 154674 0037 5648 3141 894
5 Vert d 1776 513 228539 0072 6681 6681 1320
Figure 5-21 Details of weld attaching stiffener
388 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Vessel Internals 389
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Miscellaneous Baffle Configurations
Table 5-27Dimension A
Nozzle Size (in) A (in) Nozzle Size (in) A (in)
2 5 14 18
3 7 16 20
4 8 18 22
6 10 20 24
8 12 24 28
10 14
12 16
390 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
Procedure 5-13 Design of Impingement Plates
Notation
A frac14 Cross sectional area of nozzle in2
d frac14 Density of liquid PCFF frac14 Equivalent static force LbsFb frac14 Allowable bending stress PSIFy frac14 Minimum specified yield strength PSI
FU frac14 Minimum specified tensile strength PSIFW frac14 Allowable shear stress PSIfb frac14 Bending stress PSIfw frac14 Fillet weld sizeg frac14 Acceleration due to gravity 32 FtSec2
LW frac14 Length of weld inr frac14 Inside radius of nozzle inV frac14 Velocity FPSsS frac14 Shear stress per inch of weld PSI
Calculation
bull Equivalent static force F
F frac14 ethV A dTHORN=gbull Maximum bending stress at center of plate fbn frac14 w=h lt 1ethUse 1 for square plateTHORNfb frac14
53 F
1thorn 24 n2 t2THORNbull Allowable stressa Bending Fb
Lesser of 6 Fy or 3 FUb Weld in Shear FS
frac14 4 Fy
Size of weld required
bull Length of weld LWa Welded from one side only
LW frac14 2 w
b Welded both sides top and bottom
LW frac14 4 w
bull Shear per inch of weld sSsS frac14 F=LW
bull Size of weld required fWfW frac14 sS=707 FS
F r
TYP
h
h
Dimensions of baffle impingement plate
t
fw
fw
r
w
Figure 5-22 Dimensions of Baffle Impingement Plate
Vessel Internals 391
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual
References
[1] Ackley EJ Film Coefficient of Heat Transfer forAgitated Process Vessels Chemical EngineeringAugust 22 1960
[2] Stuhlbarg D How to Design Tank Heating CoilsPetroleum Refiner April 1959
[3] Steve EH Refine Temperature Control in an Odd-Shaped Vessel Hydrocarbon Processing July 1999
[4] Bisi F Menicatti S How to Calculate Tank HeatLosses Hydrocarbon Processing February 1967
[5] Kumana JD Kothari SP Predict Storage Tank HeatTransfer Precisely Chemical Engineering March 221982
[6] Kern DQ Process Heat Transfer McGraw-Hill1950
[7] Bondy F Lippa S Heat Transfer in AgitatedVessels Chemical Engineering April 4 1983
[8] Steam Its Generation and Use 40th ed Babcockand Wilcox Company 1992 section 3ndash12
[9] ldquoFlow of Fluids through Valves Fittings and PiperdquoCrane Company Technical Paper No 410
[10] Blodgett OW Design of Welded structures JFLincoln Arc Welding Foundation 1966 Section 53
[11] Manual of Steel Construction 8th ed AmericanInstitute of Steel Construction Inc 1988
392 Pressure Vessel Design Manual