AB S T R A C T     As the pressure vessel operates under high internal pressure, the choice of material and accuracy in design play a vital role in ensuring its safety and reliability. Proper design is essential because any failure in a pressure vessel can lead to serious hazards, financial losses, and operational shutdowns. In compliance with the ASME Code (Section VIII, Division 1) and the process data sheet, this article describes how to design a pressure vessel. To guarantee structural integrity and operational effectiveness, the entire design process adheres to established engineering procedures. The design methodology involved detailed manual calculations to determine the required thickness of the shell and dished ends, considering both internal and external pressures, material properties, allowable stress values, corrosion allowance, joint efficiency, and suitable safety factors. Special attention was given to selecting appropriate materials that can withstand the specified operating temperature and pressure conditions. The calculations were carefully performed to maintain compliance with code requirements and ensure long service life. Manual results were subsequently validated using PV Elite, a widely used pressure vessel design and analysis software. The software verification helped confirm the accuracy of the manual calculations and ensured that all stress limits were within permissible values. All calculations were carried out to ensure the vessel can safely handle the operating pressure and temperature. The final design was thoroughly reviewed to confirm that it meets ASME code requirements. This work demonstrates how the proper application of design standards and accurate interpretation of process data can help develop safe and reliable pressure vessels used in chemical and oil and gas industries.

Keywords-Thermal analysis, ASME code, pressure vessel, fracture mechanics, alternate materials, thickness optimization.