TABLE OF CONTENTS

S. NO NO TITLE PAGE

1. 4

INTRODUCTION TO PRESSURE VESSELS

1.1. 1.2 2. 26

BASIC TERMINOLOGIES USED CYLINDERS AND SPHERS ANALYTICAL DESIGN OF METHANATOR

5 19

2.1 2.2 2.3 2.4 2.5 2." 2.# 2.8 2.9 2.10 45

GIVEN DATA REQUIRED DIMENTIONS OF METHANATOR METHANATOR AS A THIN CYLINDER THIC NESS OF SHELL THIC NESS OF 2!1 ELLIPSOIDAL HEAD OPENING IN THE PRESSURE VESSELS SELECTION OF FLANGES THIC NESS OF S IRT OR DESIGN OF SUPPORTS LOADINGS STRESSES IN RESPONSE TO DIFFERENT LOADS a) INTERNAL PRESSURE

28 29 30 32 34 35 3# 39 44 45

b) WEIGHT c) WIND LOAD d) SEISMIC LOAD 2.11 2.12 2.13 2.14 3. 67 COMBINATION OF STRESSES COMPARISION DESIGN OF ANCHOR BOLTS $ELDING OF PRESSURE VESSELS ANALYSIS BY ANSYS

46 49 54 5# 58 58 "2

3.1 3.2 3.3 3.4 3.5 3." 3.# 3.8

ANSYS ANSYS INPUT METHODS SHELL 51 ANALYSIS OF METHANATOR UNDER INTERNAL PRESSURE

"8 "9 #0 #1 #2 #2 88 91

USING SHELL 51 ANALYSIS OF METHANATOR TO COMMAND $INDO$ ANALYSIS OF METHANATOR THROUGH GUI TO FIND THE HOOP AND LONGITUDINAL STRESS ON ANSYS DISPLACEMENTS OF NODES

4. 92

COMARISION AND CONCLUSION

4.1 4.2 4.3

MEMBRENE STRESSE IN METHANATOR COMARISION OF ANSYS AND ANALYTICAL SOLUTION CONCLUSION

93 94 9"

REFERENCES%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

TABLES %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%

INTRODUCTION TO PRESSUREVESSEL S

1.1
VESSEL:

BASIC TERIMINOLOGIES USED

A container or structural envelope in which materials are processed, treated, or stored; for e ample, pressure vessel, reactor vessel, a!itator vessel, and stora!e vessels "tan#s$% &'ESS('E VESSEL: A metal container !enerall) c)lindrical or spheroid, capa*le or withstandin! various loadin!s% S+'A,-: An) forced chan!e in the dimensions of a *od)% A stretch is a tensile strain; a shortenin! is a compressive strain; an an!ular distortion is a shear strain% +he word strain is commonl) used to connote unit strain% S+'ESS: ,nternal force e erted *) either of two ad.acent parts of a *od) upon the other across an ima!ined plane of separation% /hen the forces are parallel to the plane, the stress is called shear stress; when the forces are normal to the plane the stress is called normal stress; when the normal stress is directed toward the part on which it acts is called compressive stress; when it is directed awa) from the part on which it acts it is called tensile stress.

S+'ESSES ,- &'ESS('E VESSEL: Lon!itudinal S1 stress% 1ircumferential "hoop$ S2 stress% S1 and S2 called mem*rane "diaphra!m$ stress 2or vessel havin! a fi!ure of revolution 3endin! stress Shear stress 4iscontinuit) stress at an a*rupt chan!e in thic#ness or Shape of the vessel +E-S,LE S+'E-5+6: +he ma imum stress a material su*.ected to a stretchin! load can withstand without tearin!% +E-S,LE S+'ESS: Stress developed *) a material *earin! tensile load% +ES+ &'ESS('E: +he re7uirements for determinin! the test pressure *ased on calculations are out lined in (5899"c$ for the h)drostatic test and (581::"*$ for the pneumatic test% +he *asis for calculated test pressure in either of these para!raphs is the hi!hest permissi*le internal pressure as determined *) the desi!n formulas, for each element of the vessel usin! nominal thic#ness with corrosion allowances included and usin! the allowa*le stress values for the temperature of the test% "1ode (A8;:$

+6E'<AL S+'ESS: A self8*alancin! stress produced *) a non uniform distri*ution of temperature or *) differin! thermal coefficients of e pansion% +hermal stress developed in a solid *od) whenever a volume of material is prevented from assumin! the si=e and shape that it normall) should under a chan!e in temperature% +6,1>-ESS ?2 VESSEL /ALL: 1% +he @re7uired thic#nessA is that computed *) the formulas in this division, *efore corrosion allowance is added% 2% +he @desi!n thic#nessA is the sum of the re7uired thic#ness and the corrosion allowance% 3% +he @nominal thic#nessA is the thic#ness selected as commerciall) availa*le, and as supplied to the manufacturer; it ma) e ceed the desi!n thic#ness% (-,+ S+'A,-: (nit tensile strain is the elon!ation per unit len!th; unit compressive strain is the shortenin! per unit len!th; unit shear strain is the chan!e in an!le "radians$ *etween two lines ori!inall) at ri!ht an!les to each other% (-,+ S+'ESS: +he amount of stress per unit of area% /EL4 <E+AL: +he metal resultin! from the fusion of *ase metal and the filler metal%
B

/EL4,-5: +he metal .oinin! process in ma#in! welds% ,n the construction of vessels the weldin! process is restricted *) the code "(/82B$ as follows; 1% Shielded metal arc, su*mer!ed arc, !as metal arc, !as tun!sten arc, atomic h)dro!en metal arc, o ) fuel !as weldin!, electrosla!, and electron *eam% 2% &ressure weldin! process: flash, induction, resistance, pressure +hermit, and pressure !as% C,EL4 &?,-+: +he lowest stress at which strain increases without increase in stress% 2or some purpose it is important to distin!uish *etween the upper )ield point, which is the stress at which stress8stain curve first *ecome hori=ontal, and the lower )ield point, which is the somewhat lower and almost constant stress under which the metal continues to deform% ?nl) a few materials e hi*it a true )ield point; for some materials the term is sometimes used as s)non)mous with )ield stren!th% S&E1,2,1 5'AV,+C: +he ratio of the densit) of a material to the densit) of some standard material, such as water at a specified temperature, for e ample, 4D1 or ;:D2% ?r "for !ases$ air at standard conditions of pressure and temperature%

S+A3,L,+C ?2 VESSEL: "Elastic sta*ilit)$ +he stren!th of the vessel to resist *uc#lin! or wrin#lin! due to a ial compressive stress% +he sta*ilit) of a vessel is severel) affected *) out of roundness% S6ELL: Structural element made to enclose some space% <ost of the shells are !enerated *) the revolution of plane curve% S6EA' S+'ESS: +he component of the stress tan!ent to the plane of reference% 'A4,(S ?2 5C'A+,?-: +he radius of !)ration of an area with respect to !iven a is is the s7uare root of the 7uantit) o*tained *) dividin! the moment of inertia of the area with respect to that a is *) the area% 'ES,4(AL S+'ESS: Stress remainin! in a structure or mem*er as a result of thermal or mechanical treatment, or *oth% 'ES,S+A-1E /EL4,-5: A pressure weldin! process wherein the heat is produced *) the resistance to the flow of an electric current%

SE1?-4A'C S+'ESS: A normal stress or a shear stress developed *) the constraint of ad.acent parts or *) self8constraint of a structure% +he *asic characteristic of a secondar) stress is that it is self8limitin!% Local )ieldin! and minor distortions can satisf) the conditions which cause the stress to occur and failure from one application of the stress is not to *e e pected% E amples of secondar) stress are: !eneral thermal stress; *endin! stress at a !ross structural discontinuit)% &?,SS?-SF'A+,?: +he ratio of lateral unit strain to lon!itudinal unit strain, under the conditions of uniform and unia ial lon!itudinal stress within the proportional limit% &?S+/EL4 6EA+ +'EA+<E-+: 6eatin! a vessel to a sufficient temperature to relieve the residual stresses which are the result of mechanical treatment and weldin!% &ressure vessels and parts shall *e post weld heat treated% &'E6EA+,-5: 6eat applied to *ase metal prior to weldin! operations% &'ESS('E 'EL,E2 VALVE: A valve which relieves pressure *e)ond a specified limit and recluses upon return to normal operatin! conditions%

1:

&'ESS('E /EL4,-5: A !roup of weldin! processes wherein the weld is completed *) use of pressure% &',<A'C S+'ESS: A normal or shear stress developed *) the imposed loadin! which is necessar) to satisf) the simple laws of e7uili*rium of e ternal and internal forces and moments% +he *asic characteristic of a primar) stress is that it is not self8limitin!% &rimar) stresses which considera*l) e ceed the )ield stren!th will result in failure or at least, in !ross distortion% A thermal stress is not classified as primar) stress% &rimar) mem*rane stress is divided into local and !eneral cate!ories% A !eneral primar) mem*rane stress is one which is so distur*ed in the structure no redistri*ution of load occurs as a result of )ieldin!% E amples of primar) stress are: !eneral mem*rane in a circular c)lindrical or a spherical shell due to internal pressure or to distri*uted live load; *endin! stress in the central portion of a flat head due to pressure% ?&E'A+,-5 &'ESS('E: +he pressure at the top of a vessel at which it normall) operates% ,t shall not e ceed the ma imum allowa*le wor#in! pressure and it is usuall) #ept at a suita*le level *elow the settin! of the pressure relievin! devices to prevent their fre7uent openin!% "1ode (A8;:$ ?&E'A+,-5 +E<&E'A+('E: +he temperature that will *e maintained in the metal of the part of the vessel *ein! considered for the specified operation of the vessel% "1ode (A8 ;:$

11

-E(+'AL AG,S: +he line of =ero fi*er stress in an) !iven section of a mem*er su*.ect to *endin!; it is the line formed *) the intersection of the neutral surface and the section% <?<E-+ ?2 ,-E'+,A ?2 A- A'EA "SE1?-4 <?<E-+ ?2 AA'EA$ +he moment of inertia of an area with respect to an a is is the sum of the products o*tained *) multipl)in! each element of the area *) the s7uare of its distance from the a is% +he moment of inertia ",$ for thin walled c)linder a*out its transverse a is; , H I r3 t /here r H mean radius of c)linder t H wall thic#ness

<?4(L(S ?2 ELAS+,1,+C "C?(-5FS <?4(L(S$: +he rate of chan!e of unit tensile or compressive stress with respect to unit tensile or compressive strain for the condition of unia ial stress within the proportional limit% 2or most, *ut not all materials, the modulus of elasticit) is same for tension and compression% 2or nonisotropic materials

12

such as wood, it is necessar) to distin!uish moduli of elasticit) in different directions% <?4(L(S ?2 ',5,4,+C: +he rate of chan!e of unit shear stress with respect to unit shear strain, for the condition of pure shear within the proportional limit% <AG,<(< ALL?/A3LE S+'ESS VAL(E: +he ma imum unit stress permissi*le for an) specific material that ma) *e used in the desi!n formulas !iven in the code% "(5823$ <AG,<(< ALL?/A3LE /?'>,-5 &'ESS('E: +he ma imum !a!e pressure permissi*le at the top of a completed vessel in its operatin! position for a desi!ned temperature% +his pressure is *ased on the wea#est element of the vessel usin! nominal thic#ness e clusives of allowances for corrosion and thic#ness re7uired for loadin! other than pressure% "1ode (A8;:$ <E<3'A-E S+'ESS: +he component of normal stress which is uniform all) distri*uted and e7ual to the avera!e value of stress across the thic#ness of the section under consideration% ,S?+'?&,1: 6avin! same properties in all directions% ,n discussion pertainin! to stren!th of materials, isotropic usuall) means havin! the same stren!th and elastic properties%

13

J?,-+ E22,1,E-1C: A numerical value e pressed as the ratio of the stren!th of a riveted, welded, or *ra=e .oint to the stren!th of the parent metal% L?A4,-5: Loadin! "loads$ are the results of various forces% +he loadin!s to *e considered in desi!nin! a vessel : internal or e ternal pressure, impact loads, wei!ht of the vessel, wind and earth7ua#e, superimposed loads, local load, effect of temperature !radients%"1ode (5822$% L?/8ALL?C S+EEL: A harden a*le car*on steel !enerall) containin! not more than a*out 1K car*on and one or more of the followin! components; L "less than$ 2K man!anese, L 4Knic#el, L 2Kchromium, :%;K mol)*denum, and L :%2Kvanadium% 6EA+ +'EA+<E-+: 6eat treatin! operation performed either to produce chan!es in mechanical properties of the material or to restore its ma imum corrosion resistance% +here are three principle t)pes of heat treatment; annealing, normalizing, and post weld heat treatment . 6C4'?S+A+,1 +ES+: +he completed vessel filled with water shall *e su*.ected to test pressure which is e7ual to 1 M times the ma imum allowa*le wor#in!
14

pressure to *e mar#ed on the vessel or 1 M the desi!n pressure *) a!reement *etween the user and the manufacturer% "1ode (5899$ ,<&A1+ S+'ESS: 2orce per unit area imposed to a material *) a suddenl) applied force% ,<&A1+ +ES+: 4etermination of the de!ree of resistance of a material to *rea#in! *) impact, under *endin!, tensile and torsion loads, the ener!) a*sor*ed is measured *) *rea#in! the material *) a sin!le *low% 5A5E &'ESS('E: +he amount *) which the total a*solute pressure e ceeds the am*ient atmospheric pressure% 2,LLE' <E+AL: <aterial to *e added in ma#in! a weld% 2,3E' S+'ESS: A term used for convenience to denote the lon!itudinal tensile or compressive stress in a *eam or other mem*er su*.ect to *endin!% ,t is sometimes used to denote this stress at the point or points most remote from the neutral a is, *ut the term stress in extreme fiber is prefera*le for this purpose% Also, for convenience, the lon!itudinal elements or filaments of which a *eam ma) *e ima!ined as composed are called fibers.

10

2A1+?' ?2 SA2E+C: +he ratio of the load that would cuse a failure of a mem*er or structure, to the load that is imposed upon it in service% 2A+,5(E: +endenc) of materials to fracture under man) repetitions of a stress considera*l) less than the ultimate static stren!th% E1E-+',1,+C: A load or component of a load normal to a !iven cross section of a mem*er is eccentric with respect to that section if it does not act throu!h centroid%+he perpendicular distance from the line of action of the load to either of principle central a is is the eccentricit) with respect to that a is% E22,1,E-1C ?2 A /EL4E4 J?,-+: +he efficienc) of the welded .oint is e pressed as a numerical 7uantit) and is used in the desi!n of a .oint as a multiplier of the appropriate allowa*le stress value% "1ode (A8;:$ ELAS+,1: 1apa*le of sustainin! stress without permanent deformation; the term is also used to denote conformit) to the law stress8strain proportionalit)% An elastic stress or elastic strain is a stress or strain within the elastic limit%

1;

ELAS+,1 L,<,+: +he least stress that will cause permanent set% 4ES,5- &'ESS('E: +he pressure used in determinin! the minimum permissi*le thic#ness or ph)sical characteristics of the different parts of the vessel% "1ode (58;:$ 4ES,5- +E<&E'A+('E: +he mean metal temperature "throu!h the thic#ness$ e pected under operatin! conditions for the part considered% "1ode (582:$ 1'EE&: 1ontinuous increase in deformation under constant or decreasin! stress% +he term is usuall) with reference to the *ehavior of metal under tension at elevated temperatures% +he similar )ieldin! of a material under compressive stress is usuall) called plastic flow or flow. 1?''?S,?-: 1hemical erosion *) motionless or movin! a!ents% 5radual destruction of a metal or allo) due to chemical process such as o idation or action of a chemical a!ent% 1LA4 VESSEL: A vessel made from plate havin! a corrosion resistant material inte!rall) *onded to a *ase of a less resistant material% "1ode (A8;:$

1B

ALL?C: An) of a lar!e no% of su*stances havin! metallic properties consistin! of two or more elements; with few e ceptions, the components are usuall) metallic elements%

1E

1.2

CYLINDERS AND SPHERES:

Vessels such as steam *oilers, air compressors, stora!e tan#s,

accumulators and lar!e pipes are su*.ected to internal fluid pressure which is uniforml) distri*uted% All the a*ove mentioned vessels are classified as c)linders or spheres% +6,- 1CL,-4E': ,f the ratio of the thic#ness to the internal diameter i%e% tNd is less than a*out 1N2:, the c)linder is assumed to *e thin c)linder% +6,1> 1CL,-4E': ,f the ratio of thic#ness to the internal diameter i%e% tNd is !reater than 1N2:, the c)linder is assumed to *e thic# c)linder% S+'ESSES ,- 1CL,-4E'S: +he followin! stresses are illustrated in fi!% "1$ and fi!% "2$

1,'1(<2E'E-+,AL ?' 6??& S+'ESS: +he stress which acts tan!ent to the circumference and perpendicular to the a is of the c)linder is called circumferential or hoop stress% ,t is denoted *) fh%

19

L?-5,+(4,-AL S+'ESS: +he stress which acts normal to circumference and parallel to the a is of the c)linder is called lon!itudinal stress% ,t is denoted *) fl%

'A4,AL S+'ESS: +he stress which acts in a direction perpendicular to the internal surface is called radial stress% ,t is denoted *) fr% 'adial stress is ver) small as compared to fl and fh in case of thin c)linder and is therefore i!nored%

2:

A-ALCS,S ?2 +6,- 1CL,-4E': 1onsider the e7uili*rium of half c)linder of len!th OLF sectioned throu!h a diameteral plane as shown in fi!, "3$

Let the internal diameter *eOdF and the thic#ness OtF; OpF is the applied internal pressure, fh the hoop stress and fl the lon!itudinal stress% 6??& S+'ESS: 1onsider the elemental rin! of the c)linder su*tendin! an an!le PQ% Let ds H arc len!th of elemental rin! H r% 2orce actin! on elemental rin! H p Rarea H prPQL Vertical component of this force H prPQL SinQ +otal vertical force HprL :S1E:SinQPQ H 8prl "cos 1E: T 1os :$ H 2prL H pdL 3ut dL H hori=ontal pro.ected area%
21

e7%"1$

So +otal vertical force H pdL H intensit) of pressure R hori=ontal pro.ected area% +his force tries to *urst the c)linder into two halves and is called O*urstin! forceF% 3urstin! force And 'esistin! force 2or e7uili*rium of c)linder 3urstin! force H 'esistin! force pdL fh L?-5+(4,-AL S+'ESS: 1ross sectional area HI N4 d2 +otal force at the end of c)linder H pR IN4 d2 +his force tries to *urst the c)linder at the ends of c)linder and is called O*urstin! forceF% 3urstin! force H 2 H pR IN4 d2 'esistin! force H stress R resistin! area H flR Idt for e7uili*rium of c)linder 3urstin! force H resistin! force &R IN4 d2 H flR Idt
22

H 2 H pdL H stress R resistin! area H fh R 2tL

H fhR2tL H pdN2t e7%"A$

2l H pdN4t 1omparin! "A$ and "3$ 2l H1N2 fh +6,- S&6E',1AL S6ELL:

e7% "3$

,n case of spherical shell also, the radial stress will *e ne!lected and the circumferential or hoop stress will *e assumed to *e constant%

As shown in the fi!% the two stresses are e7ual to due to s)mmetr)% i%e% fh H f l H f 1ross8sectional area H I N4d2 3urstin! force 'esistin! force 2or e7uili*rium of shell 3urstin! force H resistin! force & R I N4d2 H f R dt f H pdN4t H pR I N4d2 H stress R resistin! area H f R dt

23

1CL,-4E',1AL S6ELL /,+6 6E<,S&6E',1AL E-4S: As shown in the fi!% let t1 *e the thic#ness of the c)linder and t2 *e the thic#ness of the hemisphere, the internal diameter *ein! assumed the same for *oth%

S+'ESSES ,- +6E 1CL,-4E',1AL &?'+,?-: ,f the shell is su*.ected to an internal pressure p, stresses in the c)linder will *e; 6oop stress, fh H pdN2t1 And Lon!itudinal stress, fl HpdN4t1 6oop strain,Uh H fhNE T V flNE H 1NE "fh T V fl$ H1NE "pdN2t1 8 pdN4t1$ H 1NE ""2pd 8 pdN4t1$$ Uh Ul H pdN4t1E "2 8 V$ H pdN4t1E "1 T 2V$ Lon!itudinal strain, Ul H flNE 8 fhNE H pdN4t1E 8 pdN2t1

24

S+'ESSES ,- +6E S&6',1AL &?'+,?-: 2or the hemispherical ends havin! thic#ness t2, we have fhW H flW H f H pdN4t2 +herefore, hoop stress, fh H pdN4t2 And Lon!itudinal stress, fl H pdN4t2 +hen 6oop strain, UhW H fhNE T flNE H pdN4t2E T pdN4t2E UhW H pdN4t2E "1 8V$ Lon!itudinal strain,U lW H flWNE 8 V fhWNE H pdN4t2E 8 VpdN4t2E Ul W H pdN4t2E "1 8V$ +herefore for spherical portion UhW H UlW At the .unction of c)lindrical and spherical portion Uh H UhW &dN4t1E "2 8V$ H pdN4t2E "1 8V$ t2Nt1 H "1 8V $N"2 8V $ for steel,H :%3 +herefore, t2Nt1 H BN1B +he ma imum hoop stress will then occur in the ends, i%e% f H pdN4t2 H "1BNB$ "pdN4t1$ /hich is !reater than the hoop stress fh in the c)linder% 2or e7ual ma imum stress t2 should e7ual to :%0%

20

ANALYTICAL DESIGN OF METHANATOR

2;

2.1 GIVEN DATA

PARAMETETS!%
2B

/or#in! temperature H 3;4 D1 4esi!n temperature H 404 D1 /or#in! pressure H 3E: &si%! 4esi!n pressure H 430 &si%!

DIMENSIONS!%
,nside diameter H 1:2X H 209:%E mm +an!ent to tan!ent len!th H 10:X H 3E1:mm +)pe of dished ends H 2:1 semi ellipsoidal 6)drostatic test pressure H E:; &si%! /elded .oint efficienc) H 1:: K 1orrosion allowance H 1%; mm

MATERIAL!%
AS+< A3EB 511

CODE RECOMMENDED

AS<E

Section E division 1

2E

2.2 REQUIRED DIMENSIONS OF METHANATOR

+he 7uantities or dimensions that are to *e determined for desi!nin! are listed *elow I II III IV V VI VII VIII I& & &I &II &III +hic#ness of shell "accordin! to (5 82B"c$$

+hic#ness of 2:1 semi ellipsoidal head "accordin! to (5832"d$$ ?penin!s in the pressure vessel as per re7uirement "accordin! to (583; "*$ "1$ "2$$ Selection of flan!es "accordin! to (5844 Y (5811 "a$ "2$$ +hic#ness of s#irt or desi!n of supports%"accordin! to (5804 Y Specif) different #inds of loads "(5822$ 2ind stresses in response to different loads% 1om*ination of stresses% 1omparison of stresses with allowa*le stress of material% ?penin!s in s#irt 4esi!n of anchor *olts 4esi!n of *ase rin!% /eldin! specification for <ethanator appendi 5$

29

2.3 METHANATOR AS A THIN CYLINDER

As we #now that if the ratio of thic#ness to internal diameter i%e% tNd is less than a*out 1N2: ":%:0$, the c)linder is assumed to *e thin c)linder otherwise it would *e thic#% 2or methanator this ratio will *e tNd H 1%43EN1:2 H :%:14 Z :%:0 So we treat methanator as thin c)linder

So incase of methanator the radial stresses can *e ne!lected% And there will *e onl) circumferential or hoop stress Y lon!itudinal stress in the methanator% 2urther the !overnin! stress will *e the !reater of the two Y we *ase our desi!n on it%

3:

31

2.4 THIC NESS OF SHELL

Accordin! to specifications in (582B "c$ which deals with the thic#ness of shells under internal pressure and clause @cA with the c)lindrical shells, !ives formulae for the thic#ness *ased on either lon!itudinal .oint or circumferential .oint% a$ 1,'1(<2E'-+,AL S+'ESS "L?-5,+(4,-AL J?,-+S$

,t means that the !overnin! stress will *e the circumferential stress "hoop stress$ in the lon! seam% 2or this it has to satisf) that & does not e ceed :%3E0SE %,n which case we shall use the followin! formulae for thic#ness of shell tH &'N "SE 8:%;&$

*$ L?-5,+(4,-AL S+'ESS "1,'(<2E'E-+,AL J?,-+S$

,t means that the !overnin! stress will *e the lon!itudinal stress in the circumferential .oint% 2or this it has to satisf) that & does not e ceed 1%20SE% ?' if the circumferential .oint efficienc) is less than than M the lon!itudinal .oint efficienc)% ,n which case we use the formula for thic#ness is

t H &'N "2SE [%4&$ As for methanator

& Z :%3E0SE
32

430 Z :%3E0"1;394%9;;$ "1%:$ 430 Z ;312%:; Satisfied

therefore hoop stress will *e !overnin! therefore desi!n is *ased on the lon!itudinal .oint Y we find the thic#ness as follows t H &' N "SE T :%;&$ /here t H min% re7uired thic#ness of shell, in & H internal desi!n pressure, psi ' H inside radius of shell, in S H ma % Allowa*le stress, psi E H .oint efficienc) "min$ &uttin! the values in the a*ove e7uation for methanator% Allowa*le stress for the material to *e used is also !iven "1;394%9;; psi$ t H "430$ "01$ N ""1;394%9;;$ "1%:$ T ":%;$ "430$$ t H 1%3B0X t H 1%3B0X [ corrosion allowance t H 34%9 [ 1%; t H 3;%0 mm t H 1%43EBX we shall ta#e a plate of 1 MX for safet) mm

33

2.5 THIC NESS OF 2:1 ELLIPSOIDAL HEAD

,t will *e found *) (5832 "d$ which states +he re7uired thic#ness of a dished head of semi ellipsoidal form, in which half the minor a is "inside depth of the head minus the s#irt$e7uals one8forth of the inside diameter of the head s#irt, shall *e determined *) t H &4 N "2SE T :%2&$ An accepta*le appro imation of a 2: 1 Ellipsoidal head is one with a #nuc#le radius of :%1B4 and a spherical radius of :%9:4%

2or methanator t H "430$ "1:2$ N "2"1;394%9;;$ "1%:$ T ":%2$ "430$$ t H 1%30;BX [ corrosion allowance t H 1%30;BX [ "1%; R :%394X$ t H 1%419BX
34

>nuc#le radius H :%1B4 H 1B%34X Spherical radius H :%9:4 H 91%EX

/here

4 H internal diameter in inches

2." OPENINGS IN A PRESSURE VESSEL

+he clause of the code concernin! with the desi!n of openin!s is (583;"a$ "*$ a$ shape of openings 1$ ?penin!s in c)lindrical or conical portions of vessels, or in formed heads, shall prefera*l) *e circular, elliptical or round openin! e ceeds twice the short dimensions, the reinforcement across the short dimensions shall *e increased as necessar) to provide a!ainst e cessive distortion due to twistin! moment%"+he openin! made *) a pipe or a circular no==le, the a is of which is not perpendicular to the vessel wall or head, ma) *e considered as elliptical openin! of desi!n purposes$

30

2$ ?penin!s ma) *e of other shapes than those !iven in "1$ a*ove, and all corners shall *e provided with a suita*le radius% /hen the openin!s are of such proportions that their stren!th cannot *e computed with assurance of accurac), or when dou*t e ists as to the safet) of a vessel with such openin!s, the part of the vessel affected shall *e su*.ected to a proof h)drostatic test as prescri*ed in (581:1% *$ size of openings 1$ &roperl) reinforced openin!s in c)lindrical shells are not limited as to si=e e cept with the followin! provisions for desi!n% +he rules in (583; throu!h (5843 appl) to openin!s not e ceedin! the followin!: for vessels ;: in% in diameter and less, one half vessel diameter, *ut not to e ceed 2: in%; for vessel over ;: in% in diameter, one third the vessel diameter, *ut not to e ceed 4: in% 2or openin!s e ceedin! these limits, supplement rules of 18 B shall *e satisfied in addition to (583; throu!h (5843% 2$ &roperl) reinforced openin!s in formed heads and spherical shells are not limited in si=e% 2or an openin! in end closure, which is lar!er than one half of inside diameter of the shell, various alternatives to reinforcement ma) also *e used%

2?' <E+6A-A+?' As we #now that openin!s in a vessel are made as per re7uirement, *ut the the factor to *e considered in is its si=e, which will re7uire various de!rees of reinforcements as stated a*ove%

3;

As there are five openin!s in the methanator all of them are in its heads% +wo of them are elliptical Y three are circular% As for methanator there is the ma imum openin! is of si=e 24X Y 24 Z 1N3"1:2$ 24 Z 34 to4: So we use (583; for openin!%

2.# SELECTION OF FLANGES

/e #now that openin!s of si=e 2%0X or lar!er shall *e flan!ed Y we shall use flan!es with raised face% 2or methanator , all the flan!es would *e of ratin! ;::l* which are selected from the pressure8temperature ratin! "A-S, 31;%0819E1$ 2or desi!n pressure of 430 psi%! Y desi!n temperature of E:;D2, which will *e rounded off to E0:2 Y 030psi%! ta*le attached% ?ther specification of the flan!es accordin! to their pipe si=es are !iven "hi!h li!hted$ for ;::l* flan!es in the ta*le attached%

3B

LE-5+6 ?2 S+(4 3?L+S

3E

2.8 THIC NESS OF S IRT OR DESIGN OF SUPPORTS

A s#irt is the most fre7uentl) used and the most satisfactor) support for vertical vessels% ,t is attached *) continuous weldin! to the head and usuall) the re7uired si=e of this weldin! determines the thic#ness of the s#irt%

39

2i!ures A and 3 show the most common t)pe of s#irt to head attachment% ,n calculations of the re7uired weld si=e, the values of the .oint efficienc) !iven *) the 1ode "(/ 12$ ma) *e used%"(5804 YA&&E-4,G 5$ t H 12 <+ N '2R I RSE [ / N 4ISE /here 4 H ?utside diameter of s#irt, in E H efficienc) of s#irt to head .oint% ":%; for *utt weld, fi! A, :%40 for lap weld, fi!% 3$ <+ H moment at s#irt to head .oint, ft% l* ' H outside radius of s#irt, in S H stress value of the head or s#irt material whichever is smaller, psi t H re7uired thic#ness of s#irt, in / H wei!ht of tower a*ove the s#irt to head .oint, in operatin! condition% l*

NOTE!%

4:

(sin! e tremel) hi!h s#irt, the stresses at the *ase ma) !overn% +o calculate the re7uired thic#ness of s#irt, in this case the a*ove formula can *e used% +he moment and wei!ht shall *e ta#en into consideration at the *ase and .oint efficienc) will *e ta#en as 1%:% 2or methanator the wei!ht of the vessel used is as appro imated later% And we are ta#in! into account the moments due to two forces firstl) due to earth7ua#e And secondl) due to wind% /hichever is !reater should *e used% As the moment at the s#irt to head .oint due to seismic load is !reater as indicated *) the calculations later% so we shall use < due to earth7ua#e 2?' <E+6A-A+?' 4 H 1:4%EB0X E H :%; <+H B;:09%0E l*ft ' H 02%43EX S H 1;394%9;; l*ft t H\ / H 41EBB%;B; l* So minimum thic#ness of s#irt t H 12RB;:09%0E N 02%43E2R3%14R1;394%9;;R%; [ 41EBB%;B; N 1:4%EB0R3%14R1;394%9;;R:%; t H :%:1:B4 [ :%:1292 t H :%:23;;X
41

] earth7ua#e ] wei!ht

+he a*ove calculations are from the @Pressure vessel hand book by Megyesy +o verif) our calculations we also used the formula from another *oo# of @Dennis R. Mossthese calculations are as under THIC NESS REQUIRED AT OPENING OF S IRT +here are five openin!s in the methanator s#irt *ut the *i!!est openin! is of 24X in dia% +herefore the desi!n is *ased on this openin! 5 H width of openin! in inches H 24X 4 H width of s#irt H 1:4%EB0X <*H moment at *ase, in8l* H B932B%39E; l*ft "earth7ua#e$ /*Hwei!ht of vessel at *ase, l* H 41EBB%;B;l* 2) H minimum specific )ield stren!th, psi H 349EE%430psi f* H *endin! stress, psi H \ f* H 1 N "I4835$ R ^4E<*N4 [ /*_

-ow after puttin! the values in a*ove formula Y solvin! we !et the value of *endin! stress as follows f* H 1E02%94B0 psi -ow the thic#ness of s#irt can *e found *) two formulae the !reater of the two values must *e ta#en

42

ts# H f*N ER2) H 1E02%94B0 N ER349EE%430 ts# H ;%;E8; ?' ts# H "f* N 4;4:,:::$1N2 ts# H :%:19X +he !reater value should *e ta#en%":%:19$ /hich nearl) e7ual to the thic#ness found earlier DETERMINE ALLO$ABLE LONGITUDANAL STRESSES!% +E-S,?-, St H lesser of :%;2) or 1%33S St H :%;2) H :%;R349EE%430 S' ( 20993.0" or St H 1%33S H 1%33R 1;394%9;; H 21E:0%3:4

1?<&'ESS,?-, Sc H :%3332) H :%333R349EE%430 S ( 11"51.148 or or H 1%33S "whichever is less$ H 21E:0%3:4

THIC NESS REQUIRED AT BASE DUE TO M)!%

43

L?-5,+(4,-AL 2?'1ES 2lt H ^4ER<* N IR42_ T ^/* N IR 4_ 2lt H 1323%:3B T 12B%1;E 2lt H 1190%E;E l*Nin 2lc H "8$ `2lt] 2lc H 8 140:%2:0 l*Nin +herefore s#irt thic#ness re7% at *ase t s# H 2ltN St H 1190%E;E N 2:993%:; H :%:0;X ?' ?' ?' H 2lc N Sc H 140:%2:0 N 11;01%14E H :%12X

+he !reater of the two values is ta#en i%e% :%12X

2.9 METHANATOR IS TO BE SUB*ECTED TO THE FOLO$ING INDS OF LOADINGS

2rom the list of the loadin!s on a pressure vessel !iven in (5822, methanator is lia*le to *e su*.ected to the followin! loads% ,nternal pressure

44

 /ei!ht of the vessel and normal contents under operatin! or test conditions"this includes additional pressure due to static head of li7uids$ /ei!hts of various attachments /ind Y seismic reactions

2.10 STRESSES IN RESPONSE TO DIFFERENT LOADS

a$ 4(E +? ,-+E'-AL &'ESS('E As we are treatin! methanator as a thin c)linder so the values of hoop stress Y lon!itudinal stress are calculated as under +herefore radial stresses are i!nored "ver) small$ so we consider the followin! primar) mem*rane stresses%

6oop Stresses Lon!itudinal Stresses 6??& S+'ESSES "S 1$ 2h H &d N2t H "430$ "1:2$ N 2"1%43E1$ H 1042;%; l*Nin2 L?-5,+(4,-AL S+'ESS "S 2$

40

2l

H &d N 4t H "430$ "1:2$ N 4"1%43E1$ H BB13%3:2 l* N in2

As hoop stress is !reater so desi!n is *ased on hoop stress%

)+ STRESS DUE TO $EIGHT OF VESSEL , ATTACHMENTS

,t is assumed that wei!ht of the vessel and its attachments results in compressive stress onl) Y eccentricit) doesnFt e ists and the resultin! force coincides with the a is of the vessel% +he wei!ht shall *e calculated for the various conditions of the tower as follows% A% Erection wei!ht 3% ?peratin! wei!ht 1% +est wei!ht +he compressive stress due to the wei!ht is !iven *) S H / N ct /here S H unit stress, psi / H wei!ht of vessel a*ove the section under consideration, l* c H circumference of shell or s#irt on the mean diameter, in t H thic#ness of shell or s#irt, in +he wei!hts of different vessel elements are !iven in the ta*les attached% $EIGHT OF METHANATOR 888888888888888888888888888888888888888888888 "a$

4;

A+ ERECTION WEIGHT 1$ S6ELLH10EER12%0"++L$ H19850 lb 2$ SE<, ELL,&S?,4AL 6EA4S H 0003R2 H11106 lb 3$ 2LA-5ES ";$ H 2a "S,bE$ H wt% of weld nec# [wt% of slip on [studs A "24X$ H 9BB [ EB; [ 3;0 Aa "12X$ H 22; "/ -$ A+ Y 3+ "2X$ H 4"1:$ [ 2"4%0$ 3 "12X$ H 22; "/-$ 1 ";X$ H B3[E;[3: +?+AL /E,56+ ?2 ; 2LA-5ES H 2908 lb 4$ &,&ES "assumin! S16% 1;:$ El*ow "12X$ H40:l* 2 pipes "1MX$ H 2R4%9 l*Nft R 1;c &ipe "2X$ &ipe H B%0 l*Nft R "9N12$c ";X$ H 40%3 R "1:0N12$c `/%- [ S+(4S]

+?+AL /E,56+ 4(E +? &,&ES Y EL3?/ H 1008.775 lb 0$ &LA+ES "+here are 4 plates in the methanator upper manhole Y which are 4X wide Y MX thic# Y also 3c lon!$ /ei!ht of one plate H ;%E:R3 /ei!ht of 4 plates H 2:%4R4 H E1%; l*%

4B

;$ ,-S(LA+,?"/e shall use an insulation of mineral wool of thic#ness 2MX% +he wei!ht of insulation !iven in the ta*le is in pounds per cu*ic feet so in order to !et the wei!ht of insulation we will have to calculate the volume of insulation to *e used on methanator% 2or that we will 1st have to find the circumference of the vessel *ased on e ternal diameter% Volume of insulation on shell H ++L [ circumference [ thic#ness H H H 12%0c [ I R 4o [ :%2:E3c 12%0 [ 2B%44 [:%2:E3 B1%44;9%ft3

Volume of insulation on the heads H 1%:9 R 42 Rthic#ness R2 H 1%:9 R E%B39d2R:%2:E3R2 H 34%;E3E ft3 +?+AL V?L(<E ?2 ,-S(LA+,?- +? 3E (SE4 ?- +6E <E+6A-A+?' H 1:;%13:BF e 11: ft3

+herefore +?+AL /E56+ ?2 ,-S(LA+,?- "<,-E'AL /6??L$ H E:l*Nft3 R11: H EE: l*% Addin! all the a*ove wei!hts H 30E34%3B0 l* 2or over wei!hts of plates Y weldin! wei!hts add ;K of the a*ove wei!hts to total wei!ht% +otal wei!ht H 30E34%3B0
4E

;K of total wei!ht H 210:%:;20 +herefore, the erection wei!ht H3B9E4%43Bl* 3$ ?&E'A+,-5 /E,56+ E'E1+,?- /E,56+ H 3B9E4%43B l* /E,56+ 2?' ?&E'A+,-5 L,f(,4 H 0K ?2 +6E E'E1+,?/E,56+
H 1E99%22 l*

+?+AL ?&E'A+,-5 /E,56+ ?2 <E+6A-A+?' H41877.676 lb STRESS DUE TO WEGHT OF METHANATOR &uttin! values in the formula "a$ /here, c H I R 4 mean H 3%14 "1:3%43E$ H324%B9 in t H 1%43E Sw H 41EBB%;B; N 324%;B;R1%43E H89.88 -./ 0123-45../65+%%%%%%%%%% 01$

1+ STRESS DUE TO $IND LOAD!

+owers under wind pressure are considered as uniforml) loaded cantilever *eams% +he computation of wind is *ased on standard A-S, A0E%1819E2% /here terrain features and local records indicate that 0: )ears at standard

49

hei!ht are hi!her than those shown in the map, those hi!her values shall *e the minimum *asic wind speed% +he minimum *asic wind speed for determinin! desi!n wind pressure shall *e ta#en from the map of wind speed% 4esi!n wind pressure shall *e determined *) the followin! formula:8 & H 7sR1e R17 /here, &H 4esi!n wind pressure, psf 7 s H /ind sta!nation pressure at the standard hei!ht of 3: feet as ta*ulated:
B7./1 8/9: .-55:; 3-<. P45..=45 >0.+; -.?

B: 13

E: 1B

9: 21

1:: 2;

11: 31

12: 3B

13: 44

1 7 H &ressure coefficient "shape factor$: 'ound or elliptical towers8888888888888888888888888888:%E 1 e H 1om*ined hei!ht, e posure and !ust factor coefficient as ta*ulated: 1oefficient 1"e$ 6ei!ht a*ove !round, ft% :82: 2:84: 4:8;: ;:81:: 1::810: 10:82:: 1%2 1%3 1%0 1%; 1%E 1%9 :%B :%E 1%: 1%1 1%3 1%4 E posure 1 E posure 3

E posure 1888888888888888888888+he most severe e posure

0:

E posure 3 888888888888888888888,ntermediate e posure 2or the methanator we will ta#e a wind speed of 13: mph, so the value of 7s H44psf 1e H :%E88888888888888888888888882or circular vessel 17 H :%E 888888888888888888888888,ntermediate e posure Y vessel hei!ht of 2Eft +here fore the value of wind pressure usin! the a*ove formula will *e; & H 2E%1; psf /e will ta#e the wind pressure 3: psf%

f(A-+,+,ES Shear <oment at *ase

2?'<(LAS VH &wR41R61 <H&wR41R61Rh1

<oment at hei!ht h"t$ Stress

<t H <8 ht`V8:%0&w41ht] SH 12<t N '2RIRt

/here, 41H width of the vessel with insulation, ft H 9%10 ft

01

E H Efficienc) of the welded .oints H 1%: h1H lever arm, ft H 6 N 2 H 12%;;c ht H distance from *ase to section under consideration, ft H 12%E 6 H len!th of vessel section, ft H20%33c < H <a imum moment "at the *ase$, ft8l* <tH <oment at hei!ht h t, l*ft &wH /ind pressure, l*% N ft2 H 3:c ' H <ean radius of vessel, in H01%BX S H Stress due to wind, psi H\ V H +otal shear, l* tH +hic#ness of shell e cludin! corrosion, in H 1%430X

+he values of shear, moment at *ase Y moment at s#irt .oint are calculated as under and then the stress developed in response to the moment <"t$ usin! the formulae listed in the ta*le a*ove% 3) puttin! the values of the parameters listed a*ove for methanator

02

Shear H V H 3:R9%10R20%33 V H ;903%:E0 l* <oment "at *ase$ < H 3:R9%10R20%33R12%;; HEE:2;%:0;1 l*ft <oment at head to s#irt .oint <t H < T 12%E33`V T :%0R3:R9%10R12%E33] <t H 214::%204;0 l*ft Stress due to wind H 12R<t N "01%B$2RIR1%430 S (wind) = 21.32 psi

:+ STRESS DUE TO SEISMIC LOAD

a$ &E',?4 ?2 V,3'A+,?As a result of wind tall towers develop vi*ration% +he period of vi*ration should *e limited, since lar!e natural periods of vi*ration can lead to fati!ue failure% +he allowa*le period has *een computed from the ma imum permissi*le deflection%

03

f(A-+,+,ES &eriod of vi*ration,+ sec <a imum allowa*le period of vi*ration,+a sec

2?'<(LAS +H:%::::2;0"6 N 4$2R"w4 Nt$dM +aH:%E:"/6 NV!$ Ms

/here, 4 H ?utside diameter of vessel, ft% HE%B0l* 6 H Len!th of vessel includin! s#irt, ft% H 2B%41;; ft 5 H 32%2 ft% N sec2 acceleration + H +hic#ness of s#irt at the *ase, in% H:%::1X V H +otal shear, l*%, H 32:3%;4 l* "calculated ahead$ /H /ei!ht of tower, l*% H 41EBB%;B; l* wH wei!ht of tower per foot of hei!ht, l*% H 10EEl* "from ta*le$ &uttin! values to !et period of vi*ration for methanator + H :%::::2;0"2B%41;; N E%B0$ 2R"10EERE%B0N%::1$ M + H :%9; sec -ow allowa*le period of vi*ration +a H :%E: `wR6 N VR!] M +a H 2%;;E sec As O+F is less than O+aF hence the condition is satisfied

STRESS DUE TO EARTHQUA E

04

+he loadin! condition of the tower under seismic forces is similar to that of the cantilever *eam when the load increases uniforml) towards the free end 2?'<(LAS Shear VHb,>1S/ <oment <H^2t6["V82t$"26 N3$_ < H <" N6$ /here 1H -umerical coefficient H 1N10"+$ @ H :%:;BN "++ @ (0.:;E"should not *e more than :%12$ E H Efficienc) of welded .oints H 1%: 2t H +otal hori=ontal seismic force at the top of the vessel, l* H :%:B+V "2t shall not e ceed :%20V$ H 6H :, for + Z :%B Len!th of vessel includin! s#irt, ft H 2B%41;;c

, H ?ccupanc) importance coefficient "use 1%: for vessels$ > H 6ori=ontal force factor "use 2%: for vessels$ < H <a imum moment at the *ase, l*ft < H <oment at distance , ft8l* S H -umerical coefficient for site structure resonance H 1%0 if + Z 2%0 +he product 1S shall not e ceed :%14 / H /ei!ht of the vessel, l* b H Seismic factor H :%3B0 for methanator

00

Shear H :%3B0R1R2R:%:;ER1%0R41EBB%;B; V H 32:3%;4l* 2t H :%:BR+RV H210%2E4 :%20V H E::%91 As condition is that 2t should not e ceed :%20V so it is satisfied for methanator +herefore, <oment < H ^210%2ER2B%41;;["32:3%;48210%2E$R"2R2B%41;;N3$

< H 1;2493%49;2l*ft <oment at s#irt to head .oint <t H <" N6$ where H12%E33

Mt = 76059.58748 lbft

0;

+herefore stress due to earth7ua#e Se7 H 12R <t N '2 RIR t H 12RB;:09%0E N "01%B$2R3%14R1%430 Seq = 75.74 psi

2.11 COMBINATION OF STRESSES

+he stresses induced *) the previousl) descri*ed loadin!s shall *e investi!ated in com*ination to esta*lish the !overnin! stresses% ,t is assumed that wind and earth7ua#e loads do not occur simultaneousl) +hus the tower should *e desi!ned for either wind or earth7ua#e load /hichever is !reater\ ,n case of methanator the stress due to internal pressure is the hoop stress "mem*rane stresses$, the stress due to earth7ua#e "!reater$ Y stress due to wei!ht "compressive$ is considered
0B

1om*ination of stresses will *e as follows A.'45.. :=5 '2 574'<>=7B5 A.'45.. :=5 '2 /9'5497C -45..=45 %.'45.. :=5 '2 85/D<' 2rom the previous calculations puttin! the values of stresses [1042;%; l*Nin2 [B0%B4 psi 8E9%99 psi 1om*ined stress at the head to s#irt .oint on the vessel in operatin! conditions =

15412.46 psi

2.12 COMPARISON
+he !overnin! stress will *e tensile as shown *) the positive si!n, which is lesser than allowa*le stress of the !iven material at that particular temperature +herefore the desi!n is safe.

2.13 DESIGN OF ANCHOR BOLTS

Vertical vessels, must *e fastened to the concrete foundation, s#id or other structural frame *) means of anchor *olts and the *ase "*earin!$ rin!% +6E -(<3E' ?2 A-16?' 3?L+S +he anchor *olts must *e in multiple of 4 and for tall towers it is preferred
0E

to use minimum E *olts% SPACING OF ANCHOR BOLTS +he stren!th of too closel) spaced anchor *olts is not full) developed in concrete foundations% it is advisa*le to set the anchor *olts not closure than a*out 1EX %to hold this minimum spacin!, in the case of small diameter vessel the enlar!in! of the *olt circle ma) *e necessar) *) usin! conical s#irt or wider *ase rin! with !ussets% 4,A<E+E' ?2 A-16?' 3?L+S 1omputin! the re7uired si=e of *olts the area within the root of the threads onl) can *e ta#en into consideration% +he root areas of the *olts are shown *elow in ta*le A% for corrosion allowance 1NE of an inch should *e added to the calculated diameter of anchor *olts% 2or anchor *olts and *ase desi!n is descri*ed for methanator 1$ An appro imate method which ma) *e satisfactor) in a num*er of cases% 2$ A method which offers closer investi!ation when the loadin! conditions and other circumstances ma#e it necessar)%

09

R Source

&ressure Vessel 6and 3oo# *)

/e will use the appro imate method +he desi!n of anchor *olts is to assume the *olts replaced *) a continuous rin! whose diameter is e7ual to the *olt circle% +he re7uired area of the *olts shall *e calculated for empt) condition of tower%

2?'<(LAS <a imum tension l*% Nlin% ,n% + 'e7uired area of one *olt S7%8in% 3a +H12<NA*8/N1* 3aH+1*NS*;:

Stress in Anchor 3olt psi%

S*

S*H+1*N3a-

/here, A* H area within the *olt circle, s7% 8 in% 1* H 1ircumference of *olt circle in% < H <oment at the *ase due to wind or earth7ua#e, ft% T l*% - H-um*er of anchor volts S* H ma imum allowa*le stress value of *olt material psi% /H /ei!ht of the vessel durin! erection, l*%

4iameter of *olt circle H 1:2 [ 2"1%43E$ [2"l "2$$ Let us assume l "2$ H 3%3B0

4iameter of *olt circle H 1:2[2R1%43E[2R3%3B0 H 111%;2X 2rom ta*le 3 minimum no% of *oltsH1; ma imum no% of *oltsH2: *olt si=e H 2 gX *olt root area H 4%;1E s7% in 2rom ta*le 1 specimen no%HSA 1933B ma % allowa*le stress H 1;,::: psi 2or chec#in! stress in anchor *olts
;1

5iven, 3olt circle dia% H 111%;2X Area with in the *olt circle H A* H I r2 H9BE:%33 s7%in 1ircumference of *olt circle H I 4 H 30:%;X <oment at *ase due to earth7ua#e H1;2493%49;2l*ft /ei!ht durin! errectionH/ H 41EBB%;B; l* <a % allowa*le stressH S* H 1;,::: psi - H1; Area within one *olt H 4%;1E s7%in <a imum tension + H 12R1;2493%49;2N9BE:%33 8 41EBB%;B;N30:%; + H 199%3B2;8119%420 +HB9%94 e E: l*Nin Stress in anchor *olts S"*$ H E: R 30:%; N 4%;1E R1; S"*$ H 3B9%;: psi /hich is less than the allowa*le stress so it is satisfied

2.14 !ELDING OF PRESSURE VESSELS :

+here are several methods to ma#e welded .oints% ,n a particular case the choice of a t)pe from the numerous alternatives depend on: 1% +he circumstances of weldin!% 2% +he re7uirements of the code% 3% +he aspect of econom)% +6E 1,'1(<S+A-1ES ?2 /EL4,-5:

;2

,n man) cases the accessi*ilit) of the .oint determines the t)pe of weldin!% ,n a small diameter vessel "under 1E824 inches$ from the inside, no manual weldin! can *e applied% (sin! *ac#in! strip it must remain in plate% ,n lar!er diameter vessels if a man wa) is not used, the last "closin!$ .oint can *e welded from outside onl)% +he t)pe of weldin! ma) *e determined also *) the e7uipment of the manufacturer% 1?4E 'Ef(,'E<E-+S: 'e!ardin! the t)pe of .oint the 1ode esta*lishes re7uirements *ased on service, material and location of the weldin!% +he weldin! processes that ma) *e used in the construction of vessels are also restricted *) the 1ode% +he 1ode8re!ulations are ta*ulated on the followin! pa!es under the titles: "a$% +C&ES ?2 /EL4E4 J?,-+S: "Joints permitted *) the code, their efficienc) and limitations of their applications%$ +a*le (/812

"*$% 4ES,5- ?2 /EL4E4 J?,-+S: "+)pes of .oints to *e used for vessels in various services and under certain desi!n conditions%$ (/82, (/83 "c$%J?,-+ E2,1,E-1,ES A-4 S+'ESS 'E4(1+,?-S: "Efficiencies of .oints at certain locations and reduced allowa*le stress to *e used in calculations of vessel components%$ +he data of the ta*le are *ased on the followin! 1ode re!ulations: 2ull, spot, partial radio!raphic e amination or no radio!raph) of A, 3, and 1 .oints% (/811
;3

2or lon!itudinal stress calculation the efficienc) of partiall) radio !raphed .oints is the same as for spot radio !raphed .oints% Seamless vessel sections and heads with 1ate!or) 3,1 or 4 *utt .oints that are spot radio !raphed shall *e desi!ned for circumferential stress usin! a stress value e7ual to E0K of the allowa*le stress value of the material; (/812"*$ /hen the .oints are not radio !raphed and for .oint efficienc), E the value in column of ta*le @+)pes of welded .ointsA are used, in all other desi!n calculation, a stress value e7ual to E:K of the allowa*le stress value of material shall *e used e cept for unsta)ed flat heads, etc% (/812"c$ +6E E1?-?<C ?2 /EL4,-5: ,f the two precedin! factors allow free choice, then the aspect of econom) must *e the decidin! factor% Some consideration concernin! the econom) of weldin!: V8ed!e preparation, which can *e made *) torch cuttin!, is alwa)s more economical than the use of J or ( preparation% 4ou*le V preparation re7uires onl) half the deposited weld metal re7uired for sin!le V preparation%

,ncreasin! the si=e of a fillet weld, its stren!th increases in direct proportion, while the deposited weld metal increases with the s7uare of its si=e% Lower 7ualit) weldin! ma#es necessar) the use of thic#er plate for the vessel% /hether usin! stron!er weldin! and thinner plate or the

;4

opposite is more economical, depends on the si=e of vessel, weldin! e7uipment, etc% this must *e decided in each particular case%

/EL4,-5 ?- <E+6A-A+?':
+o the .oints under certain conditions special re7uirements appl)% +hese special re7uirements which are *ased on service, material, thic#ness% Accordin! to the desi!ned conditions, service environment, material, and desi!n thic#ness it is recommended to use a dou*le V8t)pe *utt .oint% +his dou*le V8t)pe *utt .oint can *e applied with out a *ac#in! strip, thus reducin! the cost of material% +he .oint efficienc) of each ever) .oint in the vessel should *e one accordin! to radio!raph)% A dou*le V8t)pe *utt .oint is shown in the fi!% *elow%

+here will *e a circumferential .oint at each shell head .unction% +here will *e another circumferential .oint in the middle havin! a lon!itudinal seam on each side% As evident from the fi!%

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;;

ANALYSIS BY ANSYS

;B

3.1 ANSYS
A-SCS is software of 2EA "2inite Element Anal)sis$ which !ives )ou a wa) to test )our model *efore manufacturin!% )ou can calculate stress, strain, displacement, thermal stresses, resonance, also optimum desi!n parameters, points where our model *ecomes unsta*le and much more% An) of seven anal)sis t)pes offered in A-SCS: S+A+,1 <?4AL 6A'<?-,1 +'A-S,E-+ S&E1+'(< E,5E-VAL(E 3(1>L,-5 S(3S+'(1+(',-5 124 "1?<&(+A+,?-AL 2L(,4 4C-A<,1S$ All of these anal)sis t)pes help us in desi!n optimi=ation to a !reat e tent% /hether the pro*lem is linear or non8linear i%e% isotropic or orthotropic, we can solve it with the help of this software% 4esi!n optimi=ation also helps )ou in findin! suita*le desi!n parameters of a failed structure% So, in short, A-SCS is a complete anal)sis tool which can !ive )ou all what )ou want%

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3%2 ANSYS INPUT METHODS

GUI " G ap!i"al #se inte fa"e# COMMAND !INDO! INPUT" $ata# FILE

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3%3

B:

3.4 ANALYSIS OF METHANATOR UNDER INTERNAL PRESSURE USING $SHELL 51%

B1

3.5 ANALYSIS OF METHANATOR THROUGH COMMAND !INDO!

&PREP7 &TITLE' METHANATOR ANTYPE'STATIC ET'1'SHELL51 R'1'1.43( MP'E)'1'3*E6 MP'NU)Y'1'.3 N'1'51 N'2'51'1* E'1'2 CP'1'U)'1'2 + COUPLE RADIAL DIRECTION D'1'UY'''''U,'ROT, D'2'ROT, F'2'FY'35545*7.( + CAP FORCE SFE'1'1'PRES''435 + INTERNAL PRESSURE FINISH &SOLU OUTPR'ALL'1 SOLVE FINISH &POST1 ETABLE'STRS-HOOP'NMISC'6..........", DIR# ETABLE'STRS-LONGI'NMISC'7........."Y DIR#

3.6 ANALYSIS OF METHANATOR THROUGH GUI

Since the material of methanator is same throu!hout therefore we will use istroptropic material for structural anal)sis% +he units specified in 3,"3+($ %

B2

MAIN MENUE / PREFERENCES / STRUCTURAL

,n order to !ive title to our modal% 2,LEh16A-5E +,+LEh<E+6A-A+?'

B3

MAIN MENU /SOLUTION / NE! ANALYSIS / STATIC

DEFINIG THE ELEMENT TYPE

As we are usin! @Shell 01A for the anal)sis of methanator therefore, define thhe element t)pe as follows,
MAIN MENU/PREPROCESSOR/ELEMENT TYPE /ADD&EDIT&DELETE/SHELL51

B4

DEFINING REAL CONSTANTS

,n @shell 01A we will onl) ta#e two nodes of the vessel material % as it is a a 24?2 case therefore the thic#ness of the vessel could *e entered in the real constants% Since the shell is of uniform thic#ness and the dished ends are of comparativel) less thic#er than the shell "as calculated in anal)tical desi!n$, to compensate for the increase in stren!th due to *endin!% +herefore, the thic#ness remains the same throu!hout the vessel%i%e% 1%43E in%

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MAIN MENU/PREPRCESSOR/REALCONSTANTS/1.43(0

DEFINIG MATERIAL PROPERTIES 2or isotropic materials, the properties remains the same in ever) direction% 6ere we have entered the )oun!Fs modulus "3:e;$, the densit) of material is ":%2E$, the posionFs ratio ":%3$% all of these values are !iven in the ta*le of material for the methanator%
MAIN MENU/PREPRCEESOR/MATERIAL PROP/CONSTANT.ISOTROPIC

B;

+he two nodes are plotted at a distance of 01 inches from the ori!in which is infact, the radius of methanator% +hr hei!ht of element is ta#en at 1: inches%

M123 4536/78595853:5;/:851<5/3=>5;/I3 1:<2?5 CS

BB

CREATING ELEMENT

MAIN MENU/PREFERENCES/CREATE/ELEMENTS/THRU NODES

BE

APPLYING CONSTRAINTS MAIN MENU/SOLUTION/APPLY/DISPLACEMENT

B9

E:

APPLYING LOADS

E1

,n order to see the effect of lon!itudinal component of pressure which causes the lon!it)udinal stress in the shell mem*rane, lon!itudinal force is applied as caculated earlier in addition to the internal pressure which is 430 psi% MAIN MENU/SOLUTION/APPLY/FORCE&MOMENT/FY

E2

E3

after creatin! element of the methanator material% And after appl)in! the *oundar) conditions Y loads % +he element is read) for the solution% As shown on the previous pa!e% solve the element as shown *elow% MAIN MENU/SOLUTION/SOLVE.CURRENT LS

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POSTPROCESSING ,t is the environment where the results of the anal)sis can *e listed or ploted% 2or our case the resuts are ploted as follows% As we are interested in the stress therefore we have listed or plotted the e7uivalent stress or von mises%
MAIN MENU/ GENERAL POSTPROCESSOR/LIST RESULTS/NODAL SOLU/STRESS.COMPONENTS

RESULTS

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MAIN MENU/GENERAL POST PROCESSOR/LIST RESULTS/NODAL SOLU/STRESS.PRINCIPALS

RESULTS

E;

MAIN MENU/GENERAL POSTPROCESSOR/PLOT RESULTS/NODAL SOLU/STRESS.VON MISES

EB

3.7 TO FIND THE HOOP AND LONGITUDINAL STRESS

H22- .'45.. 8/CC )5 7C29D '<5 E%7F/. , C29D/'=:/97C .'45.. 8/CC )5 7C29D GH7F/.. S'74'/9D ?423 37/9359= '<5 ?2CC28/9D -7'< /. ?2CC285: '2 .55 '<5 <22- 79: C29D/'=:/97C .'45..5..
GEN. POSTPROC/ELEM. TABLE/DEFINE TABLE/STRESS.HOOP.NMISC'6

888888888888888888888888888888888888 /STRESS-LONG.NMISC.7

EE

TO SEE THE STRESSES "HOOP @LONG#

GEN.POSTPROC/LIST RESULTS/ELEM. SOLN/BY SEAUENCE.NMISC'6

BY DOING THIS HOOP STRESS IS OBTAINED.

E9

TO SEE THE LONGITUDINAL STRESS

............................................../BY SEAUENCE.NMISC'7

THE LONGITUDINAL STRESS IS OBTAINED.

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3.( DISPLACEMENTS OF THE 4 DOFB;

91

COMPARISON & CONCLUSION

92

4.1 MEMBRANE STRESSES IN METHANATOR

+he mem*rane stresses i%e hoop Y lon!itudinal stresses ploted are in pound per s7uare inch%

93

4.2 COMPARISON OF ANSYS @ ANALYTICAL SOLUTION

As it is evident from the chart that our lon!itudinal stress is e actl) the same *ut the circumferential stress varies sli!htl) owin! to roundin! off data%

CONCLUSION
F=8 131CD<2:1C >5;2E3 F5 G1?5 6;5> <G5

>2?2;2=3 1 FG2:G E2?5; <G5 6C<241<5 >5;2E3 :1C:6C1<2=3;. A; F5 G1?5 E=< <G5 ;145 ?1C65; 98=4 <G5 ;=9<F185 <G5859=85 ANSYS 2;
1 85C21HC5 ;=9<F185.

ASME SECTION.(

94

REFERENCES
SECTION VIII
VESSELS RULES FOR CONSTRUCTION OF PRESSURE

DIVISION 1 0Seventh Edition !"

PRESSURE VESSEL HANDBOO !" # $. M "% &%

#RESSURE $ESSE% DESIGN MANUA% by DENNIS R& MOSS

90

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