Design of Pressure Vessels Under ASME Section VIII

ACKNOWLEGEMENT:
First of all thanks to Allah Almighty who has guided us and

made difficult thing easier for us throughout our project and
secondly to our respected teachers and dear parents for their help
and prayers…
MAIN CONTENTS
CHAPTER NO 1: introduction to pressure vessels

1.1 INTRODUCTION.
1.2 TYPES OF VESSELS.
1.3 STRESSES IN PRESSURE VESSELS.
1.4 PRESSURE VESSEL SAFETY
1.5 VESSELS IN REFRIGRATION SYSTEM
1.6 FACTOR OF SAFETY
1.7 STRESS ANALYSIS.
1.8 STRESS/FAILURE THEORIES.
1.9 FAILURES IN PRESSURE VESSELS.
1.10 LOADINGS.
1.11 ASME SECTION VIII DIVISION 1
1.12 TYPES AND CLASSES OF STRESS.
1.13 DEFINITIONS.
1.14 WEIGHTS OF PRESSURE VESSEL COMPONENTS
1.15 DESIGN PRINCIPLES.
CHAPTER NO 2: stresses and their effects
2.1 STRESS
2.2 TYPES OF STRESSES
2.3 TENSOR
2.3 (a) DUAL SPACE
2.3 (b) STRESS ENERGY TENSOR
2.3 (c ) CAUCHY STRESS TENSOR
2.4 FORMS OF DEFORMATION DUE TO APPLIED LOAD
2.5 MECHANICAL FAILURE MODES
2.6 TYPES OF STRUCTURAL ELEMENTS
2.7 TYPES OF CROSS-SECTIONS USED
2.8 TYPES OF SUPPORTS USED
2.9 STATICAL DETERMINANCY
2.10 STRESS STRAIN DIGRAM
ULTIMATE TENSILE STRENGTH
YIELD STRENGTH
FRACTURE STRESS
NECKING
2.11 STRESS CONCENTRATION
2.12 VON MISSES CRITERION
2.13 PLANE STRESS
2.14 PLANE STRAIN
2.15 MOHR STRESS CIRCLE
2.16 PRESSURE VESSEL DESIGN MODEL FOR CYLINDERS
CHAPTER NO 3: materials for pressure vessels
ASME pressure vessel codes

ASME section viii division 1
CHAPTER NO 4: design of pressure vessel
 Summary
 Diagram
 Material Properties
 Shell & Plate design
 Head design
 N-1 4`` sch-160
 N-2 4`` sch-160 on head
 N-1&N-2 Flanges
 N-3 1``NPT6000# H.cplg
 N-4&N-5 4`` process conn
 M-1 12``x16`` MWY on shell
 M-2 12``x16`` MWY on Head
 Vessel Weight & Volume
 Lifting Lugs
CHAPTER NO 1
INTRODUCTION TO PRESSURE VESSELS

CONTENTS:-
1.1 INTRODUCTION.
1.2 TYPES OF VESSELS.
1.3 STRESSES IN PRESSURE VESSELS.
1.5 VESSELS IN REFRIGRATION SYSTEM
1.6 FACTOR OF SAFETY
1.7 STRESS ANALYSIS.
1.8 STRESS/FAILURE THEORIES.
1.9 FAILURES IN PRESSURE VESSELS.
1.10 LOADINGS.
1.11 ASME SECTION VIII DIVISION 1
1.12 TYPES AND CLASSES OF STRESS.
1.13 DEFINITIONS.
1.14 WEIGHTS OF PRESSURE VESSEL COMPONENTS
1.15 DESIGN PRINCIPLES.
1.1 INTRODUCTION:-
What is a pressure vessel?
Definition:
A pressure vessel is any container that has pressure that is

different than atmospheric pressure. Also, any container...vessel that
has the potential to pressurize should be considered a pressure
vessel.
figure1.1 horizontal pressure vessel
figure 1.2 horizontal pressure vessel

1.2 How many types of pressure vessels are there?
There are many types -
 Thinned wall
 Thick walled
 Storage tanks
 Transportable Containers
 Propane bottles
 Gas cylinders
A pressure vessel is a container that holds a liquid, vapor, or gas at a

different pressure other than atmospheric pressure at the same
elevation.
You could even say that a carbonated soda bottle is a pressure

vessel. In fact, there is over 15-psi of pressure in a high carbonated
soda bottle. We must be practical too.
Pressure vessel types?
 Thinned wall -
These pressure vessels are the most categorized. A thinned walled

pressure vessel is any cylinder [shell] ratio that is 10% or less the ratio
of the thickness to the diameter. Another way of saying this is a
pressure vessel is thinned walled if the diameter is 10-times or more
the thickness.
t < 0.1
d
figure1.3 stress distribution in thin walled pressure vessel
 Thick walled -
These pressure vessels are the least common. A thick walled

pressure vessel is any cylinder [shell] ratio that is 10% or more the
ratio of the thickness to the inside diameter.
t > 0.1
d
figure 1.4 thick walled pressure vessel

 Storage tanks -
Storage tanks are a category of thin walled pressure vessels except

that are typically under 15-psi and are super thin when compared to
the ratio above.
figure 1.5 hot water storage tank
Transportable Containers -
These are the most common pressure vessel and potentially the most
ignored. These are mass produced and require testing every 10-years
for propane and gas.
Propane bottles - Fork trucks, barbecues,
Gas cylinders - CO2, O2,...
Other - Containers, gas cans, bubblers,...

1.3 STRESSES
A pressure vessel has to retain to pressure. In doing this the pressure

applies two types of stresses in a pressure vessel. They are
circumferential and longitudinal.
figure 1.6
What is important to remember is longitudinal stresses are half as

much as the circumferential stresses. Therefore, we can say that
longitudinal strength is twice as strong as circumferential strength.
This is only true for illustration purposes.
FACTOR OF SAFETY:-
Factors of Safety are used because no manufacture can guarantee

100% quality. Every pressure vessel has a factor of safety. A factor of
safety accounts for uncertainties in materials, design,…,and
fabrication.
Factory of Safety [FS] = Actual Breaking Strength

Load
To believe in that a F.S. makes a PV [Pressure Vessel] safe is

DANGEROUS and unwise. Putting this in another way, a factor of
safety compensate for imperfections in the pressure vessel; therefore,
every pressure vessel should be treated the same regardless of the
factor of safety.
There are four types of over pressurization devices:
 Rupture Disks.
 Relief Valves.
 Safety Relief Valves.
 Safety Valves.
What should you expect on an over-pressurization device?
Every device must have a name tag. The name tag must have one of
the following ASME symbols ‘UV’ [spring loaded over pressurization
device] ‘UD’ [rupture disk]. The name tag will have the set pressure
and capacity. The set pressure should never be greater than the
pressure vessels MAWP [maximum allowable working pressure].
Here are some special rules to the set pressure-
• Relief Valves, Safety Relief Valves, and Safety Valves should be

set at or below pressure vessel ASME nameplate MAWP.
• Rupture Disks should be set not higher than the PV [pressure

vessel] nameplate. Under special circumstances the rupture disk
can be set up to 110% of the MAWP. In addition to this special
condition, whenever there is a possibility of internal fire in the
pressure vessel the rupture disk can be set not higher than
160%, but a pressure vessel engineer will need to be consulted.
Remember There should never be a shut off valve between the PV

and over pressurization device.
How should the over-pressurization device be installed?
• Always in an Upright installation.

• Installed the over pressurization device a few pipe diameters
away from the PV, but consult the code and manufacture for
maximum distance.
• Make sure the exhaust discharges safely away, so no one could
be injured.
TYPES OF OVER PRESSURIZATION DEVICES:-
Safety Valves -
Safety valves are strictly for vapor or gas service. The vapor or gas
should be relatively clean to ensure continued and successful
operation. A typical vapor is steam, an example for gas would be
compressed air. These are not meant for liquids. These valves pop
open at a set pressure and reset at a lower pressure called blow down.
Safety Relief Valves -
These valves differ from safety valves in that they are meant to handle
fluid streams that have liquids and vapor. These valves pop open at a
set pressure and reset [blow down] at a lower pressure [very much like
a safety valve].
Relief Valves -
Relief valves open at a set pressure and re-close at the same

pressure. These devices are suitable for liquid service.
Rupture Disks -
Rupture disks are probably the most versatile over- pressurization

device. These can only be used once. They are the only device that
can be used in conjunction with other over-pressurization devices.
1.5 VESSELS IN INDUSTRIAL REFRIGERATION SYSTEMS
HIGH PRESSURE RECIEVERS:-
Figure High pressure receiver

LOW PRESSURE RECEIVERS:-
figure liquid level maintained in a low pressure receiver

OIL POTS:-
figure OIL POTS WITH THEIR TYPICAL

CONNECTIONS.
SEPARATION ENHANCERS:-
The fig (a) shows drawing inlet flows downward and drawing vapor from the
top.
(b) installation of a metal mesh for mist elimination.
THERMOSYPHON RECEIVERS:-
figure combination of a thermosyphon receiver with a system receiver [1]

1.6 STRESSES IN PRESSURE VESSELS:-
Structural elements must be considered).

1.7 STRESS ANALYSIS
“STRESS ANALYSIS IS THE DETERMINATION OF THE

RELATIONSHIP BETWEEN EXTERNAL FORCES
APPLIED TO A VESSEL AND THE CORRESPONDING
STRESS.” [2]
1.8 STRESS/FAILURE THEORIES
They are
1. MAXIMUM STRESS THEORY.
2. MAXIMUM SHEAR STRESS THEORY.
MAXIMUM STRESS THEORY:-

MAXIMUM SHEAR STRESS THEORY:-
GRAPH OF MAXIMUM STRESS THEORY
QUADRANT 1: BIAXIAL TENSION.
QUADRANT 2: TENSION.
QUADRANT 3: BIAXIAL COMPRESSION.
QUADRANT 4: COMPRESSION.
GRAPH OF SHEAR STRESS THEORY.
COMPARISON OF TWO THEORIES:-

1.9 FAILURES IN PRESSURE VESSELS
CATEGORIES OF FAILURES:-
TYPES OF FAILURES:-
1.10 LOADINGS
1.11 STRESS
ASME CODE , SECTION VIII, DIVISION1
VERSES DIVISION 2:-
1.12 TYPES AND CLASSES OF STRESS
Simultaneously are called stress categories.

TYPES OF STRESS:-
CLASSES OF STRESS:-
1.13 DEFINITIONS
mum design temperature would be the MDMT.
1.14 WEIGHTS OF VESSELS AND IT’S COMPONENTS

1.15 DESIGN PRINCIPLES
DESIGN LOADS:-
the design.
[3]
CHAPTER NO 2
STRESSES AND THEIR EFFECTS
CONTENTS:
2.1 STRESS
2.2 TYPES OF STRESSES
2.3 TENSOR
2.3 (a) DUAL SPACE
2.3 (b) STRESS ENERGY TENSOR
2.3 (c ) CAUCHY STRESS TENSOR
2.6 TYPES OF STRUCTURAL ELEMENTS
TYPES OF CROSS-SECTIONS USED
2.7 TYPES OF SUPPORTS USED
2.8 STATICAL DETERMINANCY
2.9 STRESS STRAIN DIGRAM
ULTIMATE TENSILE STRENGTH
YIELD STRENGTH
FRACTURE STRESS
NECKING
2.10 STRESS CONCENTRATION
2.11 VON MISSES CRITERION
2.12 PLANE STRESS
2.13 PLANE STRAIN
2.14 MOHR STRESS CIRCLE
2.15 PRESSURE VESSEL DESIGN MODEL FOR CYLINDERS
2.1 STRESS:
The concept of stress was introduced by Cauchy around 1822 as;

Stress is a measure of the average amount of force exerted per unit area of the
surface on which internal forces act within a deformable body. In other words,
it is a measure of the intensity, or internal distribution of the total internal
forces acting within a deformable body across imaginary surfaces. These
internal forces are produced between the particles in the body as a reaction to
external forces applied on the body. External forces are either surface forces
or body forces. Because the loaded deformable body is assumed as a
continuum, these internal forces are distributed continuously within the
volume of the material body, i.e. the stress distribution in the body is
expressed as a piecewise continuous function of space coordinates and time.
UNITS:
The SI unit for stress is the pascal (symbol Pa), which is equivalent to one
newton (force) per square meter (unit area). The unit for stress is the same as
that of pressure, which is also a measure of force per unit area. Engineering
quantities are usually measured in Megapascals (MPa) or gigapascals (GPa).
In imperial units, stress is expressed in pounds-force per square inch (psi) or
kilopounds-force per square inch (ksi). [4]
figure 2.1 Stress in a loaded deformable material body assumed as a

continuum. 40
41
The most general definition of stress is;
“ force per unit area”
mathematically;
σ=F/A
A = UNIT AREA
F = FORCE
Structural and solid body mechanics are concerned with analyzing the effects
of applied loads. These are external to the material of the structure body and
result is internal reacting forces. These internal reacting forces are termed
as stresses, together with the deformations are displacements, conforming to
the principles of Newtonian mechanics.
Both the analysis and design of a given structure involves the determination
of stresses and deformations. [5]
DESCRIPTION:
Equilibrium:
A particle is in the state of equilibrium if the resultant force and moment

acting on it is zero.
Hence according to Newton’s law of motion it will have no acceleration and

will be at rest. This hypothesis can be extended to the clusters of particles
42
that interact with each other with equal and opposite forces but have no
overall resultant. Thus it is evident that solid bodies, structures, or any
subdivided part, will be in equilibrium if the resultant of all external forces
and moments is zero.
A material body can be acted upon by external forces, which are of two kind:
surface forces and body forces. Surface forces or contact forces act on the
bounding surface as a result of mechanical contact between bodies, and their
intensity is proportional to the area of contact. Body forces, such as
gravitational and magnetic forces, are forces distributed over the volume of a
body, and their intensity is proportional to the mass of the body. Surface
forces can also occur within internal surfaces of a body.
These acting external forces are then transmitted from point to point within
the material body, leading to the generation of internal forces. The
transmission of such forces is governed by the conservation laws of linear and
angular momenta Newton's Second Law of motion. For bodies in static
equilibrium, these laws are related to the principles of equilibrium of forces
and moments, respectively.
The measure of the intensity of this internal forces acting within the material
body across imaginary surfaces is called stress. In other words, stress is a
measure of the average quantity of force exerted per unit area of the surface
on which these internal forces act. For example, if we compare a force applied
to a small area and a distributed load of the same resulting magnitude applied
to a larger area, we find that the effects or intensities of these two forces are
locally different because the stresses are not the same.
2.2 TYPES OF STRESSES:
Following are the basic types of stresses;
(i). normal stresses

(ii). shearing stresses
(iii). bearing stresses
(i) Normal Stresses:
“ this types of stresses occurs in the member under axial loading”

normally denoted by “σ”
figure 2.2
Normal stress is the intensity of forces acting perpendicular to infinitely
small area dA with and object per unit area. If the normal stress acting on dA
pulls on it then it is called as tensile stress whereas if it pushes on the area
then it is called as compressive stress.
The plane of a tensile or compressive stress lies perpendicular to the axis of

operation of the force from which it originates.
figure2.3 tensile stress
Compressive stress:
“Compressive stress is the stress applied to materials resulting in their

compaction (decrease of volume).”
When a material is subjected to compressive stress, then this material is under

compression. Usually, compressive stress applied to bars, columns, etc. leads
to shortening.
Loading a structural element or a specimen will increase the compressive
stress until the reach of compressive strength. According to the properties of
the material, failure will occur as yield for materials with ductile behaviour
(most metals, some soils and plastics) or as rupture for brittle behaviour
(geomaterials, cast iron, glass, etc).
In long, slender structural elements -- such as columns or truss bars -- an

increase of compressive force F leads to structural failure due to buckling at
lower stress than the compressive strength.
Compressive stress has stress units (force per unit area), usually with
negative values to indicate the compaction.
figure2.4 compressive stress
(ii) Shearing Stresses:
“ shearing stresses are caused by the application of equal and opposite

transverse forces”
normally denoted by “τ”
figure 2.5
shear stress is applied parallel or tangential to the face of the material as
opposed to the normal stress which is applied perpendicularly…
The plane of a shear stress lies in the plane of the force system from which
it originates.
figure 2.6 description of planes in tensile compressive and shear stresses
figure 2.7 description of tensile and shear stress
(iii) Bearing Stresses:
“ bearing stresses are created by bolts and pins in the members they connect”
normally denoted by “σ”
σ = P / td
where;
P = load
t = thickness of member
d = diameter of pin of bolt
figure 2.7 bearing stress
The applied load divided by the bearing area. Maximum bearing stress is the
maximum load in pounds, sustained by the specimen during the test, divided
by the original bearing area.
For the two force member under axial loading; stress analysis is done by
estimating the normal and shearing stresses in an oblique plane. Secondly
ultimate strength of the material is determined and finally by using the factor
of safety of any component the allowable load for the structural component is
determined.
DISCONTIUITY STRESSES:
Discontinuity stresses occurs in case of compound cylinders…compound
cylinders are used to increase the range of pressure that can be used inside a
cylinder.
Membrane stresses:
“ Membrane stress in mechanics means the average stress across the cross
section involved”
Thermal stresses:
“ Thermal stresses arises in the material when they are heated and cooled”
Principal stresses:
“Normal stresses along principal directions are called as principal stresses”
Tangential stresses:
“ tangential stresses occurs in the direction perpendicular to the
circumference”
Radial stresses:
“ radial stress is a stress towards or away from the central axis of the curved
member”
Circumferential stresses:
Longitudinal stresses:
“ Longitudinal stresses occurs along the longitudinal axis”

it usually occurs in case of pipe shaped objects [6]
2.3 TENSOR
“An element as a result of tensor product of vector spaces is called as tensor”
Given a finite set { V1, ... , Vn } of vector spaces over a common field F. One
may form their tensor product V1 ⊗ ... ⊗ Vn. An element of this tensor product
is referred to as a tensor.
figure 2.8 stress tensor
2.3( a) Dual Space:
“In mathematics, any vector space, V, has a corresponding dual vector space
(or just dual space for short) consisting of all linear functionals on V”.
Dual vector spaces defined on finite-dimensional vector spaces can be used

for defining tensors which are studied in tensor algebra.
2.3 (b) STRESS ENERGY TENSOR:
“The stress-energy tensor (sometimes stress-energy-momentum tensor) is a

tensor quantity in physics that describes the density and flux of energy and
momentum in spacetime”
figure 2.9 stress energy tensor

2.3 ( c) CAUCHY STRESS TENSOR:
In general, however, the stress is not uniformly distributed over a cross

section of a material body, and consequently the stress at a point on a given
area is different than the average stress over the entire area. Therefore, it is
necessary to define the stress not at a given area but at a specific point in the
body .
figure 2.10 a point in an object under stress
According to Cauchy, the stress at any point in an object, assumed to be a

continuum, is completely defined by the nine components of a second order
tensor known as the Cauchy stress tensor
9 components of a second order tensor

The Cauchy stress tensor obeys the tensor transformation law under a change
in the system of coordinates. A graphical representation of this transformation
law is the Mohr's circle for stress.
According to the principle of conservation of linear momentum, if the

continuum body is in static equilibrium it can be demonstrated that the
components of the Cauchy stress tensor in every material point in the body
satisfy the equilibrium equations (Cauchy's equations of motion for zero
acceleration). At the same time, according to the principle of conservation of
angular momentum, equilibrium requires that the summation of moments with
respect to an arbitrary point is zero, which leads to the conclusion that the
stress tensor is symmetric, thus having only six independent stress
components, instead of the original nine.
By continuum body we mean anybody which undergoes gradual transition

from one state to another state without abrupt changes example ductile
materials..
Forces results into four basic forms of deformations or displacement of

structures or solid bodies
1. TENSION
2. COMPRESSION
3. BENDING
4. TWISTING OR TORSION
TENSION:
is the magnitude of the pulling force exerted by a string, cable, chain, or

similar object on another object.
It is the opposite of compression. As tension is a force, it is measured in
newtons (or sometimes pounds-force) and is always measured parallel to the
string on which it applies.
COMPRESSION:
Due to applied load there is a decrease in length or volume of the material

It is opposite to tension. It is subjected force applied by one object on another
object
Since compression is also expressed in terms of force so it is measured in

Newton and pound.
BENDING:
In the force analysis of frame works the members were only subjected to the
axial force, namely tension or compression then due to the effect transverse
loads acting on the structure, the resulting deformation is called as bending.
Bending is very common in structures and machines i.e, floor joists, railway
axles, aeroplane wings, leaf springs etc.
The external applied loads which cause bending give rise to internal reacting
forces.
In engineering mechanics, bending (also known as flexure) characterizes the

behavior of a slender structural element subjected to an external load applied
perpendicularly to an axis of the element. The structural element is assumed
to be such that at least one of its dimensions is a small fraction, typically 1/10
or less, of the other two. When the length is considerably larger than the
width and the thickness, the element is called a beam.
TORSION:
In torsion a solid or tubular member is subjected to torque about it’s

longitudinal axis resulting in twisting deformation.
The engineering examples of the above are obtained in shafts transmitting
power in machinery and transport, structural members in aeroplanes, springs.
figure 2.11 torsion

Following are the failure modes that commonly exists in mechanical

applications.
 BUCKLING
 CORROSION
 CREEP
 FATIQUE
 FRACTURE
 IMPACT
 MECHANICAL OVERLOAD
 RUPTURE
 THERMAL SHOCK
BUCKLING:
In engineering,
“ buckling is a failure mode characterized by a sudden failure of a structural

member subjected to high compressive stresses, where the actual compressive
stress at the point of failure is less than the ultimate compressive stresses that
the material is capable of withstanding”
This mode of failure is also described as failure due to elastic instability.

Mathematical analysis of buckling makes use of an axial load eccentricity that
introduces a moment, which does not form part of the primary forces to which
the member is subjected.
figure 2. 12 buckling of a column
CORROSION:
“Corrosion can be defined as the disintegration of a material into its

constituent atoms due to chemical reactions with its surroundings”
. In the most common use of the word, this means a loss of electrons of metals
reacting with water and oxygen. Weakening of iron due to oxidation of the
iron atoms is a well-known example of electrochemical corrosion. This is
commonly known as rusting. This type of damage typically produces oxide
and/or salt of the original metal. Corrosion can also refer to other materials
than metals, such as ceramics or polymers. Although in this context, the term
degradation is more common.
Most structural alloys corrode merely from exposure to moisture in the air but
the process can be strongly affected by exposure to certain substances .
Corrosion can be concentrated locally to form a pit or crack, or it can extend
across a wide area to produce general deterioration. While some efforts to
reduce corrosion merely redirect the damage into less visible, less predictable
forms, controlled corrosion treatments such as passivation and chromate-
conversion will increase a material's corrosion resistance.
fig 2.13 effect of oxygen concentration on the corrosion of a material in mm
CREEP:
“Creep is the tendency of a solid material to slowly move or deform

permanently under the influence of stresses. It occurs as a result of long term
exposure to levels of stress that are below the yield strength of the material”
Creep is more severe in materials that are subjected to heat for long periods,
and near the melting point.
Creep always increases with temperature.

FACTORS:
The rate of this deformation is a function of the material properties, exposure

time, exposure temperature and the applied structural load. Depending on the
magnitude of the applied stress and its duration, the deformation may become
so large that a component can no longer perform its function
example creep of a turbine blade will cause the blade to contact the casing,
resulting in the failure of the blade.
Creep is usually of concern to engineers and metallurgists when evaluating

components that operate under high stresses or high temperatures. Creep is a
deformation mechanism that may or may not constitute a failure mode.
Moderate creep in concrete is sometimes welcomed because it relieves tensile
stresses that might otherwise lead to cracking.
Difference from brittle fracture:
Unlike brittle fracture, creep deformation does not occur suddenly upon the
application of stress. Instead, strain accumulates as a result of long-term
stress.
Creep deformation is "time-dependent" deformation.
Creep deformation is important not only in systems where high temperatures

are endured such as nuclear power plants, jet engines and heat exchangers, but
also in the design of many everyday objects.
FATIGUE:
In materials science,
“ fatigue is the progressive and localized structural damage that occurs when
a material is subjected to cyclic loading”
The maximum stress values are less than the ultimate tensile stress limit, and
may be below the yield stress limit of the material.
MECHANICAL OVERLOAD:
“failure or fracture of a product or component in a single event is known as

mechanical overload”
It is a common failure mode, and may be contrasted with fatigue, creep,

rupture, or stress relaxation. In structural engineering this term is used when
analysing product failure. Failure may occur because either the product is
weaker than expected owing to a stress concentration, or the applied load is
greater than expected and exceeds the normal tensile strength, shear strength
or compressive strengthof the product.
Examples include the many components which fail in car crashes, train
crashes, and airplane crashes as a result of impact loading. The problem for
the investigator is to determine which failures have been caused by the crash,
and which may have caused the crash. It usually involves examining the
broken parts for signs of fatigue crack growth or other damage to the part
which cannot be attributed to the crash itself. For very large structural failures
such as the collapse of bridges, it is necessarily a long and tedious process of
sifting the broken parts.
THERMAL SHOCK:
“Thermal shock is the name given to cracking as a result of rapid

temperature change”.
Glass and ceramic objects are commonly exposed to this form of failure, due
to their low toughness, low thermal conductivity, and high thermal expansion
coefficients. However, they are used in many high temperature applications
due to their high melting point.
Thermal shock occurs when a thermal gradient causes different parts of an

object to expand by different amounts. This differential expansion can be
understood in terms of stress or of strain, equivalently. At some point, this
stress overcomes the strength of the material, causing a crack to form. If
nothing stops this crack from propagating through the material, it will cause
the object's structure to fail.
Prevention from thermal shock:
Thermal shock can be prevented by:
1. Reducing the thermal gradient seen by the object, by:

a) changing its temperature more slowly
b) increasing the material's thermal conductivity
2. Reducing the material's coefficient of thermal expansion
3. Increasing its strength
4. Decreasing its Young's modulus
5. Increasing its toughness, by
a) crack tip blunting, i.e., plasticity
b) crack deflection [7]
2.6 TYPES OF STRUCTURAL AND SOLID BODY COMPONENTS
1. TIE:
“A member that prevents two parts of a structure from moving apart is

subjected to a pull at each end, or tensile force, and is termed as tie”
figure 2.14 tie

2. STRUT:
“A slender member which prevents parts of a structure moving toward each

other is under compressive force and is termed as strut”
figure 2.15 strut

3. COLUMN:
“A vertical member which is perhaps not too slender and supports some of the
mass of the structure is called as column”
Column is capable of supporting axial loads
4. CABLE:
“A cable is generally recognized term for a flexible string under tension

which connects two bodies”
It cannot supply resistance to the bending action.
5. BEAM:
“It is supported horizontally and carries transverse loading or vertical

loading”
6. CANTILEVER BEAM:
“A common special case of beam is cantilever beam where one end is fixed
and provides all the necessary support”
figure 2.16 cantilever beam geometry
7. BEAM COLUMN:
“As the name implies it combines the functions of beam and a column.”
figure 2.17 beam column

ARCH:
“The arch has the same function as the beam or beam-column, but is curved
in shape”
the filling and carrying of load over an area or space are achieved by flat
slabs or plates by panels and also by shells, which are the curved versions of
the former.
8. SHAFT:
“The transmission of torque and twist is achieved through a member which is

frequently termed as shaft”
figure 2.18 shaft [8]
\
DIFFERENT TYPES OF CROSS- SECTIONS USED:
The members described above can have variety of cross-sectional shapes

depending upon the particular type of loading to be carried. Some typical
cross sections are;
1. angle
figure 2.19 angle
2. channel
figure 2.20 channel
3. I-section
figure 2.21 I-Section
4. T-section
figure 2.22 T-Section
6. Z-section
figure 2.23
7. Tubes:
figure 2.24 [9]
2.7 TYPES OF SUPPORTS USED FOR STRUCTURAL MEMBERS
1. built-in or fixed support
one horizontal and one vertical reaction and in case of welded joint 2-
reactions plus one moment in addition
fig 2.25 built on or fixed support
2. pin connection:
one horizontal and one vertical reaction

figure 2.26 pin connection
3. roller support
one vertical reaction
fig 2.27 roller support
4. sliding support
fig 2.28
one horizontal reaction
the applied loading on the structural component is transmitted to the

supports which provide the required reacting forces to maintain the
overall equilibrium. [10]
The separate members of the structure are joined together by bolting, riveting
or welding. If the joints are stiff when the members of the framework were
deformed under load, the angles between the members at the joint would not
change. This would also imply that the joint is capable of transmitting a
couple.
It is found in practice that there is some degree of rotation between members

at a joint to the elasticity of the system. For the purposes of calculations, it is
assumed that these joints may be represented by a simple ball and socket or
pin in a hole. Even with this arrangement, which is of course cannot transmit
a couple or bending moment (other than by friction which is ignored),
deformation of the members are relatively small. Consequently, changes in
angle at the joints are also small. [11]
2.8 STATICAL DETERMINANCY:
If the number of unknown reactions or internal forces in the structure or

component is greater than the number of equilibrium equations available,
then the problem is said to be statically indeterminate.
Additional equations have to be found by considering the displacement or

deformation of the body.
Conditions:
There are three conditions;
Under-stiff: if there are more equilibrium equations than unknown forces

or reactions the system is unstable and is not a structure but a mechanism
Just-stiff: this is the statically determinate case for which there are the
same number of equilibrium equations as unknown forces. If any member
is removed then a part of the whole of the frame will collapse
Over-stiff: this is the statically indeterminate case in which there are more
unknown forces than available equilibrium equations. There is at least one
member more than is required for the frame to be just stiff
2.9 STRESS STRAIN DIAGRAM:
During testing of a material sample, the stress–strain curve is a graphical

representation of the relationship between stress, derived from measuring
the load applied on the sample, and strain derived from measuring the
deformation of the sample, i.e. elongation, compression, or distortion.
The nature of the curve varies from material to material.
The following diagrams illustrate the stress–strain behaviour of typical

materials in terms of the engineering stress and engineering strain where the
stress and strain are calculated based on the original dimensions of the sample
and not the instantaneous values.
fig 2.29 Stress-strain diagram of ductile material:
Steel generally exhibits a very linear stress–strain relationship up to a well

defined yield point . The linear portion of the curve is the elastic region and
the slope is the modulus of elasticity or Young's Modulus. After the yield
point, the curve typically decreases slightly because of dislocations. As
deformation continues, the stress increases on account of strain hardening
until it reaches the ultimate strength. Until this point, the cross-sectional area
decreases uniformly because of Poisson contractions. The actual rupture
point is in the same vertical line as the visual rupture point.
However, beyond this point a neck forms where the local cross-sectional area
decreases more quickly than the rest of the sample resulting in an increase in
the true stress. On an engineering stress–strain curve this is seen as a decrease
in the stress. Conversely, if the curve is plotted in terms of true stress and true
strain the stress will continue to rise until failure. Eventually the neck
becomes unstable and the specimen ruptures.
2.9 (a) Offset method:
Less ductile materials such as aluminum and medium to high carbon steels
do not have a well-defined yield point.
For these materials the yield strength is typically determined by the "offset
yield method", by which a line is drawn parallel to the linear elastic portion of
the curve and intersecting the abscissa at some arbitrary value (most
commonly 0.2%). The intersection of this line and the stress–strain curve is
reported as the yield point. Also the yield point is how much pressure and
weight a piece of metal can hold before it gets to the elasticity point.
figure 2.30 stress strain diagram for a ductile material
2.9 (b) stress-diagram for brittle material:
Brittle materials such as concrete and carbon fiber do not have a yield point,
and do not strain-harden which means that the ultimate strength and breaking
strength are the same.. Typical brittle materials like glass do not show any
plastic deformation but fail while the deformation is elastic. One of the
characteristics of a brittle failure is that the two broken parts can be
reassembled to produce the same shape as the original component as there
will not be a neck formation like in the case of ductile materials. A typical
stress strain curve for a brittle material will be linear.
Testing of several identical specimen, cast iron, or soil, tensile strength is

negligible compared to the compressive strength and it is assumed zero for
many engineering applications. Glass fibers have a tensile strength stronger
than steel, but bulk glass usually does not. This is because of the Stress
Intensity Factor associated with defects in the material. As the size of the
sample gets larger, the size of defects also grows. In general, the tensile
strength of a rope is always less than the tensile strength of its individual
fibers.
figure 2.31 stress strain diagram for a brittle material
2.9 ( c ) LINEAR ELASTICITY:
Linear elasticity is the mathematical study of how solid objects deform and
become internally stressed due to prescribed loading conditions..
The fundamental "linearizing" assumptions of linear elasticity are:

infinitesimal strains or "small" deformations (or strains) and linear
relationships between the components of stress and strain. In addition linear
elasticity is only valid for stress states that do not produce yielding . These
assumptions are reasonable for many engineering materials and engineering
design scenarios. Linear elasticity is therefore used extensively in structural
analysis and engineering design, often through the aid of finite element
analysis.
2.9 (d) YIELDING:
The yield strength or yield point of a material is defined in engineering and

materials science as the stress at which a material begins to deform
plastically.
Prior to the yield point the material will deform elastically and will return to
its original shape when the applied stress is removed. Once the yield point is
passed some fraction of the deformation will be permanent and non-
reversible.
In the three-dimensional space of the principal stresses (σ1,σ2,σ3), an infinite
number of yield points form together a yield surface.
Knowledge of the yield point is vital when designing a component since it

generally represents an upper limit to the load that can be applied. It is also
important for the control of many materials production techniques such as
forging, rolling, or pressing. In structural engineering, this is a soft failure
mode which does not normally cause catastrophic failure or ultimate failure
unless it accelerates buckling.
fig 2.32
fig 2.33
(e) RESIDUAL STRESSES :
Residual stresses are stresses that remain after the original cause of the
stresses (external forces, heat gradient) has been removed.
They remain along a cross section of the component, even without the
external cause. Residual stresses occur for a variety of reasons, including
inelastic deformations and heat treatment.
Example:
Heat from welding may cause localized expansion, which is taken up during
welding by either the molten metal or the placement of parts being welded.
When the finished weldment cools, some areas cool and contract more than
others, leaving residual stresses.
2.9 (f) STRESS CONCENTRATION:
“A stress concentration (often called stress raisers or stress risers) is a

location in an object where stress is concentrated”
. An object is strongest when force is evenly distributed over its area, so a

reduction in area, e.g. caused by a crack, results in a localized increase in
stress. A material can fail, via a propagating crack, when a concentrated stress
exceeds the material's theoretical cohesive strength. The real fracture strength
of a material is always lower than the theoretical value because most materials
contain small cracks that concentrate stress. Fatigue cracks always start at
stress raisers, so removing such defects increases the fatigue strength.
figure 2.34 stress concenctration
2.9 (g) fatigue strength:
In materials science, fatigue is the progressive and localized structural

damage that occurs when a material is subjected to cyclic loading. The
maximum stress values are less than the ultimate tensile stress limit, and may
be below the yield stress limit of the material.
2.9 (h)ultimate tensile strength:
Tensile strength (σUTS or SU ) is indicated by the maxima of a stress-strain

curve and, in general, indicates when necking will occur. As it is an intensive
property, its value does not depend on the size of the test specimen. It is,
however, dependent on the preparation of the specimen and the temperature
of the test environment and material.
Tensile strength, along with elastic modulus and corrosion resistance, is an

important parameter of engineering materials used in structures and
mechanical devices. It is specified for materials such as alloy, composite
materials, ceramics, plastics and wood.
figure 2.35 figure showing ultimate tensile strength of a ductile material
2.9 (i) frature stress:
The true normal stress on the minimum • cross-sectional area at the

beginning of fracture. In a tensile test, it is the load at fracture divided by the
cross-sectional area of the specimen.
figure 2.36
2.9(j) necking:
Necking, in engineering or materials science, is a mode of tensile deformation

where relatively large amounts of strain localize disproportionately in a
small region of the material
The resulting prominent decrease in local cross-sectional area provides the

basis for the name "neck". Because the local strains in the neck are large,
necking is often closely associated with yielding, a form of plastic
deformation associated with ductile materials, often metals or polymers
figure 2.37 necking
figure 2.38 stress analysis of ductile material showing necking

phenomenon
2.10 OCTAHEDRAL STRESSES:
Considering the principal directions as the coordinate axes, a plane whose

normal vector makes equal angles with each of the principal axes is called an
octahedral plane. There are a total of eight octahedral planes . The normal
and shear components of the stress tensor on these planes are called
octahedral normal stress and octahedral shear stress , respectively
Figure 2.39 octahedral stresses
2.11 VON MISSES CRITERION:
The von Mises yield criterion suggests that the yielding of materials begins
when the second deviatoric stress invariant reaches a critical value . For
this reason, it is sometimes called the -plasticity or flow theory. It is part of a
plasticity theory that applies best to ductile materials, such as metals. Prior to
yield, material response is assumed to be elastic.
In material science and engineering the von Mises yield criterion can be also
formulated in terms of the von Mises stress or equivalent tensile stress, , a
scalar stress value that can be computed from the stress tensor. In this case, a
material is said to start yielding when its von Mises stress reaches a critical
value known as the yield strength, . The von Mises stress is used to predict
yielding of materials under any loading condition from results of simple
uniaxial tensile tests. The von Mises stress satisfies the property that two
stress states with equal distortion energy have equal von Mises stress.
Figure 2.40 von-misses criterion yield envelope
2.12 PLANE STRESS:
A state of plane stress exist when one of the three principal , stresses is zero.
This usually occurs in structural elements where one dimension is very small
compared to the other two, i.e. the element is flat or thin. In this case, the
stresses are negligible with respect to the smaller dimension as they are not
able to develop within the material and are small compared to the in-plane
stresses. Therefore, the face of the element is not acted by loads and the
structural element can be analyzed as two-dimensional, e.g. thin-walled
structures such as plates subject to in-plane loading or thin cylinders subject
to pressure loading.
Figure 2.41
2.13 PLANE STRAIN:
If one dimension is very large compared to the others, the princpal strain
in the direction of the longest dimension is constrained and can be assumed
as zero, yielding a plane strain condition.
In this case, though all principal stresses are non-zero, the principal stress in
the direction of the longest dimension can be disregarded for calculations.
Thus, allowing a two dimensional analysis of stresses, e.g. a dam analyzed at
a cross section loaded by the reservoir.
figure 2.42 plane stress and plane strain
2.14 MOHR STRESS CIRCLE:
The Mohr's circle, named after Otto mohr
is a two-dimensional graphical representation of the state of stress at a

point.
The abscissa , , and ordinate , , of each point on the circle are the normal
stress and shear stress components, respectively, acting on a particular cut
plane with a unit vector with components . In other words, the circumference
of the circle is the locus of points that represent state of stress on individual
planes at all their orientations.
Mohr stress circle for plane stress and plane strain:
The circle represents all possible states of normal and shear stress on any
plane through a stressed point in a material.
σ n – ½ ( σ x + σ y ) = 1/ 2 (σ x - σ y ) cos 2θ + τ xy sin 2θ
-τ s = ½ (σ x - σ y ) sin 2θ - τ xy cos 2θ
squaring both sides and adding the equations;
[σ n – ½ ( σ x + σ y ) ] ^2 + τ s ^ 2 = ¼ (σ x - σ y ) ^ 2 + τ xy ^ 2
this the equation of circle of radius
[ 1 /4(σ x - σ y ) ^ 2 + τ xy ^ 2] ^1/2
Figure 2.43
SIGN CONVENTIONS:
The sign conventions used on the circle will be, for normal stress, positive to
right and negative to the left of the origin. Shear stresses which might be
described as trying to cause a clockwise rotation of an element are plotted
above the abscissa axis i.e, “positive” and shear stresses appearing as
antclockwise rotation are plotted above the axis i.e, “negative”.
Maximum shear stress:
τ smax = [1 /4(σ x - σ y )^2 + τ xy ^ 2 ] ^ 1/2 τ xy
plane on which maximum shear stress acts is calculated by the formula
tan 2θ = - (σ x - σ y / 2 τ xy)
principle stresses and planes:
σ1=( σ x +σ y)/2 + ½ [σ x - σ y )^2 +4τ xy ^ 2] ^1/2
σ 2 =( σ x +σ y)/2 – 1/2[σ x - σ y )^2 +4τ xy ^ 2] ^1/2

planes:
θ = ½ tan -1 ( 2τxy/ σx-σy)
maximum shear stress in terms of principal stresses:
τ smax = ½ (σ1 - σ 2)
2.14 (b) mohr stress circle in three dimensional state of stress:
figure 2.44
to obtain the true maximum shear stress for use in design calculations it is
necessary to consider all three principal planes. The three dimensional
element subjected to the principal stresses is considered. The principal stress σ
3 is zero in this principal case because only plane stress condition is
considered. Considering each of the three principal stresses to be labeled as 1,
2 and 3 it is possible to construct the Mohr’s diagram for each. Then the
composite Mohr’s diagram is constructed by superimposing these diagrams
then enables the maximum shear stress in the material to be determined.
figure 2.45 [12]

2.15
CYLINDER UNDER PRESSURE:
A
equation A;
CASE STUDY : STRESS ANALYSIS OF THICK WALLED
CYLINDER:
Figure 7. Mohr's circle for a three-dimensional state of stress
CASE STUDY: THIN WALLED THEROY APPLIED TO
CYLINDRICAL ANALYSIS
COMBINED STRESSES IN PRESSURE VESSELS:
THIN-WALLED PRESSURE VESSEL:
thin-walled pressure vessel

A
Cylindrical thin-walled pressure vessel showing co-ordinate axes

And cutting planes ( a, b and c)
free body diagram of segment of cylindrical pressure vessel

showing pressure and internal hoop stresses
free body diagram of end section of cylindrical thin-walled
pressure vessel
showing pressure and internal axial stress
SPHERICAL PRESSURE VESSEL:
Spherical pressure vessel can be analyzed in the similar way as the

cylindrical pressure vessel. The axial stresses results from the pressure acting
on the projected area of the sphere such that;
free body diagram of end section of spherical thin-walled pressure

vessel showing pressure and internal hoop and axial stresses
Analysis of equation A and C shows that element either cylindrical or

spherical is subjected to biaxial stresses ( a normal stress acting in two
direction)
THICK WALLED PRESSURE VESSEL:
stress distribution of radial and hoop stresses
elasticity method is used for thick walled pressure vessel it is very difficult
only results are displayed
[13]
CHAPTER # 4
DESIGN OF PRESSURE VESSEL
CONTENTS:
 Summary
 Diagram
 Material Properties
 Shell & Plate design
 Head design
 N-1 4`` sch-160
 N-2 4`` sch-160 on head
 N-1&N-2 Flanges
 N-3 1``NPT6000# H.cplg
 N-4&N-5 4`` process conn
 M-1 12``x16`` MWY on shell
 M-2 12``x16`` MWY on Head
 Vessel Weight & Volume
 Lifting Lugs
Pressure Vessel Design Summary:
PVE Sample Vessels Customer
Sample Vertical Vessel Vessel
Sample 4 Part Number
Sample 4 Drawing
Sample 4 Job
60" Outside Diameter [inch]

120" straight Shell (not including straight flange on heads)
213 Volume [cuft]
Non-lethal Fluid (value from Material Properties)
6000 Weight Empty [lbs.]
19000 Weight Full
19000 Weight Under Test
Maximum Internal pressure, psi Maximum External Pressure, psi At Temperature, ºF

Maximum Allowed Working Pressure
150 0 120
Maximum Temperature, ºF Minimum Temperature, ºF At Pressure, psi
Maximum Design Metal Temperature
120 -20 150
Test Pressure, psi At a Minimum Temperature of: ºF For a Minimum Duration of:
Hydrostatic Test
195 Ambient 1/2 hr
0.75 Seismic Zone

0.3 Foundation Factor
SA-516 Gr.70 Primary Material of Construction

20,000 Allowable Stress
0.09375 Minimum allowed thickness per UG-16(b)
No Material Normalized
No Material Impact Tested (not required per UG-20(f))
None Radiography required
0.125 Corrosion Allowance
ASME VIII-1 Code

2007 Edition
- Addenda
IID Materials
None Code Cases Required
UG-22 Loadings Considered

Yes (a) Internal pressure
No (a) External pressure
Yes (b) Vessel weight full, empty and at hydro
No test (c) Weight of attached equipment and
No piping (d)(1) Attachment of internals
Yes (d)(2) Attachment of vessel supports
No (d) Cyclic or dynamic reactions
No (f) Wind
No (f) Snow
Yes (f) Seismic
No (g) Fluid impact shock reactions
No (h) Temperature gradients
No (h) Differential thermal expansion
No (i) Abnormal pressures like deflagration
1 Material Properties ver
2
2.01
3 Sample Vertical Vessel <- Vessel
4
5 Design Pressure UG-

6 22(a) 150.0 <- P, internal operating pressure at top of vessel (psig)
7 0.0 <- mPa, external operation pressure
8 Water. fresh <- Operating Fluid
9 12.000 <- h, fluid height (ft)
10 1.000 <- rho, fluid density (1.0 for water)
11 Design Pressure = P + 0.4331*rho*h = 150 + 0.4331 * 1 * 12 mDp = 155.2
12
13 Hydro Test (UG-99(b)) pressure measured at top of vessel, rounded up

14 Test Press = P * 1.3 * MR = 150 * 1.3 * 1 mTp = 195
15
16 Material (ASME IID)

17 Properties 120 <- mTemp, design temp ºF Test at ambient temp
Material Where Used Ambient Design Strength Max ºF Ext
18 Strength Strength Ratio Graph
19 SA-516 70 Plate Shell, Heads 20000 20000 1.000 1000 CS-2
20 SA-106 B Seamless Pipe Nozzles, Manway 17100 17100 1.000 1000 CS-2
21 SA-240 316 Plate Flange Pads 20000 20000 1.000 1500 HA-2
22 SA-105 Forging Flanges, Couplings 20000 20000 1.000 1000 CS-2
23 SA/CSA-G40.21 44W (38W Stresses used) Legs 17100 17100 1.000 650 CS-2
24 SA-193 B7 Bolts <= 2.5" 25000 25000 1.000 1000
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44 Min Ratio (MR) = 1.000

45
46
47
48
1 Pipe and Shell :
2 Rolled Plate Shell Description
Do
3 Options:
4 Interior ip? - Calculate interior pressure
5 No Exterior ep? - Calculate exterior pressure
pr? - Pipe or rolled plate
t
6 Rolled Plate
7 Non-Threaded pt? - Type of pipe
Length
No relief? - Stress Relief Calculations Required
Long Seam
8
9 Dimensions:
10 60.000 Do [in] - outside diameter
11 0.5000 t [in] - nominal wall thickness
12 0.094 tminUG16b [in] - minimum wall per UG-16(b)
13 120.000 L [in] - length for volume and weight
14 0.125 Corr [in] - corrosion allowance
15 Material and Conditions:
16 SA-516 70 Material
17 20,000 S [psi] - allowable stress level
18 0.70 El - longitudinal efficiency (circ. stress)
19 0.70 Ec - circ. connecting efficiency (longitudinal stress)
20 0.000% UTP [%] - undertolerance allowance
21 0.000 UTI [in] - undertolerance allowance
22 155.20 P [psi] - interior pressure
23 Stress Classification:
24 NOTE: Both validity checks need to be "Acceptable" in order to use this sheet
25 If not, refer to sheet "Thick Cylindrical Shell"
26 ckValidity1 = tmin < 0.5*(Do/2) 0.331 < 0.5*(60/2) = Acceptable
27 ckValidity2 = P< 0.385*S*El 155.2< 0.385*20000*0.7 = Acceptable
28 Variables:
29 Td = 0.000 0= 0.000
30 UT [in] = t*UTP+UTI 0.5*0+0 = 0.000
31 nt [in] = t-Corr-UT-Td 0.5-0.125-0-0 = 0.375
32 Ri [in] = Do/2-nt 60/2-0.375 = 29.625
33 Volume [cuft] = ((Do/2-t)^2)* *L/1728 ((60/2-0.5)^2)*3.1416*120/1728 = 189.859
Weight [lb] = (Do-t)* *L*t*40.84/144
34 (60-0.5)*3.1416*120*0.5*40.84/144 = 3180.84
35 Interior Pressure: VIII-1 UG-27(c)(1,2)
36 ta [in] = P*Ri/(S*El-0.6*P) 155.2*29.625/(20000*0.7-0.6*155.2) = 0.331
37 tb [in] = P*Ri/(2*S*Ec+0.4*P) 155.2*29.625/(2*20000*0.7+0.4*155.2) = 0.164
38 tmin [in] = MAX(ta,tb,tminUG16b) MAX(0.331,0.164,0.094) = 0.331
39 tr1 [in] = P*Ri/(S*1-0.6*P) 155.2*29.625/(20000*1-0.6*155.2) = 0.231
40 Checkt = tmin <= nt 0.331 <= 0.375 = Acceptable
41 PMaxA [psi] = (S*El*nt)/(Ri+0.6*nt) (20000*0.7*0.375)/(29.625+0.6*0.375) = 176
42 PMaxB [psi] = (2*S*Ec*nt)/(Ri-0.4*nt) (2*20000*0.7*0.375)/(29.625-0.4*0.375) = 356
43 PMax [psi] = Min(PMaxA,PMaxB) MIN(176,356) = 176
44 CheckP = PMax >= P 176 >= 155.2 = Acceptable
39 Heads : Torispherical
40

42 F & D Heads <- Desc
43
44 Dimensions:
45 60.000 <- Do, outside diameter
48 60.000 <- L, inside crown radius
49 3.600 <- IKR, inside knuckle radius
51 0.750 <- tb, thickness before forming
53 0.675 <- tf, thickness after forming
54 0.094 <- tminUG16(b) - Min.t. Per UG-16(b)
55 0.125 <- Corr, corrosion allowance
56 1.500 <- Skirt, straight skirt length
57
58 Material and Conditions:

59 SA-516 70 <- material
60 20,000 <- S, allowable stress level (psi)
61 0.85 <- E, efficiency
65 155.2 <- P, interior pressure
66 0.0 <- Pa, exterior pressure
69
70 Calculated Properties:
74 68.7 <- Approx. blank dia (inch) 11.66 <- Volume (cuft, includes skirt)
75 789.5 <- Approx. weight (lbs, steel) 54.574 <- Spherical Limit
76 9.770153 <- Depth of Head
78
115 Variables:
116 D= Do-2*t = 60-2*0.55 D= 58.90
123 t= tf-corr = 0.675-0.125 t= 0.55
125 L /r = L/IKR = 60/3.6 L /r = 16.667
126 M= 0.25*(3+sqrt(L/ikr)) = 0.25*(3+sqrt(60/3.6)) M= 1.771
128 Ro = L + tb = 60 + 0.75 Ro = 60.750
131
134 Interior Pressure App 1-4(a), App 1-4(d):

137 App. 1-4(a) check: 0.0005 =< tf/L < 0.002 = 0.0005=<0.675/60<0.002 tf/L = 0.0113
138 IF(tf/L<0.002,IF(tf/L>=0.0005,"Calculation required","Error"),"Calculation not required") App. 1-4(f) calculation not required
141 TMinI = (P*L*M)/(2*S*E - 0.2*P) <= t TminI = 0.485
142 = (155.197*60*1.771)/(2*20000*0.85 - 0.2*155.197) <= 0.55
146 TMin = Max(Tminl,tminUG16(b))<=tf-corr Acceptable TMin = 0.485
149 PMax = (2*S*E*t)/(L*M + 0.2*t) >= P (2*20000*0.85*0.55)/ Acceptable PMax = 175.8
150 = (60*1.771 + 0.2*0.55) >= 155.197
153
157 Interior Pressure for Nozzles App 1-4(a), App 1-4(d), UG-37(a)(1):
158 TMinE1 = (P*L*M)/(2*S*1 - 0.2*P) <= t (Nozzle in Knuckle) TMinE1 = 0.413
159 = (155.197*60*1.771)/(2*20000*1 - 0.2*155.197) <= 0.55
165 TSp = (P*L*1)/(2*S*1 - 0.2*P) (155.197*60*1)/ (Nozzle in Crown) Tsp = 0.233
166 = (2*20000*1 - 0.2*155.197)
167
177 Head stress relief UCS-79(d), UNF-79(d), UHA-44(d)

180 Rf = IKR+tb/2 = 3.6+0.75/2 Rf = 3.975
181 % elong = ((75*tb)/Rf)*(1-Rf/Ro) = ((75*0.75)/3.975)*(1) % elongation = 14.2
184 5.0% <- Max Elongation
185 Yes <- Cold Formed 14.2% <- Elongation Required Yes ?
186 no <- Vessel carries lethal substances(Yes/no) no no
187 no <- Impact testing is required (Yes/no) no no
188 no <- Formed between 250 and 900 Degrees F no no
189 no <- Greater than 10% reduction in thickness no no
190 Yes <- Head is greater than 5/8" thick before forming Yes ? YES
191 Stress Relieve ? YES
30 Nozzle Reinforcement UW16(c) <- SavedDesign
31 Automatic dh - not hillside
22 Sample Vertical Vessel <- Vessel Automatic Limit Diameter
33 N1 - 4" SCH 160 Pipe <- Description Curved Shell or Head Section
34 Shell:
35 SA-516 70 <- Shell Material
36 20,000 <- Sv, shell allowable stress level, PSI Do
37 1.00 <- E1, efficiency of shell at nozzle
38 59.00 <- Ds, Shell ID Nt
39 0.500 <- Vt, shell wall thick, uncorroded, UT removed
40 0.231 <- tr, required shell wall thickness int. press.(E=1) t
0.000 <- trE, required shell wall thickness ext. press.
41
Leg41
Nozzle
42 0.125 (E=1)
43 0.094 <- sca, shell corrosion allowance
44 Nozzle: <- tmin16b, Min allowed wall per UG-16(b) Leg4 1 She ll
45 SA-106B <- Nozzle Material
46 17,100 <- Sn, allowable stress level (Sn) Vt
47 17,600 <- B, from A = 0.09590
48 1.00 <- E, nozzle efficiency
49 155.20 <- P, internal design pressure
50 0.0 <- Pa, external design pressure UW-16 .1 (c)
54 0.531 <- Nt, wall thick, uncorroded
55 12.5% <- UTp, undertolerance (%)
57 0.125 <- nca, nozzle corrosion
58 6.000 allowance
61 Reinforcing: <- L, exterior Projection
71 0.375 <- Leg41, size of weld fillet
74 1.000 <- F
87 Variables:
88 UT = Nt*UTp = 0.531 * 0.125 Undertolerance UT = 0.066
90 Rn = Do/2 - (Nt-nca) + UT = 4.5/2 - (0.531-0.125) + 0.066 Effective Radius Rn = 1.910
95 t = Vt-sca = 0.5 - 0.125 Effective Shell Thickness t = 0.375
101 tn = Nt-nca Do- = 0.531-0.125 Avail. Nozzle Thick. No UT tn = 0.406
102 d = 2*tn = 4.5 - 2*0.406 Opening Dia. d = 3.688
108 fr1 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr1 = 0.855
111 fr2 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr2 = 0.855
127 tcLeg41 = Min(0.25,0.7*Min(0.75,tn,t)) = Min(0.25,0.7*Min(0.75,0.406,0.375)) tc41 = 0.250
133 F = Min(Fenterered, 1) F = 1.000
141 Pipe Required Wall Thickness - trn from internal, trnE from external
142 pressure LDo = L/Do LDo = 1.333 Dot = Do/trnE Dot = 0.000
143 trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT = (155.2*1.91)/(17100*1 - 0.6*155.2) trn = 0.017 Acceptable
145 trnR = (P*Rn)/(Sn*1 - 0.6*P) = (155.2*1.91)/(17100*1 - 0.6*155.2) E=1 trnR = 0.017
146 trnE = (3*Do*Pa)/(4*B) <= tn-ut = (3*4.5*0)/(4*17600) trnE = 0.000 Acceptable
148 Geometry Constraints:
149 0.7*Leg41 >= tc41 0.7*0.375 >= 0.25 0.263 >= 0.250 Acceptable
180 Appendix 1-7 Necessary
181 CheckDs>60,if(2*Rn<=Ds/3,if(2*Rn<=40, "App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations
when
182 required")
183 when Ds<=60,if(2*Rn<Ds/2,if(2*Rn<20,"App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
207 Area Replacement: Fig UG-37.1 App. 1-7 calculations
Pressure From:not Internal
required External
208 A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1) A Required (internal) = 0.879
209 = 1.0*3.688*0.231*1 + 2*0.406*0.231*1*(1-
212 Ae = 0.855)
0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1)) = 0.5*(3.688*0*1 + 2*0.406*0*1*(1- A Requ ired (external) = 0.000
215 0.855))
A1 = max(d, 2*(t+tn)) * (E1*t-F*tr)-2*tn*(E1*t-F*tr)*(1-fr1) A1 = 0.514
216 = max(3.688,2*(0.375+0.406))* (1*0.375-1*0.231)-2*0.406*(1*0.375-1*0.231)*(1-
219 A1e = 0.855) A1e = 1.339
220 = max(d, 2*(t+tn)) * (E1*t-F*trE)-2*tn*(E1*t-F*trE)*(1-fr1)
225 A2 = max(3.688,2*(0.375+0.406))* (1*0.375-1*0)-2*0.406*(1*0.375-1*0)*(1- A2 = 0.623
226 = 0.855) min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L))
230 A2e = min((0.406-0.017)*0.855*Min(5*0.375,2*6) , (0.406-0.017)*0.855*Min(5*0.406,2*6)) A2e = 0.651
231 = min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L))
240 A41 = Leg41^2*fr2
min((0.406-0)*0.855*Min(5*0.375,2*6) , (0.406-0)*0.855*Min(5*0.406,2*6))
= 0.375^2*0.855 A41 = 0.120 0.120
249 Actual Area = 1.257 2.110
250 Acceptable Actual-Required = 0.378 2.110
331 Tstd = Standard pipe wall thickness from Tstd =0.237
332 Swre = chart
tr * Pa / P = 0.231 * 0 / 155.197 Req. Exterior pressure Swre = 0.000
333 Nact = Nt * (1-UTp) = 0.531 * (1-0.125) Actual Wall Thick. Nact = 0.465
334 Tt = 0.8/Nth = 0.8/0 Ug-31(c)(2) threads Tt =0.000
335 UG-45 Acceptable
336 UG45 = Max(UG45a, UG45b) <= = Max(0.142, 0.332) <= 0.465 UG45 = 0.332
337 UG45a = Nact Max(trn,trnE) + Nca + Tt = Max(0.017,0) + 0.125 + 0 UG45a = 0.142
338 UG45b = Min(UG45b3,UG45b4) = Min(0.356, 0.332) UG45b = 0.332
339 UG45b1 = Max(tr + Sca, tmin16b + Sca) = Max(0.231 + 0.125, 0.094 + 0.125) UG45b1 = 0.356
340 UG45b2 = Max(Swre + Sca,tmin16b + = Max(0 + 0.125,0.094 + 0.125) UG45b2 =
341 UG45b3 = Sca) Max(UG45b1,UG45b2) = Max(0.356,) UG45b3 = 0.356
342 UG45b4 = Tstd*0.875 + Nca = 0.237*0.875 + 0.125 UG45b4 = 0.332
30 Nozzle Reinforcement
33 N2 - 4" SCH 160 Pipe on Bot. Head <- Description Curved Shell or Head Section
34 Shell:
39 0.500 <- Vt, shell wall thick, uncorroded, UT removed Nt
40 0.233 <- tr, required shell wall thickness int. press.(E=1)
41 0.000 <- trE, required shell wall thickness ext. press.(E=1) t
0.125 <- sca, shell corrosion allowance
42
Leg41
0.094 <- tmin16b, Min allowed wall per UG-16(b)
Nozzle
43
44 Nozzle:
45 SA-106B <- Nozzle Material Leg4 1 Shell
46 17,100 <- Sn, allowable stress level (Sn)
47 17,600 <- B, from A = 0.09590 Vt
48 1.00 <- E, nozzle efficiency
50 0.0 <- Pa, external design pressure
51 4.500 <- Do, outside diameter UW- 16.1 (c)
57 0.125 <- nca, nozzle corrosion allowance
58 6.000 <- L, exterior Projection
61 Reinforcing:
74 1.000 <- F
87 Variables:
88 UT = Nt*UTp = 0.531 * 0.125 Undertolerance UT = 0.066
90 Rn = Do/2 - (Nt-nca) + UT = 4.5/2 - (0.531-0.125) + 0.066 Effective Radius Rn = 1.910
95 t = Vt-sca = 0.5 - 0.125 Effective Shell Thickness t= 0.375
101 tn = Nt-nca Do- = 0.531-0.125 Avail. Nozzle Thick. No UT tn = 0.406
102 d = 2*tn = 4.5 - 2*0.406 Opening Dia. d= 3.688
108 fr1 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr1 = 0.855
111 fr2 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr2 = 0.855
133 F = Min(Fenterered, 1) F= 1.000
141 Pipe Required Wall Thickness - trn from internal, trnE from external pressure
142 LDo = L/Do LDo = 1.333 Dot = Do/trnE Dot = 0.000
207 Area Replacement: Fig UG-37.1 Pressure From: Internal External
209 = 1.0*3.688*0.233*1 + 2*0.406*0.233*1*(1-0.855)
212 Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1)) = 0.5*(3.688*0*1 + 2*0.406*0*1*(1-0.855)) A Requi red (external) = 0.000
215 A1 = max(d, 2*(t+tn)) * (E1*t-F*tr)-2*tn*(E1*t-F*tr)*(1-fr1) A1 = 0.507
216 = max(3.688,2*(0.375+0.406))* (1*0.375-1*0.233)-2*0.406*(1*0.375-1*0.233)*(1-0.855)
219 A1e = max(d, 2*(t+tn)) * (E1*t-F*trE)-2*tn*(E1*t-F*trE)*(1-fr1) A1e = 1.339
220 = max(3.688,2*(0.375+0.406))* (1*0.375-1*0)-2*0.406*(1*0.375-1*0)*(1-0.855)
225 A2 = min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L)) A2 = 0.623
226 = min((0.406-0.017)*0.855*Min(5*0.375,2*6) , (0.406-0.017)*0.855*Min(5*0.406,2*6))
230 A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L)) A2e = 0.651
231 = min((0.406-0)*0.855*Min(5*0.375,2*6) , (0.406-0)*0.855*Min(5*0.406,2*6))
240 A41 = Leg41^2*fr2 = 0.375^2*0.855 A41 = 0.120 0.120
249 Actual Area = 1.250 2.110
331 Tstd = Standard pipe wall thickness from chart Tstd = 0.237
332 Swre = tr * Pa / P = 0.233 * 0 / 155.197 Req. Exterior pressure Swre = 0.000
333 Nact = Nt * (1-UTp) = 0.531 * (1-0.125) Actual Wall Thick. Nact = 0.465
334 Tt = 0.8/Nth = 0.8/0 Ug-31(c)(2) threads Tt = 0.000
336 UG45 = Max(UG45a, UG45b) <= Nact = Max(0.142, 0.332) <= 0.465 UG45 = 0.332
337 UG45a = Max(trn,trnE) + Nca + Tt = Max(0.017,0) + 0.125 + 0 UG45a = 0.142
340 UG45b2 = Max(Swre + Sca,tmin16b + Sca) = Max(0 + 0.125,0.094 + 0.125) UG45b2 =
341 UG45b3 = Max(UG45b1,UG45b2) = Max(0.358,) UG45b3 = 0.358
342 UG45b4 = Tstd*0.875 + Nca = 0.237*0.875 + 0.125 UG45b4 = 0.332
18 B16.5/16.47 Flange SlipOn
19
20

22 N1 & N2 - 4" Class 150 RFSO <- Description
23
24 Select Flange
25 SA <- Category
26 Forged <- Material Type
27 SA 105 <- Material
28 150 <- Pressure Class
29 4.00 <- Nominal Size
31
32 Nominal - C-Si
33 Table - 2-1.1
34 Max Temp ºF - 1000
35 Pod, pipe OD - 4.500
36 Nozzle
37 0.531 <- tn, Nozzle Wall Thickness (inch)
38 0.017 <- tnr, Required Nozzle Wall Thickness (inch)
39
40 Operating Conditions Acceptable

41 120 <- T, temperature ºF Max press @100ºF [p1] 285
42 155.2 <- P, pressure, psig Max press @120ºF [p2] 280
43 0.125 <- Corr, corrosion allowance
44
45 Flange Welds:
47 0.531 <- F1, pipe fillet size
48 0.531 <- F2, flange fillet size F2
49 17100 <- Sp, allowable stress, pipe
50 20000 <- Sf, allowable stress, flange
53
54 Geometry constraint: VIII UW-21 (b)

61 wtmin = 0.7*tn = 0.7*0.531 Req. weld throat wtmin = 0.372
63 wt = 0.7*MIN(F1,F2) Actual weld throat wt = 0.372
64 = 0.7*MIN(0.531,0.531) Acceptable
67
68 Weld Strength:
69 Min Sa = MIN(Sp,Sf) = MIN(17100,20000) Min Sa = 17,100
70 Max Weld Stress = Sa * 0.49 = 17100 * 0.49 Max S = 8,379
72 Weld Load = POD^2*pi*P/4 = 4.5^2*pi*155.197/4 Load = 2,468
74 Weld Area = Pod*pi*(F1-corr + F2) Area = 13.247
75 = 4.5*pi*(0.531-0.125 + 0.531)
78 Weld Stress = Load/Area = 2468.305/13.247 Stress = 186
79 Acceptable
81
82
83
15 Coupling UW16.1Z1M
16

18 N3 - 1" Class 6000 NPT Half Coupling <- Description
COD
20 Shell:
FUL
23 0.675 <- t, Shell Wall Thick (inch) POD t L
24 0.233 <- tMin, Min Required Wall at E=1 (inch) F1
PEN.
26 1.875 <- D, Shell Opening Diameter (inch) Outsid
28 155.2 <- P,design Pressure (psi) e
29 t
t1
30 Coupling:
Inside
31 1 inch 6000# <- Coupling Vessel
32 SA-105 <- Coupling Material
D
33 20,000 <- Sn, Allowable Stress Level (Sn)
35 0.3750 <- F1, Weld Size
37 0.094 <- tmin16b, Min allowed wall per UG-16(b) UW-16.1 (Z-1)
38 0.125 <- Corrc, Coupling Corrosion Allowance (inch) (Modified)
39 2.250 <- COD - Coupling OD
40 1.315 <- POD - Pipe OD
42 11.500 <- n, Threads Per Inch
44 0.358 <- pt, Corresponding sch XXS Wall Thickness (inch)
46 12.5% <- UT, Under Tolerence (%)
47
49 Geometry Restrictions Fig. UW-16.1

50 tcp = (COD-POD)/2-CORRC = (2.25-1.315)/2-0.125 Tcp = 0.343
51 Tmin = Min(0.75,tcp,t) = Min(0.75,0.343,0.675) Tmin = 0.343
53 tcmin = Min(0.25,0.7*Tmin) = Min(0.25,0.7*0.343) tcmin = 0.240
56 t1 = 0.7*F1 = 0.7*0.375 t1 = 0.263
64 t1 > = tcMin = 0.263 >= 0.24 Acceptable
74
75 Required Coupling Wall Thickness UG-44(c), B16.11 - 2.1.1 and UG-31(c)(2)

76 Ro = POD/2-0.8/n = 1.315/2-0.8/11.5 Ro = 0.588
77 tp = (1-UT)*pt-Corrc-0.8/n = (1-0.125)*0.358-0.125-0.8/11.5 tp = 0.119
78 Min Thick = P*Ro/(Sn*1+0.4*P) = 155*0.588/(20000*1+0.4*155. Acceptable trn = 0.005
79
80 Pressure Weld Stress UW-18(d) - Pressure Load only UW-16(f)(3)(a)(3)(b)

81 Load = COD^2*(PI()/4)*P = 2.25^2*(PI()/4)*155.197 Load = 617
82 Weld Area = pi()*((COD+F1)^2-COD^2)/4 Weld Area = 1.436
83 = pi()*((2.25+0.375)^2-2.25^2)/4
88 Max Stress = Min(Sn,Sv) * 0.55 = Min(20000,0) * 0.55 Max Stress = 11000
89 Weld Stress = Load / Area = 617 / 1.436 Weld Stress = 430
90 Acceptable
95 UG-45
96 Tstd = Standard pipe wall thickness from chart Tstd = 0.133
97 Nact = Pt * (1-UT) Actual Wall Thick. Nact = 0.313
98 Tt = 0.8/n Ug-31(c)(2) threads Tt = 0.070
99 UG45 = Max(UG45a, UG45b) <= Nact UG45 = 0.241
100 = Max(0.199, 0.241) <= 0.313 Acceptable
101 UG45a = trn + corrc + Tt UG45a = 0.199
102 0.005 + 0.125 + 0.07
103 UB45b = Min(UG45b1, UG45b4) UB45b = 0.241
104 = Min(0.358, 0.241)
105 UG45b1 = Max(tmin+ CORRC, Tmin16b + CORRC) UG45b1 = 0.358
106 = Max(0.233 + 0.125, 0.094 + 0.125)
107 UG45b4 = Tstd*0.875 + corrc = 0.133*0.875 + 0.125 UG45b4 = 0.241
108
109
30 Nozzle Reinforcement UG40(a-2) <- SavedDesign
33 N4 & N5 - 4" Double Sided Flange Pad <- Description Curved Shell or Head Section
34 Shell:
36 20,000 <- Sv, shell allowable stress level, PSI Full
F
t Penn.
37 1.00 <- E1, efficiency of shell at nozzle Dp
Leg42
39 0.500 <- Vt, shell wall thick, uncorroded, UT removed
40 0.231 <- tr, required shell wall thickness int. press.(E=1) Leg42 Shell
41 0.000 <- trE, required shell wall thickness ext. press.(E=1) tp
42 0.125 <- sca, shell corrosion allowance di Vt
62 Flange Pad: UG-4 0 (a-2)
64 SA-240 316 <- Flange Pad Material
65 20,000 <- Sp, allowable stress level
66 9.000 <- Dp, outside diameter
67 4.500 <- di, inside (uncorroded)
70 1.500 <- tp, pad thick
74 1.000 <- F
77 5.500 <- GOD - gasket OD
78 4.500 <- GID - gasket ID
79 3.000 <- m - gasket factor
80 1,800 <- gy - gasket factor y
81 7.500 <- varC - bolt circle dia
82 0.625 <- BoltOD, bolt size
83 8 <- Nbolt, number of bolts
84 1.000 <- DepthT, depth of bolt holes
85 25,000 <- Sb - allowable bolt stress at DESIGN temp
86 25,000 <- Sba - allowable bolt stress at ASSEMBLY temp
87 Variables:
91 Dp = Min(2*d,DpEntered) = Min(2*4.75,9) Effective Reinforcing Dp = 9.000
98 te = tp-Vt = 1.5-0.5 Effective Reinf. Thick. te = 1.000
104 d = di+2*nca = 4.5 - 2 * 0.125 Finished Opening Dia. d= 4.750
112 fr2 = MIN(Sp/Sv,1) = MIN(20000/20000, 1) fr2 = 1.000
115 fr4 = MIN(Sp/Sv,1) = MIN(20000/20000,1) fr4 = 1.000
119 varN = (GOD-GID)/2 = (5.5-4.5)/2 Gasket Width in Contact varN = 0.500
120 b0 = varN / 2 = 0.5 / 2 gasket seating width b0 = 0.250
121 varb = min(Sqrt(b0)/2,b0) = min(Sqrt(0.25)/2,0.25) eff seating width varb = 0.250
122 varG = max(GOD-2*varb,(GOD-GID)/2 + GID) gasket load reaction diameter varG = 5.000
123 = max(5.5-2*0.25,(5.5-4.5)/2 + 4.5)
124 Ro = Dp/2 = 9/2 Ro = 4.500
130 tcLeg42 = Min(0.25,0.7*MIN(0.75,te,t)) = Min(0.25,0.7*MIN(0.75,1,0.375)) tc42 = 0.250
133 F = Min(Fenterered, 1) F = 1.000
185 Bolt Loads:
199 H = 0.785*varG^2*P = 0.785*5^2*155.197 end load H= 3046
200 HP = 2*varb*3.14*varG*m*P = 2*0.25*3.14*5*3*155.197 contact loadHP = 3655
201 HD = pi/4 * di^2 * P = pi/4 * 4.5^2 * 155.197 end load HD = 2468
202 HT = H - HD = 3046 - 2468 face load HT = 577
203 Wm1 = H + HP pi*varb*varG*gy = 3046 + 3655 bolt load Wm1 = 6701
204 Wm2 = max(Wm1/Sb, Wm2/Sa) = pi*0.25*5*1800 seating load Wm2 = 7069
205 Am = Root*Nbolt >= Am = max(6701/25000, 7069/25000) req bolt area Am = 0.283
206 Ab = = 0.207*8 Acceptable Ab = 1.656
210 A = 1.0*d*tr*F = 1.0*4.75*0.231*1 A Required (internal) = 1.097
213 Ae = 0.5*d*trE*1 = 0.5*4.75*0*1 A Required (external) = 0.000
217 A1 = (d)* (E1*t-F*tr) = (4.75) * (1*0.38-1*0.23) A1 = 0.684
221 A1e = (d) * (Eone*t-F*trE) = (4.75) * (1*0.375-1*0) A1e = 1.781
237 A5 = ((Dp - d)te-BoltOD*DepthT*2)*fr4 = ((9-4.75)*1-0.625*1*2)*1 A5 = 3.000 3.000
245 A42 = Leg42^2*fr2 = 0.5^2*1 A42 = 0.250 0.250
249 Actual Area = 3.934 5.031
1 Flange
2 ASME VIII Div I Appendix 2
3 N4 & N5 - 4" Process Connections Description
4 Dimensions: hG
5 Fig2-13.2modified fd? - Select a flange design W

6 9.000 A [in] - flange OD HG
7 4.500 Bn [in] - ID, uncorroded B
t
8 1.500 t [in] - flange thickness
tn Shell hT
9 0.500 tn [in] - nozzle wall thickness
Gasket: HD HT
10 G
11 5.500 GOD [in] - gasket OD hD C
12 4.500 GID [in] - gasket ID A
13 3.00 m - gasket factor
Fig 2-13.2 Modified
14 1,800 gy - gasket factor y
15 Bolting:
16 7.500 varC [in] - bolt circle dia
17 0.625 BoltOD [in] - bolt size
18 8.0 Nbolt - number of bolts
19 1.000 DepthT [in] - thread depth
20 0.500 Leg1 [in]
21 Operating Conditions:
22 0.125 Corr [in] - corrosion allowance
23 155.2 P [psi] - internal operating pressure
24 Material Properties:
25 NonCast CastMaterial? - Cast Or NonCast
26 20,000 Sf [psi] - allowable flange stress at DESIGN temp.
27 20,000 Sfa [psi] - Allowable Flange Stress at ASSEMBLY temp.
28 27,900,000 Efo [psi] -Operating Flange Modulus
29 27,900,000 Efs [psi] - Seating Flange Modulus
30 20,000 Sb [psi] - allowable bolt stress at DESIGN temp
31 20,000 Sba [psi] - allowable bolt stress at ASSEMBLY temp
33 tmin = min(0.75,tn,t) MIN(0.75,0.5,1.5) = 0.500
34 tc = max(0.25,0.7*tmin) MAX(0.25,0.7*0.5) = 0.350
35 ThroatLeg1 = 0.7*Leg1 0.7*0.5 = 0.350
36 ChTL1 = ThroatLeg1 >= tc 0.35 >= 0.35 = Acceptable
37 Calculated Dimensions:
38 B = Bn+2*Corr 4.5+2*0.125 = 4.750
39 varN = (GOD-GID)/2 Gasket width in contact (5.5-4.5)/2 = 0.500
40 b0 = varN / 2 Gasket seating width 0.5 / 2 = 0.250
41 varb = IF(b0>0.25,Sqrt(b0)/2,b0) Effective seating width
42 IF(0.25>0.25,SQRT(0.25)/2,0.25) = 0.250
43 varG = IF(b0>0.25,GOD-2*varb,(GOD-GID)/2 + GID)
44 IF(0.25>0.25,5.5-2*0.25,(5.5-4.5)/2 + 4.5) = 5.000
45 ThreadMin = 0.75*Sf/Sb UG-43(g)
46 0.75*20000/20000 = 0.750
47 CheckTrdMin = ThreadMin <= DepthT 0.75 <= 1 = Acceptable
48 Bolt Loads: (VIII App 2-5)
49 H= 0.785*varG^2*P end load 0.785*5^2*155.2 = 3,046
50 HP = 2*varb*3.14*varG*m*P contact load 2*0.25*3.14*5*3*155.2 = 3,655
51 HD = pi()/4 * A^2 * P end load PI()/4 * 9^2 * 155.2 = 9,873
52 HT = H - HD face load 3046 - 9873 = -6,827
Flange :
1 Wm1 = H + HP bolt load 3046 + 3655 = 6,701
2 Wm2 = pi()*varb*varG*gy seating load PI()*0.25*5*1800 = 7,069
3 Am = Max(Wm1/Sb, Wm2/Sba) Bolt area required
4 MAX(6701/20000, 7069/20000) = 0.353
5 RootArea [sq. in] = PVELookup("BoltSizing","Lookup","Root Area",BoltOD) 0.208
6 Ab = RootArea*Nbolt 0.208*8 = 1.664
7 CheckExcess = Ab>=Am 1.664>=0.353 = Acceptable
8 Flange Loads: (App 2-5)
9 W [lb] = (Am + Ab)*Sba/2 seating conditions (0.353 + 1.664)*20000/2 = 20,174
10 HG [lb] = Wm1 - H operating conditions 6701 - 3046 = 3,655
11 TBoltLoad [lb] = (W+Wm1)/Nbolt (20174+6701)/8 = 3,359
12 Flange Moment Arms: (Table App 2-6 - loose flanges)
13 mhD [in] = (varC-A)/2 (7.5-9)/2 = -0.750
14 mhT [in] = (varC-(A+varG)/2)/2 (7.5-(9+5)/2)/2 = 0.250
15 mhG [in] = (varC-varG)/2 (7.5-5)/2 = 1.250
16 Flange Moments: (App 2-6)
17 MD [in-lb] = HD * mhD end pressure 9873 * -0.75 = -7,405
18 MT [in-lb] = HT * mhT face pressure -6827 * 0.25 = -1,707
19 MG [in-lb] = HG * mhG gasket load 3655 * 1.25 = 4,569
20 Mo1 [in-lb] = MD+MT+MG total operating -7405+-1707+4569 = -4,543
21 Mo2 [in-lb] = W*(varC-varG)/2 total seating 20174*(7.5-5)/2 = 25,218
22 Graph: App 2-7.1 Value of Y
23 K = A/B 9/4.75 = 1.895
24 Y = PVELookup("Y","FlangeFactorK",K) 3.205
25 Flange Seating Stress: (App 2-7,8)
26 STs = Y*ABS(Mo2) / (t^2*B) 3.205*ABS(25218) / (1.5^2*4.75) = 7,563
27 CheckSTs = ABS(STs) <= Sfa ABS(7563) <= 20000 = Acceptable
28 Flange Operating Stress: (App 2-7,8)
29 STo = Y*ABS(Mo1) / (t^2*B) 3.205*ABS(-4543) / (1.5^2*4.75) = 1,362
30 CheckSTo = STo <= Sf 1362 <= 20000 = Acceptable
31 Flange Flexibility: (App 2-14)
32 Jseating = (109.4*Mo2) / (Efs*t^3*ln(K)*0.2)
33 (109.4*25218) / (27900000*1.5^3*LN(1.895)*0.2) = 0.229
34 CheckJSt = ABS(Jseating) <= 1 ABS(0.229) <= 1 = Acceptable
35 Joperating = (109.4*Mo1) / (Efo*t^3*ln(K)*0.2)
36 (109.4*-4543) / (27900000*1.5^3*LN(1.895)*0.2) = -0.041
37 CheckJOp = ABS(Joperating) <= 1 ABS(-0.041) <= 1 = Acceptable
30 Nozzle Reinforcement : UW16(h) <- SavedDesign
33 M1 - 12" x 16" Manway on Head c/w 3" x 3/4" Ring <- Description Curved Shell or Head Section
34 Shell:
37 1.00 <- E1, efficiency of shell at nozzle Nt

39 0.675 <- Vt, shell wall thick, uncorroded, UT removed Leg41
40 0.413 <- tr, required shell wall thickness int. press.(E=1)
41 0.000 <- trE, required shell wall thickness ext. press.(E=1) Leg42
Nozzle
43 0.094 <- tmin16b, Min allowed wall per UG-16(b) Ring te
44 Nozzle:
45 SA-106B <- Nozzle Material g Vt
She ll
46 17,100 <- Sn, allowable stress level (Sn)
47 17,600 <- B, from A = 0.09590 Proj
48 1.00 <- E, nozzle efficiency Dp
Weld to conne ct
50 0.0 <- Pa, external design pressure t to reinforcing pad
Leg43
55 0.0% <- UTp, undertolerance (%) UW-16.1 ( h)
59 0.750 <- Ip, interior projection
61 Reinforcing:
63 SA-516 70 <- Reinforcing plate material At least one telltale hole (max. size NPS 1/4 tap) in repad required
65 20,000 <- Sp, allowable stress level
66 21.500 <- Dp, outside diameter
69 0.500 <- te, reinforcement thick
75 0.675 <- LegG, depth of groove
87 Variables:
88 UT = Nt*UTp = 0.75 * 0 Undertolerance UT = 0.000
90 Rn = Do/2 - (Nt-nca) + UT = 17.5/2 - (0.75-0) + 0 Effective Radius Rn = 8.000
91 Dp = Min(2*d,DpEntered) = Min(2*16,21.5) Effective Reinforcing Dp = 21.500
95 t = Vt-sca = 0.675 - 0.125 Effective Shell Thickness t = 0.550
96 ti = Nt-2*nca = 0.75 - 2 * 0 Nom Thick of Int. Proj. ti = 0.750
97 te = teEntered Effective Reinf. Thick. te = 0.500
101 tn = Nt-nca = 0.75-0 Avail. Nozzle Thick. No UT tn = 0.750
102 d = Do-2*tn = 17.5 - 2*0.75 Opening Dia. d = 16.000
108 fr1 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr1 = 0.855
111 fr2 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr2 = 0.855
114 fr3 = MIN(Sn/Sv,Sp/Sv,1) = MIN(17100/20000, 20000/20000,1) fr3 = 0.855
115 fr4 = MIN(Sp/Sv,1) = MIN(20000/20000,1) fr4 = 1.000
126 h = MIN(Ip-sca,2.5*t,2.5*ti) = MIN(0.75-0.125,2.5*0.55,2.5*0.75) h = 0.625
131 tcLeg43 = Min(0.25,0.7*Min(0.75,t,tn)) = Min(0.25,0.7*Min(0.75,0.55,0.75)) tc43 = 0.250
132 F = 1.000 F = 1.000
143 trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT = (155.2*8)/(17100*1 - 0.6*155.2) trn = 0.073 Acceptable
145 trnR = (P*Rn)/(Sn*1 - 0.6*P) = (155.2*8)/(17100*1 - 0.6*155.2) E=1 trnR = 0.073
151 0.7*Leg41 >= 0.7*min(0.75,te,tn) 0.7*0.5 >= 0.7*Min(0.75,0.5,0.75) 0.350 >= 0.350 Acceptable
155 0.7*Leg42 >= 0.5*Min(0.75,te,t) 0.7*0.375 >= 0.5*Min(0.75,0.5,0.55) 0.263 >= 0.250 Acceptable
158 0.7*Leg43-nca >= tc43 0.7*0.375-0 >= 0.25 0.263 >= 0.250 Acceptable
171
175
M1 - 12" x 16" Manway on Head c/w 3" x 3/4" Ring Pressure From:
207 A Required (internal) = Internal External
Area Replacement: Fig UG-37.1
208 A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1) 6.690
209 = 1.0*16*0.413*1 + 2*0.75*0.413*1*(1-0.855)
212 Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1)) = 0.5*(16*0*1 + 2*0.75*0*1*(1-0.855)) A Requi red (external) = 0.000
216 = max(16,2*(0.55+0.75))* (1*0.55-1*0.413)-2*0.75*(1*0.55-1*0.413)*(1-0.855)
220 = max(16,2*(0.55+0.75))* (1*0.55-1*0)-2*0.75*(1*0.55-1*0)*(1-0.855)
223 A2 = min((tn-trnR)*fr2*min(5*t,2*L) , (tn-trnR)*(Min(2.5*tn+te,L)*fr2*2) A2 = 1.592
224 = min((0.75-0.073)*0.855*min(5*0.55,2*1.5) , (0.75-0.073)*(Min(2.5*0.75+0.5,2*1.5)*0.855*2)
228 A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , 2*(tn-trnE)*Min(2.5*tn+te,L)*fr2) A2e = 1.763
229 = min((0.75-0)*0.855*Min(5*0.55,2*1.5) , 2*(0.75-0)*Min(2.5*0.75+0.5,1.5)*0.855)
233 A3 = Min(5*t*ti*fr2, 5*ti*ti*fr2, 2*h*ti*fr2) A3 = 0.802 0.802
234 = Min(5*0.55*0.75*0.855, 5*0.75*0.75*0.855, 2*0.625*0.75*0.855)
236 A5 = (Dp - d - 2tn)te*fr4 =(21.5 - 16 - 2*0.75)*0.5*1 A5 = 2.000 2.000
241 A41 = Leg41^2*fr3 A41 = 0.5^2*0.855 A41 = 0.214 0.214
244 A42 = Leg42^2*fr4 A42 = 0.375^2*1 A42 = 0.141 0.141
247 A43 = (Leg43-nca)^2*fr2 = (0.375-0)^2*0.855 A43 = 0.120 0.120
249 Actual Area = 7.038 13.720
256 Internal Weld Load: (UG-41)
257 WmaxI = (A - A1 + 2*Tn*Fr1*(E1*t-F*tr))*Sv, min0 = (6.69 - 2.17 + 2*0.75*0.855*(1*0.55-1*0.413))*20000 WmaxI = 93,927
260
261 W 1-1 = MIN((A2 + A5 + A41 + A42)*Sv,WmaxI) = MIN((1.592 + 2 + 0.214 + 0.141)*20000,93927) W 1-1 = 78,923
262 W 2-2 = Min((A2 + A3 + A41 + A43 + 2*Tn*t*frone)*Sv,WmaxI) = Min((1.592 + 0.802 + 0.214 + 0.12 + 2*0 W 2-2 = 68,654
266 W 3-3 = Min((A2 + A3 + A5 + A41 + A42 + A43 + 2*Tn*t*fr1)*Sv,WmaxI) Weld load W 3-3 = 93,927
267 = Min((1.592 + 0.802 + 2 + 0.214 + 0.141 + 0.12 + 2*0.75*0.55*0.855)*20000,93927)
271
272 External Weld Load: (UG-41)

273 WmaxE = (Ae - A1e + 2*Tn*Fr1*(E1*t-F*tr))*Sv, min0 = (0 - 8.68 + 2*0.75*0.855*(1*0.55-1*0.413))*20000 WmaxE = 0
276
277 W1-1 = MIN((A2e + A5 + A41 + A42)*Sv,WmaxE) Weld load W 1-1e = 0

278 = MIN((1.763 + 2 + 0.214 + 0.141)*20000,0)
279 W 2-2 = Min((A2e + A3 + A41 + A43 + 2*Tn*t*frone)*Sv,WmaxE) = Min((1.763 + 0.802 + 0.214 + 0.12 + 2*0 W 2-2e = 0
283 W 3-3 = Min((A2e + A3 + A5 + A41 + A42 + A43 + 2*Tn*t*fr1)*Sv,WmaxE) Weld load W 3-3e = 0
284 = Min((1.763 + 0.802 + 2 + 0.214 + 0.141 + 0.12 + 2*0.75*0.55*0.855)*20000,0)
288
294 Component Strength (UG-45(c), UW-15(c))

295 A2 shear = PI()/2*(Do-tn)*tn*Sn*0.7 = PI()/2*(17.5-0.75)*0.75*17100*0.7 A2s = 236,206
296 g tension = PI()/2*Do*LegG*Min(Sv,Sn)*0.74 = PI()/2*17.5*0.675*Min(20000,17100)*0.74 gt = 234,795
297 A41 shear = PI()/2*Do*Leg41*Min(Sn,Sp)*0.49 = PI()/2*17.5*0.5*Min(17100,20000)*0.49 A41s = 115,165
301 A42 shear = PI()/2*DP*Leg42*Min(Sv,Sp)*0.49 = PI()/2*21.5*0.375*Min(20000,20000)*0.49 A42s = 124,113
308
309 Failure mode along strength path (Greater than Weld Load, see App L-7)
312 S1-1 = A42s + A2s >= W1-1 Acceptable S1-1 = 360,318
313 = 124113 + 236206 >= 78923
320 S2-2 = A41s + gt >= W2-2 Acceptable S2-2 = 349,960
321 = 115165 + 234795 >= 68654
326 S3-3 = gt + A42s >= W3-3 Acceptable S3-3 = 358,908
327 = 234795 + 124113 >= 93927
331 Tstd = Standard pipe wall thickness from chart Tstd =
0.375
332 Swre = tr * Pa / P = 0.413 * 0 / 155.197 Req. Exterior pressure Swre =
0.000
333 Nact = Nt * (1-UTp) = 0.75 * (1-0) Actual Wall Thick. Nact =
0.750
334 Tt = 0.8/Nth = 0.8/0 Ug-31(c)(2) threads Tt =
0.000
337 UG45a = Max(trn,trnE) + Nca + Tt = Max(0.073,0) + 0 + 0 UG45a = 0.073
342 UG45b4 = Tstd*0.875 + Nca = 0.375*0.875 + 0 UG45b4 = 0.328
30 Nozzle Reinforcement UW16(c)mod <- SavedDesign Page 16 of 22
33 M2 - 12" x 16" Manway c/w 4 x 3/4" Ring on Shell <- Description Curved Shell or Head Section
34 Shell:
36 20,000 <- Sv, shell allowable stress level, PSI OD Nozzle
38 59.00 <- Ds, Shell ID Nt Leg43
39 0.500 <- Vt, shell wall thick, uncorroded, UT removed Full
40 0.231 <- tr, required shell wall thickness int. press.(E=1) t Penn.
41 0.000 <- trE, required shell wall thickness ext. press.(E=1) Leg41
Nozzle
43 0.094 <- tmin16b, Min allowed wall per UG-16(b)
44 Nozzle:
Leg41 Shell
45 SA-106B <- Nozzle Material
46 17,100 <- Sn, allowable stress level (Sn) Vt
47 17,600 <- B, from A = 0.09590
48 1.00 <- E, nozzle efficiency Leg43
49 155.20 <- P, internal design pressure Proj
50 0.0 <- Pa, external design pressure
54 0.750 <- Nt, wall thick, uncorroded UW-16.1 (c) modified
59 0.875 <- Ip, interior projection
61 Reinforcing:
74 1.000 <- F
87 Variables:
88 UT = Nt*UTp = 0.75 * 0 Undertolerance UT = 0.000
90 Rn = Do/2 - (Nt-nca) + UT = 17.5/2 - (0.75-0.125) + 0 Effective Radius Rn = 8.125
96 ti = Nt-2*nca = 0.75 - 2 * 0.125 Nom Thick of Int. Proj. ti = 0.500
101 tn = Nt-nca = 0.75-0.125 Avail. Nozzle Thick. No tn = 0.625
102 d = Do-2*tn = 17.5 - 2*0.625 UT Opening Dia. d= 16.250
108 fr1 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr1 = 0.855
111 fr2 = MIN(Sn/Sv,1) = MIN(17100/20000, 1) fr2 = 0.855
126 h = MIN(Ip-sca,2.5*t,2.5*ti) = MIN(0.875-0.125,2.5*0.375,2.5*0.5) h= 0.750
131 tcLeg43 = Min(0.25,0.7*Min(0.75,t,tn)) = Min(0.25,0.7*Min(0.75,0.375,0.625)) tc43 = 0.250
133 F = Min(Fenterered, 1) F= 1.000
142 LDo = L/Do LDo = 0.150 Dot = Do/trnE Dot = 0.000
158 0.7*Leg43-nca >= tc43 0.7*0.625-0.125 >= 0.25 0.313 >= 0.250 Acceptable
171
180 Appendix 1-7 Necessary Check

181 when Ds>60,if(2*Rn<=Ds/3,if(2*Rn<=40, "App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
182 when Ds<=60,if(2*Rn<Ds/2,if(2*Rn<20,"App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
183 App. 1-7 calculations not required
209 = 1.0*16.25*0.231*1 + 2*0.625*0.231*1*(1-0.855)
212 Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1)) = 0.5*(16.25*0*1 + 2*0.625*0*1*(1-0.855)) A Required (external) = 0.000
216 = max(16.25,2*(0.375+0.625))* (1*0.375-1*0.231)-2*0.625*(1*0.375-1*0.231)*(1-0.855)
220 = max(16.25,2*(0.375+0.625))* (1*0.375-1*0)-2*0.625*(1*0.375-1*0)*(1-0.855)
225 A2 = min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L)) A2 = 0.883
226 = min((0.625-0.074)*0.855*Min(5*0.375,2*2.625) , (0.625-0.074)*0.855*Min(5*0.625,2*2.625))
230 A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L)) A2e = 1.002
231 = min((0.625-0)*0.855*Min(5*0.375,2*2.625) , (0.625-0)*0.855*Min(5*0.625,2*2.625))
233 A3 = Min(5*t*ti*fr2, 5*ti*ti*fr2, 2*h*ti*fr2) A3 = 0.641 0.641
234 = Min(5*0.375*0.5*0.855, 5*0.5*0.5*0.855, 2*0.75*0.5*0.855)
240 A41 = Leg41^2*fr2 = 0.375^2*0.855 A41 = 0.120 0.120
247 A43 = (Leg43-nca)^2*fr2 = (0.625-0.125)^2*0.855 A43 = 0.214 0.214
249 Actual Area = 4.173 8.003
331 Tstd = Standard pipe wall thickness from chart Tstd =0.375
332 Swre = tr * Pa / P = 0.231 * 0 / 155.197 Req. Exterior pressure Swre = 0.000
333 Nact = Nt * (1-UTp) = 0.75 * (1-0) Actual Wall Thick. Nact = 0.750
334 Tt = 0.8/Nth = 0.8/0 Ug-31(c)(2) threads Tt =0.000
337 UG45a = Max(trn,trnE) + Nca + Tt = Max(0.074,0) + 0.125 + 0 UG45a = 0.199
342 UG45b4 = Tstd*0.875 + Nca = 0.375*0.875 + 0.125 UG45b4 = 0.453
1 Vessel Weight and Volume
2 Sample Vertical Vessel Description
3 Volume:
4 2 nhead - Number of heads?
5 1.00 SG - Fluid Specific Gravity
6 12.00 VE [ft3] - Volume of Each Head
7 190.00 VS [ft3] - Volume of Shell
8 Construction:
9 789 Wh [lb] - Weight of Each Head
10 3181 Ws [lb] - Weight of Shell
11 650 Wm [lb] - Misc Weight
12 Calculations:
13 V [ft3] = VE*nhead + VS total volume 12*2 + 190 = 214.00
14 V2 [Imp. Gallons] = V*6.229 214*6.229 = 1,333.01
15 V3 [US Gallons] = V*7.4805 214*7.4805 = 1,600.83
16 Wf [lb] = 62.37*SG*V fluid weight 62.37*1*214 = 13,347.18
17 WC [lb] = Wh*nhead + Ws + Wm construction weight 789*2 + 3181 + 650 = 5,409.83
18 WT [lb] = WC + Wf total weight 5409.83 + 13347.18 = 18,757.01
1 Lifting Lugs
2 Sample Vessel 4 Liftng Lugs Description Load Case
3 Dimensions: 1
4 6,000 Load [lb] - vessel weight empty OR
5 8.000 W [in] - width
6 0.500 Thick [in] - lug thickness Dia
7 2.500 H [in] - hole height
8 1.500 Dia [in] - hole diameter Load C
Load Case
9 2.500 OR [in] - outside radius 2
10 0.250 Weld [in] - leg size H
11 SA-516 70 Material
12 20,000 SA [psi] - allowed stress in tension
13 All of load assumed carried by one lug Weld
14 All load cases analyzed independently
15 Never load lug perpendicular to face W
16 Contour lug to fit vessel
17 Do not move or support vessel with this lug when full or pressurized
18 SB = UG-34(b) Max Bending Stress, SS = IID Tbl 1A(d) Max Shear Stress, SSw = UW-15(c) UW-15 Max Weld Shear
19 SB [psi] = SA * 1.5 20000 * 1.5 = 30,000

20 SS [psi] = SA * 0.8 20000 * 0.8 = 16,000
21 SSw [psi] = SA * 0.49 20000 * 0.49 = 9,800
22 Tensile Stress (case 1):
23 A1 [in ] = Thick*(OR-Dia/2)
2
0.5*(2.5-1.5/2) = 0.875
24 A [in ] = A1 * 2
2
0.875 * 2 = 1.750
25 Stress [psi] = Load / A 6000 / 1.75 = 3,429
26 CheckTenStr = Stress <= SA 3429 <= 20000 = Acceptable
27 Pin Bearing Stress (case 1 and 2):
28 Area [in ] = Dia * Thick PinStress
2
1.5 * 0.5 = 0.750
29 [psi] = Load / Area CheckPinStr = 6000 / 0.75 = 8,000
30 PinStress <= (1.6 * SA) 8000 <= (1.6 * 20000) = Acceptable
31 Bending Stress (case 2):
32 Moment [in-lb] = Load * H 6000 * 2.5 = 15,000
33 I [in ] = Thick * W^3 / 12
4
0.5 * 8^3 / 12 = 21.333
34 c [in] = W/2 8/2 = 4.000
35 BendStress [psi] = Moment*c/I 15000*4/21.333 = 2,813
36 CheckBendStr = BendStress <= SB 2813 <= 30000 = Acceptable
37 Shear Stress (case 2):
38 ShrArea [in ] = W*Thick
2
8*0.5 = 4.000
39 ShrStress [psi] = Load/ShrArea 6000/4 = 1,500
40 CheckShStr = ShrStress <= SS 1500 <= 16000 = Acceptable
41 Weld Stress (case 1):
42 Circ [in] = W*2+Thick*2+Weld*4 8*2+0.5*2+0.25*4 = 18.000
43 WeldArea [in ] = Circ * Weld
2
18 * 0.25 = 4.500
44 WeldStress [psi] = Load / WeldArea 6000 / 4.5 = 1,333
45 CheckWldStr = WeldStress <= SSw 1333 <= 9800 = Acceptable
46 Weld Stress (case 2):
47 Moment2 [in-lb] = Load * H 6000 * 2.5 = 15,000
I2 [in ] = (Thick +2*Weld)* (W+2*Weld)^3 / 12 - I
4
48 (0.5 +2*0.25)* (8+2*0.25)^3 / 12 - 21.333 = 29.844

49 c2 [in] = W/2 + Weld 8/2 + 0.25 = 4.250
50 WldStress2 [psi] = Moment2*c2/I2 15000*4.25/29.844 = 2,136
51 CheckWldStr2 = WldStress2 <= SSw 2136 <= 9800 = Acceptable
15 Vessel On Beams Ver 2.24 7-Jan-09
IBC-2000
18
19 Vessel Dimensions (Inch and Lbs):

20 162.500 <- H, height
21 90.000 <- L, center of gravity
22 27.000 <- ls, leg free length
23 60.000 <- Do, shell outside diameter
24 60.500 <- ds, leg pitch diameter
25 0.500 <- t, shell corroded thickness
26 0.250 <- ws - leg weld size
27 18.000 <- lw - length of leg to shell weld
28 35.000 <- lwf - length of weld on foot
29 19,000 <- W, Weight lbs
30 155.2 <- Pr, Pressure
31
32 Site Specific Seismic Information per IBC-2000:

35 1.000 <- I, occupation importance factor
38 E <- Site Class
39 0.750 <- Ss, Acc
Acceleration at Short Periods
40 0.300 <- S1, Acceleration at a period of one second
41 1.200 <- Fa, Site Coefficient
42 2.800 <- Fv, Site Coefficient
43 3.000 <- R, Res
Response Modification Factor
51
52 Leg Supports:
53 W6x15 <- Structural Description
54 4 <- n, number of legs
55 29.100 <- Ix, for one leg
56 9.320 <- Iy, for one leg
57 1.460 <- fFactor, Least radius of Gyration
58 4.430 <- A, Leg Cross Sectional Area
59 6.000 <- 2cx, Beam Depth
60 6.000 <- 2cy, Beam Width
61 0.800 <- K1, Leg Anchor Factor
62
63 Material Properties:
64 17,100 <- maximum leg bending stress (Sb)
65 20,000 <- maximum shell stress (Sa)
66
67 Attachment Dimensions:
68 6.000 <- 2C1, Width of rectangular loading
69 6.000 <- 2C2, Length of rectangular loading
71 Static Deflection
72 E = 30,000,000
73 bc = 12.0 leg boundary condition based on fixed or loose leg
74 y = (2*W*ls^3)/(bc*n*E*(Ix + Iy)) y = 0.014
75 = (2*19000*27^3)/(12*4*30000000*(29.1 + 9.32))
76
77 Period of Vibration
78 g = 386
79 T = 2*pi*sqrt(y/g) =2 * 3.14 * sqrt(0.01/386) T = 0.037
80
84 Base Shear
94 Sms = Fa*Ss = 1.2*0.75 Sms = 0.9
95 Sm1 = Fv*S1 = 2.8*0.3 Sm1 = 0.84
96 Sds = 2/3*Sms = 2/3*0.9 Sds = 0.600
97 Sd1 = 2/3*Sm1 = 2/3*0.84 Sd1 = 0.560
98 Cs = Sds/(R/I) = 0.6/(3/1) Cs = 0.200
99 CsMAX = Sd1/(T*R/I) = 0.56/(0.037*3/1) CsMAX = 5.020
100 CsMIN = 0.044*Sds*I = 0.044*0.6*1 CsMIN = 0.026
101 Csfinal = if(cs<=csmax, if(cs>csmin, cs, csmin), csmax) Csfinal = 0.200
102 V= Csfinal*W = 0.2*19000 V= 3800
112
115 Sample Vertical Vessel Vessel On Beams 7-Jan-09
117 Horizontal Seismic Force at Top of Vessel
118 Ftmax = 0.25*V = 0.25 * 3800 Ftmax = 950
119 Ftp = 0.07 * T * V = 0.07 * 0.037 * 3800 Ftp = 9.89
120 Ft = if (T < 0.7, 0, min(0.07*T*V, Ftmax)) Ft = 0
121
122 Horizontal Seismic Force at cg

123 Fh = V - Ft = 3800 - 0 Fh = 3,800
124
125 Vertical force at cg

126 Fv = W Fv = 19,000
127
128 Overturning Moment at Base

129 Mb = L*Fh + H*Ft = 90 * 3800 + 162.5 * 0 Mb = 342,000
130
131 Overturning Moment at Bottom Tangent Line

132 Mt = (L-ls)*Fh + (H-ls)*Ft = (90 - 27) * 3800 + (162.5 - 27) * 0 Mt = 239,400
133
134 Maximum eccentric load

135 f1 = Fv/n + 4*Mto/(n*Do) = 19000/4 + 4*239400/(4 * 60) f1 = 8,740
136
137 Axial Load

138 f2 = Fv/n + 4*Mb/(n*ds) = 19000/4 + 4*342000/(4 * 60.5) f2 = 10,403
139
140 Leg Loads

141 f3x = 0.5*V*Ix/(Ix+Iy) =0.5* 3800*29.1 /( 29.1+9.32) f3x = 1,439
142 f3y = 0.5*V*Iy/(Ix+Iy) =0.5* 3800*9.32 /( 29.1+9.32) f3y = 461
143
144 Leg Bending Moments

145 e = (ds-Do)/2 =(60.5-60)/2 e = 0.25
146 Mx = f1*e + f3x*ls =8740*0.25 + 1439*27 Mx = 41,041
147 My = f1*e + f3y*ls =8740*0.25 + 461*27 My = 14,629
148
149 Leg Bending Stress

150 Sbmax = Sb * 1.25 =17100 * 1.25 Sbmax = 21,375
151 fx = Mx*cx/Ix =41041 * 3 / 29.1 Acceptable fx = 4,231
152 fy = My*cy/Iy =14629 * 3 / 9.32 Acceptable fy = 4,709
153
154 Leg axial stress

155 K1*ls/fFactor = =0.8 * 27 / 1.46 K1*ls/fFactor = 14.795
156 Fa max = AISC code lookup based on K1*ls/r Fa max = 25,675
157 fa = f2/A =10403 / 4.43 Acceptable fa = 2,348
158
159 Maximum Euler Stress

160 Fe = 12*pi^2*E/(23*(K1*L/r)^2)
161 = 12*pi^2*30000000/(23*14.795^2) Fe = 705,785
162
163 Combined Stress

164 Fc1 = fa/Famax + 0.85*fx/((1-fa/Fe)*Sbmax) Acceptable
165 = 2348/25675 + 0.85*4231/((1-2348/705785)*21375) Fc1 = 0.26
166 Fc2 = fa/Famax + 0.85*fy/((1-fa/Fe)*Sbmax) Acceptable
167 = 2348/25675 + 0.85*4709/((1-2348/705785)*21375) Fc2 = 0.28
168
171 Sample Vertical Vessel Vessel On Bea 7-Jan-09
172
173
174
Beam to Shell Attachment Stresses
175 Beam Dimensions
176 cx = 2cx/2 cx = 3.000
177 cy = 2cy/2 cy = 3.000
178
179
180
181 C dimensions for weld stress

182 weld area = ws*lw wa = 4.500
183 wcx = lw/2 wcx = 9.000
184 wcz = cy + ws wcz = 3.250
185 wcy = sqrt(wcx^2 + wcy^2) = sqrt(9^2 + 9.569^2) wcy = 9.569
186
187 Shear Force Distribution

188 Vx = (V*Ix)/((n/2)*(Ix+Iy)) = (3800*29.1)/ Vx = 1,439
189 Vy = (V*Iy)/((n/2)*(Ix+Iy)) ((4/2)*(29.1+9.32)) Vy = 461
190 Vg = W/n gravity = (3800*9.32)/ Vg = 4,750
191 ((4/2)*(29.1+9.32))
192 Weld Moments of Inertias
193 Iwx = (ws*lw^3/12)*2 = (0.25*18^3/12)*2 Iwx = 243.0
194 Iwz = (lw*ws^3/12 + wa*(cy+ws/2)^2)*2 Iwz = 87.9
195 = (18*0.25^3/12 + 4.5*(3+0.25/2)^2)*2
196 Iwy = Iwx + Iwz = 243 + 88 Iwy = 330.9
197
198 Weld Moments

199 Mx = Vx*(ls+lw/2) + Vg*(ds-Do)/2 Mx = 52,995
200 = 1439*(27+18/2) + 4750*(60.5-60)/2
201 My1 = Vy*(ls+lw/2) = 461*(27+18/2) My1 = 16,593
202 Mz = Vy*(ds-Do)/2 = 461*(60.5-60)/2 Mz = 115
203
204 Weld Stresses

205 Sx = Mx*wcx/Iwx Bending = 41041*9/243 Sx = 1,520
206 Sy = My1*wcy/Iwy Twisting = 16593*9.569/330.9 Sy = 480
207 Sz = Mz*wcz/Iwz Torision = 115*3.25/87.9 Sz = 4
208 Sg = Vg/(wa*2) Gravity = 4750/(4.5*2) Sg = 528
209
210 Stress Limits and Ratios

211 Slim = min(Sb,Sa)*0.49 = min(17100,20000)*0.49 Slim = 8,379
212
213 SxR = Sx/Slim = 1520/8379 SxR = 0.181

214 SyR = Sy/Slim = 480/8379 SyR = 0.057
215 SzR = Sz/Slim = 4/8379 SzR = 0.001
216 SgR = Sg/Slim = 528/8379 SgR = 0.063
217 Acceptable total (<1) 0.302
218 Foot Plate Attachment Stresses
219 waf = ws*lwf weld area in foot = 0.25*35 waf = 8.750
220 Vv = V/n = 3800/4 Vv = 950
221
222 Sv = Vv/waf = 950/8.75 Sv = 109

223 Sgf = Vg/waf = 4750/8.75 Sgf = 543
224
225 SvRf = Sv/Slim = 109/8379 SvRf = 0.013

226 SgRf = Sgf/Slim = 542.857/8379 SgRf = 0.065
227 Acceptable total (<1) 0.078
231 7-Jan-09
232 WRC 107 - shell local stress at support
233
234 Loads (psi and lb)

235 1,439.1 <- P, Axial Load (=vx)
236 10,402.9 <- VL, Longitudinal load(=f2)
237 0.0 <- Vc, Circumferential load
238 14,629.5 <- ML, Moment (=My)
239 0.0 <- Mc, Moment
240 0.0 <- MT, Torisional
241
242 Parameters
243 MaxSPm = Sa for Pm stresses Pm - primary membrance stress MaxSPm = 20,000
244 MaxSPmb = 1.5*Sa for Pm + Pb stresses Pb - primary bending stress MaxSPmb = 30,000
245 MaxSPmbQ = 1.5*Sa for Pm + Pb + Q Q - secondary stress MaxSPmbQ = 30,000
246 Ri = (Do-2*T)/2 stresses Ri = 29.5
247 Rm = (Do-T)/2 Rm = 29.75
248 r = Rm/T = 29.75/0.5 r= 59.50
249 Beta1 = 2C1/2/Rm = 6/2/29.75 Beta1 = 0.101
250 Beta2 = 2C2/2/Rm = 6/2/29.75 Beta2 = 0.101
280 SL = (Ri-0.4*T)*Pr/(2*T) = (29.5-0.4*0.5)*155.197/(2*0.5) SL = 4,547
281 Sc = (Ri+0.6*T)*Pr/T = (29.5+0.6*0.5)*155.197/0.5 Sc = 9,250
282 Stress concentration factors Kb = 1 Kn = 1
283 Shell Combined Stresses:
284 Lookup A Curve A Value A Value Equation Cat Au AL Bu BL Cu CL Du DL
285 Pressure Stress VIII-1 Code 4C 3C SC Pm 9250 9250 9250 9250 9250 9250 9250 9250
286 No/(P/Rm) 3C or 4C 9.80981 7.99937 Kn*A*P/(Rm*T) Pm -949 -949 -949 -949 -774 -774 -774 -774
287 Mo/P 1C or 2C-1 0.10736 0.07214 Kb*A*6*P/T^2 Pb -2492 2492 -2492 2492 -3708 3708 -3708 3708
288 No/(Mc/ 3A 2.00349 Kn*A*Mc/(Rm^2*beta*T) Pm 0 0 0 0
289
(Rm^2*beta))
Mo/(Mc/(Rm*beta)) 1A 0.08976 Kb*A*6*Mc/(Rm*beta*T^2) Q 0 0 0 0
290 No/(ML/(Rm^2*beta)) 3B 6.62238 Kn*A*ML/(Rm^2*beta*T) Pm -2171 -2171 2171 2171
291 Mo/(ML/(Rm*beta)) 1B or 1B-1 0.04054 Kb*A*6*ML/(Rm*beta*T^2) Q -4661 4661 4661 -4661
292 Pm So 6130 6130 10472 10472 8476 8476 8476 8476
293 Pm+Pb So 3638 8621 7980 12963 4768 12184 4768 12184
294 Pm+Pb+Q So -1023 13282 12641 8302 4768 12184 4768 12184
295 Pressure Stress VIII-1 Code SL Pm 4547 4547 4547 4547 4547 4547 4547 4547
296 Nx/(P/Rm) 3C or 4C 9.80981 7.99937 Kn*A*P/(Rm*T) Pm -774 -774 -774 -774 -949 -949 -949 -949
297 Mx/P 1C-1 or 2C 0.07151 0.10957 Kb*A*6*P/T^2 Pb -3784 3784 -3784 3784 -2470 2470 -2470 2470
298 Nx/(Mc/ 4A 3.02513 Kn*A*Mc/(Rm^2*beta*T) Pm 0 0 0 0
299
(Rm^2*beta))
Mx/(Mc/(Rm*beta)) 2A 0.04374 Kb*A*6*Mc/(Rm*beta*T^2) Q 0 0 0 0
300 Nx/(ML/ 4B 1.96743 Kn*A*ML/(Rm^2*beta*T) Pm -645 -645 645 645
301
(Rm^2*beta))
Mx/(ML/(Rm*beta)) 2B or 2B-1 0.05817 Kb*A*6*ML/(Rm*beta*T^2) Q -6486 6486 6486 -6486
302 Pm Sx 3128 3128 4418 4418 3598 3598 3598 3598
303 Pm+Pb Sx -656 6913 634 8203 1128 6068 1128 6068
304 Pm+Pb+Q Sx -7142 13399 7120 1717 1128 6068 1128 6068
305 Shear VL VL/(Pi*sqrt(c1*c2)*T) -2208 -2208 2208 2208
306 Shear VC VC/(Pi*sqrt(c1*c2)*T) 0 0 0 0
307 Total Shear Sum of shears Txo 0 0 0 0 -2208 -2208 2208 2208
308 S1m ((Sx+So)/2)+SQRT(((Sx-So)/2)^2+Txo^2) 6,130 6,130 10,472 10,472 9,327 9,327 9,327 9,327
309 S2m ((Sx+So)/2)-SQRT(((Sx-So)/2)^2+Txo^2) 3,128 3,128 4,418 4,418 2,747 2,747 2,747 2,747
310 S12 abs(S1m - S2m) 3,001 3,001 6,053 6,053 6,579 6,579 6,579 6,579
311 S23 abs(S2m-0) 3,128 3,128 4,418 4,418 2,747 2,747 2,747 2,747
312 S31 abs(0-S1m) 6,130 6,130 10,472 10,472 9,327 9,327 9,327 9,327
313 Sm<= MaxSPmb max(S12,S23,S31)<=30000 Acceptable 6,130 6,130 10,472 10,472 9,327 9,327 9,327 9,327
314 S1m+b ((Sx+So)/2)+SQRT(((Sx-So)/2)^2+Txo^2) 3,638 8,621 7,980 12,963 5,809 12,897 5,809 12,897
315 S2m+b ((Sx+So)/2)-SQRT(((Sx-So)/2)^2+Txo^2) -656 6,913 634 8,203 87 5,354 87 5,354
316 S12 abs(S1m - S2m) 4,294 1,709 7,346 4,761 5,722 7,543 5,722 7,543
317 S23 abs(S2m-0) 656 6,913 634 8,203 87 5,354 87 5,354
318 S31 abs(0-S1m) 3,638 8,621 7,980 12,963 5,809 12,897 5,809 12,897
319 Smb<= MaxSPmb max(S12,S23,S31)<=30000 Acceptable 4,294 8,621 7,980 12,963 5,809 12,897 5,809 12,897
320 S1m+b+Q ((Sx+So)/2)+SQRT(((Sx-So)/2)^2+Txo^2) -1,023 13,399 12,641 8,302 5,809 12,897 5,809 12,897
321 S2m+b+Q ((Sx+So)/2)-SQRT(((Sx-So)/2)^2+Txo^2) -7,142 13,282 7,120 1,717 87 5,354 87 5,354
322 S12 abs(S1m - S2m) 6,119 116 5,521 6,585 5,722 7,543 5,722 7,543
323 S23 abs(S2m-0) 7,142 13,282 7,120 1,717 87 5,354 87 5,354
324 S31 abs(0-S1m) 1,023 13,399 12,641 8,302 5,809 12,897 5,809 12,897
325 Smb<= MaxSPmbQ max(S12,S23,S31)<=60000 Acceptable 7,142 13,399 12,641 8,302 5,809 12,897 5,809 12,897
123
124

Design of Pressure Vessels Under ASME Section VIII

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Design of Pressure Vessels Under ASME Section VIII

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ACKNOWLEGEMENT:

First of all thanks to Allah Almighty who has guided us and

CHAPTER NO 1: introduction to pressure vessels

CHAPTER NO 2: stresses and their effects

CHAPTER NO 3: materials for pressure vessels

ASME pressure vessel codes

CHAPTER NO 4: design of pressure vessel

INTRODUCTION TO PRESSURE VESSELS

What is a pressure vessel?

A pressure vessel is any container that has pressure that is

figure1.1 horizontal pressure vessel

figure 1.2 horizontal pressure vessel

There are many types -

A pressure vessel is a container that holds a liquid, vapor, or gas at a

You could even say that a carbonated soda bottle is a pressure

Pressure vessel types?

These pressure vessels are the most categorized. A thinned walled

These pressure vessels are the least common. A thick walled

figure 1.4 thick walled pressure vessel

Storage tanks are a category of thin walled pressure vessels except

figure 1.5 hot water storage tank

Propane bottles - Fork trucks, barbecues,

Gas cylinders - CO2, O2,...

Other - Containers, gas cans, bubblers,...

A pressure vessel has to retain to pressure. In doing this the pressure

What is important to remember is longitudinal stresses are half as

Factors of Safety are used because no manufacture can guarantee

Factory of Safety [FS] = Actual Breaking Strength

To believe in that a F.S. makes a PV [Pressure Vessel] safe is

1.4 PRESSURE VESSEL SAFETY

There are four types of over pressurization devices:

What should you expect on an over-pressurization device?

Here are some special rules to the set pressure-

• Relief Valves, Safety Relief Valves, and Safety Valves should be

• Rupture Disks should be set not higher than the PV [pressure

Remember There should never be a shut off valve between the PV

How should the over-pressurization device be installed?

• Always in an Upright installation.

TYPES OF OVER PRESSURIZATION DEVICES:-

Safety Relief Valves -

Relief valves open at a set pressure and re-close at the same

Rupture disks are probably the most versatile over- pressurization

HIGH PRESSURE RECIEVERS:-

Figure High pressure receiver

figure liquid level maintained in a low pressure receiver

figure OIL POTS WITH THEIR TYPICAL

figure combination of a thermosyphon receiver with a system receiver [1]

Structural elements must be considered).

“STRESS ANALYSIS IS THE DETERMINATION OF THE

MAXIMUM STRESS THEORY:-

COMPARISON OF TWO THEORIES:-

Simultaneously are called stress categories.

1.14 WEIGHTS OF VESSELS AND IT’S COMPONENTS

STRESSES AND THEIR EFFECTS

The concept of stress was introduced by Cauchy around 1822 as;

figure 2.1 Stress in a loaded deformable material body assumed as a

“ force per unit area”

A particle is in the state of equilibrium if the resultant force and moment

Hence according to Newton’s law of motion it will have no acceleration and

2.2 TYPES OF STRESSES:

Following are the basic types of stresses;

(i). normal stresses

(i) Normal Stresses: