Alemsew and Aman PDF

Section 3
Prepared by
ALEMSEW AZIMERAW……………………………GUR/0086/07
AMANUEL G/HIWOT………………………………GUR/0103/07
SUBMITTED
TO: INS.PUNEET U
DATE: 22/09/2009
UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17

Design of vertical layout Pressure Vessel
UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 i

Nomenclatures
σt =Tensile stress
σD =Design stress
C= corrosion allowance
E=weld joint factor
L =Shell length
Do=outer diameter
Di =internal diameter
to =minimum thickness
t= thickness with corrosion allowance
Dm=mean diameter
𝛅max =maximum stress
𝛅k= 𝐡𝐨𝐨𝐩 𝐬𝐭𝐫𝐞𝐬𝐬
𝛅 L =Longitudinal stress
𝛅r=Radial stress
𝐝𝐢 = inlet pipe diameter
𝐞m= the minimum thickness of the nozzle
𝐭 𝐧 = thickness of the nozzle
𝐭 𝐫𝐬 = the required minimum thickness of the head
𝐭 𝐫𝐧 = The required minimum thickness of the nozzle
𝐡 = The distance nozzle project beyond the outer surface of shell thickness
𝐡𝟏 = The distance of nozzle project beyond the inner surface of the shell thickness
Fw = loading per unit length
Pw= Dynamic wind pressure
Deff= Effective diameter
K = Factors
𝛔w=weld stress
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Acknowledgment
The group members is indebted to a number of people for their help and support; in particular
the following are thanked. We wishes to acknowledge and express our appreciation for the co-
operation of our teacher Mr. Puneet U. as well as our classmates who helped to make this paper
possible and is gratefully acknowledged. We thank our academic lectures, for their expertise,
advice, and support.
UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 iii

Abstract
This technical paper presents design, and analysis of pressure vessel. High pressure rise is
developed in the pressure vessel and pressure vessel has to withstand severe forces. So this project
work deals with a detailed study and design procedure of pressure vessel. A detailed study of
various parts of pressure vessels like shell, head, closure, support, flanges, nozzles etc.
The analysis models utilized realistic geometry, includingl leg (lateral) supports, Vessel heads
actual boundary conditions the stresses are distributed over the section of the walls so we consider
every stresses in the boundary.
Generally it deals with detailed study of pressure vessel i.e. the various materials used in pressure
and temperature construction. It also deals with the study of various parts like head, support, inlet
and outlets etc. Various methods of fabrication and testing are also included.
It also includes the design criteria .This is followed by procedure of design, which include design
shell and its components, nozzles, reinforcements etc.
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Table of Contents
CHAPTER ONE ...................................................................................... 1
1.1 Introduction ...................................................................................................................................... 1
1.2 Classification of pressure vessel ................................................................................................. 3
1.2.1 According to the dimension ....................................................................................................... 3
1.2.2 According to the end construction ..................................................................................... 3
1.2.3 According to the geometrical shapes ........................................................................................ 3
1.2.4 According to the position arrangement.................................................................................... 3
1.2.5 According to the materials ........................................................................................................ 4
1.2.6 According to the direction of force acting on the wall of vessels. .......................................... 4
1.3 Component of pressure vessels ........................................................................................................ 4
1.3.1 HEAD .......................................................................................................................................... 4
1.3.2SHELL ......................................................................................................................................... 5
1.3.3 NOZZLE ..................................................................................................................................... 5
1.3.4 SUPPORT ................................................................................................................................... 6
1.4 Background of pressure vessel ....................................................................................................... 8
1.5 Statement of the problem ............................................................................................................... 10
1.6 Objective of the project .................................................................................................................. 11
1.7 Methodology .................................................................................................................................. 11
1.7 Scope and Limitation of the Project .............................................................................................. 13
CHAPTER TWO ................................................................................... 14

2.1 Literature Review ............................................................................................................................. 14
CHAPTER –THREE ............................................................................ 17

3.1 Detail Design and Analysis ............................................................. 17
3.1.1 General Design Considerations................................................................................................... 18
3.1.1.1 Material selection .................................................................................................................. 18
3.1.1.2 Design pressure ..................................................................................................................... 19
3.1.1.3 Design temperature ............................................................................................................... 19
3.1.1.4 Corrosion allowance ............................................................................................................. 19
3.2 Design of Shell ............................................................................................................................. 20
3.2.1 Stress analysis of shell............................................................................................................. 22
3.3 Design of Head................................................................................................................................. 25
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3.3.1 Stress analysis of Hemispherical Head................................................................................ 26

3.4 Design of nozzle ............................................................................................................................... 27
3.4.1. Design 0f bottom discharge pipe ............................................................................................ 28
3.4.2 Calculation of reinforcement limits. ........................................................................................... 29
3.4.3 Calculation of reinforcement required. ..................................................................................... 29
3.4.4 Stress analysis for the opening .................................................................................................... 31
3.5 Design of circular handhold:.......................................................................................................... 34
3.5.1 Stress analysis for hand hole ....................................................................................................... 35
3.6 Design of vessels subjected to combined loading .......................................................................... 35
3.6.1 Dead weight of vessel ............................................................................................................... 35
3.6.2 Weight of fluid .......................................................................................................................... 36
3.6.3 Weight of hemispherical head ................................................................................................. 36
3.6.4 Weight of the nozzle material (𝐖𝐧) for bottom discharge ................................................... 37
3.6.5 Weight of the nozzle material (𝐖𝐧) for longitudinal and lateral ........................................ 38
3.6.6 Weight of insulation ................................................................................................................. 38
3.6.7 Wind loading ............................................................................................................................ 39
3.6.7.1 Stress analysis ........................................................................................................................ 40
3.6.7.2 Dead weight stress ................................................................................................................. 41
3.6.7.3 Bending stress ........................................................................................................................ 41
3.7 Design of vessel support.................................................................................................................. 44
3.7.2 Circumferential stress.............................................................................................................. 48
3.8 Design of Welding ........................................................................................................................... 49
3.8.1 The Circumstances of Welding ............................................................................................... 49
3.8.2 Code Requirements .................................................................................................................. 49
3.8.3 The Economy of Welding ........................................................................................................ 50
3.8.4 Selection of welding.................................................................................................................. 50
3.8.5 Stress analysis for welding ...................................................................................................... 50
3.9 Selection of a standard flange ........................................................................................................ 52
3.9.1 Types of flange, and selection.................................................................................................. 52
3.10 Gaskets ........................................................................................................................................... 54
3.10.1 Selection of standard Gasket ................................................................................................. 55
3.11 RESULT AND DISCUTION ....................................................................................................... 56
3.12 COST ANALYSIS ........................................................................................................................ 58
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3.13 Manufacturing Process ................................................................................................................. 59

3.13.1 Methods of fabrication ............................................................................................................. 59
Chapter four........................................................................................... 62
4.1 Conclusion ....................................................................................................................................... 62
4.2 Recommendation............................................................................................................................. 62
REFERENCE ........................................................................................................................................ 63
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List of figures
Figure 1. Different Type of Heads ................................................................................................................ 5
Figure 2 Material Selection ......................................................................................................................... 18
Figure 3 Cylindrical Pressure Vessel .......................................................................................................... 22
Figure 4 View and Cross Section of Shell .................................................................................................. 22
Figure 5 View and Cross Section of Shell .................................................................................................. 23
Figure 6 Radial Stress Analysis .................................................................................................................. 24
Figure 7 Design of Head ............................................................................................................................. 25
Figure 8 Reinforcement Limit..................................................................................................................... 29
Figure 9 Length of Coupling And Pipes For Openings .............................................................................. 37
Figure 10 Wind Stress ................................................................................................................................. 40
Figure 11 Stresses In a Cylindrical Shell .................................................................................................... 42
Figure 12 Principal Stresses of Up-Wind and Down-Wind ....................................................................... 43
Figure 13 Stress In Vessel on Leg Support ................................................................................................. 44
Figure 14 Stress on Leg Vessel Support K1 & K5 .................................................................................... 46
Figure 15 Stress on Leg Vessel Support K2 & K6 ..................................................................................... 46
Figure 16 Stress on Leg Vessel Support K3 & K7 .................................................................................... 46
Figure 17 Stress on Leg Vessel Support K4 & K8 ..................................................................................... 47
Figure 18 Standard Flange .......................................................................................................................... 53
Figure 19 Welded Neck Flange for 150mm Openings ............................................................................... 53
Figure 20 Selection of Standard Gasket ...................................................................................................... 55
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List of Table
Table 1.1 given parameter…………………………………………………………………….. 19
Table 3.2 ratio table of length and diameter…………………………………………………… 20
Table 3.3 density of various fluid…………………………………………………………....... 36
Table 3.4 density of different metals………………………………………………………… 37
Table3.5 Flange dimension for openings ………………………………………………………54
UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 ix

CHAPTER ONE
1.1 Introduction
A pressure vessel is a closed container designed to hold gases or liquids at a pressure
substantially different from the ambient pressure. The fluid may be at elevated temperatures and
in a pressurized state. It also defined as a container with a pressure differential between inside and
outside. The inside pressure is usually higher than the outside, except for some isolated situations.
Pressure vessels are leak proof containers, as the name implies, their main purpose is to
contain a given medium under pressure and temperature. They may theoretically be almost any
shapes made of section spheres and cones are usually employed. Pressure vessels; commonly have
the cylindrical, spherical, ellipsoidal, conical or a combination of these shapes.
A common design is a cylindrical with hemispherical ends caps or heads. The cylindrical
vessels are generally preferred because;
 They present simple manufacturing problem and
 Make better use of the available space.
Boiler drums, heat exchangers, chemical reactors, and so on, are generally cylindrical.
Spherical vessels have the advantage of requiring thinner walls for a given pressure and
diameter than the equivalent cylinder. Therefore they are used for large gas or liquid containers,
gas-cooled nuclear reactors, containment buildings for nuclear plant, and so on. Containment
vessels for liquids at very low pressures are sometimes in the form of lobed spheroids or in the
shape of a drop. This has the advantage of providing the best possible stress distribution when the
tank is full.
The vessel geometries can be broadly divided into two:
 Plate type configurations and
 Shell type configurations.
The plate-type construction used in flat covers (closures for pressure vessels and heat exchangers)
resists pressure in bending, while the shell-type’s membrane action operates in a fashion analogous
to what happens in balloons under pressure. Generally speaking the shell-type construction is the
preferred form because it requires less thickness (as can be demonstrated analytically) and
therefore less material is required for its manufacture. Shell-type pressure components such as
UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 1

pressure vessel and heat exchanger shells, heads of different geometric configurations, and nozzles
resist pressure primarily by membrane action.
Pressure vessels are commonly used in industry to carry both liquid and gases under required
pressure and temperature limit. This pressure and temperature comes from an external source or
by the application of heat from a direct or indirect source or any combination of them. They may
be of any shape and size ranging beer canes, automobile tires or gas storage tank, to more
sophisticated ones encountered in engineering applications.
The material of pressure vessels may be brittle such as cast iron, or ductile such as mild steel.
Many pressure vessels are made of steel. To manufacture a pressure vessel, forged parts would
have to be welded together. Some mechanical properties of steel are increased by forging, but
welding can sometimes reduce these desirable properties. In case of welding, in order to make the
pressure vessel meet international safety standards, carefully selected steel with a high impact
resistance & corrosion resistant material should also be used.
When discussing pressure vessels we must also consider tanks. Pressure vessels and tanks are
significantly different in both design and construction: tanks, unlike pressure vessels, are limited
to atmospheric pressure; and pressure vessels often have internals while most tanks do not (and
those that do are limited to heating coils or mixers).
Pressure vessels are used in a number of industries; for example,
 The power generation industry.
 For fossil.
 Nuclear power.
 The petrochemical industry.
 For storing and processing crude petroleum oil.
 In tank farms.
 Storing gasoline in service stations.
 As well as the chemical industry (in chemical reactors).
To name but a few their use has expanded throughout the world.
Generally speaking, pressurized equipment is required for a wide range of industrial plant
for storage and manufacturing purposes. The size and geometric form of pressure vessels vary
greatly from the large cylindrical vessels used for high-pressure gas storage to the small size used

as hydraulic units for aircraft. Some are buried in the ground or deep in the ocean, but most are
positioned on ground or supported in platforms.
Finally, pressure vessel are refers to those reservoirs and apparatus which work under internal
and external pressure and operate under the pressure.
1.2 Classification of pressure vessel
Pressure vessels can be classified in different categories as follows:-
1.2.1 According to the dimension

The pressure vessels according to their dimensions may be classified as thin shell or thick
shell the ratio of equal thickness (t) of the shell to its diameters (D) deciding factor.
t 1
a) Thin shell: - if the ratio of is less than is called a thin shells.
D 10
t 1
b) Thick shell:- if the ratio of is equal or greater than is called thick shell used in
D 10
high pressure cylinders, gun, barrels and other equipment’s where as thin shell are used
in boiler, tanks and pipes
.
1.2.2 According to the end construction
This can be classified in to two groups:-
a) Open end construction pressure vessels

b) Closed end construction pressure vessels
1.2.3 According to the geometrical shapes

a) Cylindrical geometrical shapes
b) Conical and
c) Spherical vessel with one or two cones.
1.2.4 According to the position arrangement
a) Horizontal pressure vessel
b) Vertical pressure vessel

c) Spherical pressure vessel
1.2.5 According to the materials
The pressure vessels are according the material classified as:-
a) Brittle material pressures vessels

b) Ductile material pressure vessels
1.2.6 According to the direction of force acting on the wall of vessels.

a) Subjected to internal pressure  pi 
b) Subjected to external pressure  p 
1.3 Component of pressure vessels

There are four components of pressure vessels this are:-
1.3.1 Head
1.3.2 Shell
1.3.3 Nozzle and
1.3.4 Support
1.3.1 HEAD
All pressure vessel shells must be closed at the ends by heads (or another shell section).
Heads are typically curved rather than flat. Curved configurations are stronger and allow the heads
to be thinner, lighter, and less expensive than flat heads. Heads can also be used inside a vessel.
Head are usually categorized by their shapes. Ellipsoidal, hemispherical, tori spherical, conical,
tori conical and flat are the common types of heads.

Figure 1. 1 different type of heads
1.3.2SHELL
The shell is the primary component that contains the pressure. Pressure vessel shells are
welded together to form a structure that has a common rotational axis. Most pressure vessel shells
are cylindrical, spherical, or conical in shape. Horizontal drums have cylindrical shells and are
fabricated in a wide range of diameters and lengths.
1.3.3 NOZZLE
A nozzle is a cylindrical component that penetrates the shell or heads of a pressure Vessel.
The nozzle ends are usually flanged to allow for the necessary connections and to permit easy
disassembly for maintenance or access. Nozzles are used for the following applications:-
o Attach piping for flow into or out of the vessel.

o Attach instrument connections, (e.g., level gauges, thermo wells, or pressure
gauges).

o Provide access to the vessel interior at many ways.

o Provide for direct attachment of other equipment items, (e.g., a heat exchanger
or Mixer)
1.3.4 SUPPORT
The type of support that is used depends primarily on the size and orientation of the
pressure vessel. In all cases, the pressure vessel support must be adequate for the applied weight,
wind, and earthquake loads. Calculated base loads are used to design of anchorage and foundation
for the pressure vessels.
Typical kinds of supports are as follow:-

1.3.4.1 Skirt support
Tall, vertical, cylindrical pressure vessels are typically supported by skirts. A support
skirt is a cylindrical shell section that is welded either to the lower portion of the vessel shell
or to the bottom head (for cylindrical vessels). Skirts for spherical vessels are welded to the
vessel near the mid-plane of the shell. The skirt is normally long enough to provide enough
flexibility so that radial thermal expansion of the shell does not cause high thermal stresses at
its junction with the skirt
1.3.4.2 Leg support
Small vertical drums are typically supported on legs that are welded to the lower portion
of the shell. The maximum ratio of support leg length to drum diameter is typically 2:1. The
number of legs needed depends on the drum size and the loads to be carried. Support legs are also
typically used for spherical pressurized storage vessels. The support legs for small vertical drums
and spherical pressurized Storage vessels may be made from structural steel columns or pipe
sections, whichever provides a more efficient design.
1.3.4.3 Saddle support

Horizontal drums are typically supported at two locations by saddle supports.
A saddle Support spreads the weight load over a large area of the shell to prevent an excessive
local stress in the shell at the support points. The width of the saddle, among other design details,
is determined by the specific size and design conditions of the pressure vessel. One saddle support
is normally fixed or anchored to its foundation

1.3.4.4 Lug support

Lugs that are welded to the pressure vessel shell, which are shown on, may also be used to
support vertical pressure vessels. The use of lugs is typically limited to vessels of small to medium
diameter (1 to 10 ft.) and moderate height-to-diameter ratios in the range of 2:1 to 5:1. Lug supports
are often used for vessels of this size that are located above grade within structural steel. The lugs
are typically bolted to horizontal structural members to provide stability against overturning loads;
however, the bolt holes are often slotted to permit free radial thermal expansion of the drum.

1.4 Background of pressure vessel

The earliest documented design of pressure vessels is described in the book Codex Madrid
I, by Leonardo da Vinci, in 1495, where containers of pressurized air were theorized to lift heavy
weights underwater, however vessels resembling what are used today did not come about until the
1800s where steam was generated in boilers helping to spur the industrial revolution. However,
with poor material quality and manufacturing techniques along with improper knowledge of
design, operation and maintenance there was a large number of damaging and often fatal
explosions associated with these boilers and pressure vessels.
In an early effort to design a tank capable of withstanding pressures up to 10,000 psi

(69 MPa), a 6-inch (150 mm) diameter tank was developed in 1919 that was spirally-wound with
two layers of high tensile strength steel wire to prevent sidewall rupture, and the end caps
longitudinally reinforced with lengthwise high-tensile rods. The need for high pressure and
temperature vessels for petroleum refineries and chemical plants gave rise to vessels joined with
welding instead of rivets (which were unsuitable for the pressures and temperatures required) and
in 1920s and 1930s the BPVC included welding as an acceptable means of construction, and
welding is the main means of joining metal vessels today.
Numerous boiler explosions took place through the late 1800s and early 1900s. This led to the
enactment of the first code for construction of steam boilers by the Commonwealth of
Massachusetts in 1907. This subsequently resulted in the development and publication of the
ASME Boiler and Pressure Vessel Code in 1914, which sought to standardize the design,
manufacturing, and inspection of boilers and pressure vessels.
The ASME and the ASTM (American Society for Testing and Materials) material specification
merged in 1924. The first publication of Section VIII ‘‘Unfired Pressure Vessels,’’ appeared in
1925. This document was referred to as one of a theoretical factor of safety of 5. The petroleum
industry did not consider it to be adequate for their purposes and also desired better utilization of
available materials. The year 1928 saw the advent of welded pressure vessels. For higher pressures
the welded shells were made thicker than 70 mm. These required nondestructive examination
(NDE) before service. In 1934, a joint API–ASME Committee published the first edition of an
unfired pressure vessel code specifically for the petroleum industry. In 1952 these two separate
codes merged into a single code – the ASME Unfired Pressure Vessel Code, Section VIII. The

ASME Pressure Vessel Code, Section VIII Division 2: ‘‘Alternative Rules for Pressure Vessels,’’
was published in 1968 and the original code became Section VIII Division 1: ‘‘Pressure Vessels.’’
A considerable boost was provided to the understanding of the basic behavior of pressure
vessel components following the development of the nuclear power program in the U.S. and
Europe in the late 1950s and early 1960s. Similar developments can be found in the British, French,
German and Japanese codes, to name but a few. By 1960 the need for a code for pressure vessels
for commercial nuclear plants became imperative. This resulted in publication of the 1963 Edition,
Section III: ‘‘Nuclear Pressure Vessels.’’ This was a design by analysis code with a theoretical
safety factor of 3. After the publication of Section III: ‘‘Nuclear Pressure Vessels’’ in 1963, it was
necessary to modify Section VIII for general pressure vessels. ASME Code Section VIII Division
2: ‘‘Alternate Rules for Pressure Vessels’’ appeared as a result and provided a theoretical factor
of safety of 3. In 1971, Section III: ‘‘Nuclear Power Components’’ were classified as (a) pumps,
(b) valves, and (c) piping. The stress limits for emergency and faulted conditions were introduced
Some of the significant features of the latest version of the ASME Code Section III are:
 Explicit consideration of thermal stress;
 Recognition of fatigue as a possible mode of failure;
 The use of plastic limit analysis;
 Reliable prediction of ductile failure after some plastic action.
Safety in boiler and pressure vessels can be achieved by:

 Proper design and construction;
 Proper maintenance and inspection;
 Proper operator performance and vessel operation.

1.5 Statement of the problem

Pressure vessel design is an important part of oil and gas production equipment manufacturing.
Pressurized oilfield storage tanks are used to hold fluids under pressure that are critical to a wide
variety of applications. Given the importance of pressure vessels to operations. Regardless of the
nature of application of the vessels, a number of factors usually must be considered in designing
of the pressure vessel component. The most important consideration often taken in the selection
of the type of pressure vessels are:
 The Ambient, operating pressure and temperature;

 Functions of the pressure vessel;
 Location of the pressure vessel;
 Nature of the working fluid that used in the pressure vessel which performs the required
services in the most satisfactory manner.
Pressure vessels should be designed to suit the exact operating conditions they will be
functioning under. In developing the design, a number of other criteria must be considered such as
the properties of material used, the induced stresses, the elastic stability, and the aesthetic
appearance of the unit. The cost of fabricated vessel is also important in relation to its service and
useful life.
Designing of a perfect pressure vessel is almost impossible due to the large number of
influences listed above which can change the behavior of the pressure vessel. Although, it is
possible to decrease this influencing factors to a minimum, if the pressure vessel is used on a proper
way. In this project we will try to describe some problems, which influence the working
appearance of the pressure vessel. In order to reduce the above problems as much as possible it is
important to design the pressure vessel with in the given data accordingly.
Vertical pressure vessel now a days are provided using fluids like water, air, septic and others.
Under this project we try to design a pressure vessel with mineral oil or paraffin oil that operates
under the pressure of 10MPa and internal volume of 0.25m3 with in a temperature of 4500c.

1.6 Objective of the project

Main objective
The main objective of our project is to design a vertical pressure vessels position with some
head by the given internal pressure and temperature on its effect and having some material
properties that can be functional under the given temperature of 450 0c and pressure 10 MPa
Specific objective
To the near point, we would like to design different parts of pressure vessel like:
o The supports of the pressure vessel(legs);
o Head of the pressure vessel;
o Shell of the pressure vessel;
o Nozzle of the pressure vessel etc.
And also the project has its own procedures to design each component and to design the hole
assembled of pressure vessels.
1.7 Methodology
In order to design a pressure vessel with hemispherical end connection, up with design pressure
of 10 MPa with total volume of 0.25 m3, we follow the following procedures.
A. Literature survey phase:-

Literature survey of relevant material on different types of a pressure vessel and what are the
mechanism that are responsible for designing of a horizontal pressure vessel that can work
properly at the given design pressure and temperature. The literatures are obtained from
journals, newspapers, articles, websites, books…etc.
B. Specify the components of the pressure vessel:-

In order to perform a full design of pressure vessel we need to determine the components of
the pressure vessel. That are the main things should be considered since the pressure vessels
are made from the assembling of those components.
C. Problem identification:-

This is the most advantages step for any project. So in order to perform our project as much as
having the smallest problem (if so no problem) we must consider the things that can affect our
project.
D. Material selection:-
This step has a great contribution for our work that used to select a proper material for each
component as the required property based on the general criteria of selection.
The selection of a proper material, for engineering purposes, is one of the most difficult problems
for the designer. The best material is one which serves the desired objective at the given conditions
with the minimum cost. We will select the materials based on the following criteria:-
1. performance characteristics (properties)
2. processing (manufacturing) properties
3. environmental profile
4. availability of the material
5. economical consideration
In detail the following are the most important characteristics to be considered when selecting
a material of constructions. These are:-
a) Mechanical properties:
This includes the following properties.
I. Strength: - Tensile strength is required.
II. Stiffness: - The material should have high Elastic modulus (Young’s modulus).
III. Toughness: - Fracture resistance needed.
IV. Hardness: - high wear resistance required.
b) The effect of high and low temperature on the mechanical properties.

c) Corrosion resistance
d) Any special properties required such as thermal conductivity.
e) Case of fabrication: forming, welding, casting etc.

f) Availability in standard sizes.

g) Cost of the material.
E. Design procedure: - the tasks to do in this step are:-
 Identify the specifications,
 Geometry analysis,
 Force analysis,
 Stress analysis,
 Prepare part and assembly drawing.
1.7 Scope and Limitation of the Project

In pressure vessels encountered in engineering construction; high pressure, extremes of
temperature and severity of functional performance requirements pose exciting design problems.
The word "DESIGN" does not mean only the calculation of the detailed dimensions of a member,
but rather is an all-inclusive term, incorporating:
 The reasoning that established the most likely mode of damage or failure;
 The method of stress analysis employed and significance of results;
 The selection of material type and its environmental behavior;
 The way of construction needs a skilled engineer or man power to sustain the problems
that related to the fluid that vessel subjected.
The ever-increasing use of vessel has given special emphasis to analytical and experimental
methods for determining their operating stresses. Of equal importance is the appraising the
significance of these stresses. Knowledge of material behavior is required not only to avoid
failures, but also equally to permit maximum economy of material choice and amount used.

CHAPTER TWO
2.1 Literature Review
Pressure vessels are used as ammonia converter, urea reactor and supercritical fluid extractor at
higher level are widely used in chemical, oil refining, energy industries, and so on. Such vessels
are key equipment’s in various processes industries and have potential hazards. Much attention
has been paid to using them safely and to lowering their costs, with great progress being made in
the last century. For example:
 Analysis of Pressure Vessel junction by the Finite element Method written by
Mahadeva Sivaramakrishna Iyer not only tells the use of method to solve such high
tension zone problems but also gives a way to predict results for stresses and optimize
the design ;
 Finite element analysis of Pressure vessel by David Heckman also tells the use of
computer programs instead of hand calculations for analyzing the high stress area’s
and different end connections;
 The different types of stresses and modeling of pressure vessel joints are also
depicted in ASME code in section “Design by analysis”.
The use of hemispherical end in pressure vessels is the most economical and common use
which can be seen in different developing countries. Although with the recent trends in Mechanical
engineering with the use of Finite element software’s the sheet thicknesses are validated for
different end connections and for cylinder shell itself. As per the conventional theory of mechanics
of materials stated by S Timoshenko, the required thickness of the hemispherical end is one-half
the thickness of the shell to result in equivalent stresses in the cylinder.
The following persons are done a wide and deep research on pressure vessel design
1. M Javed Hyder and M Asif
Presented work to optimize location and size of opening in pressure vessel cylinder using ANSYS,
Analysis performed for three thick-walled cylinders with internal diameter 20, 25 and 30 cm
having 30 cm height and wall thickness of 20 mm.
2. V.N. Kolinsky, A.B. SMETANKIN
Presented work on modeling and stress analysis of nozzle connection in Ellipsoidal head of
pressure vessel under external loading,

3. James j Xu, benedict C. Sun, Bernard Koplik

Had did work on local pressure stress on lateral pipe-nozzle with various angle of interaction, this
paper report variation of local pressure stress factor at the junction of pipe-nozzle when its angle
varies from 90 to 30 degree, the circumferential and longitudinal stress at four symmetric points
around the pipe nozzle junction are plotted as function of an angle
4. J. Fang, Q.H.Tang
Presented work on a comparative study of strength behavior for cylindrical shell interaction with
and without pad reinforcement under out-of-plane moment loading on nozzle, three pairs of full-
scale test vessel with different mean diameter of nozzle to mean diameter of cylindrical vessel
ratio were designed and fabricated for testing and analysis
5. Amran Ayob
Worked on stress analysis of tori spherical shell with radial nozzle, in this paper experimental
reading was taken with help of 0.0625-inch foil string gauge which was bonded to the outer and
inner surface of the shell,
6. Pravin Naral and P S Kachare
Presented work on structural analysis of nozzle attachment on pressure vessel design, they said if
the nozzle is kept on peak of the dished end it do not disturb the symmetry of the vessel, but if it
is placed on the placed on the periphery of the vessel, it may be disturb the symmetry of the vessel.
7. H. V. N. Skopinsky
Had worked on stresses in ellipsoidal pressure vessel heads with non-centrally nozzle, the
objective of this paper is more investigation of shell intersection problem, the shell theory and
finite element method are used for stress analysis of nozzle connections in ellipsoidal heads of the
pressure vessel,
8. B.S.Thakkar and S.A.Thakkar
Did a case study and put efforts to design the pressure vessel using ASME codes & standards to
legalize the design. The performance of a pressure vessel under pressure can be determined by
conducting a series of tests to the relevant ASME standard in future scope they have mentioned
Design of pressure vessel
9. Jaroslav Mackerle
had worked on bibliographical review of finite element method(FEMs) applied for the analysis of
pressure vessel structural/components and piping from the theoretical as well as practical points

of view, he searched paper contains 856 reference to papers and conference proceeding on the
subject that were published in 2001-2004,
10. P balicevic, D Kozak, D. Karlievic
presented work on ANLYTICAL and NUMERICAL solution of internal forces by cylindrical
pressure vessel with semielliptical heads, in this paper the solution for internal forces and
displacement in the thin-walled cylindrical pressure vessel with ellipsoidal head using general
theory of thin walled shell of resolution have been proposed, distribution of the forces and
displacement in thin walled shell are given in mathematical form,
11. M J Mungla
Had conducted design and analysis of various components of pressure vessels like shell, heads,
flanges, and nozzle and support structures along using ASME code. Design of base ring and skirt
sections has not been covered under ASME code and their dimensions are calculated with general
design principles. Stress analysis of these components has been carried out with combined load
cases,
CONCLUSIONS:
From the literature review it is seen that ASME and other code are providing solutions for more
general cases and required higher factor of safety, also limit load and stress concentration formulae
are not available for non-standard shape and intersection and geometrical discontinuity, most of
researcher have worked in thin-pressure vessels and there is scope in studying the opening in thick
pressure vessel, from above discussion it is cleared that study of the effect of change in size,
position, location of the opening in pressure vessel to study the stress concentration is essential,
the position and location of the opening on cylinder is not studied in past by researcher and there
is no code provision for such design, Finite element analysis is an extremely powerful tool for
pressure vessel. A structural analysis of the high pressure vessel will be implemented. The
maximum load on a saddle may be conservative or liberal, depending upon the value of the ratio
A/L used. Furthermore, the design of the saddle structures.

CHAPTER –THREE
3.1 Detail Design and Analysis

Detail design of vertical pressure vessel refers design of each and every component of the vessel
using mathematical analysis and graphical representation if it needs. Our design of vertical
pressure vessel we have general specifications given above in table that we should consider to
design. To design this vertical pressure vessel we have consider several design considerations.
Design of horizontal layout pressure vessel

Parameters Value Unit
Design pressure 11 Mpa
Design temperature 450 ℃
Volume 0.25 m3
Corrosion allowance 2 -
Working fluid Mineral oil/paraffin
Vessel orientation Vertical
Support Leg
Table 1.1 given parameter

3.1.1 General Design Considerations

3.1.1.1 Material selection
Selection of a suitable material must take into account the suitability of the material for fabrication
(particularly welding) as well as the compatibility of the material with the process environment.
The pressure vessel design codes and standards include lists of acceptable materials in accordance
with the appropriate material standard
Figure 2 material selection
The main thing we should to consider is the strength of the material So at a given temperature
450℃ we have select the material low alloy steel (contain, Ni, Cr, Mo, V) because it has good
strength, low in cost and relatively good at corrosion resistant. All components of vessel are
composed of this material because it makes easy to weld together and all will have similar strength.
The pressure vessel design codes and standards include lists of acceptable materials;
in accordance with the appropriate material standards.

3.1.1.2 Design pressure

A vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation. For vessels under internal pressure, the design pressure is normally taken
as the pressure at which the relief device is set. This will normally be 5 to 10 cent above the normal
Working pressure, to avoid spurious operation during minor process upsets. The design pressure
to be
10
PD =P0 +P0× 100
10
=10N/mm2 +10 N/mm2 × 100
=11N/mm2
Where PD =Maximum allowable design pressure
P0 = given design pressure
3.1.1.3 Design temperature

The strength of metals decreases with increasing temperature so the maximum allowable design
stress will depend on the material temperature. The design temperature at which the design stress
is evaluated should be taken as the maximum working temperature of the material, with due
allowance for any uncertainty involved in predicting vessel wall temperatures.
So maximum temperature, T0= 450C0
Tensile stress &design stress for low alloy steel at T =450 C0 can be read as follow,
- Tensile stress, σt =550 N/mm2
- Design stress, σD =190 N/mm2
3.1.1.4 Corrosion allowance

The “corrosion allowance” is the additional thickness of metal added to allow for material lost
by corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer. Corrosion is a complex phenomenon, and it is not possible to give
specific rules for the estimation of the corrosion allowance required for all circumstances. The

allowance should be based on experience with the material of construction under similar service
conditions to those for the proposed design. For carbon and low-alloy steels, where severe
corrosion is not expected, a minimum allowance of 2.0 mm should be used; where more severe
conditions are anticipated this should be increased to 4.0 mm. Most design codes and standards
specify a minimum allowance of 1.0 mm.
Now for low alloy steel we use corrosion allowance of Ca=2 mm. where Ca=corrosion allowance
3.2 Design of Shell

For cylindrical shell design the minimum thickness required to resist internal pressure, the length
of shell, internal & external diameter of shell, volume of shell, and general stresses applied on the
shell can be determined using mathematical analysis as follow.
σD=Design stress =190 N/mm2
PD=Design pressure =11 N/mm2
J=weld joint factor =1
𝐿
We can determine (𝐷𝑖 ) ratio from table given below on procedure using the following relation.
Using unit conversion, 1 MPa =145.04 Psi
PD = 11MPa= 1595.44 Psi
PRESSURE (Psi) L/D ratio

0-250 3
250-500 4
>500 5
Table 1.2 ratio table of length and diameter
Implies, PD =1595.44 Psi is >500, so we take L/Di ratio to be 5
𝑳
= 5…………………………………………………………………………… (1)
𝑫𝒊

Where L =Shell length
Di =internal diameter
Now to find internal diameter use given volume,
Total volume of vessel =Volume of shell +Volume of two half sphere (make one full sphere)
𝑉𝑡 = 𝑉𝑠 + 𝑉𝑠𝑝
𝜋𝐷𝑖2 ×𝐿 𝜋 𝐷𝑖3
0.25 m3 = + but, L = 5 Di
4 6
By substituting it
5×𝜋 𝐷𝑖3 𝜋 ×𝐷𝑖3

0 .25m3 = +
4 6
0.25
0.25m3 =4.4506 Di3 implies, Di =3√4.4506 m =0.383m
for design case use Di ≈ 𝟑𝟖𝟒𝒎𝒎 because enlarging diameter leads to greater volume than
the expected to be, so it has no problem. Now we can get length of shell now from equation (1)
L =5 × 0.384 𝑚 =1.92 m is length of shell.
Now let’s find the find the value of thickness of shell or cylinder without corrosion allowance:
PD  Di 11N / mm2  384mm

t0  = 2 = 11.44mm
2 J D  PD 2  1  190 N / mm2  11N / mm
The minimum wall thickness required for design is given as:
t = to + Ca =11.44 mm +2 mm =13.44 mm≈ 14mm
Using the ratio of t/Di we can estimate the type of cylinder based on their thickness.
t 14mm
  0.03646  0.036 , Which leads to the following relation,
Di 384mm
1
0.036< 10 = 0.1
Hence, the cylinder is thin cylinder.

The outer diameter of the shell would be:
Do=Di +2t=384mm+2× 14𝑚𝑚=412mm
3.2.1 Stress analysis of shell
Figure 3 cylindrical pressure vessel
 Circumferential or hoop stress (𝜹 h ) analysis

Circumferential or hoop stress refers to the stress occurred along the direction of circumference
of shell of vessel. It can be calculated as follow:
Figure 4 view and cross section of shell
PD  Dm
𝜹h = , but, Dm =Di +t =384mm +14mm
2t
Dm = 398mm where Dm=mean diameter

11MPa  398mm
𝜹h = 156.36MPa
2  14mm
From this, 𝛿 h =156.36 MPa< 𝛿 D =190MPa
This indicate that our design hoop stress is safe.
II. Longitudinal stress (𝜹 L ) analysis

It the stress applied along the direction of its axis. It can be calculated using the following
formula.
Figure 5 view and cross section of shell
PD  Dm 11MPa  398mm
𝛿L = = = 𝟕𝟖. 𝟏𝟖𝑴𝑷𝒂
4t 4 14mm
This result shows that the design stress for longitudinal stress is also safe. Because it
has lesser value than the design stress.
i.e. 𝟕𝟖. 𝟏𝟖𝑴𝑷𝒂 < 190 MPa shows safe.
III. Radial stress (𝜹 r ) analysis

Radial stress refers the stress experienced along the radius of the cylinder’s shell. But this value
of stress is neglected in stress analysis for thin cylinder.
i.e. 𝜹 r ≈ 𝟎, For thin cylinder only.

Maximum stress applied on the shell will be expressed as;
𝜹 h −𝜹
L
𝜹Max=
2
Figure 6 radial stress analysis
𝜹 h −𝜹
L
𝜹max=
2
𝟏𝟓𝟔.𝟑𝟔𝐌𝐏𝐚−𝟕𝟖.𝟏𝟖𝑴𝑷𝒂
= 2
𝝉
=39.09Mpa < = 95Mpa
𝟐
Therefore our design of shell is safe.

3.3 Design of Head

The type of head we have selected is that hemispherical head.
Figure 7 design of head
These is because:
A hemispherical head is the strongest shape; capable of resisting about twice the pressure of a tori
spherical head of the same thickness. Even if the cost of forming a hemispherical head will be
higher than that for a shallow tori spherical head.so strength is the primary concern of my design.
Hemispherical heads are used for high pressures which helps it not to fail easily with increased
pressure.
Now let’s find the minimum thickness required to design hemispherical head using the formula
given in table 2.1 with only symbol change.
PD  Ri 11MPa  192mm
to = =5.59 mm
2   D  J  (0.2  PD ) 2  190MPa  1  (0.2  11MPa)
It can be that for equal stress in the cylindrical section and hemispherical head of a vessel the
thickness of the head nee only be half that of the cylinder. However, as the dilation of the two parts
would then be different, discontinuity stresses would be set up at the head and cylinder junction.
For no difference in dilation between the two parts (equal diametrical strain) it can be shown that
for steels (Poisson’s ratio=0.3) the ratio of the hemispherical head thickness to cylinder thickness
should be 7/17. However, the stress in the head would then be greater than that in the cylindrical
section; and the optimum thickness ratio is normally taken as 0.6;

So by using these we find head thickness,

Hemispherical head=0.5 thickness
=0.5*14
=7mm
Head/thickness=7/17
Head = (7/17)*14mm
=5.76mm
Head/thickness=0.6
Head =0.6thickness
=0.6*14mm
=8.4mm
From the four equations we take the maximum.
Therefore our head thickness is 8.4mm.
Therefore our total thickness is:
t=t o +Ca
=8.4 mm+2 mm
=10.4mm ……With corrosion allowance.
t ≈11mm The minimum head thickness is 11mm so t ≥ 11
But we can take the value greater than this to weld effectively in coincidence (to coincide) with
thickness of shell to avoid collection of any dirt and formation of plug.
Say: t =12mm for safety.so the minimum thickness for the shell head is 12mm we can use it for
economical purpose but for safety we take a uniform thickness with that of shell t=14mm.
3.3.1 Stress analysis of Hemispherical Head

I. Circumferential or hoop stress (𝜹 h ) analysis
Circumferential or hoop stress refers to the stress occurred along the direction of circumference
of head of vessel. It can be calculated as follow:
Taking minimum t=12mm

PD  Dm
𝜹h = , but, Dm =Di +t =384 mm +12mm
2t
Dm = 396mm where Dm=mean diameter
11MPa  396mm
𝜹h = 181.5 MPa
2  12mm
From this, 𝛿 h =181.5 MPa < 𝛿 D =190 MPa
This indicate that our design hoop stress is safe.
I. Longitudinal stress(𝜹 L ) analysis
It the stress applied along the direction of its axis. It can be calculated using the following
formula.
PD  Dm 11MPa  396mm
𝛿L = = = 𝟗𝟎. 𝟕𝟓𝑴𝑷𝒂
4t 4 12mm
This result shows that the design stress for longitudinal stress is also safe. Because it has less
value than the design stress.
i.e. 90.75 MPa < 95 MPa shows safe.
It is possible for economical case but we should prefer thickness of head be equal with that of
shell.
II. Radial stress (𝜹 r ) analysis
Radial stress refers the stress experienced along the radius of the cylinder’s head. But this value
of stress is neglected in stress analysis for thin cylinder.
i.e. 𝜹 r ≈ 𝟎, For thin cylinder only.
3.4 Design of nozzle

A nozzle is a cylindrical component that penetrates the shell or heads of a pressure vessel. The
nozzle ends are usually flanged to allow for the necessary connections and to permit easy
disassembly for maintenance or access.

Nozzles are used for the following applications:

 Attach piping for flow into or out of the vessel.
 Attach instrument connections, (e.g., level gauges or pressure

gauges).
 Provide access to the vessel interior at many ways.
 Provide for direct attachment of other equipment items, (e.g., a

heat exchanger or mixer).
3.4.1. Design 0f bottom discharge pipe

Take the inlet pipe diameter is (𝑑𝑖 ) = 65mm
𝑑𝑖
𝑟𝑖 = = 65/2 = 32.5mm
2
Assume: - our outlet opening pipe is placed at the bottom of the head
The minimum thickness of the nozzle for discharge pipe is given by:-
𝑃𝐷×𝑟𝑖 11𝑀𝑝𝑎 ×32.5𝑚𝑚
𝑒= = = 𝟏. 𝟗𝟑𝒎𝒎
𝑆𝐸−0.4×𝑃𝐷 1×190𝑀𝑝𝑎−(0.4×11𝑀𝑝𝑎)
𝑡𝑛 = e + Ca= 1.93mm+2mm = 3.93.mm≈ 𝟒𝒎𝒎

Where e = minimum thickness of the nozzle without corrosion allowance
Ca=corrosion allowance
𝑡𝑛 = thickness of the nozzle
Or
𝐷flange−𝐷opening 76.1−65
tn= = =5.5mm
2 2
The outer diameter of the nozzle is given by:-
𝑑𝑜 = d + 2𝑡𝑛 = 65 + 2× 4 = 73mm but d = 𝑑𝑖
The required minimum thickness of the nozzle is given by:-
𝑃𝐷×𝑟 11𝑀𝑝𝑎 ×32.5𝑚𝑚
𝑡𝑟𝑛= = = = 1.94m where, r =d/2 =65/2 = 32.5mm
𝑆𝐸−0.6×𝑃𝐷 1×190𝑀𝑝𝑎−0.6×11𝑀𝑝𝑎
The required minimum thickness of the head (𝑡𝑟𝑠 ) is given by:-
𝑃𝐷 ×𝑅 11×192
𝑡𝑟𝑠 = = (190×1)−0.6×11𝑀𝑝𝑎 = 11.52mm
𝑆𝐸−0.6𝑃𝐷

Diameter = 0.065meter (65mm).

3.4.2 Calculation of reinforcement limits.
Figure 8 Reinforcement limit
Horizontal limit /Parallel to shell surface/:-First take the value of tn (nozzle thickness) take
tn=4mm
=0.5d+t+tn = 0.5×65+14+4 =50.5mm
Compare and take the greater value, Therefore the horizontal limit is =65mm.
Vertical limit /Perpendicular to shell surface/:- Compare and take the smaller value.
Know find “h” and “ℎ1 ”
h = 2.5t = 2.5 × 14 = 𝟑𝟓𝒎𝒎
ℎ1 = 2.5tn = 2.5× 4 = 𝟗𝒎𝒎
For safe design take; ℎ1 = 9mm
Where, ℎ = the distance nozzle project beyond the outer surface of shell thickness
ℎ1 = The distance of nozzle project beyond the inner surface of the shell thickness
Therefore the vertical limit is =9mm.
3.4.3 Calculation of reinforcement required.
Area required

Ar = d×trn =65mm×2.189mm
Ar = 142.285mm2
Area available
1. Area available in vessel head A1

A1= d × (t-tr)
A1=2 × (t-tr) ×(tn+t)
A1=2×(14-2.189) × (4+14)
A1=425.196mm2
2. Area available in nozzle wall(out ward)
A2=5t×(tn-trn)
A2=5×14× (4-2.189)
A2=126.77mm2
3. Area available in nozzle wall(inward)

A3=5t×tn
A3=5×14×4
A3=280mm2
4. Area of weld
A4=t2
A4=142
A4=196mm2
Total available area of the bottom opening is;
∑4𝑖=1 𝐴i = A1+A2+A3+A4
=425.196mm2+126.77mm2+280mm2+196mm2
=1027.960mm2

3.4.4 Stress analysis for the opening

We use the following formulas to find the stress in the man-hole openings.
𝜎h= 𝑝d×𝑑𝑖
2𝑡
11𝑀𝑝𝑎×65mm
= 2×4mm = 89.375Mpa
𝜎l= 𝑝d×𝑑𝑖
4𝑡
= 4×4mm = 44.687Mpa
Next find the maximum shear and compare it with the design stress. if this condition fulfill the
design is safe.
𝜎ℎ−𝜎𝑙
𝝉max = < 𝜎𝑑⁄2
2
22.344Mpa<95Mpa
Therefore our design is safe.
3.6.1. Design 0f inlet opening pipe
Take the inlet pipe diameter is (𝑑𝑖 ) = 150mm

𝑑𝑖
𝑟𝑖 = = 150/2 = 75mm
2
Assume: - our inlet opening pipe is placed at the cylindrical shell

The minimum thickness of the nozzle for inlet pipe is given by:-
𝑃𝐷×𝑟 11𝑀𝑝𝑎 ×75𝑚𝑚
𝑒 = 𝑆𝐸−0.4×𝑃
𝑖
= 1×190𝑀𝑝𝑎−(0.4×11𝑀𝑝𝑎)
= 𝟒. 𝟒𝟒𝟓𝒎𝒎
𝐷
𝑡𝑛 = e + CA = 4.445mm+2mm = 6.445mm≈7mm
Where e = minimum thickness of the nozzle without corrosion allowance
𝑡𝑛 = thickness of the nozzle
Or
𝐷flange−𝐷opening 168.3−150
tn= = =9.15mm
2 2
The outer diameter of the nozzle is given by:-
𝑑𝑜 = d + 2𝑡𝑛 = 150 + 2× 7 = 164mm but d = 𝑑𝑖

The required minimum thickness of the nozzle is given by:-

𝑃𝐷×𝑟 11𝑀𝑝𝑎 ×75𝑚𝑚
𝑡𝑟𝑛= = = = 4.498mm. Where, r = d/2=150/2 =75mm
𝑆𝐸−0.6×𝑃𝐷 1×190𝑀𝑝𝑎−0.6×11𝑀𝑝𝑎
The required minimum thickness of the shell (𝑡𝑟𝑠 ) is given by:-
𝑃𝐷 ×𝑅 11×192
𝑡𝑟𝑠 = = (190×1)−0.6×11𝑀𝑝𝑎 = 11.52mm
𝑆𝐸−0.6𝑃𝐷
Diameter = 0.15meter (150mm).
Calculation of reinforcement limits.
Horizontal limit /Parallel to shell surface/:-First take the value of tn (nozzle thickness) take tn=7mm
=0.5d+t+tn = 0.5×150+14+7 =96mm
Compare and take the greater value, Therefore the horizontal limit is =150mm.
Vertical limit /Perpendicular to shell surface/:- Compare and take the smaller value.
Know find “h” and “ℎ1 ”
h = 2.5t = 2.5 × 14 = 𝟑𝟓𝒎𝒎
ℎ1 = 2.5tn = 2.5× 7 = 𝟏𝟕. 𝟓𝒎𝒎
For safe design take; ℎ1 = 17.5mm
Where, ℎ = the distance nozzle project beyond the outer surface of shell thickness
ℎ1 = The distance of nozzle project beyond the inner surface of the shell thickness
Therefore the vertical limit is =17.5mm.
Calculation of reinforcement required.

Area required
Ar = d×trn =150mm×4.498mm
Ar = 674.7mm2
Area available
1. Area available in vessel wall A1

A1= d × (t-tr)
A1=2 × (t-tr) × (tn+t)

A1=2× (14-4.498) × (7+14)

A1=399.084mm2
2. Area available in nozzle wall(out ward)
A2=5t× (tn-trn)
A2=5×14× (7-4.498)
A2=175.14mm2
3. Area available in nozzle wall(inward)

A3=5t×tn
A3=5×14×7
A3=490mm2
4. Area of weld
A4=t2
A4=142
A4=196mm2
Total available area of the inlet opening is;
∑4𝑖=1 𝐴i = A1+A2+A3+A4
=399.084mm2+175.14mm2+490mm2+196mm2
=1260.224mm2.
Thus, the result show that Aa> Ar. Available area is greater than the required area, therefore
additional reinforcement not required.
Stress analysis for the opening

We use the following formulas to find the stress in the man-hole openings.
𝜎h= 𝑝d×𝑑𝑖
2𝑡
=
2×7mm
= 117.86Mpa

𝜎l= 𝑝d×𝑑𝑖
4𝑡
=
4×7mm
= 58.92Mpa
Next find the maximum shear and compare it with the design stress. if this condition fulfill the
design is safe.
𝜎ℎ−𝜎𝑙
𝝉max = < 𝜎𝑙⁄2 ,
2
29.464Mpa<95Mpa Therefore our design is safe.
We have three the same dimensional nozzles two in longitudinal and one in lateral.
3.5 Design of circular handhold:

Since in our design we get smaller shell diameter the hand hole should be used in order to do some
operations on the pressure vessel. We take the diameter of hand hole as 0.12m. The material
selected for hand hold is stillness steel for its resistivity to corrosion.
Then the wall thickness of the handhold can be calculated as follows:
t handhole = (PD ×R handhole )/ (ᵟd E-0.6PD)
Where, PD =deign pressure (11Mpa)
R handhole= radius of hand hole(R=D/2=0.06m)
S=Design stress for the materials of hand hole (stainless steel 18Cr/8Ni unstabilised (304))
=108N/mm2 E =Joint efficiency factor (E =1)
t handhole = (PD ×R handhole )/ (SE-0.6PD)
t handhole = (11× 60)/ (108×1 - 0.6×11)
𝐭 𝐡𝐚𝐧𝐝𝐡𝐨𝐥𝐞 = 6.51mm
Total thickness of the hand hole including the corrosion allowance calculated as follows:
t handhole= t handhole + CA where CA=corrosion allowance
t handhole= 6.51mm + 1.2mm
𝐭 𝐡𝐚𝐧𝐝𝐡𝐨𝐥𝐞 = 7.71mm
Area for the hand hole will be:
πDhandhole 2
Ahandhole = 4
π∗602
Ahandhole = 4

𝐀 𝐡𝐚𝐧𝐝𝐡𝐨𝐥𝐞 =2827.4mm2
3.5.1 Stress analysis for hand hole

Longitudinal stress (𝝈𝐋 ):
𝜎L = (PD ×Dhandhole )/ (4×t handhole )
𝜎L = (11Mpa×120mm)/ (4×7.71mm)
𝝈𝐋 = 42.8N/mm2
The hoop (circumferential stress) or ( 𝝈𝐇 )
𝜎H = (PD ×Dhandhole )/ (2×t handhole )
𝜎H = (11Mpa×120mm)/ (2×7.71mm)
𝝈𝐇 =85.6N/mm2
Since both longitudinal and circumferential stress less than the allowable or design stress
therefore our design is safe. 𝝈𝐋 , 𝝈𝐇 < 𝟏𝟎𝟖𝑴𝒑𝒂.
3.6 Design of vessels subjected to combined loading

A minimum thickness required for pressure loading is 14mm. A much thicker wall will be needed
at the column base to withstand the wind and dead weight loads.
3.6.1 Dead weight of vessel

For preliminary calculations the approximate weight of a cylindrical vessel with domed ends, and
uniform wall thickness, can be estimated from the following equation:
W𝛎 = C𝛎πρ𝓶D𝓶g (H𝛎 + 0.8D𝓶) t × 10-3
Where;
Wν = total weight of the shell, excluding internal fittings, such as plates, N,
Cν= a factor to account for the weight of nozzles, man ways, internal supports, etc; which can be
taken as= 1.08 for vessels with only a few internal fittings, = 1.15 for distillation columns, or
similar vessels, with several man ways, and with plate support rings, or equivalent fittings,
Hν = height, or length, between tangent lines (the length of the cylindrical section), m,
g= gravitational acceleration, 9.81 m/s2,
t = wall thickness, mm
ρ𝓂= density of vessel material, kg/m3,
D𝓶=mean diameter of vessel = (Di + t ×10-3 ) m.
For a steel vessel, equation reduces to:

W𝛎 = 240 CνD𝓂 (Hν + 0.8D𝓂 ) t × 10−3
=240×1.15×0.384(1.91+0.8×0.384) ×14×10−3
=3.29KN
3.6.2 Weight of fluid

Fluids Density in (kg/m3)
Gasoline 720
Kerosene 790
Crude oil 870-920
Sulfuric acid 1890
Mineral oil /paraffin 900
Table 1.3 density of various fluid
To find the weight of fluid which score the maximum weight the density of mineral oil or
paraffin from the table 900kg / m3
Wf =mf g
Wf =vs𝜌f g
Wf =0.25m3×900kg/m3×9.81m/s2
Wf =2207.25N
Where, Wf =weight of fluid
vs=volume of shell
𝝆f =density of fluid
g= acceleration due to gravity
3.6.3 Weight of hemispherical head

Wh = 𝜌a×g×Vh
𝜋𝐷𝑖3 𝜋×(0.384)3
Vh= = =0.0296m3
6 6

Where, Vh=volume of head
𝜌a=density of the alloy material MIM-2700 (Fe-7%Ni) as-sintered
g=acceleration due to gravity
Material Group Alloy Density (kg/m3)

Low Alloy & Alloy Steels MIM-2700 (Fe-7%Ni) as- 7600
sintered
Low Alloy & Alloy Steels MIM-2700 (Fe-7%Ni) 7600
Carbonitrided
Stainless Steels MIM-316L 7800
Stainless Steels 304 L 7750
Table 1.4 density of different metals
Wh=7600kg/m3×9.81m/s2×0.0296m3
Wh=2.206kN
3.6.4 Weight of the nozzle material (𝐖𝐧 ) for bottom discharge
Figure 9 Length of coupling and pipes for openings
𝜋
𝐖𝐧 = (𝑑𝑜 2 − 𝑑𝑖 2 )𝐿𝑛 𝜌𝑔 Therefore the design is become safe.
4
𝐿𝑛 = C + t + n where, C = the length of the nozzle entering to the shell

C = 𝑅 − √(𝑅 2 − 𝑟𝑖 2 ) t = thickness of the shell

=192mm-√[(192𝑚𝑚)2 − (32.5𝑚𝑚)2] n = length of the nozzle out of the shell assume n = 50mm
=2.77mm 𝐿𝑛 = length of the nozzle
𝐿𝑛 = (2.77+4+50) mm
𝑳𝒏 =56.77mm
𝜋
𝐖𝐧 = 4 (𝑑𝑜 2 − 𝑑𝑖 2 )𝐿𝑛 𝜌𝑔
𝜋
𝐖𝐧= 4 (732-652) ×10-6× (56.77×10-3) ×7600×9.81
𝐖𝐧=3.67N
3.6.5 Weight of the nozzle material (𝐖𝐧 ) for longitudinal and lateral
𝜋
𝐖𝐧 = 4 (𝑑𝑜 2 − 𝑑𝑖 2 )𝐿𝑛 𝜌𝑔 Therefore the design is become safe.
n=50
C= =192mm-√[(192𝑚𝑚)2 − (75𝑚𝑚)2]
C=15.25mm
𝐿𝑛 = C + t + n
=15.25+7+50
=72.25mm
𝜋
𝐖𝐧 = (𝑑𝑜 2 − 𝑑𝑖 2 )𝐿𝑛 𝜌𝑔
4
𝜋
𝐖𝐧= (1642-1502) ×10-6× (72.25×10-3) ×7600×9.81
4
𝐖𝐧 =18.6N, but we have three pipes with 150mm diameter so total weight will be
𝐖𝐧= 3×18.6=55.8N
Total nozzle weight =55.8N+3.67N=59.47N
3.6.6 Weight of insulation

To have a constant working temperature throughout we should insulate the pressure vessel with
proper insulation material. The proper material is mineral wool.
Weight of mineral wool insulation From Coulson & Richardson’s Chemical Engineering
Handbook, R. K. Sinnott, Third Edition, Volume 6. We get we get density of mineral wool-
130kg/m3.
𝜋
Volume of insulation= 4 (Do2-Di2)×Hv
Where-Di=inner diameter of the vessel

Do =Outer diameter of the vessel
Hv =Length of cylinder

Do = Di + 2(tshell+ tinsulation)
= 384mm + 2(14 + 50)= 512mm
𝜋
Volume of insulation= 4 (Do-Di) × Hv
𝜋
= 4 (0.5122m2-0.3842m2) ×2.294m
=0.2066m3
W=m×g
=ρ×V×g
= 130kg/m3 × 0.2066m3 × 9.81m/s where, ρ=density of mineral wool =130kg/m3
= 263.52N
The above value is often doubled to allow for fitting, etc.
Weight of insulation= 527.04N
Total weight
Wt=W1+W2+W3+W4+W5
=3.29kN+2.207kN+2.206kN+0.527kN+0.895kN+0.0595kN
=8.29KN
3.6.7 Wind loading

The wind speed is not given in the specification; the wind speed can be predicted by studying
metrological records for the place where the pressure is to be erect.
For preliminary design the wind speed can be taken as 160km/hr which is equivalent to a wind
pressure of 1280 N/m2. The loading per unit length of the column can be obtained from the wind
pressure by multiplying the effective column diameter: the outside diameter plus an allowance for
thermal insulation and attachments such as pipe.
Fw = Pw × Deff
Where: Fw − loading per unit length
Pw− Dynamic wind pressure
Deff− Effective diameter

Figure 10 wind stress
Deff =di+2(tshell + tinsulation)
Deff=384mm+(14+50)mm
Deff=512mm=0.512m
Fw=Pw×Deff
Fw=1280N/m2×0.512m
Fw=655.36N/m
Fw×L2
M= 𝟐
𝟔𝟓𝟓.𝟑𝟔×(𝟐.𝟐𝟗𝟒)𝟐
M= 𝟐
M=1724.4Nm
3.6.7.1 Stress analysis

It is often that a designer should design machine components which operates in a severe
condition, in this typical design project the severe condition exist and it is located at the bottom of

the cylinder because the vessel at that location subjected to pressure, dead weight and wind induced
stress.
𝑃𝑑×𝑑𝑖
𝝈h=
2𝑡
11N/mm2×384mm
𝝈h=
2×14𝑚𝑚
𝝈h=150.86N/mm2
𝑃𝑑×𝑑𝑖
𝝈 l=
4𝑡
11N/mm2×384mm
𝝈 l=
4×14𝑚𝑚
𝝈l=75.43N/mm2
3.6.7.2 Dead weight stress

𝑾𝑡𝑜𝑡𝑎𝑙
𝝈ws=
π(di+t)t
𝟖𝟑𝟎𝟎𝑵
𝝈ws =
π(384mm+14mm)14mm
𝝈ws=0.4741N/mm2 (Compressive)
The above value is negative (compressive) because it is subjected above the plane of support.
3.6.7.3 Bending stress

𝐌 𝒅𝒊
𝝈b=± 𝐈𝐯 [ 𝟐 + 𝒕]
𝝅
𝑰v= (do4-di4)
𝟔𝟒
𝝅
𝑰v= [(412mm)4-(384mm)4]
𝟔𝟒
𝑰v=347,035,718.3mm4
1724.4K𝑁𝑚𝑚 384𝑚𝑚
𝝈b=± [ + 14mm]
347,035,718.3mm4 2

𝝈b=1.0236N/mm2
Figure 11 stresses in a cylindrical shell
Torsional shear stress(𝜏) resulting from torque caused by loads which are offset from the vessel
axis but in this particular pressure vessel design project the effect of such type of offset loads are
not considered.
Thus, the resulting longitudinal stress is:
𝝈z=𝝈l+𝝈w± 𝝈b
𝝈w -is compressive and therefore it’s negative.
σz(up wind )
𝝈z=75.43N/mm2-0.4701N/mm2+1.0236N/mm2
𝝈z=75.98N/mm2
𝝈z (downwind)
𝝈z=75.43N/mm2-0.4701N/mm2-1.0236N/mm2
𝝈z=73.94N/mm2

As there is no torsional shear stress, the principal stresses are σz (in the y direction) and σh (in the
x direction).The magnitude of radial stress as compared to other stress it’s very small and
negligible.
75.98N/mm2 73.94N/mm2
150.86N/mm2
Up wind down wind
Figure 12 Principal stresses of up-wind and down-wind
By comparing the difference of the two stresses in both cases we can get the maximum
difference between the principal stresses.
Case I –up-wind
=𝝈h-𝝈l
=150.86N/mm2-75.98N/mm2
=74.88N/mm2
Case II-down wind
=𝝈h-𝝈l
=150.86N/mm2-73.94N/mm2
=76.92N/mm2
The greatest difference between the principal stresses will be on the down-wind side and its
76.92N/mm2.
loose of function streangth or 𝐷𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠
Design factor (nd) = (𝜎)𝑜𝑟(𝜏)
190𝑁/𝑚𝑚2
=
76.92N/mm2
nd = 2.47

This design stress factor is responsible for any uncertainty in the design methods, the loading, the
quality of the materials, and the workmanship. As a result our design is more satisfactory.
3.7 Design of vessel support

The method used to design the support of the vessel will depend on the weight of the vessel, the
size, the shape, design temperature, design pressure, the vessel location and arrangement and
internal and external fitting
Figure 13 Stress in vessel on leg support
Note;
Positive values denotes tensile stress and negative value denotes compression.
Computing the maximum tensile stress in formulas for S1, S2 and K1, K3, K5 and K7 denotes
negative factors and K2, K4, K6 and K8 denotes positive factors.
Computing the maximum compression stress in formulas for S1, S2 and K1, K2 ,K3, K4, K5, K6, K7
and K8, denotes negative factors.

The maximum tensile stress S1, S2 respectively plus the tensile stresses due to internal pressure
shall not exceed the allowable tensile stress value of head material.
The maximum compression stresses S1 and S2 respectively plus the tensile stress due to internal
pressure shall not exceed the allowable compression stress value of head material.
NOTATIONS; W = Weight of vessel,

n = number of legs
WD
Q = Load on one leg,
n
R = Radius of head,
H = Lever arm of load=80
2A, 2B = Dimensions of wear plate
t = wall thickness of head,
K = Factors
C = radius of circular wear plate
E=welding efficiency=1
Take   36.86 and H  80mm (maximum holding efficiency)
WD 8300 N
Q   2075N
n 4
c  A * B  2 A  200mm  2 B
c R
D  1.82 *
R t
c  100mm * 100mm  100mm

100mm 220.526
D  1.82 *  3.46mm
220.526 12.56

From the chart we can get K1 and K5
K1= 0.025
K5=0.01
Figure 14 stress on leg vessel support K1 & K5
K2= 0.015
K6=0.0001
K3= 0.025
K7= 0.012

K4= 0
K8= 0.00001
3.7.1 Longitudinal stress

1. Maximum tensile stress
 
cos   k1  6k2    k3  6k4 
Q H R
S1 
t2
 R t 
2075 N  
0.8 0.025  6 * 0.0001   0.025  6 * 0
80mm 192mm
S1  2 
(14mm)  192mm 14mm 
S1  10.587 N / mm (0.0249)  (0.038576)   0.672 MPa
2
Stress due to internal pressure:

PdRi

2t
11MPa * 192mm

2 * 14mm
 75.43MPa
The sum of the tensile stress is  (75.43  (0.672) MPa  76.43MPa
S * E  190MPa *1  190MPa Which exceed from the sum of tensile stress so the design is
safe. Or 76.43<190 so safe design.
2. Maximum compressive stress

Q 
cos   k1  6k 2    k 3  6k 4 
H R
S2  2 
t  R t 
2075 N  
0.8 0.025  6 * 0.0001   0.025  6 * 0
80mm 192mm
S2  2 
(14mm)  192mm 14mm 
S 2  10.587 0.02048mm  (0.03858)   0.6252 MPa

PdRi

2t
11MPa * 192mm

2 * 14mm
 75.43MPa
The sum of the tensile stress is  (75.43  0.6252) MPa  74.80MPa
safe. Or 74.80MPa <190 so safe design
3.7.2 Circumferential stress

1. Maximum tensile stress
Q 
cos   k 5  6k 6    k 7  6k8 
H R
S1  2 
t  R t 
 
0.8 0.01  6 * 0.015   0.012  6 * 0.00001
2075 N 80mm 192mm
S1 
(14mm) 2
 192mm 14mm 
S1  10.50.064mm  (0.0049)  0.6203MPa
PdRi

2t
11MPa * 192mm

2 * 14mm
 75.43MPa
The sum of the tensile stress is  (75.43  0.6203) MPa  76.05MPa
S * E  190MPa *1  190MPa Which exceed from the sum of tensile stress so
the design is safe. Or 76.05MPa <190 so the design is safe
2. Maximum compressive stress

Q 
cos   k 5  6k 6    k 7  6k8 
H R
S1  2 
t  R t 
2075 N  
0.8 0.01  6 * 0.015   0.012  6 * 0.00001
80mm 192mm
S1  2 
(14mm)  192mm 14mm 
S1  10.5(0.064)  (0.01861)  0.8674MPa
PdRi

2t
11MPa * 192mm

2 * 14mm
 75.43MPa
The sum of the tensile stress is  (75.43  0.8674) MPa  74.56MPa
safe. Or 74.56MPa <190 The design is safe.
3.8 Design of Welding

There are several methods to make welded joints. In a particular case the choice of a type from the
numerous alternatives depend on:
1 The circumstances of welding
2 The requirements of the Code
3 The aspect of economy
3.8.1 The Circumstances of Welding

In many cases the accessibility of the joint determines the type of welding. In a small diameter
vessel (under 18 - 24 inches) from the inside, no manual welding can be applied. Using backing
strip it must remain in place. In larger diameter vessels if a man way is not used, the last (closing)
joint can be welded from outside only. The type of welding may be determined also by the
equipment of the manufacturer.
3.8.2 Code Requirements

Regarding the type of joint the Code establishes requirements based on service, material and
location of the welding. The welding processes that may be used in the construction of vessels are
also restricted by the Code.

Figure 18 Stresses Permitted by the AISC Code for Weld Metal
3.8.3 The Economy of Welding

If the two preceding factors allow free choice, then the aspect of economy must be the deciding
factor. Some considerations concerning the economy of welding:
I, V-edge preparation, which can be made by torch cutting, is always more economical than the
use of J or U preparation.
II, Double V preparation requires only half the deposited weld metal required for single V
preparation. Increasing the size of a fillet weld, its strength increasing in direct proportion, while
the deposited weld metal increasing with the square its size.
III, Lower quality welding makes necessary the use of thicker plate for the vessel.
Whether using stronger welding and thinner plate or the opposite is more economical, depends on
the size of vessel, welding equipment, etc. This must be decided in each particular case.
3.8.4 Selection of welding

1. Shell to shell and welded Head connection: for this kind of connections Category A butt
welding is recommended.
2 .Head to shell connections: for this kind of connections Category B butt welding is
recommended.
3. Openings and flange: for this kind of connections Category B butt welding is recommended.
5. Support: for support and support to vessel connection use E80XX electrode and for all
contacting edges fillet welding is recommended.
3.8.5 Stress analysis for welding

Stress of welding shell to head connections

The force of internal pressure where, Fi=force of internal pressure (N)

Fi=Pd×Ai2 Fr=resisting force of weld (N)
𝜋
Fi=11Mpa× 4 × (384mm) 2 𝜎w=weld stress (N/mm2)
Fi= 1,273,928.4N 𝜎d=design stress (N/mm2)

The resisting force weld is Aw=area of weld (mm2)
Fr=Fi
𝜋
Fr=𝜎w×Aw Aw= 4 × (do2-di2) =17,505mm2
1273928.4N= 𝝈w17, 505mm2

𝝈w=72.77N/mm2
𝝈w< 𝝈d, 72.77N/mm2<190N/mm2
There will be safe welding design on heads
Stress of welding shell to nozzle (bottom) connections
Fi=Pd×Ai2
𝜋
Fi=11Mpa× 4 × (65mm) 2
Fi=36501.4N
The resisting force weld is
Fr=Fi
𝜋
Fr=𝜎w×Aw Aw= 4 × (do2-di2) =867.1mm2
36501.4N= 𝝈w867.1mm2
𝝈w=42.1N/mm2
𝝈w< 𝝈d, 42.1N/mm2<190N/mm2
There will be safe welding design on bottom discharge
Stress of welding shell to nozzle (lateral and longitudinal) connections
Fi=Pd×Ai2
𝜋
Fi=11Mpa× 4 × (150mm) 2
Fi=194386.04N
The resisting force weld is
Fr=Fi
𝜋
Fr=𝜎w×Aw Aw= 4 × (do2-di2) =3452.61mm2

194386.04N= 𝝈w3452.6mm2
𝝈w=56.3N/mm2
𝝈w< 𝝈d, 56.3N/mm2<190N/mm2
There will be safe welding design on lateral and longitudinal pipes
3.9 Selection of a standard flange

Flanged joints are used for connecting pipes and instruments to vessels, for opening covers, and
for removable vessel heads when ease of access is required. Flanges may also be used on the vessel
body, when it is necessary to divide the vessel into sections for transport or maintenance. Flanged
joints are also used to connect pipes to other equipment, such as pumps and valves. Screwed joints
are often used for small-diameter pipe connections, below 40 mm. Flanged joints are also used for
connecting pipe sections where ease of assembly and dismantling is required for maintenance, but
pipework will normally be welded to reduce costs.
Standard flanges are available in a range of types, sizes, and materials; and are uses extensively
for pipes, nozzles and other attachments to pressure vessels. Many standard codes give a wide
range of specific data and dimensions of standard flanges for different applications. Some of the
standards of ASME B16.5-2003 which are taken from Perry’s Chemical Engineers’ Handbook,
8th Edition, Don W. Green & Robert H. Perry.
3.9.1 Types of flange, and selection

Several different types of flange are used for various applications. The principal types used in the
process industries are:
 Welding-neck flanges.
 Slip-on flanges,
 Hub and plate types. Lap-joint Flanges
 Screwed Flanges.
 Blank, or blind, flanges.
Welding-neck flanges, as shown in the Fig. , have a long tapered hub between the flange ring and
the welded joint. This gradual transition of the section reduces the discontinuity stresses between
the flange and branch, and increases the strength of the flange assembly. Welding-neck flanges
are suitable for extreme service conditions; where the flange is likely to be subjected to
temperature, shear and vibration loads.

Figure 19 standard flange
3.9.2Flange for the longitudinal, lateral and bottom pipe product

These openings have nominal diameter of 150 mm and 65mm for this reason, we select the
standard ASME B16.5 Class 1500 flange. We select welded neck flange because it offer the
highest mechanical strength and are the type most suitable for extreme temperature and cyclic
loading.
Figure 20 Welded neck flange for 150mm openings

Table 3.5 Flange dimension for openings

Essential parameters Bottom discharge flanges Longitudinal and
lateral flanges
Nominal diameter 65mm 150mm

Outside diameter of flange 76.1mm 168.3mm
Thickness of flange, minimum 32mm 44mm
Bolting M12 M16
No of bolt 4 8
3.10 Gaskets
Gaskets are used to make a leak-tight joint between two surfaces. It is impractical to
machine flanges to the degree of surface finish that would be required to make a satisfactory seal
under pressure without a gasket. Gaskets are made from “semi-plastic” materials; which will
deform and flow under load to fill the surface irregularities between the flange faces, yet retain
sufficient elasticity to take up the changes in the flange alignment that occur under load. A great
variety of proprietary gasket materials is used, and reference should be made to the manufacturers'
catalogues and technical manuals when selecting gaskets for a particular application. Which is
taken from Dr. Sadhu Singh, Design of Machine Elements (Machine design), fifth edition.
The following factors must be considered when selecting a gasket material:
1. The process conditions: pressure, temperature, corrosive nature of the process fluid.
2. Whether repeated assembly and disassembly of the joint is required.
3. The type of flange and flange face
The gasket factor m is the ratio of the gasket stress (pressure) under the operating conditions to the
internal pressure in the vessel or pipe.
The internal pressure will force the flanges' faces apart, so the pressure on the gasket under
operating conditions will be lower than the initial tightening-up pressure. The gasket factor gives
the minimum pressure that must be maintained on the gasket to ensure a satisfactory seal.
For this particular pressure vessel we select ring joint type gasket material which is made from
iron or soft steel. The selection is based on the above requirement.

3.10.1 Selection of standard Gasket

Topic only we select the gasket material according to design stress from Coulson and Richardson
chemical engineering book.
Figure 21 Selection of standard Gasket
So as we see in the above table which is taken from Coulson and Richardson chemical engineering
book. We select a gasket of solid flat metal with an iron soft steel Monel or 4%-6% chrome stainless
steel for lateral and longitudinal nozzles with yield stress of (124-179) N/mm2 and a ring joint for
bottom discharge nozzles.

3.11 RESULT AND DISCUTION

Shell
 Length of vessel = 2.4
 Length of shell = 1.92m
 Volume of shell = 0 .25m3
 Outer diameter = 0.412m
 Inner diameter =0.384m
 Thickness of shell = 0.014m
 Circumferential or hoop stress =156.36MPa
 Longitudinal stress = 78.18𝑀𝑃𝑎
 Radial stress =0 𝑀𝑃𝑎
Head
 Thickness of shell = 0.014m
 Volume of shell = 0.02965𝑚3
 Outer head diameter = 0.412m
 Inner head = 0.384m
 Circumferential or hoop stress =181.5MPa
 Longitudinal stress = 90.75𝑀𝑃𝑎
 Radial stress =0 𝑀𝑃𝑎
Nozzle bottom
 Inner diameter of nozzle (bottom) = 0.065m
 Thickness of nozzle = 0.004m
 Outer diameter of the nozzle = 0.069m
 Length of the nozzle entering to the shell = 0.00141m
 Total length of nozzle =0.057m
Nozzle lateral and longitudinal
 Inner diameter of nozzle = 0.150m
 Thickness of nozzle = 0.007m
 Outer diameter of the nozzle = 0.157m
 Length of the nozzle entering to the shell = 0.00141m
 Total length of nozzle =0.057m

Hand hole
 Diameter of hand hole = 0.12m
 Thickness of hand hole = 0.008m

3.12 COST ANALYSIS

Purchasing cost
In this topic only the purchasing cost of materials are listed below.
1. Cost of Shell and Head: first let’s calculate the mass of the vessel.
weight of vessel 3290+2206N
Mass of vessel = gravity
= 9.81
= 560.24kg
Then from our data the coast of low alloy steel per kg is 0.4$/kg with a minimum manufacturer coast
which is 9.2birr/kg
=560.24×9.2=5154.208birr
2. Cost of Insulation: first let’s calculate the mass of the insulation.
weight of insulation 527.04

Mass of insulation= = =53.725kg
gravity 9.81
Then from our data the cost of insulation (mineral wool) per Kg is 8.92 ETB. Thus the total cost is:
=53.725kg×8.92birr=479.22birr
3. Cost of nozzle: first let’s calculate the mass of the nozzle.

weight of nozzel 59.47N
Mass of nozzle= = = 6.06kg
gravity 9.81
Then from our data the coast of low alloy steel per kg is 0.4$/kg with a minimum manufacturer coast
which is 9.2birr/kg
=6.06×9.2=36.748birr
4. Cost of Flange and Gasket: let’s find the cost of the flange.
 Flange for 150mm inside diameter: the cost of one flange is 250$ multiply this by 22we get 5,500
ETB. Thus only we desired three flanges the cost is 16,500 ETB.
 Flange for 65 mm inside diameter: the cost of one flange is 58.00 $ multiply this by 22 we get
1,276 ETB. Thus we desired 0ne flanges the cost is 1,276 ETB.
Thus, the total cost of flange is: 16500+1276=17,776 ETB.
Also the cost of gasket is:
 Gasket for 150 mm inside diameter: the cost of one gasket is 70$ multiply this by 22 we get
1,540 ETB. Thus we desired three gasket the cost is 4,620 ETB.
 Gasket for 65mm inside diameter: the cost of one gasket is 58.00 $ multiply this by 22 we get
1,276 ETB. Thus we desired one gaskets the cost is 1,276 ETB.

Thus, the total cost of gasket is: 4,620+1,276=5,896 ETB.

5. Cost of the support
Mass of the support is = ρ × v
= 7600kg/m3×(200×200×80) × 10-9
=24.32kg
Coast of the support will be=24.32×9.02=219.36 ETB
The total manufacturing cost will be =5154.208 ETB+219.36 ETB+5,896 ETB+17,776 ETB+36.748
ETB+ 36.748 ETB
=29, 045.56ETB
This consideration is only for a manufacturing cost which is not include the power coast, labor coast and
any subsidiary coasts. If we evaluate with some contingency our coast value will be increased with 10%-
15% which means 33, 403 ETB.
3.13 Manufacturing Process

3.13.1 Methods of fabrication
Process equipment is fabricated by a number of well-established methods such as fusion
welding, casting, forging, machining, brazing and soldering and sheet metal forming. Each method
has certain advantages for particular types of equipment. However, fusion welding is the most
important method. The size, shape, service and material properties of the equipment all may
influence the selection of the fabrication method.
Gray iron casting have been widely used for the mass production of small pipe fittings and
are used to a considerable extent for large items such as cast iron pipe, heat exchanger shells and
evaporator bodies because of the superior corrosion resistance of cast iron as compared with steel.
Large diameter vessels cannot be easily cast, and the strength of gray iron is not reliable for
pressure vessels service. Cast steel may be used £>r small diameter thick walled vessels.
Furthermore, because of its higher strength and greater reliability as compared with cast iron; it is
more suitable for high-pressure service where metal porosity is not a problem. The vessel diameter
is still limiting because of a problem in casting. Alloy cast steel vessels can be used for high-
temperature and high-pressure installation.
1. Forging; is a method of shaping metal that is commonly used for certain vessel parts such as
closures, flanges and fittings. Vessels with wall thickness greater than 10cm ire often forged. Other
special methods of shaping metal such as pressing, spinning and rolling of plates are used for
forming closures for vessel shells.

2. Riveting; was widely used prior to the improvement of modern welding techniques, for many
different kinds of vessels, such as storage tanks, boilers and verity |tf pressure vessels. It is still
used for fabrication of non-ferrous vessels such as copper and aluminum. However, welding
techniques have become so advanced, that even these materials are often welded today.
3. Machining is the only method other than cold forming that can be used to exact tenure
tolerances. Close tolerances are required for the mating parts of the equipment. Flange faces,
bushings, and bearing surfaces are usually machined in order to provide satisfactory alignment.
Laboratory and pilot plant equipment for very high-pressure service is sometimes machined for
solid stock, pierced ingots and forgings.
4. Rolling is the process of plastically deforming metals by passing it between rolls. It is the most
widely used forming process, which provides high production and close control of final product.
5. Extrusion is a process where a billet is forced through a die. Parts have constant cross-section.
Typical Products of Extrusion, tubing having various cross-sections and so on.
6. Fusion welding is the most widely used method of fabrication for the construction of steel
vessels. This method of construction is virtually unlimited with regard to size and is extensively
used for the fabrication and erection of large size product equipment in the field. There are two
types of fusion welding that are extensively used for fabrication of welds. These are,
1. The gas welding process in which a combustible, mixture of acetylene and oxygen supply the
necessary heat for fusion
2. The electric arc welding process, in which the heat of fusion is supplied by an electric arc. Arc
welding is preferred because of the reduction of heat in the weld material, reduces the oxidation
and better control of deposited weld metal.
Steps of manufacturing
 Materials shall be specified by purchaser and their designation indicated on the shop
drawings. Materials shall not be substituted for those specified without prior written
approval of purchaser.
 The thickness of plate used for shell and heads shall be 1/4-inch minimum
 Pressure vessel which is design here is fabricated or manufactured through different
processes. Pressure vessel shell and head is fabricated and welded together using titanium
coat. Shell of vessel can be manufactured using rolling and head of shell is manufactured
using extrusion process.

And forming is the type of manufacturing process in which the size or shape of the part is cluttered
by the application of force that forms stresses in the part that is greater the yield strength and less
than the fracture strength.
 Manufacturer’s welding procedure and qualification records shall be submitted for
approval upon receipt of purchase order. Welding shall not be performed prior to
purchaser’s approval of welding procedure and qualification. All welding shall be done
by the metallic shielded arc or the submerged arc welding process. Permanently installed
backing strips shall not be used without written approval of purchaser. When used, backing
strip s shall be the same composition steel as that which they are attached to.
 Longitudinal seams in cylindrical or conical shells, all seams in spherical shells and built-
up heads shall be located to clear openings, their reinforcing pad and saddle wear plates.
Circumferential seams of shell shall be located to clear open their reinforcing pads, tray
and insulation support rings , and saddle wear plates When the covering of circumferential
seam by reinforcing pad is unavoidable at seam shall be ground flush and examined prior
to welding the reinforcing pad in place . No longitudinal joints shall be allowed with in
the down comer area or at any other place where proper visual inspection of the weld is
impossible. The minimum size of fillet weld serving as strength weld for internals shall be
1/ 4 inch.
 Legs shall be welded to the vessel, except when specifically order to be shipped loose.
Legs to be shipped loose shall be fitted to the vessel and match marked for field
installation. The shop drawing shall be a detail instruction concerning this. When
temperature expansion will cause more than 3/ 8 inch change in the distance between the
legs, a slide bearing plate shall be used. Where the vessel is supported by concrete legs 1/
4 inch thick, corrosion the concrete legs shall be welded to the shell with corrosion plate
shall be provide d with a 1/ 4 inch vent sealant after the vessel has been pressure tested.

Chapter four
Conclusion and recommendation
4.1 Conclusion
We conclude that a pressure vessel must be designed carefully and there shouldn’t be any force
out of designers control because if some errors made there would be a big faller. So from this
vertical pressure vessel design the pressure with nominal volume 0.25m3 which is used to store
mineral oil at 11Mpa and 450 ℃ designed above is designed to satisfy all the required requirements
to be able to work under the above parameters. A safety factor of ≥ 2.5 is applied during the design
to prevent failure due to design uncertainties and unexpected adverse working conditions. The
pressure vessel is made of a material that is cheaper and at the same time reliable therefore, the
above pressure vessel can be manufactured with low cost and it can be used with in its capacity
and working conditions
4.2 Recommendation
We recommended that the manufacturer industries that during the manufacturing process they
basically consider the maximum dimension. Because our design is minimum in dimension. And
they should select the best way of manufacturing process for the best efficiency.
Selection of appropriate processes can be maximized the efficiency and safety of the pressure
vessel. The cost of the pressure vessel can be minimized by searching material industries with a
minimum cost. Finally pressure vessels are designed to stand with a high pressure we should be
care for its safety and effectiveness. When we design some part we have to collect information
from different source. This means the design is performed by using many references and web sites.
So the materials needed for design case must be fulfilled in order to perform applicable design for
all users.
We recommended that the pressure vessel design should include the earthquake loading, vibration,
loading from piping and external equipment and wobble effect in which the pressure vessel
delivered with. More try to study the load analysis by recent software and it is our suggestion to
test the pressure vessel in laboratory before we apply to the real world application.

REFERENCE
 Coulson and Richardson‘s , Chemical Engineering Design, Volume 6, Second Edition,
Butterworth Heinemann, 1996
 R.S. khurmi, 𝑆. 𝐾. 𝐺𝑢𝑝𝑡𝑎, Text book of machine design, S.chanda2005
 Merges, Pressure vessel Hand Book 10th edition
 Bednar, Pressure vessel Hand Book
 Dennis Moss, Pressure vessel design manual, 3rd edition
 Mechanical Engineering, 𝑆ℎ𝑖𝑔𝑙𝑒𝑦’𝑠 Mechanical Engineering Design, Budynas – Nisbett,
Eighth Edition.
 Pressure vessel design manual third edition by Dennis R. moss.
 pressure vessel design and practice 2 , somnath chattopadhyay

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Section 3

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17

Design of vertical layout Pressure Vessel

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 i

𝛅max =maximum stress

𝛅k= 𝐡𝐨𝐨𝐩 𝐬𝐭𝐫𝐞𝐬𝐬

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 ii

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 iii

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 iv

CHAPTER TWO ................................................................................... 14

CHAPTER –THREE ............................................................................ 17

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 v

3.3.1 Stress analysis of Hemispherical Head................................................................................ 26

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 vi

3.13 Manufacturing Process ................................................................................................................. 59

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 vii

Table 3.3 density of various fluid…………………………………………………………....... 36

Table 3.4 density of different metals………………………………………………………… 37

Table3.5 Flange dimension for openings ………………………………………………………54

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 ix

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 1

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 2

1.2.1 According to the dimension

This can be classified in to two groups:-

a) Open end construction pressure vessels

1.2.3 According to the geometrical shapes

c) Spherical vessel with one or two cones.

1.2.4 According to the position arrangement

a) Horizontal pressure vessel

b) Vertical pressure vessel

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 3

c) Spherical pressure vessel

1.2.5 According to the materials

The pressure vessels are according the material classified as:-

a) Brittle material pressures vessels

1.2.6 According to the direction of force acting on the wall of vessels.

b) Subjected to external pressure  p 

1.3 Component of pressure vessels

1.3.3 Nozzle and

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 4

Figure 1. 1 different type of heads

o Attach piping for flow into or out of the vessel.

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 5

o Provide access to the vessel interior at many ways.

Typical kinds of supports are as follow:-

1.3.4.3 Saddle support

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 6

1.3.4.4 Lug support

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 7

1.4 Background of pressure vessel

In an early effort to design a tank capable of withstanding pressures up to 10,000 psi

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 8

Safety in boiler and pressure vessels can be achieved by:

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 9

1.5 Statement of the problem

 The Ambient, operating pressure and temperature;

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 10

1.6 Objective of the project

A. Literature survey phase:-

B. Specify the components of the pressure vessel:-

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 11

b) The effect of high and low temperature on the mechanical properties.

UOG, IOT, SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING 2016/17 12