UCIAFREDDO - Coupled Flare System Design Southern Swamp Associated Gas Solution SSAGS Project Located in Nigeria Advanced Solution of Thermoengineering

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Alireza Ghalamkari
Coupled Flare System Design
SSAGS project located in Nigeria
Advanced Solution of ThermoEngineering Co.
POLITECNICO DI MILANO
School of Industrial Engineering
Master of Science in Mechanical Engineering

southern swamp associated gas solution (SSAGS) project
located in Nigeria
Supervisor of Politecnico di Milano:
Full Prof. Angelo Onorati
Supervisor of ThermoEngineering Co.:
Eng. Chiara Ferlini

Eng. Diego Bruciafreddo
Thesis of
Alireza Ghalamkari
Student ID: 787671
Academic year 2013-2014
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Table of contents
1
FLARE EQUIPMENT FOR GENERAL SERVICE ...................................................................................................... 9

1.1
Flare system in industrial plants ............................................................................................................... 11
1.2
Types of flares ................................................................................................................................................... 13
1.3
1.2.1
Vertical Flare ..................................................................................................................................................... 13
1.2.2
Horizontal ........................................................................................................................................................... 22
1.2.3
Enclosed Flame Flares ................................................................................................................................... 22
1.2.4
Single-point and Multi-burner ................................................................................................................... 23
1.2.5
Smokeless and Non-smokeless Flares ................................................................................................... 25
Flares as a pressure vessel........................................................................................................................... 26

1.3.1
Pressure equipment Types and components ..................................................................................... 26
1.3.2
Flare component .............................................................................................................................................. 36
1.3.3
ASME Code ......................................................................................................................................................... 38
1.3.4
Pressure vessel Designing Software packages ................................................................................... 52
The Aim of the thesis ................................................................................................................................. 56
Flare System Design ................................................................................................................................... 58

3.1
3.1.1
Geometry ............................................................................................................................................................. 58
3.1.2
Loading Data ...................................................................................................................................................... 61
Conclusion ..................................................................................................................................................... 77
4.1
4.2
Modeling .............................................................................................................................................................. 58
Result .................................................................................................................................................................... 77
4.1.1
Compatibility ..................................................................................................................................................... 77
4.1.2
Stress check........................................................................................................................................................ 81
4.1.3
Vortex Shedding ............................................................................................................................................... 88
Bolt design .......................................................................................................................................................... 91
Reference .................................................................................................................................................... 100
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Figures
Figure 1 Flare in Asaluyeh (Iran) South Pars phase 6-7-8....................................................... 9
Figure 2 Schematic flow diagram of an overall vertical, elevated flare system. .............. 11
Figure 3 Self Supported Flare .............................................................................................................. 14
Figure 4 schematic model of self supported flare against lateral load ................................ 14
Figure 5 trend of the thickness vs the stack height ..................................................................... 16
Figure 6 Guyed wire supported Flare ............................................................................................... 17
Figure 7 cable tension ............................................................................................................................. 18
Figure 8 stiffness trend .......................................................................................................................... 19
Figure 9 Fixed Derrick Supported Flare .......................................................................................... 20
Figure 10 Demountable Derricl Multi section ............................................................................... 21
Figure 11 Demountable Derrick Single section ............................................................................ 21
Figure 12 Horizontal Flare .................................................................................................................... 22
Figure 13 Enclosed Flare ....................................................................................................................... 22
Figure 14 Multi burner staged Flare ................................................................................................. 24
Figure 15 1 Multi burner flare staging curve ................................................................................. 24
Figure 16 Air assisted Flare .................................................................................................................. 26
Figure 17 Horizontal drum ................................................................................................................... 29
Figure 18 Vertical drum ......................................................................................................................... 29
Figure 19 Tower ........................................................................................................................................ 30
Figure 20 reactor ...................................................................................................................................... 31
Figure 21 Spherical tank ........................................................................................................................ 31
Figure 22 Heads ........................................................................................................................................ 32
Figure 23 Saddle ....................................................................................................................................... 34
Figure 24 Lug.............................................................................................................................................. 35
Figure 25 Shoe factory before and after boiler explosion ........................................................ 38
Figure 26 Allowable Nozzle Loads ..................................................................................................... 47
Figure 27 Skirt with anchor bolts....................................................................................................... 50
Figure 28 3D model of the project ..................................................................................................... 59
Figure 29 Model in PV-Elite / MIDAS................................................................................................ 60
Figure 30 Coupled system ..................................................................................................................... 61
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Figure 31 Service piping orientation ................................................................................................ 62

Figure 32 Service piping dead load ................................................................................................... 62
Figure 33 Ladder dead load .................................................................................................................. 63
Figure 34 Platforms dead load ............................................................................................................ 64
Figure 35 Ladder/Platform details in PV-elite .............................................................................. 65
Figure 36 Live load................................................................................................................................... 66
Figure 37 Nozzle load ............................................................................................................................. 67
Figure 38 Mean wind speed calculation .......................................................................................... 69
Figure 39 wind profile along the stack ............................................................................................. 70
Figure 40 force coefficient .................................................................................................................... 71
Figure 41 structural factor .................................................................................................................... 72
Figure 42 load distribution along Bigger flare .............................................................................. 72
Figure 43 load distribution along smaller flare ............................................................................ 73
Figure 44 wind load distribution........................................................................................................ 74
Figure 45 load combinations................................................................................................................ 76
Figure 46 Lateral deflection comparison ........................................................................................ 77
Figure 47 Shear Force comparison .................................................................................................... 78
Figure 48 total weight comparison................................................................................................... 79
Figure 49 beam diagram ........................................................................................................................ 81
Figure 50 stress distribution ................................................................................................................ 82
Figure 51 Steel checks ............................................................................................................................ 84
Figure 52 Internal Pressure Calculation for bigger flare (F-4302) ....................................... 85
Figure 53 stress combination for bigger flare (F-4302) ........................................................... 87
Figure 54 vortex shedding check........................................................................................................ 88
Figure 55 Helical stakes ......................................................................................................................... 90
Figure 56 reaction forces due to single load cases ...................................................................... 91
Figure 57 Allowable loads for anchor bolts ................................................................................... 92
Figure 58 anchor bolts checks according to client specification ............................................ 92
Figure 59 envelope of reaction forces used for bolt design ..................................................... 93
Figure 60Base plate details for bigger flare ................................................................................... 94
Figure 61 Anchor bolts checks for bigger flare ............................................................................. 95
Figure 62 Baseplate details for smaller flare ................................................................................. 97
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Figure 63 anchor bolts checks for smaller flare ........................................................................... 98
Tables
Table 1 Pressure equipment categories .......................................................................................... 27
Table 2 2Max. allowable deflection ................................................................................................... 48
Table 3 Pressure vessel software packages ................................................................................... 53
Table 4 comparison between PV-Elite and Compress ............................................................... 55
Table 5 General design information .................................................................................................. 58
Table 6 wind design information ....................................................................................................... 68
Table 7 Summary of required bolts ................................................................................................... 93
Table 8 Designed data ............................................................................................................................. 99
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Acknowledgments
I would like to thank my kind Supervisor, Full Professor Angelo Onorati for his full
support throughout the entire duration of the project.
Special thanks to the managers of the company, Mr. Ugo Levi, Mr. Arnaldo Thevenet,
Mr. Vittorio Thevenet who gave me the opportunity of attending internship in the company
and also for their hospitality
I also would like to thank everybody in the company for the support, especially ENG.
Chiara Ferlini and ENG. Diego Bruciafreddo for the opportunity of technical work. and also
for their hospitality
I would like to thank my parents for supporting me during my whole life and my
sister who has always motivated me. At last but not least gratitude goes to all of my friends
who directly or indirectly helped me to complete this thesis.
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Abstract
The aim of this document is to carry out the mechanical and structural calculation and
checks, concerning the design of the self-supported elevated flare (Items F-4301, F-4302) for
southern swamp associated gas solution (SSAGS) project in Ogbotobo located in Nigeria.
The Southern Swamp area comprises 16 fields (12 producing and 4 partially
appraised fields (PAFs) ) with Scope for Recovery (SFR) volumes in the order of 858 MMboe.
The fields are situated in OMLs 35, 36 and 46 in the coastal swamp area, 65km South of
Warri.
All existing production in the area is gathered into a total of four flow stations located
at Tunu, Ogbotobo, Benisede and Opukushi. The produced oil in the area is evacuated via the
Trans Ramos pipeline to the Forcados Terminal whilst the associated gas is currently flared.
The scope of SSAGS Project, is to modify the existing flowstations located in Benisede,
Opukushi, Ogbotobo, Tunu and to install a new gas Centralized Production Facilities (CPF) in
Tunu in order to gather all Associated Gas, flared at the moment, and to export the NAG / AG
Gas to the domestic market at the required specification.
COMPANY: Shell Petroleum Development Company of Nigeria
CONTRACTOR: Saipem Contracting Nigeria Ltd, Snamprogetti Engineering BV and
DesiconEngineering Ltd (CONS)
SUPPLIER: Thermoengineering Co.
Thermoengineering, established in 1979 in Milano (Italy), is an International group
offering a wide range of advanced combustion systems for all the applications required in the
Oil & Gas industries and in the petrochemical fields. Thermoengineering has the capability to
design, fabricate, supply and quality control of the several types of systems.
Thermoengineering offers a wide range of products as mentioned below:
Elevated Flares
Grounded Flares
Incinerators
Indirect Heaters
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In this document, First of all, the functionality of flare system and different types of
flares will be demonstrated and then, since frequently, flares are considered and designed in
compliance with pressure vessel requirements, the different types of pressure vessels and
also various components and attachments of the pressure vessel will be described. Later,
design loads and methods for supporting will be presented.
Finally a specific case of support (coupled-system) which the smaller flare system is
supported by the bigger flare system will be studied, it will be modeled by FEM software, and
the reaction forces at the base of the flares will be obtained. Consequently, required size and
number of anchor bolts will be verified and designed.
The system is considered as the pressure vessel and it is designed with respect to
ASME VIII div.1. The F.E. Software used to prepare and analyze this models is MIDAS Gen.
2011 (v.1.1); thanks to it, it is possible to enter the several load conditions and then combine
their stresses output. MIDAS software is used only to calculate the foundation loads and
anchor bolts. The limitation of MIDAS software is that it is not possible to apply pressure on
beam element, thus the presence of the internal pressure cant be studied
Besides, the system is modeled in PV-Elite to take in to account the effect of internal
pressure. MIDAS model is required to be able to study the interactions of the coupled system
and to obtain more precise reaction forces, while PV-elite model checks the loads and stress
according to ASME code.
By reviewing both models results, similar and comparable results are obtained, which
indicates that calculation in both software are compatible. It should be highlighted that since
it the system is considered as a Pressure vessel , the materials yield value, is substituted with
the allowable stress acquired from ASME II D (except for the skirt , because it is not a
pressure part) to respect the code and to increase the safety margin.
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FLARE EQUIPMENT FOR GENERAL SERVICE

Flaring is a volatile organic compound (VOC) combustion control process in which the
VOCs are piped to a remote, usually elevated and burned in an open flame in the open air
using a specially designed burner tip, auxiliary fuel, and steam or air to promote mixing for
nearly complete (>98%) VOC destruction. Completeness of combustion in a flare is governed
by flame temperature, residence time in the combustion zone, turbulent mixing of the
components to complete the oxidation reaction, and available oxygen for free radical
formation. Combustion is complete if all VOCs are converted to carbon dioxide and water.
Incomplete combustion results in some of the VOC being unaltered or converted to other
organic compounds such as aldehydes or acids. The flaring process can produce some
undesirable by-products including noise, smoke, heat radiation, light, SO , NO , CO, and an
additional source of ignition where not desired. However, by proper design these can be
minimized.
A gas flare, alternatively known as a flare stack, is a gas combustion device used in
industrial plants such as petroleum refineries, chemical plants, natural gas processing plants
as well as at oil or gas production sites having oil wells, gas wells, offshore oil and gas
facilities and landfills.
Figure 1 Flare in Asaluyeh (Iran) South Pars phase 6-7-8
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In industrial plants, flare stacks are primarily used for burning off flammable gas
released by pressure relief valves during unplanned over-pressuring of plant equipment.
During plant or partial plant startups and shutdowns, flare stacks are also often used for the
planned combustion of gases over relatively short periods.
A flaring system is provided in a refinery or petrochemical plant to ensure the safe and
efficient disposal of relieved gases or liquids. The disposal fluids are collected in a flare
header and routed to the flare. It is extremely important in the event of a plant emergency
such as a fire or power failure. A properly operating flare system is the critical component to
prevent a plant disruption from turning into a disaster. A flare is expected to operate twentyfour hours a day. Flare must be in service for several years without a need to shut it down. It
always be available for flaring whenever a plant disruption occurs. Proper design, operation
and maintenance of emergency flaring systems are extremely important. These can ensure
the safety of personnel, facility, and the surrounding community. The intention and
operational limitations of the Flare System should be documented clearly and all operational
staff made aware of this documentation.
The flaring system must be designed to do the following:
Reduce ground level concentrations of hazardous materials.
Provide the safe disposal of flammable materials.
Reduce volatile organic compound (VOC) and hydro-carbon emissions.
Also it is important to know that great deal of gas flaring at many oil and gas
production sites has nothing to do with protection against the dangers of over-pressuring
industrial plant equipment. When petroleum crude oil is extracted and produced from
onshore or offshore oil wells, raw natural gas associated with the oil is produced to the
surface as well. Especially in areas of the world lacking pipelines and other gas transportation
infrastructure, vast amounts of such associated gas are commonly flared as waste or
unusable gas. The flaring of associated gas may occur at the top of a vertical flare stack (as in
the previous photo) or it may occur in a ground-level flare in an earthen pit.
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1.1
Flare system in industrial plants

The flare stack plays a main role for the safety of the entire oil and gas industrial
plants. In fact, whenever industrial plant equipment items are over-pressured, the pressure
relief valves provided as essential safety devices on the equipment automatically release
gases and sometimes liquids as well. Those pressure relief valves are required by industrial
design codes and standards as well as by law.
Next figure shows a schematic flow diagram of a flare stack system in an industrial
plant.
Figure 2 Schematic flow diagram of an overall vertical, elevated flare system.
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The flow diagram depicts the typical components of an overall industrial flare stack
system:
A knockout drum to remove any oil and/or water from the relieved gases.
A water seal drum to prevent any flashback of the flame from the top of the flare stack.
An alternative gas recovery system for use during partial plant startups and/or
shutdowns as well as other times when required. The recovered gas is routed into the
fuel gas system of the overall industrial plant.
A steam injection system to provide an external momentum force used for efficient
mixing of air with the relieved gas, which promotes smokeless burning.
A pilot flame (with its ignition system) that burns all the time so that it is available to
ignite relieved gases whenever needed.[6]
The flare stack, including a flashback prevention section at the upper part of the flare
stack.
The released gases and liquids are routed through large piping systems called flare
headers to a vertical elevated flare. The released gases are burned as they exit the flare
stacks. The size and brightness of the resulting flame depends upon the flammable material's
flow rate in terms of Joules per hour (or btu per hour).
Most industrial plant flares have a vapor-liquid separator (also known as a knockout
drum) upstream of the flare to remove any large amounts of liquid that may accompany the
relieved gases.
Steam is very often injected into the flame to reduce the formation of black smoke.
When too much steam is added to the flame, a condition known as "over steaming" can occur
resulting in reduced combustion efficiency and higher emissions. In order to keep the flare
system functional, a small amount of gas is continuously burned, like a pilot light, so that the
system is always ready for its primary purpose as an over-pressure safety system.
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1.2
Types of flares
As mentioned before there are many different kind of flare and they can be grouped
under the following major categories:
Vertical Flare
Horizontal Flare
Enclosed flame Flares
Single-point Flares
Multi burner staged flares
Smokeless and Non smokeless
1.2.1 Vertical Flare

Vertical flares are generally oriented to fire upward. The discharge point is in an
elevated position relative to the surrounding grade and/or nearby equipment. There are
several types of support methods for vertical flares.
1.2.1.1 Self Supported

A mechanically and structurally designed riser supports the flare burner.
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Figure 3 Self Supported Flare
To understand the behavior of the self-supported flare consider the following sample
of cantilever of height H subjected to lateral force uniform distributed p with transversal
section of radius R and thickness t.
Figure 4 schematic model of self supported flare against lateral load
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The displacement d of the system from the beam theory is
where
young modulus
inertia moment of the transversal section
Consider a maximum allowed top displacement of H/150 by the previous formula it is

possible to obtain a function for the required inertia moment
The moment of inertia for a thin circular hollow section is approximated by
Where D is the diameter and t the thickness. explicit the equation in the relation
thickness-height:
The formula shows that the thickness is proportional to the cubic of the height that
means if the height is double the thickness shall be 8 times.
In order to have some number we consider the following value common for flare
That means (with H in meter)
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The following graph shows the trend thickness required
Figure 5 trend of the thickness vs the stack height
It is possible to see that a length above 40 m requires a very thick section, thus selfsupported solution for vertical flares is usually used for height up to 40 meters.
1.2.1.2 Guy wired supported

Cables are attached to the flare riser at one or more elevations to limit the deflection of
the structure. The cables (guy-wires) are typically positioned in a triangular plan to provide
strong support in all direction against lateral loads.
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Figure 6 Guyed wire supported Flare
This kind of support is the most economical solution to support vertical flare taller
than 30 m. The main role of the wire is to act as a horizontal support along the height against
the horizontal external load for which as explained before, a self-supported solution is not
economical.
To understand a wire mechanism, consider a guy wire with inclination angle with
the ground. After a horizontal displacement the tension on the wire can be calculated as
below:
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H
h
d
Figure 7 cable tension
Projecting this force on the flare stack it can be realized how it works as a horizontal
support with stiffness
For a given wire, the maximum stiffness is theoretically reached at 0 and it becomes
null at 90.
In this way it is possible to control the maximum displacement better than the selfsupported method.
Considering that the length of the wire is equal to
Where h is the elevation from the ground to the anchor point of the wire on the flare it
is possible to write the stiffness as
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One time that the position of the support is given one problem is to select the best
angle to have the maximum stiffness.
Figure 8 stiffness trend
The best solution is to have an angle around 35 and for which means the horizontal
distance of dead-man from the flare base is equal to:
From above, it is possible to understand that the main limitation of using guy wired
flare is that a wide distance for installation of wire on the ground is required.
Another issue is the imposing of vertical stiffness along the flare stake that restrains
the expansion due to thermal load causing a very big normal force on the flare stack.
1.2.1.3 Derrick supported

The flare is supported by a steel trussed structure so-called Derrick. the advantage is
that the required width is minor than the one required for guy wired flare, and also more
than one flare can be supported by the same derrick. Usually a derrick supported system is
used high elevated flare systems
It is possible to recognize two different types.
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Fixed Derrick
The riser is permanently supported by the structure. The tip can be maintained by
lowering it with a davit or crane. The flare system must be out of service when the tip is
removed. Refer to Figure 9 for a typical fixed derrick support structure.
Figure 9 Fixed Derrick Supported Flare
Demountable Derrick
o Multiple section riser: A derrick with the riser(s) mounted to permit lowering the
flare burner to grade for service. The riser is typically assembled in sections that
can be raised and lowered using a track and guide system. This allows grade level
access to the flare burner. Many demountable derricks are designed to support
multiple risers with their flare burners. Such a derrick can be designed so that all
the flares, except the one being maintained, can be operational during the
maintenance. Figure 10 illustrates a derrick with a multiple section
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Figure 10 Demountable Derricl Multi section
o Single section riser: A derrick with a single riser utilizing a track and guide system
which allows the flare riser and burner to be lowered to grade in a single piece.
Figure11 illustrates a derrick with a single section
Figure 11 Demountable Derrick Single section
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1.2.2 Horizontal
The flared liquids and gases are piped to a horizontal flare burner that discharges into
a pit or excavation (see Figure 12).
Figure 12 Horizontal Flare
1.2.3 Enclosed Flame Flares

Enclosed flares are constructed to conceal the fame from direct view. They can reduce
noise and minimize radiation. Unlike an incinerator, a wide turndown is inherent with these
systems. The normal flow rate allows the connected facility to start up, shutdown, and
operate on a day to day basis without exposed flame flaring. Multiple stages within the
enclosed flares are sometimes used. Figure 13 illustrates a side-fired enclosed flare.
Figure 13 Enclosed Flare
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1.2.4 Single-point and Multi-burner

Single and multi-burner flares may be provided with each of the above flare
categories.
Single-point Flares
A single-point flare is an open pipe tip with a single exit point. Single-point flares may
be of the smokeless or non-smokeless design. They are generally vertical types. A singlepoint flare usually has a lower pressure differential than a multi-burner flare
Multi-burner Staged Flares

Multi-burner flare systems utilize the available pressure energy of the gas to entrain
additional air. This improves combustion as flare gas is better mixed with the air. Multiburner
flares are usually designed to achieve smokeless combustion if adequate pressure and space
are available. The multiple burning points may be arranged in arrays located near grade or at
an elevated position. Figure2-8 illustrates a multiburner staged flare. Figure 14,15 illustrates
the performance of a three-stage flare system. Each stage adds incremental exit area. Staging
allows operation of each stage to be at pressures where smoking will not occur. As the flow
increases in the first stage, the system pressure increases. When the system pressure reaches
a maximum for the first stage, the second stage opens providing additional capacity. The
additional capacity decreases the system pressure while maintaining the same flow. This
process then repeats with the third stage. Decreasing flow reverses the staging process.
Single and multi-burner, staged flares are fed from a manifold. The manifold
distributes the flow of flare gas to individual branches containing one or more burner tips.
ON/OFF Valves direct the flow of flare gas to each branch. The operation is described above.
Flare system safety considerations require valve bypasses, each of which must contain
a fail-safe device e.g., rupture disc, pin actuated device. Smokeless or non-smokeless flares
are applicable to all of the above types of flares.
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Figure 14 Multi burner staged Flare
Figure 15 1 Multi burner flare staging curve
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1.2.5 Smokeless and Non-smokeless Flares

1.2.5.1 Smokeless Flares
Smokeless flares eliminate any noticeable smoke over a specified range of flows.
Smokeless combustion is achieved by utilizing air, steam, pressure energy, or other means to
create turbulence and entrain air within the flared gas stream.
Local regulations and plant specific requirements generally define smokeless burning.
Opacity is defined by Ringelmann numbering scale (#1 Ringelmann is 20 percent opacity;
Ringelmann 0 is clear). Typically the smoking tendency is a function of the gas calorific value
and of the bonding structure of the hydrocarbons. The Paraffinic series of hydrocarbons have
the lowest tendency to produce smoke, whereas olefins, dioleffinic, and aromatic series of
hydrocarbons have a much higher tendency to produce smoke. Smokeless flares can be
provided with a steam-assist or air-assist system to improve combustion. An air-assist
system utilizes fans to provide mixing energy at the tip (See figure16 ).
1.2.5.2 Non-smokeless Flares

Non-smokeless flares utilize no outside methods (air, steam, etc.) to improve
combustion. This sometimes results in the presence of some smoke at certain operating
conditions. Non-smokeless flares are typically, but not exclusively, single-point flares. Nonsmokeless flares can be used to supplement smokeless flares when the capacity on the
smokeless flare is exceeded. Non-smokeless flares are used for hydrocarbon or vapor streams
that do not cause smoking (i.e., methane, hydrogen, carbon monoxide, clean coke oven gas,
ammonia, hydrogen sulfide) or when smoke is not a concern.
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Figure 16 Air assisted Flare
1.3
Flares as a pressure vessel

Since Flare system is usually considered as a pressure vessel it is needed at first to
introduce the pressure vessels.
1.3.1 Pressure equipment Types and components

1.3.1.1 What is a Pressure Equipment
A unanimously agreed def
f wh
u e pre ure equ pme
h r
find. The terms pressure equipment, pressure vessel and pressure system, while appearing
technically straightforward, are bound up as the subject matter of discussion by the
numerous technical committees that draft legislation, regulations and technical standards.
Due to the way that various international and national directives, standards, etc. are
structured, there are often differences and contradictions in meaning between technical
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Alireza Ghalamkari
terms. The end result is that definition may differ between countries, industry and technical
application.
Thankfully, fundamental technical aspects of pressure equipment do not change that
quickly. Design and manufacturing practices have been developed over the past 100 years
and the technology of pressure equipment is well supported by technical standards and
e
f pr
e fr m m
y f he w rl
evel pe
u re
1.3.1.2 Pressure Equipment Categories

Table 1 shows the scope of some common technical categories of pressure equipment
used in the main stream engineering industries. Note that these categories represent
arbitrary technical divisions only and have no direct relevance to the inclusion of the
equipment under any directives or regulations. From the engineering point of view, pressure
equipment types and components are all surprisingly similar.
Categories
Items
Simple pressure vessel
Simple receivers(unfired) low pressure
Gas cylinders
LPG cylinders
Complex air receivers, boiler drums,
Unfired pressure vessel
pressurized
storage containers, condensers, super heaters heat

exchanger, Economizers, Nuclear vessels
Boilers
Heating boiler , package shell boiler, coal/oil-fired

power boiler, general water tube boiler
Valves
Stop
valves(Globe,
Gate,
Butterfly),
check
valves ,safety valves, control valves , metering valves

Pipework
Pipeline, power piping, service piping , flanges,

fittings
Miscellaneous
Turbines, autoclaves, road transport vehicles
Gauge pressure
Equipment is subject to a positive gauge pressure or

negative gauge ( vaccum) pressure
Table 1 Pressure equipment categories
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1.3.1.3 Introduction to Pressure Vessel

Vessel, tanks and pipe lines that carry, store or receive fluids are called pressure
vessel. A pressure vessel is defined as a container with a pressure differential between inside
and outside. The inside pressure is usually higher than outside, except for some isolated
situations. The fluid inside the vessel may undergo a change in state as in the case of steam
boiler or may combine with other reagents as in the case of a chemical reactor. Pressure
vessels often have a combination of high pressures together with high temperatures and in
some cases flammable fluids or highly radioactive materials. Because of such a hazard it is
imperative that the design be such that no leakage can occur. In addition these vessels have to
be designed carefully to cope with the operating temperature and pressure. It should be
borne in mind that the rupture of a pressure vessel has a potential to cause extensive physical
injury and property damage. Plant safety and integrity are of fundamental concern in
pressure vessel design and these of course depend on the adequacy of design codes.
Pressure vessels are used in a number of industries, for example the power
generation, the petrochemical industry for storing processing crude petroleum oil as well as
storing gasoline in service station and chemical industry.
The size and geometric form of pressure vessels vary greatly from the large cylindrical
vessels used for high-pressure to the small size used as hydraulic units for aircraft.
Pressure vessels are usually spherical or cylindrical with domed ends. The cylindrical
vessels are generally preferred since they present simpler manufacturing problems and make
better use of available space. Spherical vessels have the advantage of requiring thinner wall
for a given pressure and diameter that the equivalent cylinder.
1.3.1.4 Pressure vessel classification

Pressure vessels are made in all shapes and sizes, with various pressures. The
American society of Mechanical engineers (ASME) boiler and pressure vessel code, section
VIII, Division 1, specifies a range of internal pressure from 15 psi to 3000 psi. the static
equipment which are exposed to this range are as follow:
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Drum (horizontal, vertical)

Figure 17 illustrates a typical horizontal drum. Horizontal drums have cylindrical
shells and are fabricated in a wide range of diameters and lengths they are normally located
on saddle support.
Figure 17 Horizontal drum
Figure 18 illustrates a small vertical drum. Vertical drums are normally located at
grade on support (Skirt, leg , lug). The maximum shell length to diameter ratio for a small
vertical drum is about 5:1
Figure 18 Vertical drum
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Tower
Figure 19 illustrates a typical tall , vertical tower. Tall vertical towers are constructed
in a wide range of shell diameters and heights. Towers can be relatively small in diameter and
very tall ( e.g. a 4 ft. diameter and 200 ft. tall distillation column) or very large diameter and
moderately tall (e.g. 30 ft. diameter and 150 ft. tall ) the shell section of a tall tower may be
constructed of different materials , thickness and diameters. This is because temperature and
phase changes of the process fluid which are the factors that affect the corrosiveness of the
process fluids.
Figure 19 Tower
Reactor
Figure 20 illustrates a typical reactor vessel with a cylindrical shell. The process fluid
undergoes a chemical reaction inside a reactor. This reaction is normally facilitated by the
presence of catalyst which is held in one or more catalyst beds.
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Figure 20 reactor
Spherical tank
Figure 21illustrates a pressurized storage vessel with a spherical shell. Spherical tanks
are usually used for gas storage under high pressure
Figure 21 Spherical tank
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1.3.1.5 Component of Pressure Vessel

The main pressure vessel components are as follow:
Shell
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 and conical in shape.
Head
All pressure vessel shells can be closed at the ends by heads. 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. These
erme
e he
ep r e e
f he pre ure ve el
perm
ffere
e g
condition in each section. Heads are usually categorized by their shapes. Ellipsoidal,
hemispherical, torispherical, conical, toriconical and flat are the common types of heads
Figure 22 shows various types of head. Ellipsoidal(2:1) would be the most common
type of heads which is used during the designing of pressure vessel.
Figure 22 Heads
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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 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 vessel
Attach instrument connection (level gauge thermowells, pressure gauge)
Provide access to the vessel interior at manways
Provide for direct attachment of the other equipment items (e.g. a heat exchanger or
mixer)
Nozzles are also sometimes extended into the vessel interior for some applications,
such as for inlet flow distribution or permit the enrty of thermowells.
Support
The type of support that is used depends primarily in the size and orientation of the
pressure vessel. In all cases, the pressure vessel support must be adequate for the applied
weights, wind, earthquake loads.
Calculated base loads are used for design of anchorage and foundation for the
pressure vessels.
o Skirt
Tall, vertical, cylindrical pressure vessels (e.g. the Flare, tower) are typically
supported by skirts. A skirt is a cylindrical shell section that is welded either to the lower
portion of the vessel shell or the bottom of the head (for cylindrical vessels) skirts for
spherical vessels are welded to the vessel near the mid-plane for 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.
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o Leg
Small vertical drums are typically supported on legs that are welded to the lower
portion of the shell. The maximum ratio of the support leg ti 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 structure
steel columns or pipe sections, whichever provides a more efficient design. Cross bracing
between the legs is typically used to help absorb wind or earthquake loads.
o Saddle
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. The other support is normally
free to permit unrestrained longitudinal thermal expansion of the drum. A typical scheme of
saddle support is shown in figure 23
Figure 23 Saddle
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o Lug
Lugs that are welded to the pressure vessel shell, which are shown on Figure 24, may
also be used to support vertical pressure vessels. The use of lugs is typically limited to vessels
of small to medium diameter 1to10 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.
Figure 24 Lug
1.3.1.6 External Attachments

Common external attachments which are connected to pressure vessels are as follows:
Lifting and transportation attachments (e.g. lugs, trunnion)
Manway and handway davits
Accessories (e.g. ladder, platform)
Supports (e.g. clip for piping , insulation support, earthing , pipe davit)
Insulation
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The requirements of external attachments are usually specified by standard drawings

in lieu of direct design calculations.
1.3.1.7 Internal Attachments

Typical internal attachments which are attached to pressure vessels are as follow:
Internal piping
Trays
Internal support
Vortex breaker
Impingement plate
Internal ladder
Rungs
Other internal parts are specified based on pressure vessel service. The requirements
of internal attachments are specified by using standard drawings or direct design
calculations.
1.3.2 Flare component

There are different attachments along the flare system that should be considered for
structural design. The most common components are the following.
1.3.2.1 Piping
Typical piping requirements on the support structure include piping for steam, pilot
gas, assist gas, buoyancy seal drain, pilot ignition, electrical conduit, and instrumentation
conduit. There are intermediate supports at different elevation along the flare rise to support
the piping. All piping must be considered in the structural analysis of the wind and
earthquake loads, including any insulation that is installed on the pipe or may be installed in
the field.
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1.3.2.2 Aircraft Warning Light

Lighting of the support structure shall be in accordance with the latest edition of the
appropriate code as defined by the local aviation authority. Warning lights supported by the
structure may be fixed or retractable, and shielded from radiation as necessary.
1.3.2.3 Platforms and Ladders

An elevated flare can meet its purpose without being equipped with platforms or
ladders.
However, it is recommended that, as a minimum, a 360 platform be provided near the
top of elevated flares more than 15 m (50 ft.) height. This elevation may be increased
depending on site specific capabilities and maintenance practices. This platform should be
located below the flare burner mounting flange or connecting weld and be positioned so that
it can be used during inspections, maintenance and flare burner replacement.
An access ladder is preferred but not mandatory. Alternative access can be achieved
via a crane basket or helicopter.
An access platform may be desirable for inspection and maintenance of aircraft
warning lights of the type located above grade and attached or supported by the flare stack.
The location and size of such platforms will depend on the aircraft warning light design and
location. Access to warning light maintenance platforms is normally via a ladder.
Additional access platforms may be located at other locations as necessary. For
example, the erection plan for the flare stack may make a full 360-degree or partial platform
desirable at each stack assembly joint.
If any platforms are at an elevation greater than about 9 m (30 ft.) or if ladder access is
used, intermediate landing platforms may be required by regulation, e.g. OSHA, or company
policy. Normally, platforms and ladders shall be fabricated from carbon steel and protected
from corrosion by hot dip galvanizing.
There are different attachments along the flare system that should be considered for
structural design. The most common components are the following:
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1.3.3 ASME Code

1.3.3.1 ASME Boiler and pressure vessel code
History
On march 20, 1905 ,a disastrous boiler explosion occurred in a shoe factory in
Brockton, Massachusetts, killing 58 persons, injuring 117 others and causing a quarter of a
million dollars in property damage. For years prior to 1905, boiler explosions had been
regarded as e her
ev
ble ev l an act of G
(see figure 25)
Figure 25 Shoe factory before and after boiler explosion
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But this catastrophic accident had the effect of making the people of Massachusetts see
the necessity and desirability of legislating rules and regulations for the construction of
steam boilers in order to secure their maximum safety. After much debate and discussion, the
state enacted the first legal code of rules for the construction of steam boilers in 1907. In
1908, the state of Ohio passed similar legislation, the Ohio board of boiler Rules adopting,
with a few changes, the rules of the Massachusetts Board. Therefore, other states and cities in
which explosions had taken place began to realize that accidents could be prevented by the
proper design, construction and inspection of boilers and pressure vessels and began to
formulate rules and regulations for this purpose. As regulations differed from state to state
and often conflicted with one another, manufacturers began to find it difficult to construct
vessels for use in one state that would be accepted in another. Because of this lack of
uniformity, both manufactures and users made an appeal in 1911 to Council of the American
Society of Mechanical Engineers to correct the situation. The Council answered the appeal by
pp
b ler
mm ee
f rmul e
her pre ure ve el
r
f r he r
pe f
f r
re
erv e
ru
The f r
e m
mm ee
consisted of seven members, all experts in their respective fields: one boiler insurance
engineer, one material manufacturer, two boiler manufacturers, two professors of
engineering and one consulting engineer. The committee was assisted by an advisory
committee of 18 engineers representing various phases of design, construction, installation
and operation of boilers.
Following a thorough study of the Massachusetts and Ohio rules and other useful data,
the committee made its preliminary report in 1913 and sent 2000 copies of it to professors of
mechanical engineering, engineering departments of boiler insurance companies, chief
inspectors of boiler inspection departments of states and cities, manufacturers of steam
boilers, editors of engineering journals and others interested in the construction and
operation of steam boilers, with a request for suggestions of changes or additions to the
proposed regulations. After three years of countless meetings and public hearings, a final
draft of the first ASME Rules for Construction of Stationary Boilers and for allowable Working
Pressure, known as the 1914 edition, was adopted in spring of 1915.
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Since 1914, many changes have been made and new sections added to the code as the
need arose.
ASME Boiler and Pressure Vessel Committee

The increase in the size the code reflects the progress of industry in this country. To
keep up with this spontaneous growth, constant revisions have been required. The ASME
Code has been kept up to date by the Boiler and Pressure Vessel Committee (currently
consisting of more than 800 volunteer engineers and other technical professionals) which
considers the needs of the users, manufacturers and inspectors of boilers and pressure
vessels. In the formulation of its rules for the establishment of design and operating
pressures, the Committee considers materials, construction, methods of fabrication,
inspection, certification and safety devices. The ASME works closely with the American
National documents meet the ANSI criteria for publication as American National Standards.
The members of the committee do not represent particular organizations or
companies but have recognized background and experience by which they are placed in
categories, which include manufacturers, users of the products for which the codes are
written , insurance inspection, regulatory and general. The committee meets on a regular
basis to consider request for interpretations and revisions and additions to Code Rules as
dictated by advances in technology. Approved revisions and additions are published
semiannually as addenda to the Code.
Each new material, design, fabrication method and protective device brought new
problems to the Boiler Code Committee , requiring the expert technical advice of many
subcommittees in order to expedite proper additions to and revisions of the Code. As a result
of the splendid work done by these committees, the ASME Boiler and Pressure Vessel Code
has been developed ; it is a set of standards that assures every state of the safe design and
construction of all boiler and pressure vessels used within its borders and is used around the
world as a basis for enhancing public health, safety and welfare. Many foreign manufacturers
are accredited under the provisions of the ASME Boiler and Pressure Vessel Code.
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Outline of the ASME Boiler and Pressure Vessel Code
The structure of ASME code is listed in the following order, in accordance with the
ASME Code 2007.
o Section I. Rules for construction of power boilers
o Section II. Materials
Part A: Ferrous Material Specifications
Part B: Nonferrous Material Specifications
Part C: Specifications for Welding, Rods, Electrodes and filler Metals
Part D: Properties (customary)
o Section III: Rules for construction of Nuclear Facility Component
Division 1.
Subsection NCA: General Requirements for Division 1 and Division 2
Subsection NB: Class1 Components
Subsection NC: Class 2 Components
Subsection ND: Class 3 Components
Subsection NE: Class MC Components
Subsection NF: Supports
Subsection NG: Core Support Structures
Subsection NH: Class 1 Components in Elevated Temperature Serivce
Appendices
Division 2. Code for concrete containments
Division3. containment for Transportation and Storage of Spent Nuclear Fuel and High
Level Radioactive Materials and Waste
o Section IV. Rules for Construction of Heating Boilers
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o Section V. Nondestructive Examination

o Section VI. Recommended Rules for the Care and Operation of Heating Boilers
o Section VII. Recommended Guidelines for the Care of Power Boilers
o Section VIII. Rules for Construction of Pressure Vessels
Division 1.
Division2. Alternative Rules
Division3. Alternative Rules for Construction of High Pressure Vessels
o Section IX. Welding and Brazing Qualifications
o Section X. Fiber-Reinforced Plastic Pressure Vessels
o Section XI. Rules for Inservice Inspection of Nuclear Power Plant Components.
o Section XII. Rules for Construction and Continued Service of Transport Tanks.
ASME Boiler and Pressure Vessel Code Sec. VIII

Pressure vessels are typically designed in accordance with the ASME Code Section VIII.
The section is divided into three divisions. Among these, Division 1 is used very often since it
contains sufficient requirements for the majority of pressure vessel applications.
The main objective of ASME Code rules is to establish the minimum requirements that
are necessary for safe construction and operation. The ASME code protects the public by
defining the material design, fabrication, inspection and testing requirements that are needed
to achieve a safe design. Experience has shown that the probability of a catastrophic pressure
vessel failure is reduced to an acceptable level by use of the ASME Code.
The ASME code is written to apply many industries. Accordingly, it cannot anticipate
and address every possible design requirement or service application. Therefore, user must
supplement the ASME code by specifying additional requirements that are appropriate for
their particular industry and applications
The ASME Code Section VIII, Division 1 applies for pressure that exceed 15psi
(100kps) and through 3000 psi (20MPa). At pressures below 15 psi (100Kpa), the ASME
Code is not applicable. At pressure above 3000 psi (20Mpa), additional design rules are
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required to cover the design and construction requirements that are needed at such high
pressures.
It is divided in to three subsections:
Subsection A: This part consists of Part UG, which is the general requirements for all
methods of construction and materials that apply to all pressure vessels in its scope
Subsection B: it covers requirements pertaining ti various fabrication methods of
pressure vessels.
Subsection C: this part covers requirements pertaining to several classes of materials
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1.3.3.2 Design loads

The design of a support structure for a vertical elevated flare shall consider, as a
minimum, the design loads given below. The designer shall review the intended application
and eliminate those loads that are not applicable
Dead Load
The dead load shall consist of the weight of steel stack, coatings, internal liner,
insulation, cladding, and all permanent accessories such as ladders, platforms. For dead load,
the full plate thickness shall be used. The corroded plate area shall be used for stress
calculations. For stacks possessing refractory lining, the applied weight of the refractory
material shall be used to calculate dead load stresses.
Wind Load
Wind loadings shall take into account the riser and all of its appurtenances such as but
not limited to piping (including insulation, if any), access platforms, and ladders. When
appropriate the wind loading on supporting derrick structures must be included.
Seismic Load
Earthquake induced loads shall be based on international codes (e.g. UBC Uniform
Building Code or ASCE 7 Minimum Design Loads) for Buildings and other Structures.
Structural design shall be based on wind loads and earthquake loads occurring separately.
Wind-induced Vibration Load

The structural design shall include an analysis of the loads imposed by wind induced
vibration and a determination of the critical wind velocity for the first and second modes of
vibration for the new and corroded conditions. The critical wind velocity of the first and/or
second vibration mode shall fall within an acceptable range as set forth in either ASME/ ANSI
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STS- S eel S
r API S
, F re Pr e
He er f r Ge er l Re ery Serv e
If the critical wind velocity of the first and/or second mode falls outside the acceptable range
the design of the structure must be modified in order to change the natural frequency of the
structure. Means to modify the natural frequency include, but are not limited to:
-
Changes in riser diameter or length
Use of multiple diameters
Changes to the wall thickness
Changes in the mass of the riser
Use of a tuned mass damper
Use of strakes or the like
Changes in foundation design

Wind loads of modified structures should be reviewed and revised if necessary.
Internal Pressure
Flare stacks are generally operated at near atmospheric pressure and are not
specifically designed as a pressure vessel. In some cases the bottom portion of the stack
incorporates a Knockout drum or liquid seal or both. When specified in the Flare Data Sheets
the stack portion containing the Knock-out drum or liquid seal may be designed as a pressure
vessel including, if specified, hydrostatic testing and code stamping. In such cases, the design
of the pressure vessel portion shall be in accordance with ASME Boiler and Pressure Vessel
Code, Section VIII, Division I and shall be based on the design pressure and temperature
stated in the Flare Data Sheets or a minimum of 105 kPa (15 psig). It is common practice for
the riser portion of the stack to be designed for structural loads and the anticipated
maximum operating pressure when the base section of the stack is designed as a pressure
vessel. For design purposes the riser section is deemed to start at the pressure vessel outlet.
The design of a stack base section, that is a pressure vessel, shall
include provision for internal pressure loads and for simultaneous wind loads based
on 70 percent of the design wind velocity. The design pressure (Maximum Allowable
Working Pressure) of a stack base section that is a pressure vessel shall not be increased due
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to any material thickness that is in excess of that thickness required to meet the design
pressure.
Live Load
Live loads are produced during maintenance by workers, equipment and materials,
the live load shall be included for platforms and walkways.
Nozzle Load
The nozzle loads imposed upon the stack by the flare header to stack connection can
have a major influence on the design and cost of the flare stack. This influence becomes
greater as the elevation of the flare header increases. In general the flare stack itself should
not be used as a major fixed point for the flare header piping. If possible, the purchaser shall
note the preliminary flare header imposed nozzle loads on the Flare Data Sheets furnished to
the vendor with the request for quotation. The purchaser shall provide final flare header
imposed nozzle loads during the design phase. The purchaser should minimize the nozzle
loads imposed on the stack by other service connections. If the purchaser does not furnish
nozzle load information either at the quotation stage or the order stage, the flare supplier
shall base the nozzle design on Section 5 of API Standard 560, Fired Heaters for General
Renery Services (See Figure 26).
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Figure 26 Allowable Nozzle Loads
Thermal Loads
Some of the relief gas cases described in the Flare Data Sheets may have a gas
temperature that is different than ambient. The flare stack designer shall provide for thermal
expansion (+ or -) that can be caused by specified gas temperature or temperature
differences caused by wind or rain. Thermal loads are of greatest concern on guyed stacks
and derricks. The freedom of movement of a self-supported stack reduces the thermal load
concerns providing that the thermally induced deflection does not exceed 450 mm per 30 m
(18 in. per 100 ft.). The designer shall also provide for thermally induced differential changes
in length between the stack and the piping attached to the stack.
The following design details shall be incorporated into the support structure design.
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stack deflection shall not exceed the following guidelines:

SUPPORT TYPE
MAX. ALLOWABLE DEFLECTION
Derrick-Supported
150mm per 30m
Guyed-Supported
300m per 30m
Self-Supported
225mm per 30m
Table 2 2Max. allowable deflection
A minimum corrosion allowance of 1.6 mm (0.0625 in.) is recommended and shall be

added to the minimum metal thickness. No corrosion allowance is required on alloy
steel portions of the stack unless specifically noted on the Flare Data Sheets. Non-alloy
steel internal parts of liquid seal or knockout drums that are normally wetted shall
have the 1.6 mm (0.0625 in.) corrosion allowance applied to each side. No corrosion
allowance is required for derrick structures and other metal objects that do not
normally come into contact with the relief gas stream.
1.3.3.3
Skirt Design
Tall vertical vessels are usually supported by skirts. Because cylindrical shells have all
the metal area located at the maximum distance (for a given diameter) from the neutral axis,
the section modulus Z, is maximum, and the induced stress minimum for the metal involved.
Thus the cylindrical skirt is an economical design for a support for a tall vertical vessel. The
skirt is usually welded directly to the vessel. Because the skirt is not required to withstand
the pressure in the vessel, the selection of material is not limited to the steels permitted by
the Pressure Vessel codes, and structural steels with corresponding allowable stresses may
be used with some economy.
The skirt may be welded directly to the bottom dished head, flush with the shell, or to
the outside of the shell. If the skirt is welded flush with the shell, the weight of the vessel in
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the absence of wind and seismic loads places the weld in compression. On the other hand, if
the skirt is welded to the outside of the vessel, the weld joint is in shear; therefore this
method is not so satisfactory, but it is an easy method of erection and is often used for small
vessels.
There will be no stress from internal or external pressure for the skirt, unlike for the
shell of the vessel, But design of the skirt consists of first determining the dead weight of the
vessel (W) and bending moment (M) due to wind and earthquake forces. The stress in the
skirt is then determined from
In most practical applications, the ration R/t >10. Hence, the area (A) and the moment
of inertial (I) is expressed as
And the equation for the stress in a skirt becomes
R
Where
Because the compressive stress is larger than tensile stress, it usually controls the
kr
e g
kep bel w he k r
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Figure 27 Skirt with anchor bolts
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1.3.3.4
Anchor Bolts Design
The bottom of the skirt of the vessel must be securely anchored to the concrete
foundation by means of anchor bolts embedded in the concrete foundation to prevent
overturning from bending moments induced by wind or seismic loads.
The concrete foundation is poured with adequate reinforcing steel to carry tensile
loads. The anchor bolts may be formed from steel rounds threaded at one end and usually
with a curved or hooked end embedded in the concrete. The bolting material should be clean
and free of oil so that the cement in the concrete will bond to the embedded surface of the
steel.
When either a compressive or tensile load is applied to the anchor bolts, the load is
transferred from the steel through the bond to the concrete. Surface irregularities, bends, and
hooks aid in transferring loads from steel to concrete.
After the thickness of the skirt is determined, the next step is designing the anchor
bolts. For a given number of bolts (N) the total bolt area can be expressed as NA where A is
the area of one bolt. The moment of inertia of bolts b u ve el
eutral axis is I
AR
thus
R
Where
It should be kept in mind that number of bolts should always be a multiple of 4.

The maximum load/bolt is based on the allowable stress and corresponding area.
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Sb
Where
Ab = required bolt area

Sb.a = Allowable bolt stress
1.3.4 Pressure vessel Designing Software packages

There are many software packages which assist the designers to design pressure
vessels and their components for petrochemical plants. Figure1-11 illustrates the most
popular software packages for designing, modeling and drawings preparation of pressurized
equipment and theirs components in accordance with different codes/standards. There may
be other software packages which are not mentioned in the following table.
software
Description
PV elite is a comprehensive program for the complete mechanical and
structural design or analysis of tall towers and horizontal vessels according
PV-Elite
to latest standards from ASME, PD 5500 (British code), EN-13445, also

including UBC, API-579 and the welding Research Council for its
calculation in different parts of software
The standard functionality of COPRESS includes everything you require to
perform ASME VIII div. 1 and 2 pressure vessel calculations. This includes
the both U.S. customary and Metric editions of section II, Part D
Codeware compress
(materials) and a selection of Building Codes and related engineering

standards, such as WRC-107. To further assist COPRESS users, finite
element analysis of nozzles capabilities are now included with new
COPRESS license purchases.
Codecalc is the leading industry software package for design and analysis
Codecalc
of pressure vessel and heat exchanger components. It includes extensive

buit-in materials and components databases and the latest ASME, TEMA,
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PD 5500, UBC and the WRC. For many years CodeCalc was available
separately as well as within PV-Elite. From 1 January 2010 CodeCalc is only
available as part of PV-Elite
Intergraph PV Fabricator provides advanced tools for the accurate and
speedy production of fabrication drawings requirements for pressure
PV Fabricator
vessels and heat exchangers. PV Fabricators true power is realized when

it is linked to PV-Elite, as 3D models can be created complete with the
analysis data
CADWorx equipment is a parametric equipment modeler with all the
CADWorx
features needed to easily model 3D equipment for plant design. The
equipment
package lets you accurately build units such as vessels, exchangers, tanks,
pumps, etc.
The program MT-COMP allows mechanical design of pressure vessel
components and rating of existing ones. It supports the following codes:
MT-comp/Vess
ASME VIII div1, MERKBLATTER (Germany), ISPSEL-VSR (Italy) and BD 5500.

MT-VESS is the software program allows the mechanical design and
stability check of pressure vessels.
Advanced Pressure
For quick and least cost design of pressure vessels and heat exchangers in
vessel
accordance with Section VIII Div.1 of the ASME Code

Aspen B-Jac software includes a number of programs for the thermal
Aspen B-Jac
design, mechanical design, cost estimation and drawings for heat

exchangers and pressure vessels
Nozzle Pro is a template-driven finite element software package,
Nozzle Pro
specifically designed to quickly and easily evaluate nozzles, saddles, pipe

shoes and clips.
FE/PIPE is a template-driven finite element software package, specifically
FE/PIPE
designed for the needs of the piping and pressure vessels industries. It
generates automatic code compliance reports comparisons to ASME VIII
Div.2, Appendix 4 and 5 rules and stress categories.
Table 3 Pressure vessel software packages
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Table 4 compares the features available in the two most common used software
packages, PV-Elite and COMPRESS for designing Pressure vessels and their components.
Features
PV-Elite
COMPRESS
Design Codes
ASME VIII Div.1
Yes
Yes
ASME VIII Div.2
Yes
Yes
PD5500
Yes
No
EN13445
Yes
No
Stability check- Wind Codes

ASCE 7 -95
Yes
Yes
UBC 1997
Yes
Yes
IS 875
Yes
No
NBC
Yes
Yes
IBC
Yes
Yes
USER
Yes
Yes
Stability check- Seismic Codes

ASCE 7- 95
Yes
Yes
UBC 1997
Yes
Yes
NBC
Yes
Yes
IBC 2000
Yes
Yes
USER
yes
Yes
Local Loads Analysis Codes

WRC 107
Yes
Yes
WRC 297
Yes
No
BS5500
Yes
No
Materials
ASTM (USA)
Yes
Yes
EURO
yes
No
Material classes
Yes
Yes
Internal corrosion
Yes
yes
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Alireza Ghalamkari
External corrosion
Yes
Yes
Internal lining
Yes
yes
External lining
yes
Yes
Components allowed
Element types
Dished heads
Yes
Yes
Cylindrical shell
Yes
Yes
Conical section
Yes
Yes
Flat heads
Yes
Yes
Flanged flat heads
No
Yes
Radial
Yes
Yes
Offset, inclined
Yes
Yes
Welding neck
Yes
Yes
Stiffness rings
Yes
Yes
Platforms, ladders
Yes
Yes
Skirt
Yes
Yes
Leg
Yes
Yes
Saddle
Yes
Yes
Lug
yes
Yes
Internal pressure
Yes
Yes
Steel stack calculation
Yes
Yes
Nozzles
Additional components
Supports
Table 4 comparison between PV-Elite and Compress
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Alireza Ghalamkari
The Aim of the thesis

Until now three different types of the flare are introduced which can be
Self-supported
Derrick-supported
Guyed-supported
The aim of this thesis is to study and model two elevated flares in the Nigeria which
are coupled together. The codes and standard does not mentioned any methods for
calculation of the self-supported flare while they are connected to each other.
It is required to find the best solution to find the reaction forces at the base of both
flares and also to design and calculate the size of anchor bolts for both flares.
The available software to model and analysis are PV-elite and also the structural FEM
software called Midas-GEN.
the problem of the PV-Elite is that it is not possible to model both risers at the same
time and linked them together. Software is capable of modeling one self-supported stack at a
time.
The difficulty of the MIDAS-GEN is that since this is a general FEM software , the
software is not able to perform the checks according to ASME VIII since the client is asked to
consider the flares as pressure vessel and respect the ASME VIII code.
The calculation philosophy is to model both flare system in MIDAS-GEN with beam
element and apply all external loads. And find the reaction forces at each base with respect to
the applied load combinations.
But we should take to account that this method is applicable for support design, but
for modeling the pressure vessel we need to take in to account the applied internal pressure
too. But since we are using beam element, it is not possible to apply internal pressure. To
study and checks the vessel wall thickness subjected to internal pressure and other external
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Alireza Ghalamkari
loads we will model each flare separately in PV-Elite and we will estimate required wall
thickness for the pressure parts.
Then we are going to model the larger and stiffer flare in PV-Elite and model all
ladders, platforms, service piping and wind, also we will model the smaller flare as the
service pipe .
This assumption must be reasonable and reaction forces at the base of larger flare
should be more or less similar to the one obtained from MIDAS-GEN. because the smaller
flare is supported and coupled with the larger one at two different elevation, which means
most of the loads will be transferred to the larger and by modeling the smaller as service
pipe, we are sure that shear and bending loads due to wind will be transferred to the base of
larger stack. In this way the smaller flare h
b e
we
y re
f r
PV-Elite, but since we know the reaction forces must be small values, we will accept the
obtained result from MIDAS GEN. finally as mentioned before we will model the smaller flare
in PV-elite and only internal pressure will be applied without wind load and the required wall
thickness for pressure part will be estimated
In the next chapter it will be demonstrated in details that flares will be modeled in
both software and the results of the both software will be compared to each other to make
sure that the result are applicable and reliable.
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Alireza Ghalamkari
Flare System Design
3.1
Modeling
3.1.1 Geometry
The total height of the system is 25 m and the horizontal distance between the bases
are 1m. General information and design conditions are demonstrated in following table.
Smaller Flare (Item No. F-4301)
Section
Material
Diameter
Thickness
(in.)
(mm)
Skirt
API 5L Gr.B
12.7
Riser
API 5L Gr.B
12.7
Tip
AISI 310
10
Larger Flare (Item No. F-4302)

Section
Material
Diameter
Thickness
(in.)
(mm)
Skirt
API 5L Gr.B
36
12.7
Riser
API 5L Gr.B
36
12.7
Riser
API 5L Gr.B
30
12.7
Tip
AISI 310
Design Condition
Design Pressure (barg)
3.5
Design Tempreture (C)
250
Allowable stress for API 5L at design Temp. (Mpa)
117
Allowable stress for AISI310 at design Temp. (Mpa)
127
Table 5 General design information
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Alireza Ghalamkari
Figure 28 3D model of the project
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Alireza Ghalamkari
Figure 29 Model in PV-Elite / MIDAS
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Alireza Ghalamkari
In reality the smaller riser is guide supported by larger riser, which the support are modeled in
MIDAS as rigid links at four different elevations.
Figure 30 Coupled system
3.1.2 Loading Data

3.1.2.1 Dead Load
Self-weight
The self-weight of the structure is automatically evaluated by both software packages,
considering the material characteristics of steel.
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Alireza Ghalamkari
Service piping
There re
l e
f ,
l e f
l e f l
g he l rger
k The
estimated weight of 500 kg will be applied at elevation of 18m where the service piping is
fixed as a nodal load in MIDAS-GEN.
Figure 31 Service piping orientation
Figure 32 Service piping dead load
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Alireza Ghalamkari
In the PV-Elite the pipes will be model and the weight will be automatically applied by
software.
Ladders
We have three ladders at three different elevations supported along larger stack ( at
7m , 14m and 21m) the weight of ladder per unit length is considered as 35 Kg/m. these
loads will be applied at the mentioned elevation as Nodal loads in MIDAS-GEN , while in PVElite we just simply model the ladders at the proper elevation and it will automatically
estimate the weight.
Figure 33 Ladder dead load
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Alireza Ghalamkari
Platforms
We have two intermediate platform and one access platform at the top. 175 Kg per
unit area is considered as to calculate the weight of platforms and it will be applied as nodal
load in MIDAS-GEN software and for simplicity the elevation of the applied load for the
platform will be same as the elevation of the respective ladder and we will neglect the small
difference in the elevation.
Figure 34 Platforms dead load
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Alireza Ghalamkari
This step in PV-Elite is just to enter the dimension for the platform and the software
will automatically calculate the weight.
Figure 35 Ladder/Platform details in PV-elite
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Alireza Ghalamkari
3.1.2.2 Live Load

The live loads on the platforms have been entered in the both models as concentrated
nodal forces. To obtain the value we considered a weight of 5 kN/m2 on the effective area of
the access platform and 2.5 kN/m2 on the effective area of the intermediate platforms.
Figure 36 Live load
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Alireza Ghalamkari
3.1.2.3 Nozzle Load

There is one inlet nozzle connected to each flare, the client advised the nozzle load for
each nozzle according to their own study. The loads are applied at the end of nozzle as shown
in the figure.
Figure 37 Nozzle load
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Alireza Ghalamkari
3.1.2.4 Wind Load

The ASME Code does not give specific procedure for designing vessels for wind. Local ,
state or government al jurisdictions will require some form of analysis to account for wind
loadings. Client specification and standards also frequently require consideration of wind.
Client requirement is to calculate the wind pressure according to Eurocode EN-1991-1.42005 code.
Wind design is used to determine the forces and moments at each elevation to check if
the calculated shell thicknesses are adequate. The overturning moment at the base is used to
determine all of the anchorage and support details. These details include the number and size
of anchor bolts, thickness of skirt.
As a loading, wind differs from seismic in that it is more or less constant; whereas,
seismic is if relatively short duration. In addition wind pressure varies with the height of
vessel. A vessel must be designed for the worst case of wind or seismic, but need not to be
designed for both simultaneously. While typically the worst design case for seismic is with
the vessel full (maximum weight), the worst design case for wind is with the vessel empty.
This will produce the maximum uplift due to minimum restraining weight.
Wind load as calculated according to the Eurocode EN-1991-1.4-2005 considering the
following specifications by the Client.Analysis was performed for all wind rose directions
around the two coupled riser. By this implicitly the torsional effects were considered. The
worst conditions for the wind action are the ones reported in the calculation reports.
Basic wind speed for a 3 sec gust speed at a
35.6 m/s
height of 10 metres on Tr=100 years:

Terrain Category
II
Table 6 wind design information
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Alireza Ghalamkari
First of all the wind speed has to be converted on 10 min mean speed according to the
Eurocode input data.
Peak Velocity
Roughness factor
kr=
0.19
z0=
k=
Lv =
t=
T=
V m=
0.05
0.52
63.18
3
600
25.80
Turbulence intensity
Expected turbulence frequency
Peak factor
Iv =
n=
gv =
0.189
0.23
3.32
Probability factor
Pv =
0.61
Gust Factor
Gv =
1.38
Peak velocity
vp=
35.60
Roughness height
Power
Turbulence integral lenght
Period on which the peack velocity is mediated
Period on which the velocity is mediated
Mean value on T interval
m
m
s
s
m/s
Hz
m/s
Figure 38 Mean wind speed calculation
The calculation shows the mean wind speed on 10 min at 10 m height is 25.80 m/s.
The following figure shows the pressure along height of the structure
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Alireza Ghalamkari
Zcalc
v(z)
[m]
[m/s]
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
22.00
23.00
24.00
25.00
2.000
2.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
9.000
10.000
11.000
12.000
13.000
14.000
15.000
16.000
17.000
18.000
19.000
20.000
21.000
22.000
23.000
24.000
25.000
18.08
18.08
18.08
20.07
21.48
22.57
23.47
24.22
24.88
25.46
25.97
26.44
26.87
27.26
27.62
27.96
28.28
28.57
28.85
29.12
29.37
29.61
29.84
30.06
30.26
30.46
Iv(z)
qp
25.00
[N/m^2]
0.27
0.27
0.27
0.24
0.23
0.22
0.21
0.20
0.20
0.19
0.19
0.19
0.18
0.18
0.18
0.18
0.17
0.17
0.17
0.17
0.17
0.17
0.16
0.16
0.16
0.16
592.18
592.18
592.18
682.20
749.07
802.65
847.53
886.26
920.39
950.93
978.61
1003.94
1027.29
1048.98
1069.23
1088.23
1106.14
1123.07
1139.14
1154.42
1169.01
1182.95
1196.32
1209.15
1221.49
1233.37
20.00
15.00
Height [m]
Z
[m]
10.00
5.00
0.00
0
200
400
600
800
1000
1200
1400
Peak Velocity Pressure qp [Pa]
Figure 39 wind profile along the stack
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Alireza Ghalamkari
The force coefficient on a pipe is the product of base factor for cylinder without free
end flow and the slenderness factor
8 "Force Coefficent
1.Force Coefficent without free end flow
Peak Wind Velocity
Section Diameter
35.6 m/s
0.219 m
n= 1.50E-05 m2/s
k=
0.2 mm
Re= 5.20E+05 [-]
k/D= 9.13E-04 [-]
Air Kinematic viscosity

Surface roughness
Reynold's number
Reduced surface roughness
30 "Force Coefficent
Peak Wind Velocity
Section Diameter
35.6 m/s
0.762 m
36 "Force Coefficent
Peak Wind Velocity
Section Diameter
1.40
1.20
1.20
1.00
0.80
0.60
0.40
0.20
1.E+06
Coefficente di forza di base cf0
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
1.E+05
1.E+07
1.E+06
Re
Force Coefficent without free end flow
0.60
0.40
0.20
cF0=
0.8 [-]
II
L=
25 m
D=
0.219 m
l= 570.7763
f=
1
cF0=
0.73 [-]
Category ( ref.I,II,III)
Cylinder lenght
Section Diameter
Slenderness
Solidity ratio
II
L=
D=
l=
f=
25 m
0.762 m
179.772
1
Cylinder lenght
Section Diameter
Slenderness
Solidity ratio
0.80
0.80
0.80
0.40
0.60
0.40
0.20
0.20
0.00
1.E+00
0.00
1.E+00
1.E+02
Snellezza equivalente
Slenderness coefficent
Coefficente di snellezza
1.00
1.00
0.60
3.Force Coefficent
cf=
0.8
Force Coefficent
0.76 [-]
II
L=
25 m
D=
0.914 m
l= 143.9595
f=
1
0.40
0.20
1.E+01
0.00
1.E+00
1.E+02
1.E+01
1.E+02
yl=
3.Force Coefficent
Force Coefficent
cF0=
0.60
yl=
1.E+07
2.Slenderness coefficent
Ref. UK National ANNEX
1.00
1.E+01
1.E+06
Re
Cylinder lenght
Section Diameter
Slenderness
Solidity ratio
0.80
Re
35.6 m/s
0.914 m
1.00
0.00
1.E+05
1.E+07
vp=
D=
n= 1.50E-05 m2/s
k=
0.2 mm
Re= 2.17E+06 [-]
k/D= 2.19E-04 [-]

Surface roughness
Reynold's number
1.40
0.00
1.E+05
vp=
D=
n= 1.50E-05 m2/s
k=
0.2 mm
Re= 1.81E+06 [-]
k/D= 2.62E-04 [-]

Surface roughness
Reynold's number
vp=
D=
yl=
cf=
0.76
3.Force Coefficent
cf=
0.73
Force Coefficent
Figure 40 force coefficient
To be Safe the force coefficient is considered to be 0.8 for each structural pipe
diameters. For Service Piping a Force Coefficient equal to 1.0 is taken in account while is 1.3
for ladder
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Alireza Ghalamkari
Structural factor
According to Eurocode, the structural factor is 1.0.
Figure 41 structural factor
Wind load on ITEM F4302

Zcalc
v(z)
[m]
[m/s]
0.30
1.50
2.70
3.90
5.10
6.70
6.81
7.91
9.00
10.10
10.73
11.35
11.98
12.60
13.23
13.85
14.48
15.10
15.73
16.35
16.98
17.60
18.23
18.85
19.48
20.10
20.44
20.79
21.13
21.48
21.82
22.10
22.85
23.60
24.35
25.10
2.000
2.000
2.700
3.900
5.100
6.700
6.810
7.907
9.003
10.100
10.725
11.350
11.975
12.600
13.225
13.850
14.475
15.100
15.725
16.350
16.975
17.600
18.225
18.850
19.475
20.100
20.444
20.788
21.132
21.476
21.820
22.100
22.850
23.600
24.350
25.100
18.08
18.08
19.55
21.36
22.67
24.01
24.09
24.82
25.46
26.02
26.32
26.59
26.86
27.11
27.34
27.57
27.79
27.99
28.19
28.38
28.57
28.74
28.91
29.08
29.24
29.39
29.48
29.56
29.64
29.72
29.80
29.86
30.02
30.18
30.33
30.48
Iv(z)
0.27
0.27
0.25
0.23
0.22
0.20
0.20
0.20
0.19
0.19
0.19
0.18
0.18
0.18
0.18
0.18
0.18
0.18
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.16
0.16
0.16
0.16
0.16
0.16
0.16
LADDER
SERVICE PIPE
TOTAL
qp
CF
cscd
CF
cscd
A/L
CF
cscd
[N/m^2]
[-]
[-]
[m]
[N/m)
[-]
[-]
[m]
[N/m)
[-]
[-]
[m]
[N/m)
[N/m]
592.18
592.18
658.33
743.08
807.47
875.18
879.30
917.37
951.03
981.24
997.18
1012.32
1026.73
1040.49
1053.66
1066.28
1078.40
1090.07
1101.32
1112.17
1122.66
1132.81
1142.64
1152.18
1161.44
1170.43
1175.28
1180.05
1184.75
1189.39
1193.96
1197.62
1207.26
1216.61
1225.70
1234.54
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
0.80
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.914
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.762
0.219
0.219
0.219
0.219
433.19
433.19
481.58
543.58
590.68
640.21
643.22
671.07
695.70
717.80
729.46
740.53
750.75
760.81
770.43
650.00
657.40
664.51
671.36
677.98
684.37
690.56
696.55
702.37
708.01
713.49
716.45
719.36
722.23
725.05
727.84
730.07
211.61
213.25
214.84
216.39
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.30
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
0.143
109.98
109.98
122.26
138.00
149.96
162.53
163.48
165.26
171.52
177.14
182.23
182.23
185.81
189.17
191.61
194.16
196.60
198.93
200.72
202.44
204.53
206.55
208.49
210.38
212.20
213.98
215.70
217.37
218.67
219.94
220.94
222.42
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
0.000
0.000
0.000
0.000
0.000
0.000
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.260
0.00
0.00
0.00
0.00
0.00
0.00
228.87
231.36
240.13
247.99
255.12
255.12
260.13
264.84
268.26
271.82
275.24
278.51
281.00
283.42
286.34
289.16
291.89
294.53
297.09
299.57
301.97
304.31
306.14
307.92
309.32
311.38
543.17
543.17
603.85
681.58
740.64
802.75
1035.57
1067.70
1107.36
1142.93
1166.81
1177.88
1196.69
1214.82
1230.30
1115.99
1129.23
1141.95
1153.08
1163.84
1175.25
1186.27
1196.94
1207.28
1217.30
1227.04
1234.12
1241.04
1247.03
1252.92
1258.10
1263.87
211.61
213.25
214.84
216.39
25.00
20.00
15.00
Height [m]
SKIRT+RISER
Z
[m]
10.00
5.00
0.00
0
200
400
600
800
1000
1200
1400
Force N/m]
Figure 42 load distribution along Bigger flare
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Alireza Ghalamkari
Wind load on ITEM F4301

Zcalc
v(z)
[m]
[m/s]
0.30
1.50
2.70
3.90
5.10
6.70
6.81
7.91
9.00
10.10
10.73
11.35
11.98
12.60
13.23
13.85
14.48
15.10
15.73
16.35
16.98
17.60
18.23
18.85
19.48
20.10
20.44
20.79
21.13
21.48
21.82
22.10
22.85
23.60
24.35
25.10
2.000
2.000
2.700
3.900
5.100
6.700
6.810
7.907
9.003
10.100
10.725
11.350
11.975
12.600
13.225
13.850
14.475
15.100
15.725
16.350
16.975
17.600
18.225
18.850
19.475
20.100
20.444
20.788
21.132
21.476
21.820
22.100
22.850
23.600
24.350
25.100
18.08
18.08
19.55
21.36
22.67
24.01
24.09
24.82
25.46
26.02
26.32
26.59
26.86
27.11
27.34
27.57
27.79
27.99
28.19
28.38
28.57
28.74
28.91
29.08
29.24
29.39
29.48
29.56
29.64
29.72
29.80
29.86
30.02
30.18
30.33
30.48
Iv(z)
0.27
0.27
0.25
0.23
0.22
0.20
0.20
0.20
0.19
0.19
0.19
0.18
0.18
0.18
0.18
0.18
0.18
0.18
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.17
0.16
0.16
0.16
0.16
0.16
0.16
0.16
qp
CF
cscd
[N/m^2]
[-]
[-]
[m]
[N/m)
592.18
592.18
658.33
743.08
807.47
875.18
879.30
917.37
951.03
981.24
997.18
1012.32
1026.73
1040.49
1053.66
1066.28
1078.40
1090.07
1101.32
1112.17
1122.66
1132.81
1142.64
1152.18
1161.44
1170.43
1175.28
1180.05
1184.75
1189.39
1193.96
1197.62
1207.26
1216.61
1225.70
1234.54
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
0.8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
0.219
103.75
103.75
115.34
130.19
141.47
153.33
154.05
160.72
166.62
171.91
174.71
177.36
179.88
182.29
184.60
186.81
188.94
190.98
192.95
194.85
196.69
198.47
200.19
201.86
203.48
205.06
205.91
206.74
207.57
208.38
209.18
209.82
211.51
213.15
214.74
216.29
Profilo delle pressioni

25.00
20.00
15.00
Height [m]
Z
[m]
10.00
5.00
0.00
0
200
400
600
800
1000
1200
1400
Force [N/m]
Figure 43 load distribution along smaller flare
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Alireza Ghalamkari
Figure 44 wind load distribution
3.1.2.5 Thermal Load
Since both flares are free at the end and they can be elongated, thermal load is not
applicable.
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Alireza Ghalamkari
3.1.2.6 Seismic Load
he l e
hee , he e m l
ppl
ble
be
ered
for the region that the flare system will be installed. Also as a rule of thumb for flare system
are relatively light with respect to the height and geometry, wind load is usually the
predominant load.
3.1.2.7 Load combinations
Load combination is divided in to two main categories

1. Serviceability: in this load combination the maximum displacement of the flare
system is important. The factor for all load case will be equal to 1 and we will
compare the maximum displacement with the allowable displacement that is
defined in API-537 as already explained.
2. Ultimate state: in these categories several load combination will be defined and the
maximum stress that is produced in the system will be studied and it should be
lower than the allowable stress defined by the code.
The load combinations are defined in compliance with Euro code.
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Alireza Ghalamkari
Figure 45 load combinations
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Alireza Ghalamkari
Conclusion
4.1
Result
4.1.1 Compatibility
As described before, to be sure that both models are compatible and modeled with the
same geometry and input data, similar result for the maximum displacement also maximum
shear and also the weight of the system are expected. The results are shown below.
Figure 46 Lateral deflection comparison
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Alireza Ghalamkari
Figure 47 Shear Force comparison
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Alireza Ghalamkari
Figure 48 total weight comparison
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Alireza Ghalamkari
As it has been shown, there is a very small difference between the output quantities of
MIDAS comparing to output of PV-Elite and almost the same result are obtained from both
software.
It can be concluded that our verification is correct and obtained reaction forces at the
base of the each flare are reasonable. As it was expected the shear load at the base of smaller
flare is very low (about 1KN), because the loads are already transferred to the bigger flare by
means of the guide support.
The next step is to check the stress along the risers to see if the selected thickness is
adequate.
If the stresses induced due to the load combination are lower than the allowable
stress, the assumed thicknesses are applicable.
After finding the correct value for the thickness, the reaction force at the base can be
collected (vertical load, shear, overturning moment) and anchor bolt can be designed.
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Alireza Ghalamkari
4.1.2
Stress check
The stresses due to the other three load cases provided in MIDAS software shall be
lower than allowable stress. The allowable stress according to ASME Code for the selected
material at designed temperature is 117 Mpa. The following figures depict the maximum
envelope beam diagrams and the maximum enveloped beam stress
Figure 49 beam diagram
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Alireza Ghalamkari
Figure 50 stress distribution
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Alireza Ghalamkari
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Alireza Ghalamkari
Figure 51 Steel checks
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Alireza Ghalamkari
As mentioned before to take in to account the internal pressure and also to perform
the checks according to ASME VIII Div.1. it is important to review the result of the PV-Elite
software too.
For both flare systems as a sample the result for an element with the larger required
thickness due to internal pressure are demonstrated.
Figure 52 Internal Pressure Calculation for bigger flare (F-4302)
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Alireza Ghalamkari
Figure 3-8 Internal Pressure Calculation for smaller flare (F-4301)
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Alireza Ghalamkari
Since the bigger Flare system works as the support for the smaller one, the last
important check for this flare is to study the result of load combinations generated by PVElite software and to check if the stress ratio is lower than 1 for each load combination. Here
only two load combination are demonstrated as a sample, which one of them is the most
critical load combination with the stress ratio of 0.75., thus it can be concluded that all
selected thickness are adequate
Figure 53 stress combination for bigger flare (F-4302)
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Alireza Ghalamkari
4.1.3
Vortex Shedding
VORTEX SHEDDING EVALUATION AS EUROCODE FOR CIRCULAR SECTION
Material Data
g=
E=
x=
Specific Weight
Young Modulus
Damping ratio
Section Data
External Diameter
tickness
Internal diameter
De=
t=
Di=
7850 kg/m3
210000 Mpa
0.01
762 mm
8.11 mm
745.78 mm
19208 mm2
Area
A=
Flexural inertia moment

Linear mass density
I= 1364755784 mm4
g=
150.78 kg/m
Global Data
Total lenght
Restraint to the 0 lenght
Restraint to the L lenght
L=
Dynamics characteristics
Number of mode (just for simply supported beam)
Natural Frequency
Modal linear mass
n=
f1=
m1=
21.2
fixed
free
1
1.73 Hz
96.50 kg/m
Vortex shadding Characteristic parameters

Reference wind velocity at the inspected height
v m=
Strouhal number
St=
Critical velocity for resonance vortex shadding
vcr=
NECESSARY DETAILED ANALYSIS
Scrouton Number
Sc=
VORTEX SHADDING ACTION SHALL BE EVALUATED
Reynold number
Re=
42
m/s
0.2
6.576 m/s
16.7
3.3E+05
Calculation of cross wind displacement amplitude (Spectral Method)
Costant related to the cross section
Cc=
0.01
CI costant
CI=
0.90542119
Ka,max=
ka=
aL=
2
1.81084238
0.4
Aerodynamic damping parameter maximum

Aerodynamic damping parameter
Narmalised limiting amplitude
Constant c1
c1= 0.021262194
Constant C2
c2=
Amplitude standard deviation
sy =
Peak Factor Evaluation
Kp=
Maximum displacement
yp=
1.4929E-06
157.20 mm
4.18
656.79 mm
Figure 54 vortex shedding check
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Alireza Ghalamkari
The analysis shows that the amplitude of displacement is unacceptable. For this
reason an Aerodynamic
Methods is used to mitigate the vortex shedding is used.
Prevention of excessive vibration as per ASME STS-1-2000
To mitigate the vibration effect an Aerodynamic method was used in a way to disrupt
the formation of Vortices on the sides of the stack and limit the source of vibration.
We use helical strakes as is stated in ASME STS-1-2006 which gives the needed
geometrical information for the helical strakes design.
A three-start set of curved-plate helical strakes 120 degree apart on the stack
circumference is attached to the outer surface of the stack with the strake plate
approximately perpendicular to the stack surface at all points.
The pitch of the helix is five times the aerodynamic diameter and the strake should
pr je
m fr m he
aerodynamic diameter. Strakes of adequate structural thickness is provided on the top

3 f he
k he gh
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Alireza Ghalamkari
Figure 55 Helical stakes
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Alireza Ghalamkari
4.2
Bolt design
The foundation loads are demonstrated below
Figure 56 reaction forces due to single load cases
The calculation of the anchor bolts is done using the allowable loads indicated in client
Specification.
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Alireza Ghalamkari
Figure 57 Allowable loads for anchor bolts
Figure 58 anchor bolts checks according to client specification
From all reactions, the worst ones are selected (highlighted in the figure below), and
used in order to design the anchor bolts.
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Alireza Ghalamkari
Figure 59 envelope of reaction forces used for bolt design
The size and number of the bolts are assumed as the following table.
Item Number
Bolt Size (mm)
No. of anchor Bolts
F-4301
M16
F-4302
M36
12
Table 7 Summary of required bolts
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Alireza Ghalamkari
The following figures illustrate the load calculation and stress check for a single bolt of
bigger flare, according the mentioned size and number of the bolts.
Figure 60Base plate details for bigger flare
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Alireza Ghalamkari
Figure 61 Anchor bolts checks for bigger flare
As it is highlighted in the above, the bolt size or numbers are not sufficient and it the
anchor bolts fail due to tension load according to the formula..
Please note that the above calculation considers the neutral axis of bending moment in
the center of baseplate , which is more conservative. It means only half of the bolts are in
tension, which in reality is not true.
According the below calculation, by searching for the position of the neutral axis, the
exact number of the bolts involved for the tension are demonstrated.
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Alireza Ghalamkari
3.Axial Force Bending interaction diagram
Anchor bolt f36

tensile strenght [kN]
Maximum
tension from
plate and grout
4.Anchor bolts check

Total shear action on the base
Shear resistance of the anchor bolt (from the table)
Total number of bolts
Design shear on the worst anchor bolt
Shear Work ratio
MINOR THAN 30% PASSED!
3.Plate check
Plate thickness
As it can
be seen,8 anchor bolts are
Maximum distance from the restraint
bolt distance from the restraint
and number ofAnchor
anchor
bolts are adequate.
Maximum action from bolt
Bending action
Bendig resistance
Ratio between action and resistance
V=
Fv,rd=
n=
Fv,Ed=
r=
t=
65 kN
114.2 kN
12
5.42 kN
0.05
35 mm
involved for resistance of tension,,

thus the size
c= 112.962 mm
d=
48 mm
Ft= 81.33333 kN
Msd=
3.90 kN m
Mrd=
7.35 kN m
r=
0.53
PASSED!
4.Gusset check
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External plate diameter

External shell riser diameter
Number
luglio
2014 of gusset
Tickness
Lenght
Height
1150 mm
914 mm
24
15 mm
118 mm
180 mm
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Alireza Ghalamkari
The following figures depict the load calculation and stress check for a single bolt of
smaller flare, according the mentioned size and number of the bolts.
Figure 62 Baseplate details for smaller flare
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Alireza Ghalamkari
Figure 63 anchor bolts checks for smaller flare
The anchor bolts checks are passed by the first formula, therefore there is no need for further
investigation of exact position of neutral axis.
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Alireza Ghalamkari
Finally the designed data are reported as:

Smaller Flare (Item No. F-4301)
Section
Material
Diameter
Thickness
(in.)
(mm)
Skirt
API 5L Gr.B
12.7
Riser
API 5L Gr.B
12.7
Tip
AISI 310
10
10
Larger Flare (Item No. F-4302)

Skirt
API 5L Gr.B
36
12.7
Riser
API 5L Gr.B
36
12.7
Riser
API 5L Gr.B
30
12.7
Tip
AISI 310
10
Item Number
Bolt Size (mm)
No. of anchor Bolts
F-4301
M16
F-4302
M36
12
Table 8 Designed data
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Alireza Ghalamkari
Reference
1. Mattews, Clifford. E g eer Gu
Pre ure Equ pme
: Pr fe
Engineering Publishing 2001.

2. Chattapadhyay, Somnath. Pressure Vessel Design and Practice. CRC Press 2005.
3. Carruci, Vincent A. Overview of Pressure Vessel Design 1991
4. ASME, The American Society of Mechanical Engineers. Rules for Construction of
Pressure Vessels (Sec. VIII, Div. 1). ASME Boiler and Pressure Vessel Code. 2007
5. Ellenberger, J. Philip, Chuse, Robert and Carson, Bryce E. Pressure Vessel: The
ASME Code Simplified 8th Edition. McGraw-Hill 2004
6. Moen, Richard A. Practical Guidebook Series ASME Section II 1997, CASTI
Publishing 1996
7. Perry, R. H. and Chilton, C. H Perry Chem
l E g eer H
k M Gr w-
Hill, 1973
8. Bringas, John E. The Metal Black Book, CASTI Publishing 1996
9. White, R. H., and Ehauke, E.F. Materials Selection for Refineries and Assocoated
Facilities. McGraw-Hill, 1973
10. Bednar, Henry H. Pressure Vessel Design Handbook 2nd Edition Malabar
Florida: Krieger Publishing Company, 1986
11. Moss, Dennis, R. Pressure Vessel Design Manual, 3rd Edition, Burlington: Gulf
Professional Engineering 2004.
12. ASME, The American Society of Mechanical Engineers. Rules for Construction of
Pressure Vessels (Sec. VIII, Div. 2). ASME Boiler and Pressure Vessel Code. 2007
13. COAD, Engineering Physics Software. 2007 PV-Elite User Guide. Huston, Texas:
COAD/Engineering Physics Software 2007
14. Megyesy, Eugene F. Pressure Vessel Handbook 10th Edition. Pressure Vessel
Handbook Publishing Inc.,2001.
15. Venstel, Eduard And Krauthammer, Theodor. Thin Plate And Shells, Theory,
Analysis And Applications. New York : Marcel Decker, Inc 2001.
16. Steffens, Franz-Joseph Barthold And Alexander. Introductory Course In
Structural Analysis.
787671 | | luglio 2014
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Alireza Ghalamkari
17. Timoshenko, Stephen P. And Woinowsky-Krieger, S. Theory Of Plates And Shells.

2nd Edition. LA: Mc-GrawHill,1975
18. Jawad, Maan H. And Farr, James R. Structural Analysis And Design Of Process
Equipment. John Wile & Sons, Inc 1984
19. UBC, Uniform Building Code. Structural Design Requirements (Chapter 16)
Uniform Building Code. 1997
20. Moody, G.b., Mechanical design of tall stacks, September 1969
21. A.Keith Escoe. Mechanical Design of Process Systems Vol 1, Piping and Pressure
vessels. Gulf Publishing Company 1986
22. A.keith Escoe. Pressure Vessel and Stacks, Field Repair Manual. 2008
23. API Standard 537 . Flare Details for General Refinery and Petrochemical Service
. 2003
24. Steel Stacks The American Society of Mechanical Engineers ASME STS-1 2006
25. http://www.wikipeida.com/
26. http://www.tanootas.com/project/view/id/163
787671 | | luglio 2014
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Coupled Flare System Design

Supervisor of Politecnico di Milano:

Full Prof. Angelo Onorati

Supervisor of ThermoEngineering Co.:

Eng. Chiara Ferlini

FLARE EQUIPMENT FOR GENERAL SERVICE ...................................................................................................... 9

Flare system in industrial plants ............................................................................................................... 11

Types of flares ................................................................................................................................................... 13

Vertical Flare ..................................................................................................................................................... 13

Enclosed Flame Flares ................................................................................................................................... 22

Single-point and Multi-burner ................................................................................................................... 23

Smokeless and Non-smokeless Flares ................................................................................................... 25

Flares as a pressure vessel........................................................................................................................... 26

Pressure equipment Types and components ..................................................................................... 26

Flare component .............................................................................................................................................. 36

ASME Code ......................................................................................................................................................... 38

Pressure vessel Designing Software packages ................................................................................... 52

The Aim of the thesis ................................................................................................................................. 56

Flare System Design ................................................................................................................................... 58

Loading Data ...................................................................................................................................................... 61

Vortex Shedding ............................................................................................................................................... 88

Bolt design .......................................................................................................................................................... 91

Reference .................................................................................................................................................... 100

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Figure 31 Service piping orientation ................................................................................................ 62

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Figure 63 anchor bolts checks for smaller flare ........................................................................... 98

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FLARE EQUIPMENT FOR GENERAL SERVICE

Figure 1 Flare in Asaluyeh (Iran) South Pars phase 6-7-8

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Reduce ground level concentrations of hazardous materials.

Provide the safe disposal of flammable materials.

Reduce volatile organic compound (VOC) and hydro-carbon emissions.

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Flare system in industrial plants

Figure 2 Schematic flow diagram of an overall vertical, elevated flare system.

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under the following major categories:

Enclosed flame Flares

Multi burner staged flares

Smokeless and Non smokeless

1.2.1 Vertical Flare

1.2.1.1 Self Supported

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Figure 3 Self Supported Flare

Figure 4 schematic model of self supported flare against lateral load

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The displacement d of the system from the beam theory is

inertia moment of the transversal section

Consider a maximum allowed top displacement of H/150 by the previous formula it is

The moment of inertia for a thin circular hollow section is approximated by

That means (with H in meter)

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The following graph shows the trend thickness required

Figure 5 trend of the thickness vs the stack height

1.2.1.2 Guy wired supported

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Figure 6 Guyed wire supported Flare