Design of Pressure Vessels PDF

DESIGN AND ANALYSIS OF
PRESSURE VESSEL
BY
JIMIT VYAS AND MAHAVIR SOLANKI
GUIDED BY : MR BHAVESH PATEL
UVPATELCOLLEGEOFENGINEERING
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ACKNOWLEDGEMENT
Certainly, help and encouragement from others are always appreciated, but in
different times, such magnanimity is valued even more. This said, this
Dissertation would never have been completed without the generous help and
support that I received from numerous people along the way.
I wish to express my deepest thanks and gratitude to my elite guide Mr Bhavesh

P Patel, Mechanical Engineering Dept., U.V. Patel College of Engg., Mehsana, for
his invaluable guidance and advice, without that the Dissertation would not
have appear in present shape. He also motivated me at every moment during
entire dissertation.
I also hearty thankful and express deep sense of gratitude to Mr. Bhavesh
Prajapati, senior manager at GMM Pflauder, for giving opportunity to undertake
a dissertation in the industry and furnishing the details and help.
Special thanks to Mr. Ankit Prajapati, Design Engineer, at GMM Pflauder, for
his keen interest and guidance in carrying out the work.
I wish to thank the principal Dr. J. L. Juneja and all the staff members of
Mechatronics & Mechanical Dept., U. V. Patel College of Engg., especially to ,
Prof. J. M. Prajapati, Prof. J. P. Patel, Prof. V. B. Patel, for their co-operation,
guidance and support during the work.
Jimit Vyas & Mahavir Solanki
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ASTRACT
The significance of the title of the project comes to front with designing structure of the
pressure vessel for static loading and its assessment by Ansys , is basically a project
concerned with design of different pressure vessel elements such as shell, Dish end
,operating manhole ,support leg based on standards and codes ; and evolution of shell and
dish end analysed by means of ansys .The key feature included in the project is to check
the behaviour of pressure vessel in case of fluctuating load .The [procedural step includes
various aspects such as selecting the material based on ASME codes ,and then designing
on the standards procedures with referring standard manuals based on ASME .Further we
have included the different manufacturing methods practice by the industries and
different aspects of it . And step by step approaches to the NTD method practice by the
industries followed with standards and also included within the report work. This will be
making
clear
picture
this
method
among
the
reader
conclusively, this modus operandi of design based on technical standard and

codes ., can be employed on practical design of pressure vessel as per required by the
industry or the problem statement given associated to the field of pressure vessel.
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INTRODUTION:
The pressure vessels (i.e. cylinder or tanks) are used to store fluids under pressure. The
fluid being stored may undergo a change of state inside the pressure vessel as in case of
steam boilers or it may combine with other reagents as in a chemical plant. The pressure
vessels are designed with great care because rupture of pressure vessels means an explosion
which may cause loss of life and property. The material of pressure vessels may be brittle
such that cast iron or ductile such as mild steel.
Cylindrical or spherical pressure vessels (e.g., hydraulic cylinders, gun barrels, pipes,
boilers and tanks) are commonly used in industry to carry both liquids and gases under
pressure. When the pressure vessel is exposed to this pressure, the material comprising the
vessel is subjected to pressure loading, and hence stresses, from all directions. The normal
stresses resulting from this pressure are functions of the radius of the element under
consideration, the shape of the pressure vessel (i.e., open ended cylinder, closed end cylinder,
or sphere) as well as the applied pressure.
Two types of analysis are commonly applied to pressure vessels. The most
common method is based on a simple mechanics approach and is applicable to thin wall
pressure vessels which by definition have a ratio of inner radius, r, to wall thickness, t, of
r/t10. The second method is based on elasticity solution and is always applicable regardless
of the r/t ratio and can be referred to as the solution for thick wall pressure vessels. Both
types of analysis are discussed here, although for most engineering applications, the thin wall
pressure vessel can be used.
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Classification of Pressure Vessels
Unfired Cylindrical Pressure Vessels

(Classification Based on IS 2825-1969)
a) Class 1 :
Vessels that are to contain lethal or toxic substances.
Vessels designed for the operation below -20 C and
Vessels intended for any other operation not stipulated in the code.
b) Class 2:
vessels which do not fall in the scope of clas1 and class 3 are to be termed as
class2 vessels. The maximum thickness of shell is limited to 38 mm.
c) class 3:
there are vessels for relatively light duties having plate thickness not in excess of
16 mm,
and they are built for working pressures at temperatures not exceeding 250 c and
unfired .
class3 vessels are not recommended for services at temperatutre below 0c.
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Categories Of Welded Joints
The term categories specifies the location of the joint in a vessels, but not the
type of joint. These categories are intended for specifying the special requirements
regarding the joint type and degree of inspection. IS-2825 specifies 4 categories of welds.
(Refer fig.)
a) category A: longitudinal welded joints within the main sheet, communicating

chambers ,nozzles and any welded joints within a formed or flat head.
b) Category B: circumferential welded joints with in the main shell, communicating
chambers, nozzles and transitions in diameter including joints between the
transtations and a cylinder at either the large of small end, circumferential welded
joints connecting from heads to main shells to nozzles and to communicating
chambers.
c) Category c: welded joints connecting flanges, tubes sheets and flat heads to main
shells , to formed heads , to nozzles or to communicating chambers and any
welded joints connecting one side plate to another side plate of a flat sided vessel.
d) Category d: welded joints connecting communicating chambers or nozzles to
main sheels ,to heads and to flat sided vessels and those joints connecting nozzles
to communicating chambers.
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STRESS
Types of Stresses
Tensile
Compressive
Shear
Bending
Bearing
Axial
Discontinuity
Membrane
Tensile
Principal
Thermal
Tangential
Load induced
Strain induced
Circumferential
Longitudinal
Radial
Normal
Classes of stress
Primary Stress
General:
Primary general membrane stress Pm
Primary general bending stress Pb
Primary local stress, PL
Secondary stress:
Secondary membrane stress. Qm
Secondary bending stress Qb
Peak stress. F
Definition and Examples

PRIMARY GENERAL STRESS:
These stress act over a full cross section of the vessel. Primary stress are
generally due to internal or external pressure or produced by sustained external
forces and moments. Primary general stress are divided into membrane and
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bending stresses. Calculated value of a primary bending stress may be allowed to
go higher than that of a primary membrane stress.
Primary general membrane stress, Pm
Circumferential and longitudinal stress due to pressure.
Compressive and tensile axial stresses due to wind.
Longitudinal stress due to the bending of the horizontal vessel over the saddles.
Membrane stress in the centre of the flat head.
Membrane stress in the nozzle wall within the area of reinforcement due to
pressure or external loads.
Axial compression due to weight.
Primary general bending stress, Pb
Bending stress in the centre of a flat head or crown of a dished head.
Bending stress in a shallow conical head.
Bending stress in the ligaments of closely spaced openings.
LOCAL PRIMARY MEMBRANE STESS, PL

Pm+ membrane stress at local discontinuities:
Head-shell juncture
Cone-cylinder juncture
Nozzle-shell juncture
Shell-flange juncture
Head-skirt juncture
Shell-stiffening ring juncture
Pm+ membrane stresses from local sustained loads:
Support legs
Nozzle loads
Beam supports
Major attachments
SECONDARY STRESS
Secondary membrane stress Qm
Axial stress at the juncture of a flange and the hub of the flange
Thermal stresses.
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Membrane stress in the knuckle area of the head.
Membrane stress due to local relenting loads.
Secondary bending stress, Qb
Bending stress at the gross structural discontinuity: nozzle, lugs, etc., (relenting
loadings only).
The nonuniform portion of the stress distribution in a thick-walled vessels due to
internal pressure.
The stress variation of the radial stress due to internal pressure in thick-walled
vessels.
Discontinuity stresses at stiffening or support ring.
Peak Stress F
Stress at the corner of discontinuity.
Thermal stress in a wall caused by a sudden change in the surface temperature.
Thermal stresses in cladding or weld overlay.
Stress due to notch effect. (stress concentration).
LOADINGS
Loadings or forces are the causes of stress in pressure vessels. Loadings may be
applied over a large portion (general area) of the vessel or over a local area of the
vessel. General and local loads can produce membrane and bending stresses.
These stresses are additive and define the overall state of stress in the vessel or
component.
The stresses applied more or less continuously and uniformly across an entire
section of the vessel are primary stresses.
The stresses due to pressure and wind are primary membrane stresses.
O the other hand, the stresses from the inward radial load could be either a
primary local stress or secondary stress. It is primary local stress if it is produced
from an unrelenting load or a secondary stress if produced by a relenting load.
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If it is a primary stress, the stress will be redistributed; if it is a secondary stress,
the load will relax once slight deformation occurs.
Basically each combination of stresses ( stress categories will have different
allowables, i.e.,
Primary stress: Pm < SE
Primary membrane local (PL):
PL=Pm+ PL <1.5 SE
PL=Pm+Qm< 1.5SE
Primary membrane + secondary (Q):
Pm+Q< 3SE
Loading can be outlined as follows:
Categories of loadings
General loadsApplied more or less continuously across a vessel section.
Pressure loadsInternal or external pressure (design, operating,
hydrotest, and hydrostatic head of liquid).
Moment loadsDue to wind, seismic, erection, transportation.
Compressive/tensile
loadsDue
to
dead
weight,
installed
equipment, ladders, platforms, piping and vessel contents.

Thermal loadsHot box design of skirt-head attachment.
Local loadsDue to reactions from supports, internal, attached
Piping, attached equipment, i.e., platforms, mixers, etc.
a. Radial loadInward or Outward.
b. Shear loadLongitudinal or circumferential.
c. Torsional load.
d. Tangential load.
e. Moment loadLongitudinal or circumferential.
f. Thermal load.
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Types of Loadings
1) Steady loadsLong-term duration, continuous.
a. Internal/external
pressure.
b. Dead weight.
c. Vessel contents.
d. Loading due to attached
piping and equipment.
e. Loadings to and from vessel
supports.
f. Thermal loads.
g. Wind Loads
Types of Loadings
1) Non-steady loads- Short-term duration, Variable.
Shop and field hydro-test
Earthquake
Erection
Transportation
Upset, emergency
Thermal Loads
Startup, shut down
FAILURE IN PRESSURE VESSELS

Categories of Failures:
Material--Improper Selection of materials; defects in material.
DesignIncorrect design data; inaccurate or incorrect design methods;
inadequate shop testing.
Fabrication Poor quality control; improper or insufficient fabrication procedures
including welding; heat treatment or forming methods.
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ServiceChange of service condition by the user; inexperienced operations or
maintenance personnel; upset conditions. Some types of services which requires
special attention both for selection of materials, design details, and fabrication
methods are as follows:
Lethal
Fatigue (cyclic)
Brittle (low temperature)
High Temperature
High shock or vibration
Vessel contents
Hydrogen
Ammonia
Compressed air
Caustic
Chlorides
TYPES OF FAILURES
Elastic deformationElastic instability or elastic buckling, vessel geometry, and
stiffness as well as properties of materials are protecting against buckling.
Brittle fractureCan occur at low or intermediate temperature. Brittle fractures
have occurred in vessels made of low carbon steel in the 40-50 F range during
hydrotest where minor flaws exist.
Excessive plastic deformationThe primary and secondary stress limits as
outlined in ASME Section VIII, Division 2, are intended to prevent excessive
plastic deformation and incremental collapse.
Stress ruptureCreep deformation as a result of fatigue or cyclic loading, i.e.,
progressive fracture. Creep is a time-dependent phenomenon, whereas fatigue is a
cyclic-dependent phenomenon
o TYPES OF FAILURES
o
Plastic instabilityIncremental collapse; incremental collapse is cyclic strain

accumulation or cumulative cyclic deformation. Cumulative damage leads to
instability of vessel by plastic deformation.
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High StrainLow cyclic fatigue is strain-governed and occurs mainly in lowerstrength/high-ductile materials.
Stress corrosionIt is well know that chlorides cause stress corrosion cracking in
stainless steels; likewise caustic service can cause stress corrosion cracking in
carbon steel. Materials selection is critical in these services.
Corrosion
fatigueOccurs
when
corrosive
and
fatigue
effects
occur
simultaneously. Corrosion can reduce fatigue life by pitting the surface and
propagating cracks. Material selection and fatigue properties are the major
considerations.
SPECIAL PROBLEMS
Thick Walled Pressure Vessels
Mono-bloc- Solid vessel wall.

MultilayerBegins with a core about in. thick and successive layers are
applied. Each layer is vented (except the core) and welded individually with no
overlapping welds.
Multi-wallBegins with a core about in. to 2 in. thick. Outer layers about the
same thickness are successive shrunk fit over the core. This creates
compressive stress in the core, which is relaxed during pressurization. The process
of compressing layers is called auto-frettage from the French word meaning selfhooping.
Multilayer auto-frettageBegins with a core about in. thick. Bands or forged
rings are slipped outside and then the core is expanded hydraulically. The core is
stressed into plastic range but below ultimate strength. The outer
rings are
maintained at a margin below yield strength. The elastic deformation residual in

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the outer bands induces compressive stress in the core, which is relaxed during
pressurization.
Wire wrapped vessels: Begin with inner core of thickness less than required for
pressure. Core is wrapped with steel cables in tension until the desired autofrettage is achieved.
Coil wrapped vessels: Begin with a core that is subsequently wrapped or coiled
with a thin steel sheet until the desired thickness is obtained. Only two
longitudinal welds are used, one attaching the sheet to the core and the final
closures weld. Vessels 5 to 6 ft in diameter for pressure up to 5000psi have been
made in this manner.
THERMAL STRESS
Whenever the expansion or contraction that would occur normally as a result of
heating or cooling an object is prevented, thermal stresses are developed. The
stress is always caused by some form of mechanical restrain.
Thermal stresses are secondary stresses because they are self-limiting. Thermal
stresses will not cause failure by rupture. They can however, cause failure due to
excessive deformations.
DISCONTINUITY STRESSES
Vessel sections of different thickness, material, diameter and change in directions
would all have different displacements if allowed to expand freely. However, since they
are connected in a continuous structure, they must deflect and rotate together. The
stresses in the respective parts at or near the juncture are called discontinuity stresses.
Discontinuity stresses are secondary stresses and are self-limiting.
Discontinuity stresses do become an important factor in fatigue design where
cyclic loading is a consideration.
FATIGUE ANALYSIS
When a vessel is subject to repeated loading that could cause failure by the
development of a progressive fracture, the vessel is in cyclic service.
Fatigue analysis can also be a result of thermal vibrations as well as other
loadings.
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In fatigue service the localized stresses at abrupt changes in section, such as at a
head junction or nozzle opening, misalignment, defects in construction, and
thermal gradients are the significant stresses.
NOZZLE REINFORCEMENT
Fig : nozzle reinforcement

Limits.
a. No reinforcement other than that inherent in the construction is required for
nozzles.
3-in. pipe size and smaller in vessel walls 3/8 in. and less.
2-in. pipe size and smaller in vessel walls greater than 3/8 in.
b.
Normal reinforcement methods apply to
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Vessels 60-in. diameter and less-1/2 the vessel diameter but not to exceed 20 in.
Vessels greater than 60-in. diameter-1/3 the vessel
diameter but not to exceed 40.in
a. 1b, reinforcement shall be in accordance with para. 1-7 of ASME Code.
2. Strength
It is advisable but not mandatory for reinforcing pad material to be the same as the
vessel material.
a. If a higher strength material is used, either in the pad or in the nozzle neck, no
additional credit may be taken for the higher strength.
3. Thickness
It is recommended that pad be not less then 75% nor more than 150% of the part to
which they are attached.
4. Width
While no minimum is stated, it is recommended that re-pads be atleast 2in wide.
5. Forming:
Reinforcing pads should be formed as closely to the contour of the vessel as
possible. While normally put on the outside of the vessel, re-pads can also be put
inside providing they do not interfere with the vessels operation.
8. Openings in flat heads:
Reinforcements for the openings in the flats heads and blind flanges shall be as
follows
a. Openings < head diameter- area to be replaced equals 0.5(tr), or thickness of
head or flange may be increased by:
Doubling C value
Using C=0.75
Increasing head thickness by 1.414
b. Openings>1/2 head diameter shall be designed as a bolted flange connection.
9. Openings in torispherical heads.
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When a nozzle openings and all its reinforcement fall within the dished portion,
the required thickness of head for reinforcement purpose shall be computed using
M=1
10. Openings in elliptical heads
When a nozzle openings and all its reinforcement fall within 0.8 D of an elliptical
head, the required thickness of the head for reinforcement purpose shall be equal to the
thickness required for a seamless sphere of radius K(D).
11. General
Reinforcement should be calculated in the corroded condition assuming maximum
tolerance (minimum t)
12. Openings through seams.
a.
Openings that have been reinforcement may located in a welded joint. ASME
code, division 1, does not allow a welded joint to have two different weld joint
efficiencies
13. Re-pads over seams

If at all possible, pads should not cover weld seams. When unavoidable, the seam
should be ground flush before attaching the pad.
14. Openings near seams
Small nozzles ( for which the code does not require, the reinforcement to be checked)
shall not be located closer than in. to the edge of a main seam.
15. External pressures.
Reinforcement required for openings subject to external pressure only or when
longitudinal compression governs shall only be 50 % of that required for internal pressure
and tr, is thickness required for external pressure
16. Ligaments
When there is a series of closely spaced openings in a vessel shell and it is
impractical to reinforce each opening, the construction
is acceptable, provided the
efficiency of the ligaments between the holes is acceptable.

17. Multiple openings:
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a.
For two openings closer than 2 times the average diameters and where limits of
reinforcement overlap, the area between the openings shall meet the following
1. Must have a combined area equal to the sum of the two areas
2. No portion of the cross-section shall apply to more than one openings.
3. Any overlap area shall be proportional between the two openings by the ratio of
the diameters.
b. When more than two openings are to be provided with combined reinforcement:
17 b.
When more than two openings are to be provided with combined reinforcement:
1.
The minimum distance between the two centers is 1 1/3 the average diameters.
2.
The area of reinforcement between the two nozzle shall be atleast 50% of the area
required for the two openings.

c.
Multiple openings may be reinforced s an opening equal in diameter to that of a
circle circumscribing the multiple openings.

18.
Plane of reinforcement.
A correction factor f may be used for integrally reinforced nozzle to compensate
for differences in stress from longitudinal to circumferential axis of the vessel. Value of f
vary from 1.0 for the longitudinal axis to 0.5 for circumferential.
Page18
CHAPTER 2
ENGINEERING
GUIDELINES
FOR
DESIGN OF PRESSURE VESSELS
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Engineering Design Guidelines For Pressure Vessels
1.0
SCOPE
This specification covers the design basis for following equipment:
- Vessels
- Columns
- Reactors
- Spheres
- Storage Tanks
- Steel silos, Bins. Hoppers
- Steel Flare Stacks
2.0
CODES AND STANDARDS

The following codes and standards shall be followed unless otherwise specified:
ASME SEC. VIII DIV.1 /
For Pressure vessels
IS: 2825
ASME SEC. VIII DIV.2
For Pressure vessels (Selectively for high

pressure / high thickness / critical service)
For Storage Spheres
For Pressure vessels (Selectively for high pressure)
API 650 / IS: 803
For Storage Tanks.
API 620
For Low Pressure Storage Tanks,
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API 620 / BS 7777
Cryogenic Storage Tanks (Double Wall)
ASME SEC. VIIIDIV.1
For workmanship of Vessels not categorized under

any other code.
ISO R831/ IBR
For Steam producing, steam storage catch water

vessels, condensate flash drums and similar vessels
IS: 9178 / DIN 1055
For Silos Hoppers and Bins
BS: 4994 / ASME SEC X
FRP vessels / tanks.`
ASME: B 96.1
Welded Aluminium Alloy Storage Tanks.
ASME SEC.II
For material specification
ASTM / IS
For material specification (Tanks)
IS: 875 / SITE DATA
For wind load consideration
IS: 1893 / SITE DATA
For seismic design consideration
ASME SEC. IX
For welding.
WRC BULLETIN#
107, 297 / PD 5500
3.0
For Local load / stress analysis
DESIGN CRITERIA
Equipment shall be designed in compliance with the latest design code requirements, and
applicable standards/ Specifications.
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4.0
MINIMUM SHELL/HEAD THICKNESS
Minimum thickness shall be as given below

a) For carbon and low alloy steel vessels- 6mm (Including corrosion allowance not
exceeding 3.0mm), but not less than that calculated as per following:
FOR DIAMETERS LESS THAN 2400mm
Wall thickness = Dia/1000 +1.5 + Corrosion Allowance

FOR DIAMETERS 2400mm AND ABOVE
Wall thickness = Dia/1000 +2.5 + Corrosion Allowance
All dimension are in mm.
b) For stainless steel vessel and high alloy vessels -3 mm, but not less than that
calculated as per following for diameter more than 1500mm.
Wall thickness (mm) = Dia/1000 + 2.5
Corrosion Allowance, if any shall be added to minimum thickness.
c) Tangent to Tangent height (H) to Diameter (D) ratio (H/D) greater than 5 shall be
considered as column and designed accordingly.
d) For carbon and low alloy steel columns / towers -8mm (including corrosion allowance
not exceeding 3.0mm.
e) For stainless steel and high alloy columns / towers -5mm.
Corrosion allowance, if any, shall be added to minimum thickness.
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5.0
GENERAL CONSIDERATIONS
5.1
Vessel sizing
All Columns
Based on inside diameter
All Clad/Lined Vessels
Vessels (Thickness>50mm) Based on inside diameter
5.2
All Other Vessels
Based on outside diameter
Tanks & Spheres
Vessel End Closures :
- Unless otherwise specified Deep Torispherical Dished End or 2:1 Ellipsoidal Dished
End as per IS - 4049 shall be used for pressure vessels. Seamless dished end shall be used
for specific services whenever specified by process licensor.
- Hemispherical Ends shall be considered when the thickness of shell exceeds 70mm.
- Flat Covers may be used for atmospheric vessels
- Pipe Caps may be used for vessels diameter < 600mm having no internals.
- Flanged Covers shall be used for Vessels /Columns of Diameter < 900mm having
internals.
- All columns below 900mm shall be provided with intermediate body flanges. Numbers
of Intermediate flanges shall be decided based on column height and type of internals
5.3
Pressure
Pressure for each vessel shall be specified in the following manner:
5.3.1 Operating Pressure

Maximum pressure likely to occur any time during the lifetime of the vessel
5.3.2 Design Pressure

a) When operating pressure is up to 70 Kg./cm2 g , Design pressure shall be equal to
operating pressure plus 10% ( minimum 1Kg./cm2 g ).
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b) When operating pressure is over 70 Kg./cm2 g , Design pressure shall be equal to
operating pressure plus 5% ( minimum 7 Kg./cm2g).
c) Design pressure calculated above shall be at the top of vertical vessel or at the highest
point of horizontal vessel.
d) The design pressure at any lower point is to be determined by adding the maximum
operating liquid head and any pressure gradient within the vessel.
e) Vessels operating under vacuum / partial vacuum shall be designed for an external
pressure of 1.055 Kg./cm2 g.
f) Vessels shall be designed for steam out conditions if specified on process data sheet.
5.3.3 Test Pressure

a) Pressure Vessels shall be hydrostatically tested in the fabricators shop to 1.5 /1.3/ 1.25
(depending on design code) times the design pressure corrected for temperature.
b) In addition, all vertical vessels / columns shall be designed so as to permit site testing
of the vessel at a pressure of 1.5/ 1.3 / 1.25 (depending on design code) times the design
pressure measured at the top with the vessel in the vertical position and completely filled
with water. The design shall be based on fully corroded condition.
c) Vessels open to atmosphere shall be tested by filling with water to the top.
d)
1. Pressure Chambers of combination units that have been designed to operate
independently shall be hydrostatically tested to code test pressure as separate vessels i.e.
each chamber shall be tested without pressure in the adjacent chamber.
2. When pressure chambers of combination units have their common elements
designed for maximum differential pressure the common elements shall be subjected to
1.5/ 1.3 times the differential pressure.
3. Coils shall be tested separately to code test pressure.
e) Unless otherwise specified in applicable design code allowable stress during hydro test
in tension shall not exceed 90% of yield point.
f) Storage tanks shall be tested as per applicable code and specifications.
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5.4
Temperature
Temperature for each vessel shall be specified in the following manner:
5.4.1 Operating Temperature

Maximum / minimum temperature likely to occur any during the lifetime of vessel.
5.4.2 Design temperature

a) For vessels operating at 0C and over:
Design temperature shall be equal to maximum operating temperature plus 15 0C.
b) For Vessels operating below 0C:
Design temperature shall be equal to lowest operating temperature.
c) Minimum Design Metal Temperature (MDMT) shall be lower of minimum
atmospheric temperature and minimum operating temperature.
5.5
Corrosion allowance :
Unless otherwise specified by Process Licensor, minimum corrosion allowance shall be

considered as follows :
- Carbon Steel, low alloy steel column, Vessels, Spheres : 1.5 mm
- Clad / Lined vessel: Nil
- Storage Tank, shell and bottom : 1.5 mm
- Storage tank, Fixed roof / Floating Roof : Nil
For alloy lined or clad vessels, no corrosion allowance is required on the base metal. The
cladding or lining material (in no case less than 1.5 mm thickness) shall be considered for
corrosion allowance.
Cladding or lining thickness shall not be included in strength calculations.
Corrosion allowance for flange faces of Girth / Body flanges shall be considered equal to
that specified for vessel.
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5.6
Wind Consideration
Wind load shall be calculated on the basis of IS : 875 / site data.

a) Drag coefficient for cylindrical vessels shall be 0.7 minimum.
b) Drag coefficient for spherical vessel shall be 0.6 minimum.
5.7
Earthquake Consideration :
Earthquake load shall be calculated in accordance with IS : 1893 / site data if specially
developed and available
5.8
Capacity
5.8.1 Tank
Capacity shall be specified as Nominal capacity and stored capacity
Nominal capacity for fixed roof tanks be volume of cylindrical shell.
Nominal capacity for floating roof tanks shall be volume of cylindrical shell minus free
board volume.
Stored capacity shall be 90% of Nominal capacity.
5.8.2 Sphere
Stored capacity shall be 85% of nominal capacity.
5.9
Manholes :
a) Vessels and columns with diameter between 900 and 1000 mm shall be
provided with 450 NB manhole. Vessels and columns with diameter greater than
1000mm shall be provided with 500 NB manhole. However, if required vessels and
columns with diameter 1200mm and above may be provided with 600NB manhole.
b) For storage tanks minimum number of manholes (Size 500mm) shall be as
follows:
Tank Diameter
Shell
Roof
Dia. < 8m
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> 8m dia. < 36 dia
Dia. > 36m
Floating roofs (pontoon or double deck type) shall be provided with manholes to inspect
the entire interior of the roofs. Size of manhole shall be 500 mm minimum.
5.10 Floating Roof :

5.10.1 Unless otherwise specified floating roof shall be of following construction.
Tank Diameter
Type of Roof
12 M <
Double Deck Type
>12 M < 60M
Pontoon Type
> 60M
Double Deck Type
5.10.2 Floating roof design shall be in fabricators scope having proven track record.
Foam seal of proven make shall be provided unless otherwise specified.
5.11
Nozzle size : Unless otherwise specified

- Minimum nozzle Size : 40 NB
- Minimum Nozzle Size, Column : 50 NB
- Safety Valve Nozzle : Based on I.D.
- Self Reinforced Nozzle Neck : Based on I.D.
5.11.1 a) All nozzles and man-ways including self-reinforced type shall be 'set in' type
and attached to vessel with full penetration welds.
b) Self reinforced nozzles up to 80mm NB may be 'set on' type.
5.12 Flanges
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5.12.1 Unless otherwise specified nozzle flanges up to 600NB shall be as per ASME
/ANSI B16.5 and above 600 NB shall be as per ASME /ANSI B 16.47 (SERIES
'B')
5.12.2 For nozzles 100 NB and below, only weld neck flange shall be used. Slip on
flanges may be used for nozzles above 100NB in Class 150 rating only. All
flanges above Class 150 rating shall be weld neck type
5.12.3 Slip on flanges shall not be used in Lethal, Hydrogen, caustic, severe cyclic
service and corrosive service (where corrosion allowance is in excess of 3mm).
5.13 Internals :
Removable internals shall be bolted type and bolting shall be stainless steel Type 304,
unless specified otherwise.
5.14 Spares :
Gaskets :
Two sets for each installed gasket.
Fasteners:
10 % (Minimum two in each size) of installed fasteners.
Sight/Light Glass:
4 sets for each installed glass.
5.15 Vent/Drain Connections:

Vessel shall be provided with one number each, vent/drain connection as per following :
VESSEL VOLUME, m3
VENT SIZE, NB (mm)
DRAIN SIZE, NB
6.0 and smaller
40
40
6.0 to 17.0
40
50
17.0 to 71.0
50
80
71.0 and larger
80
100
(mm)
Page28

5.16 Pipe Davit :
Vertical Vessel / Column having safety valve size > 80 NB and or having internals, shall
be provided with pipe davit per relevant standard.
6.0
INSULATION THICKNESS :
As indicated on process data sheet by process licensor
7.0
PAINTING
As per Standard Specification, unless otherwise stated.
8.0
MATERIAL SELECTION :
Material of various parts of equipment shall be selected per process data sheet guidelines
and proper care shall be taken for the points as given in Annexure- I or as specified.
9.0
SPECIAL CONSIDERATION FOR TALL COLUMN DESIGN
Mechanical design of self supporting Tall Column / Tower shall be carried out for
various load combinations as per Annexure-II
10.0
STATUTORY PROVISIONS :
National laws and statutory provisions together with any local byelaws for the state shall
be complied with.
Annexure : I
1.
PRESSURE VESSEL STEEL PLATES ARE PURCHASED TO THE
REQUIREMENT OF THE STANDARD ASME SA-20, WHICH REQUIRES

TESTING OF INDIVIDUAL PLATES FOR LOW TEMPERATURE SERVICE.
CARBON
STEEL
MATERIAL
IS
ORDERED
TO
MEET
THE
IMPACT
REQUIREMENTS OF SUPPLEMENT OF STANDARD ASME SA 20. TYPICAL

Page29

MATERIAL SPECIFICATION IS AS FOLLOWS SA 516 GR.60. NORMALISED TO
MEET IMPACT REQUIREMENTS PER SUPPLEMENT SS OF SA 20 AT-50F
2.
ALL PERMANENT ATTACHMENTS WELDED DIRECTLY TO 9 %
NICKEL STEEL SHOULD BE OF THE SAME MATERIAL OR OF AN AUSTENTIC

STAINLESS STEEL TYPE WHICH CANNOT BE HARDENED BY HEAT
TREATMENT.
3.
CHECK FOR IMPACT TESTING REQUIREMENT AS PER UCS-66 FOR
COINCIDENT TEMPERATURE AND PART THICKNESS.

4.
SELECTION OF STAINLESS STEEL MATERIAL SHALL BE BASED ON
PROCESS RECOMMENDATION/PROCESS LICENSOR.

5.
ATMOSPHERIC/LOW PRESSURE STORAGE TANKS. MATERIAL SHALL
BE SELECTED AS PER API 650 /API 620 AS APPLICABLE.

6.
MATERIALS FOR CAUSTIC SERVICE SOUR SERVICE OR SOUR + HIC
SHALL BE SELECTED BASED ON SPECIFIC RECOMMENDATION OF PROCESS

LICENSOR.
7.
MATERIAL FOR PRESSURE VESSELS DESIGNED ACCORDING TO
ASME SECTION VIII DIVISION 2 SHALL BE GIVEN SPECIAL CONSIDERATION

AS PER CODE.
8.
ALL PIPES SHALL BE OF SEAMLESS CONSTRUCTION.
9.
NONFERROUS MATERIAL AND SUPER ALLOYS SHALL BE SELECTED
BASED ON SPECIFIC RECOMMENDATION.
Page30

10.
MATERIAL FOR VESSEL /COLUMN SKIRT SHALL BE THE SAME
MATERIAL AS OF VESSEL/ COLUMN SHELL FOR THE UPPER PART WITH A

MINIMUM OF 500MM.
Annexure -II
DESIGN PHILOSOPHY OF TALL COLUMNS
Mechanical design of self-supporting tall column and its anchorage block shall be carried
out considering combination of various loads.
1.0
Loadings
The loadings to be considered in designing a self-supporting tall column/tower shall

include:
1.1
Internal and or external design pressure specified on process data sheets.
1.2
Self weight of column inclusive of piping, platforms, ladders, manholes, nozzles,

trays, welded and removable attachments, insulation and operating liquid etc. The
weight of attachments to be considered shall be as per Table -1 enclosed
Other loading as specified in UG-22 of ASME Code Sec, VIII Div.1. wherever
applicable.
1.3
Seismic forces and moments shall be computed in accordance with IS 1893 (latest
edition). Unless otherwise specified importance factor and damping coefficient
shall be considered as 2 and 2% respectively.
1.4
Basic wind pressure and wind velocity (including that due to winds of short
duration as in squalls) for the computation of forces / moments and dynamic
analysis respectively shall be in accordance with IS 875 (latest edition).
Additional wind loading on column due to external attachments like platforms,
ladders piping and attached equipment should be given due consideration.
1.5
Loadings resulting in localised and gross stresses due to attachment or mounting

of reflux / reboiler / condenser etc.
Page31

2.0
Loading Condition
Analysis shall be carries out for following conditions :

2.1
Erection Condition: Column (un-corroded) erected on foundation without

insulation, platforms, trays etc. but with welded attachments plus full wind on
column.
2.2
Operation Condition: Column (in corroded condition) under design pressure,

including welded items, trays removable internals, piping, platforms, ladder,
reboiler mounted on column, insulating and operating liquid etc. plus full wind on
insulated column with all other projections open to wind, or earthquake force.
2.3
Test Condition: Column (in corroded condition) under test pressure filled with
water plus 33% of specified wind load on uninsulated column considered.
2.4
EARTHQUAKE AND WIND SHALL BE CONSIDERED NOT ACTING

CONCURRENTLY
3.0
Deflection of Column
Maximum allowable deflection at top of column shall be equal to height of the column
divided by 200.
3.1
If the deflection of column exceeds the above allowable limit the thickness of
skirt shall be increased as first trial up to a maximum value equal to the column
thickness and this exercise shall be stopped if the deflection falls within allowable
limit.
3.2
If the above step is inadequate, skirt shall be gradually flared to reduce the
deflection. Flaring of skirt shall be stopped if the deflection falls within limits or
half angle of cone reaches maximum limit of 9 deg.
3.3
If the above two steps prove inadequate in limiting the deflection within
allowable limits, the thickness of shell courses shall be increased one starting
from bottom course above skirt and proceeding upwards till the deflection falls
within allowable limits.
Page32

4.0
Stress Limits
The stresses due to pressure weight wind / seismic loads shall be combined using
maximum principle stress theory for ASME Section VIII Div. I. Thicknesses are
accordingly chosen to keep the within limits as per Table-2.
5.0
Skirt Support Base
Base supporting including base plate, anchor chairs compression ring, foundation bolting
etc. shall be designed based on overturning moment (greater of seismic or wind). A
minimum number of 8 foundation bolts shall be provided. Numbers of foundation bolts
shall be in multiple of four.
6.0
Minimum Hydrotest Pressure
Minimum Hydrotest Pressure (in Horizontal position) shall be equal to 1.3 x design
pressure x temperature correction factor as specified in ASME Code Section VIII Div. I
(Clause UG-99) at top of column.
7.0
Dynamic Analysis
Dynamic analysis of each column shall be carried out for stability under transverse wind
induced vibrations as per standard design practice. The recommended magnification
amplitude shall be limited to tower diameter divided by five.
TABLE-1
DETAILS AND WEIGHT OF COLUMN ATTACHMENT
1.
Shape factor for shell (for wind force calculation) : 0.7
2.
Weight of trays (with liquid) to be considered. : 120 Kg./m2
3.
Weight of plain Ladder: 15 Kg./m
4.
Weight of caged ladder: 37 Kg./m
Equivalent projection to be considered for wind load on caged ladder : 300 mm
6.
Distance of platform below each manhole : Approx. 1000 mm
Page33

7.
Maximum distance between consecutive platform : 5000 mm
8.
Projection of Platform : 900mm up to 1meter dia. column; 1200 mm for column

dia.> 1 meter, from column insulation surface.
9.
Equivalent height of platform (for wind load computation) : 1000 mm
10.
Weight of platforms : 170 Kg./m2.
11.
Platform shall be considered all around
TABLE -2
ALLOWABLE STRESSES FOR COMBINED LOADING
VESSEL CONDITION / TEMP./
CONDITIONS
TYPE OF STRESSES
ERECTION
OPERATING
NEW OR CORRODED
TEST
NEW
CORRODED
AMBIENT
DESIGN
KxSxE
KxSxE
KxB
KxB
CORRODED
TEMPERATURE
AMBIENT
LONGITUDINAL
0.90xY.PxE
LONGITUDINAL COMPRESSIVE
STRESS
Where
S = Basic allowable Tensile Stress as per Clause UG 23 (a) of ASME Code Sec. VIII
Div.1.
B = 'B' value calculated as per Clause UG-23 (b).
E = Weld joint efficiency of circumferential weld, depending on extent of radiography.
Page34

K = Factor for increasing basic allowable value when wind or seismic load is present, 1.2
as per ASME Sec VIII Div 1.
Note : Allowable stresses in skirt to shell joint shall be as per following :
a) 0.49S, if joint is shear type.
b) 0.70S, if joint is compression type.
Page35
CHAPTER 3
DESIGN
PROCEDURE
AND
CALUCULATION
Page36

DESIGN THEORY
Circumferential or Hoop Stress
A tensile stress acting in a direction tangential to the circumference is called
Circumferential or Hoop Stress. In other words, it is on longitudinal section(or on the
cylinder walls).
Let,
p = Intensity of internal pressure,
d = Internal diameter of the cylinder shell,
l = length of cylinder,
t = Thickness of the shell, and
t1 = hoop stress for the material of the cylinder.
Now,
We know that total force on a longitudinal section of the shell
= Intensity of pressure projected Area = p d l
..i
and the total resisting force acting on the cylinder walls

= t1 2t l
.(Q of two section)
ii
From equation (i) and (ii) , we have
Page37

t1 2t l = p d l
or
t1 =
pd
2t
or
t =
pd
2 t1
..ii
Longitudinal Stress
A tensile stress acting in a direction of the axis is called longitudinal stress. In
other words, it is a tensile stress acting on the transverse or circumferential section.
Fig of Longitudinal stress

Let
t 2 = Longitudinal stress.
In this case, the total force acting on the transverse section

= Intensity of pressure Cross- sectional Area
=p
(d)
4
and total resisting force = t 2 d.t
ii
From equation (i) and (ii), we have

t 2 d.t = p
t 2 =
(d)
4
pd
pd
or t =
4 t 2
4t
Page38
Design of Shell Due to Internal Pressure

As discussed in article on thin vessel are cylindrical pressure vessel is subjected to
tangential ( t ) and longitudinal ( L ) stresses.
t =
Pi Di
P Di
and L = i
2t
4t
where D= mean diameter

= Di + t
Rule
The design pressure is taken as 5% to 10% more than internal pressure, where as
the test pressure is taken as 30% more than internal pressure.
Considering the joint efficiency,
The thickness of shell can be found by following procedure,
Pi ( Di + t )
2t
2t = Pi ( Di + t )
t=
Pi Di
2( ) Pi
Design of Elliptical Head:

Elliptical heads are suitable for cylinders subjected to pressures over 1.5 MPa. The
shallow forming reduces manufacturing cost. Its thickness can be calculated by the
following equation:
Page39

t=
pi diW
2 J
where,
di = Major axis of ellipse
W= Stress intensification factor
1
W = (2 + k 2 )
6
Where ,
k=
Major Axis Diameter 0.5d i

=
Major Axis Diameter
c
Rule > Generally, k = 2 ( how ever k should not be greater than 2.6)
1
W = (2 + 22 )
6
=1
t=
Pi di W
2 J
Design of Manhole
Let,
d i = internal dia. Of nozzle
d = d i + 2 CA
where, CA = corrosion Allowance in mm
t = Actual thickness of shell in mm
tr = require thickness as per calculation in mm.
tn = Actual thickness of nozzle
trn = Required thickness as per calculation in mm
rn
Pi Di
2 Pi
Page40
h1actual = Height of the nozzle above the shell in mm

h 2actual = Height of the nozzle below the shell in mm
h1 = Height till where the effect of the nozzle persists above the shell in mm
h 2 = Height till where the effect of the nozzle persists below the shell in mm
To calculate h1 and h 2 consider a term h
h = 2.5 ( t CA)
or
h = 2.5 ( tn CA)
(whichever is smaller)
h1 = h
or
h1actual
h2 = h
or
h 2actual
X = Distance where the effect of the nozzle persists in mm on each side of the
centre line
X = d.
or
X=
di
+ t + tn -3CA
2
(whichever is maximum)
d op = outer dia. Of Reinforcing Pad in mm
d ip = inner dia. Of Reinforcing Pad in mm
t p = Thickness of Reinforcing Pad in mm
Page41

Area Calculation
Area pertaining to material removed,
A = d tr
Excess area in the Shell,
A1 = (2X d ) ( t tr CA)
Excess area in the Nozzle,
A2 = 2h1(tn trn CA)
Excess area in the nozzle inside the shell A3 = 2 h2 (tn 2CA)

Area Required,
A r = ( d op - d ip ) t p
Area required,
Ar = A ( A1 + A2 + A3)
When Ar = 0 or negative, no reinforcement is necessary as the vessel thickness self

compensates.
Design of Leg:
A) Legs support
In certain cases, legs can be made detachable to the vessel. These legs can
be bolted to plates. The design for leg supports is similar to that for bracket support. If
the legs are welded to the shell, then the shear stresses in the weld will be given by:
W = w2
Where,
W
P2 = KP1 H 2 Do mm 2
0.707 tW LW n
W =
W
0.707 tW LW n
tW = Weld Height
LW = Weld Length.
These types of supports are suitable only for small vessels as there is a concentrated
local stress at the joint.
B) Wind Load
Wind load can be estimated as :
Pw1 = K P H Do
1
This equation is valid for heights upto 20m. Beyond 20m, the wind pressure is
higher and hence for heights above 20m.
Pw 2 = KP2 H 2 Do
Generally, P1 lies between 400 N/ mm2 and P2 may be upto 2000 N/ m 2 .

Therefore, the bending moment due to wind at the base will be
Page42

(IF H 20 m)
Mw =
Pw1h1
2
(IF H> 20m)
Mw =
Pw1h1
h
+ Pw 2 ( h1 + 2 )
2
2
Therefore, bending stress will be,

bw =
Mw
z
Where Z= section Modulus
The wind load would create tensile stress on the wind side and compressive on the other
side.
Page43
Design Calculation
1) Thickness of cylinder
Given data
Internal pressure (P) = 0.588 MPa
Internal Diameter (Di) = 496mm
Corrosion Allowance (CA) = Nil.
Joint Efficiency for shell = 1.
As per Equation,
t=
Pi Di
+ CA
2 Pi
t=
(0.588) (496)
2 137 1 0.588
(Q CA is NIL)
= 1.066
t = 1.066mm
2) Elliptical Head
1
W = (2 + k 2 )
6
where ,
k=
0.5d i
Major Axis Diameter
=
Major Axis Diameter
c
k=2
Rule > Generally, k = 2 ( how ever k should not be greater than 2.6)
1
W = (2 + 22 )
6
=1
t=
Pi di W
2 J
where,
Page44

di = Major axis of ellipse = 496mm
W = Stress intensification factor = 1
t=
Pi di W
2 J
t=
0.588 496 1
2 137 1
= 1.06 mm
t = 1.06 mm
3) Design Of Manhole
INLET NOZZLE (N1)
GIVEN DATA
Internal pressure (Pi) = 0.588 N/ mm 2
Internal diameter (Di) = 496 mm
Thickness (t) = 6 mm.
CA = NIL
Joint Efficiency ( ) = 1
Internal diameter of nozzle (di) = 254.51 mm
d = di + CA = 254.51 mm.
tr = require thickness = 1.066 mm.
tn = Actual thickness of nozzle = 9.27 mm.
trn = Required thickness as per calculation in mm.
0.588 254.51
A = 2 137 1 0.588 t
1
rn
rn
Pi Di
2 Pi
0.588 254.51
2 137 1 0.588
Page45

= 0.547 mm.
rn
= 0.547 mm.
Area Calculation
Area Pertaining to material removed, A = d tr
= 254.51 1.066
= 271.3 mm2
Excess area in the shell, A1 = (2X d ) ( t tr CA)
Generally,
X = d = 254.51 mm.
X = di + t + tn -3CA
2
= 254.51 + 6 +9.27 0
2
= 142.52 mm.
( Take X whichever maximum)
Therefore,
A = (2 254.51-254.51)(6-1.066-0)
= 1255.75 mm2
Excess area in the nozzle, A2 = 2h1(tn trn CA)
h = 2.5 ( t CA)
or
h = 2.5 ( tn CA)
= 2.5 6
= 2.5 (9.27)
= 15mm
= 23.175 mm
( Take X whichever smaller)
h1 = h2 = h = 15 mm.
Therefore,
A2 = 2 15 ( 9.27 0.547 0)
= 261.69 mm 2
Excess area in the nozzle inside the shell A3 = 2 h2 (tn 2CA)
= 2 15 ( 9.27-0)
Page46

= 278.1 mm 2
Area required Ar = A ( A1 + A2 + A3)
= -1524.24
As Ar is ve or zero reinforcement is not necessary.
4) Design of leg
Wind load
Here ,
K = Coefficient depending on shape factor = 0.7
P = Wind pressure = 730 N/ mm 2
1
H = Height of the vessel above foundation =2413 mm
Do = Outer Diameter Of Vessels
Wind load can be estimated as :
Pw1 = K P H Do
1
= 0.77302.4130.508
= 626.38 N
(IF H 20 m)
Mw =
Pw1h1
2
(IF H> 20m)
Mw =
Pw1h1
h
+ Pw 2 ( h1 + 2 )
2
2
Here we use ,
Mw =
Pw1h1
2
= 626.38 1206.47
= 755.41 N.m
Here we use I- Section,
Therefore, Z = section Modulus
Z=
bh 3 b1h13
6h
Page47
4t(5t)3 3t(3t)3
6(5t)
= 13.96 t 3
Therefore, Bending Stress will be ,
bw =
350 106 =
Mw
z
(as bw = 350 N/mm)
755.41
13.96t 3
t = 5.36 103 m
L=
123 123
+
+ 1834
3
3
= 1916 mm
Page48

SUMMARY
SHELL
HEAD
MANHOLE
REINFORCEMENT
PAD
LEG
INTERNALDIAMETER(Di)
LENGTH(L)
THICKNESS(t)
THICKNESS(t)
HEIGHT(h)
DIAMETEROFOPENING(di)
THICKNESSOFNOZZLE(tn)
ASAREACALCULATEDISve
RFPADISNOTREQUIRED
THICKNESSOFLEGS
496mm
1734mm
6mm
6mm
173mm
254.51
9.27
5.36mm
Page49
DESIGN
APPROCH
BY
ASME
CODES
Page50

DESIGN THEORY
PRESSURE VESSEL HEAD DESIGN UNDER INTERNAL PRESSURE
THICKNESS OF HEADS/ CLOSURES:
ELLIPSOIDAL HEAD:
t
= P.Di / (2SE- 0.2P) + CA

OTHERS;
= P.K.Di/ (2SE-0.2P) + CA
=CONSTANT BASED ON THE
MAJOR &
RATIO
OF
MINOR AXIS (D/2H)
VALUES OF FACTOR K
D/2H 3.0
2.6
2.5
2.4
2.2
2.1
2.0
1.83 1.64 1.46 1.37 1.29 1.14 1.07 1.00
D/2H 1.8
2.8
1.6
1.5
1.4
1.2
1.0
0.87 0.76 0.71 0.66 0.57 0.50
TORISPHERICAL HEAD:
t=
0.885 PL/ (SE-0.1P) + CA
FOR KNUCKLE RADIUS, r = 6% OF CROWN RADIUS (L)

t =PLM/ (2S.E- 0.2P) + CA
where L=CROWN RADIUS
M=CONSTANT BASED ON RATIO OF
CROWN
AND
KNUCLE
RADIUS(L/r)
Page51

VALUES OF FACTOR M
L/r 1.0
M
1.00 1.06 1.10 1.15 1.18 1.22
L/r 5.0
M
1.50 2.00 2.50 3.00 3.50
6.0
7.0
8.0
9.0
4.0
1.25
10.0
11.0
1.31 1.36 1.41 1.46 1.50 1.54
1.58
L/r 12.0 13.0 14.0 15.0 16.0 16.67

M
1.62 1.65 1.69 1.72 1.75 1.77
(USE NEAREST VALUE OF L/r; INTERPOLATION UNNECESSARY)

NOTE:
MAXIMUM RATIO ALLOWED BY UG-32 (j) WHEN L EQUALS THE
OUTSIDE DIAMETER OF THE SKIRT OF THE HEAD. KNUCKLE
RADIUS, r SHALL NOT BE LESS THAN 3t.
CONICAL HEAD:
t = PDi/ 2 COS (SE-0.6P) + CA
= half apex angle
HEMISPHERICAL HEAD:
t = P.Ri/ (2SE- 0.2P) + CA
FLAT HEADS & COVERS (UG- 34)

CIRCULAR COVER/ HEADS
t = Di * SQRT(CP/SE) + CA
Where C = Factor, dependent on joint geometry of head cover to shell (range 0.1
0.33)
OBROUND/ NON-CIRCULAR HEADS

(INCLUDING SQUARE/ RECTANGULAR)
Page52

t = Di * SQRT(Z*CP/SE)
+ CA
where Z = 3.4 - (2.4 d / D)
PRESSURE
VESSEL
SHELL
COMPONENT
DESIGN
UNDER
INTERNAL PRESSURE
Pressure Vessel Definition:
Containers of Pressure
Internal
External
Pressure Source
External
Application of Heat
Code Coverage:
Subsections
Rule, Guidelines, Specifications
Mandatory Appendices
Specific Important Subjects to Supplement Subsections
Non-Mandatory Appendices
Additional Information, Suggested Good Practices
Inclusions:
Unfired Steam Boilers/ Generators
Evaporators
Heat Exchangers
Direct Fired Vessels

Gas Fired Jacketed Steam Kettles(Jacket Pressure less than 50
PSI)
Additional Interpretation:
Page53

The code rules may not cover all designs & constructions procedures.
Such additional design & construction procedure may be
adopted which are safe and acceptable.
Field fabrication are acceptable.

Other standards for components are acceptable
Guidelines for Designed Thickness (To be adopted):

(1/16) excluding corrosion allowance for shell & head (Min.)
The above will not apply to heat transfer surface
(1/4) min. for unfired steam boiler shell
(3/32) min. excluding corrosion allowance for compressed air/ steam/
water service(for CS/AS)
Corrosion allowance shall be based on experience/ field data(No

value/ code recommended).
THICKNESS CALCULATIONS
UNDER INTERNAL PRESSURE, CYLINDRICAL SHELL:
Circumferential stress:
t
= P.Ri / (SE- 0.6P) + CA
Longitudinal stress:
t = P.Ri / (2SE+0.4P) + CA
SPHERICAL SHELL:
t = P.Ri
/ (2SE- 0.2P) + CA
CONICAL SECTION: (INTERNAL PRESSURE)

t =P.Di/ 2COS(SE- 0.6P) + CA
Stress Calculation
UNDER INTERNAL PRESSURE,
CYLINDRICAL SHELL:
Circumferential stress:
Page54

Sc = P (Ri + 0.6t)/ Et
Longitudinal stress:
Sl = P (Ri - 0.4t)/ 2Et
SPHERICAL SHELL:
Sc = P (Ri + 0.2t)/ 2Et
CONICAL SHELL SECTION:
Sc =P (Di + 1.2 tCOS)/2Et COS
Sl =P (Di 0.8tCOS)/4Et COS
Page55
ANALYSIS OF PRESSURE VESSEL
Project
Author
jimit and mahavir

Subject
shell analysis
Prepared For
project report
Project Created
Sunday, May 25, 2008 at 10:04:27 PM

Project Last Modified
Sunday, May 25, 2008 at 10:04:27 PM
Page56

1 Introduction
The ANSYS CAE (Computer-Aided Engineering) software program was used in
conjunction with 3D CAD (Computer-Aided Design) solid geometry to simulate the
behavior of mechanical bodies under thermal/structural loading conditions. ANSYS
automated FEA (Finite Element Analysis) technologies from ANSYS, Inc. to generate
the results listed in this report.
Each scenario presented below represents one complete engineering simulation. The
definition of a simulation includes known factors about a design such as material
properties per body, contact behavior between bodies (in an assembly), and types and
magnitudes of loading conditions. The results of a simulation provide insight into how
the bodies may perform and how the design might be improved. Multiple scenarios allow
comparison of results given different loading conditions, materials or geometric
configurations.
Convergence and alert criteria may be defined for any of the results and can serve as
guides for evaluating the quality of calculated results and the acceptability of values in
the context of known design requirements.
Solution history provides a means of assessing the quality of results by examining how values change during successive
iterations of solution refinement. Convergence criteria sets a specific limit on the allowable change in a result between
iterations. A result meeting this criteria is said to be "converged".
Alert criteria define "allowable" ranges for result values. Alert ranges typically represent known aspects of the design
specification.
All values are presented in the "SI Metric (m, kg, N, C, s, V, A)" unit system.
Notice
Do not accept or reject a design based solely on the data presented in this report. Evaluate
designs by considering this information in conjunction with experimental test data and
the practical experience of design engineers and analysts. A quality approach to
engineering design usually mandates physical testing as the final means of validating
structural integrity to a measured precision.
Page57

2. Scenario 1
2.1. "Model"
"Model" obtains geometry from the Pro/ENGINEER
cylinder\SHEEL.PRT.2".
part
"H:\shaell and
The bounding box for the model measures 1.73 by 0.52 by 0.52 m along the global x, y and z axes, respectively.
The model has a total mass of 109.69 kg.
The model has a total volume of 1.410-2 m.
Table 2.1.1. Bodies
Name
Material
Nonlinear Material Effects Bounding Box(m) Mass (kg) Volume (m) Nodes Elements
"SHEEL" "Structural Steel" Yes
1.73, 0.52, 0.52
109.69
1.410-2
4968
684
2.1.1. Mesh
"Mesh", associated with "Model" has an overall relevance of 0.
"Mesh" contains 4968 nodes and 684 elements.
No mesh controls specified.
2.2. "Environment"
Simulation Type is set to Static
Analysis Type is set to Static Structural
"Environment" contains all loading conditions defined for "Model" in this scenario.
2.2.1. Structural Loading

Table 3.2.1.1. Structural Loads
Name
Type
Magnitude
Vector
"Pressure" Pressure 600,000.0 Pa N/A
Reaction
Force
Reaction
Vector
N/A
N/A
Force Reaction
Moment
N/A
Reaction
Vector
Moment
N/A
2.2.2. Structural Supports

Table 3.2.2.1. Structural Supports
Name
Type
Reaction
Force
Reaction Force Vector
"Fixed
Support"
Fixed
Surface
1.7110-3 N
[-1.7110-3 N x, 1.1610-7 N y,
1.8110-5 Nm
3.6710-9 N z]
Reaction
Moment
Reaction Moment Vector

[1.8110-5 Nm x, 3.1610-9 Nm y,
1.0610-7 Nm z]
Page58
2.3. "Solution"
Solver Type is set to Program Controlled
Weak Springs is set to Program Controlled
Large Deflection is set to Off
"Solution" contains the calculated response for "Model" given loading conditions defined
in "Environment".
Thermal expansion calculations use a constant reference temperature of 22.0 C for "SHEEL". Theoretically, at a uniform
temperature of 22.0 C no strain results from thermal expansion or contraction.
2.3.1. Structural Results

Table 3.3.1.1. Values
Minimum
Maximum
Minimum Occurs Maximum Occurs Alert

On
On
Criteria
A1.1
"Model" 8.6106 Pa
3.5107 Pa
SHEEL
SHEEL
None
None
"Model" 4.96106 Pa 1.87107 Pa SHEEL
SHEEL
None
A1.2
"Model" 0.0 m
4.2710-5 m SHEEL
SHEEL
None
Name
Figure Scope
"Equivalent Stress"
"Maximum
Stress"
Shear
"Total Deformation"
Convergence tracking not enabled.
2.3.2. Equivalent Stress Safety

Table 3.3.2.1. Definition
Name
Stress Limit
"Stress Tool" Yield strength per material.

Table 3.3.2.2. Results
Name
Scope
Type
Minimum Alert Criteria
"Stress Tool" "Model"
Safety Factor
7.13
None
"Stress Tool" "Model"
Safety Margin 6.13
None
2.3.3. Shear Stress Safety

Table 3.3.3.1. Definition
Name
Shear Limit
Shear Factor
Page59

"Stress Tool 2" Yield strength per material. 0.5
Table 3.3.3.2. Results
Name
Scope
Type
Minimum Alert Criteria
"Stress Tool 2" "Model"
Safety Factor
6.69
None
"Stress Tool 2" "Model"
Safety Margin 5.69
None
stress
Figure A1.1. "Equivalent Stress" Contours
Page60

Scenario 1 Figures
deformation
Figure A1.2. "Total Deformation" Contours
Page61

AppendicesA1.
A2. Definition of "Structural Steel"

Table A2.1. "Structural Steel" Constant Properties
Name
Value
Compressive Ultimate Strength
0.0 Pa
Compressive Yield Strength
2.5108 Pa
Density
7,850.0 kg/m
Poisson's Ratio
0.3
Tensile Yield Strength
2.5108 Pa
Tensile Ultimate Strength
4.6108 Pa
Young's Modulus
2.01011 Pa
Thermal Expansion
1.210-5 1/C
Specific Heat
434.0 J/kgC
Thermal Conductivity
60.5 W/mC
Relative Permeability
10,000.0
Resistivity
1.710-7 Ohmm
Table A2.2. Alternating Stress
Page62

Mean Value 0.0
Table A2.3. "Alternating Stress"
Cycles
Alternating Stress
10.0
4.0109 Pa
20.0
2.83109 Pa
50.0
1.9109 Pa
100.0
1.41109 Pa
200.0
1.07109 Pa
2,000.0
4.41108 Pa
10,000.0
2.62108 Pa
20,000.0
2.14108 Pa
100,000.0
1.38108 Pa
200,000.0
1.14108 Pa
1,000,000.0
8.62107 Pa
Table A2.4. Strain-Life Parameters
Table A2.5. "Strain-Life Parameters"

Strength Coefficient
9.2108 Pa
Strength Exponent
-0.11
Ductility Coefficient
0.21
Page63

Ductility Exponent
-0.47
Cyclic Strength Coefficient
1.0109 Pa
Cyclic Strain Hardening Exponent
0.2
Page64
Project
Author
Subject
Prepared for
First Saved
Last Saved
Product Version
Jimit vyas and mahavir solanki

Ellipsoidal dish end
project analysis
Sunday, May 25, 2008
Sunday, May 25, 2008
11.0 Release
Page65
Contents
Model
o Geometry
ELIPTICALHEAD
o Mesh
CFX-Mesh Method
o Static Structural
Analysis Settings
Loads
Solution
Solution Information
Results
Max Equivalent Stress
Results
Max Shear Stress
Results
Material Data
o Structural Steel
Units
TABLE 1
Unit System
Metric (m, kg, N, C, s, V, A)
Angle
Degrees
Rotational Velocity rad/s
Model
Geometry
TABLE
Model > Geometry > Parts
3
Object Name
State
Graphics Properties
Visible
Transparency
Definition
Suppressed
Material
Stiffness Behavior
Nonlinear Material Effects
Bounding Box
Length X
Length Y
Length Z
ELIPTICALHEAD
Meshed
Yes
1
No
Structural Steel
Flexible
Yes
0.508 m
0.508 m
0.173 m
Page66

Properties
Volume
Mass
Centroid X
Centroid Y
Centroid Z
Moment of Inertia Ip1
Statistics
Nodes
Elements
1.9271e-003 m
15.128 kg
-8.1168e-017 m
1.0962e-017 m
-3.7996e-002 m
0.34417 kgm
0.343 kgm
0.6178 kgm
2289
6232
Mesh
TABLE
Model > Mesh
4
Object Name
State
Defaults
Physics Preference
Relevance
Advanced
Relevance Center
Element Size
Shape Checking
Solid Element Midside Nodes
Straight Sided Elements
Initial Size Seed
Smoothing
Transition
Statistics
Nodes
Elements
TABLE
Model > Mesh > Mesh Controls
Object Name
State
Scope
Scoping Method
Geometry
Definition
Suppressed
Method
Element Midside Nodes
Mesh
Solved
CFD
0
Fine
Default
CFD
Dropped
Active Assembly
Medium
Slow
2289
6232
5
CFX-Mesh Method
Fully Defined
Geometry Selection
1 Body
No
CFX-Mesh
Dropped
Static Structural
Page67

TABLE
Model > Analysis
6
Object Name
State
Definition
Physics Type
Analysis Type
Options
Reference Temp
TABLE
Model > Static Structural > Loads
Object Name
State
Scope
Scoping Method
Geometry
Definition
Define By
Type
Magnitude
Suppressed
Static Structural
Fully Defined
Structural
Static Structural
22. C
8
Pressure
Fully Defined
Fixed Support 2
Geometry Selection
4 Faces
1 Face
Normal To
Pressure
Fixed Support
6.e+005 Pa (ramped)
No
FIGURE
Model > Static Structural > Pressure
Page68

Solution
TABLE
Model > Static Structural > Solution
Object Name
Solution
State
Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth
2.
TABLE
Model > Static Structural > Solution > Solution Information
Object Name
State
Solved
Solution Output
Solver Output
Newton-Raphson Residuals 0
Update Interval
2.5 s
Display Points
All
10
TABLE
Model > Static Structural > Solution > Results
Object Name
Equivalent Stress
State
Solved
Scope
Geometry
All Bodies
Definition
Type
Equivalent (von-Mises) Stress
Display Time
End Time
Results
Minimum
3.101e+006 Pa
Maximum
3.1378e+007 Pa
Information
Time
1. s
Load Step
1
Substep
1
Iteration Number 1
11
FIGURE
Model
>
Static
equivalent stress
Structural
>
Maximum Shear Stress Total Deformation
1.6131e+006 Pa
1.6963e+007 Pa
Solution
>
Equivalent
0. m
4.1032e-005 m
Stress
>
2
Figure
Page69
FIGURE
Model > Static Structural
maximum shear stress
>
Solution
>
Maximum
Shear
Stress
>
3
Figure
Page70
TABLE
Model > Static Structural > Solution > Stress Safety Tools
Object Name
State
Solved
Definition
Theory
Stress Limit Type Tensile Yield Per Material
12
TABLE
Model > Static Structural > Solution > Max Equivalent Stress > Results
Object Name
Safety Factor Safety Margin
State
Solved
Scope
Geometry
All Bodies
Definition
Type
Display Time
End Time
Results
Minimum
7.9674
6.9674
13
Page71

Information
Time
Load Step
Substep
Iteration Number
1. s
1
1
1
TABLE
Object Name
Max Shear Stress
State
Solved
Definition
Theory
Max Shear Stress
Factor
0.5
14
TABLE
Model > Static Structural > Solution > Max Shear Stress > Results
Object Name
State
Solved
Scope
Geometry
All Bodies
Definition
Type
Display Time
End Time
Results
Minimum
7.369
6.369
Information
Time
1. s
Load Step
1
Substep
1
Iteration Number 1
15
Material Data
Structural Steel
TABLE
Structural Steel > Constants
Structural
Young's Modulus
Poisson's Ratio
Density
Thermal Expansion
Compressive Ultimate Strength
Thermal
16
2.e+011 Pa
0.3
7850. kg/m
1.2e-005 1/C
2.5e+008 Pa
2.5e+008 Pa
4.6e+008 Pa
0. Pa
Page72

Specific Heat
Electromagnetics
Resistivity
60.5 W/mC
434. J/kgC
10000
1.7e-007 Ohmm
FIGURE
Structural Steel > Alternating Stress
TABLE
Structural Steel > Alternating Stress > Property Attributes
Interpolation
Log-Log
Mean Curve Type Mean Stress
17
TABLE
Structural Steel > Alternating Stress > Alternating Stress Curve Data
Mean Value Pa
0.
18
TABLE
Structural Steel > Alternating Stress > Alternating Stress vs. Cycles
Cycles Alternating Stress Pa
10.
3.999e+009
20.
2.827e+009
50.
1.896e+009
100.
1.413e+009
19
Page73

200.
2000.
10000
20000
1.e+005
2.e+005
1.e+006
1.069e+009
4.41e+008
2.62e+008
2.14e+008
1.38e+008
1.14e+008
8.62e+007
FIGURE
Structural Steel > Strain-Life Parameters
TABLE
Structural Steel > Strain-Life Parameters > Property Attributes
Display Curve Type Strain-Life
20
TABLE
Structural Steel > Strain-Life Parameters > Strain-Life Parameters
Strength Coefficient Pa
9.2e+008
Strength Exponent
-0.106
0.213
Ductility Exponent
-0.47
Cyclic Strength Coefficient Pa
1.e+009
Cyclic Strain Hardening Exponent 0.2
21
Page74
FATIGUE ANALYSIS
Project
Author
JIMIT AND MAHAVIR
Subject
FATIGUE ANALYSIS
Prepared for
DESIGN AND ANALYSIS OF PRESSURE VESSEL
First Saved
Monday, March 17, 2008
Last Saved
Tuesday, March 18, 2008
Product Version 11.0 Release
Page75
Contents
Model
o
Geometry
FATIGUEANALYSIS
o
Mesh
Static Structural
Analysis Settings
Loads
Solution
Results
Results
Max Shear Stress
Results
Fatigue Tool
Results
Result Charts
goodman stress life rl
Results
Material Data
Structural Steel 2
Units
TABLE 1
Unit System
Metric (m, kg, N, C, s, V, A)
Angle
Degrees
Rotational Velocity rad/s
Page76
Model
Geometry
TABLE
Model > Geometry
Object Name
Geometry
State
Fully Defined
Definition
Source
D:\pressurevesselanalysis\fatigueanalysis\FATIGUEANALYSIS.PRT.3
Type
ProEngineer
Length Unit
Millimeters
Element Control Program Controlled

Display Style
Part Color
Bounding Box
Length X
0.762 m
Length Y
0.782 m
Length Z
2.08 m
Properties
Volume
0.30847 m
Mass
2421.5 kg
Statistics
Bodies
Active Bodies
Nodes
12181
Elements
6191
TABLE
Model > Geometry > Parts
Object Name
FATIGUEANALYSIS
State
Meshed
Page77

Graphics Properties
Visible
Yes
Transparency
Definition
Suppressed
No
Material
Structural Steel 2
Stiffness Behavior
Flexible
Nonlinear Material Effects Yes

Bounding Box
Length X
0.762 m
Length Y
0.782 m
Length Z
2.08 m
Properties
Volume
0.30847 m
Mass
2421.5 kg
Centroid X
-2.3696e-003 m
Centroid Y
2.1709e-003 m
Centroid Z
-8.3295e-004 m
522.75 kgm
522.8 kgm
80.459 kgm
Statistics
Nodes
12181
Elements
6191
Common Decisions to Both Types of Fatigue Analysis

Once the decision on which type of fatigue analysis to perform, Stress Life or Strain Life,
there are 4 other topics upon which your fatigue results are dependent upon. Input decisions
that are common to both types of fatigue analyses are listed below:
Loading Type
Mean Stress Effects
Page78

Multiaxial Stress Correction
Fatigue Modification Factor
Within Mean Stress Effects, the available options are quite different. In the following
ections, we will explore all of these additional decisions.
These input decision trees for
both Stress Life and Strain Life are outlined in Figures 1 and 2.
fatigue analysis in both
predicted life and types of post processing available. We will look at each of these choices
in detail below.
Mesh
TABLE
Model > Mesh
Object Name
Mesh
State
Solved
Defaults
Physics Preference
Mechanical
Relevance
Advanced
Relevance Center
Coarse
Element Size
Default
Shape Checking
Standard Mechanical
Solid Element Midside Nodes Program Controlled

Straight Sided Elements
No
Initial Size Seed
Active Assembly
Smoothing
Low
Transition
Fast
Statistics
Nodes
12181
Elements
6191
Page79
Static Structural
TABLE
Model > Analysis
Object Name
Static Structural
State
Fully Defined
Definition
Physics Type
Structural
Analysis Type
Static Structural
Options
Reference Temp 22. C
TABLE
Model > Static Structural > Analysis Settings
Object Name
Analysis Settings
State
Fully Defined
Step Controls
Number Of Steps
1.
Current Step Number 1.

Step End Time
1. s
Program Controlled
TABLE
Model > Static Structural > Loads
Object Name
Pressure
State
Fully Defined
Fixed Support
Scope
Scoping Method Geometry Selection
Geometry
10 Faces
2 Faces
Definition
Define By
Normal To
Type
Pressure
Magnitude
-6.e+005 Pa (ramped)
Suppressed
No
Fixed Support
Page80

FIGURE
Model > Static Structural > Pressure
Solution
TABLE
Model > Static Structural > Solution
Object Name
Solution
State
Obsolete
Adaptive Mesh Refinement

Max Refinement Loops 1.
Refinement Depth
2.
TABLE
Model > Static Structural > Solution > Solution Information
Object Name
State
Not Solved
Solution Output
Solver Output
Page81

Newton-Raphson Residuals 0
Update Interval
2.5 s
Display Points
All
TABLE
Model > Static Structural > Solution > Results
Object Name
Equivalent Stress
State
Solved
Scope
Geometry
All Bodies
Definition
Type
Equivalent (von-Mises) Stress Maximum Shear Stress Total Deformation
Display Time
End Time
Results
Minimum
4.7782 Pa
2.757 Pa
0. m
Maximum
6.4722e+007 Pa
3.5341e+007 Pa
4.4133e-004 m
Information
Time
1. s
Load Step
Substep
Iteration Number 1
TABLE
Object Name
State
Solved
Definition
Theory

TABLE
Model > Static Structural > Solution > Max Equivalent Stress > Results
Object Name
State
Solved
Scope
Page82

Geometry
All Bodies
Definition
Type
Display Time
End Time
Results
Minimum
3.8627
2.8627
Information
Time
1. s
Load Step
Substep
Iteration Number 1
TABLE
Object Name
Max Shear Stress
State
Solved
Definition
Theory
Max Shear Stress
Factor
0.5

TABLE
Model > Static Structural > Solution > Max Shear Stress > Results
Object Name
State
Solved
Scope
Geometry
All Bodies
Definition
Type
Display Time
End Time
Results
Minimum
3.537
2.537
Information
Time
1. s
Page83

Load Step
Substep
Iteration Number 1
TABLE
Model > Static Structural > Solution > Fatigue Tools
Object Name
Fatigue Tool
State
Solved
Materials
Fatigue
Strength
Factor (Kf)
1.
Loading
History Data
Type
History
Data C:\Program
Files\Ansys
Inc\v110\AISOL\CommonFiles\Language\en-
Location
us\EngineeringData\Load Histories\sampleHistory2.dat
Scale Factor
5.e-003
Definition
End Time
Display Time
Options
Stress Life
Analysis Type
Mean Stress Theory Goodman

Stress Component
Equivalent (Von Mises)
Bin Size
32
Use Quick Rainflow

Counting
1.e+009 cycles
Infinite Life
Maximum
Yes
Data
Points To Plot
5000.
Life Units
Units Name
cycles
1 block is equal to
1.e+006 cycles
Non-constant amplitude, Proportional Loading

Page84

Non-constant amplitude, proportional loading also needs only one set of FE results. But
instead of using a single load ratio to calculate alternating and mean values, the load ratio
varies over time. Think of this as coupling an FE analysis with strain-gauge results
collected over a given time interval. Since loading is proportional, the critical fatigue
location can be found by looking at a single set of FE results.
However, the fatigue
loading which causes the maximum damage cannot easily be seen. Thus, cumulative
damage calculations (including cycle counting such as Rainflow and damage summation
such as Miners rule) need to be done to determine the total amount of fatigue damage and
which cycle combinations cause thatdamage. Cycle counting is a means to reduce a
complex load history into a number of events, which can be compared to the available
constant amplitude test data. Non-constantAmplitude, proportional loading within the
ANSYS Fatigue Module uses a quick counting technique to substantially reduce runtime
and memory. In quick counting, alternating andmean stresses are sorted into bins before
partial damage is calculated. Without quick counting, data is not sorted into bins until after
partial
damages
are
found.
The
accuracy
of
quick
counting is usually very good if a proper number of bins are used when counting. The bin
size defines how many divisions the cycle counting history should be organized into for the
history data loading type. Strictly speaking, bin size specifies the number of divisions of the
rainflow matrix. A larger bin size has greater precision but will take longer to solve and use
more memory. Bin size defaults to 32, meaning that the Rainflow Matrix is 32 x 32 in
dimension.
For Stress Life, another available option when conducting a variable amplitude fatigue
analysis is the ability to set the value used for infinite life. In constant amplitude loading,
if the alternating stress is lower than the lowest alternating stress on the fatigue curve, the
fatigue tool will use the life at the last point. This provides for an added level of safety
because many materials do not exhibit an endurance limit.
However, in non-constant
amplitude loading, cycles with very small alternating stresses may be present and may
incorrectly predict too much damage if the number of the small stress cycles is high
enough. To help control this, the user can set the infinite life value that will be used if the
alternating stress is beyond the limit of the SN curve. Setting a higher value will make
small stress cycles less damaging if they occur many times. The Rainflow and damage
Page85

matrix results can be helpful in determining the effects of small stress cycles in your
loading history.
FIGURE
Model > Static Structural > Solution > Fatigue Tool
FIGURE
Model > Static Structural > Solution > Fatigue Tool
Page86
TABLE
Model > Static Structural > Solution > Fatigue Tool > Results
Object Name Life

State
Safety Factor Damage
Solved
Scope
Geometry
All Bodies
Definition
Type
Life
Safety Factor Damage

1.e+009 cycles
Design Life
Results
Minimum
2.e+007 cycles 0.
Maximum
50.
TABLE
Model > Static Structural > Solution > Fatigue Tool > Result Charts
Page87

Object Name
Rainflow Matrix Damage Matrix
State
Solved
Scope
Geometry
All Bodies
Options
Chart Viewing Style Three Dimensional

Results
Minimum Range
0. Pa
Maximum Range
1.9246e+008 Pa
Minimum Mean
-3.2328e+008 Pa
Maximum Mean
6.1628e+007 Pa
Definition
Design Life
1.e+009 cycles
FIGURE
Model > Static Structural > Solution > Fatigue Tool > Rainflow Matrix
Rainflow Matrix Chart Rainflow Matrix Chart is a plot of the rainflow matrix at the
critical location. This result is onlyapplicable for non-constant amplitude loading where
rainflow counting is needed. This result may be scoped. In this 3-D histogram,
alternating and mean stress is divided into bins and plotted. The Z-axis corresponds
to the number of counts for a given alternating and mean stress bin. This result gives
the user a measure of the composition of a loading history. (Such as if most of the
alternating stress cycles occur at a negative mean stress.) From the rainflow matrix
figure, the user can see that most of the alternating stresses have a positive mean
stress and that in this case the majority of alternating stresses are quite low.
Page88
FIGURE
Model > Static Structural > Solution > Fatigue Tool > Damage Matrix
Damage Matrix Chart

Damage Matrix Chart is a plot of the damage matrix at the critical location on the
model. This result is only applicable for non-constant amplitude loading where
rainflow counting is needed. This result may be scoped. This result is similar to the
rainflow matrix except that the percent damage that each of the Rainflow bin cause is
plotted as the Z-axis. As can be seen from the \corresponding damage matrix for the
above rainflow matrix, in this particular case although most of the counts occur at the
lower stress amplitudes, most of the damage occurs at the higher stress amplitudes.
Page89
TABLE
Model > Static Structural > Solution > Fatigue Tools
Object Name
goodman stress life rl
State
Solved
Materials
Fatigue Strength Factor (Kf) 1.

Loading
Type
Fully Reversed
Scale Factor
1.
Definition
Display Time
End Time
Options
Analysis Type
Stress Life
Mean Stress Theory
Goodman
Page90

Equivalent (Von Mises)
Stress Component
Life Units
Units Name
cycles
1 cycle is equal to
1.e+006 cycles
Types of Cyclic Loading

Unlike static stress, which is analyzed with calculations for a single stress state, fatigue
damage occurs when stress at a point changes over time. There are essentially four classes
of fatigue loading, with the ANSYS Fatigue Module currently supporting the first three:
Constant amplitude, proportional loading
Constant amplitude, non-proportional loading
Non-constant amplitude, proportional loading
Non-constant amplitude, non-proportional loading
In the above descriptions, the amplitude identifier is readily understood.
Is the loading a variant of a sine wave with a single load ratio or does the
loading vary perhaps erratically, with the load ratio changing with time?
The second identifier, proportionality, describes whether the changing
load causes the principal stress axes to change.
If the principal stress
axes do not change, then it is proportional loading. If the principal stress

axes
do
change,
then
the
cycles
cannot
be
counted simply and it is non-proportional loading.

Constant amplitude, Proportional Loading
Constant amplitude, proportional loading is the classic, back of the envelope
calculation describing whether the load has a constant maximum value or continually
varies with time. Loading is of constant amplitude because only one set of FE stress
results along with a loading ratio is required to calculate the alternating and mean values.
Page91

The loading ratio is defined as the ratio of the second load to the first load (LR = L2/L1).
Loading is proportional since only one set of FE results are needed (principal stress axes
do not change over time). Common types of constant amplitude loading are fully reversed
(apply a load, then apply an equal and opposite load; a load ratio of -1) and zero-based
(apply a load then remove it; a load ratio of 0). Since loading is proportional, looking at a
single set of FE results can identify critical fatigue locations. Likewise, since there are
only two loadings, no cycle counting or cumulative damage calculations need to be done.
FIGURE
Model > Static Structural > Solution > goodman stress life rl
Value of Infinite Life

Another available option when conducting a variable amplitude fatigue analysis is the
ability to set the value used for infinite life.
In constant amplitude loading, if the
alternating stress is lower than the lowest alternating stress on the fatigue curve, the
Page92

fatigue tool will use the life at the last point. This provides for an added level of safety
because many materials do not exhibit an endurance limit. However, in non-constant
amplitude loading, cycles with very small alternating stresses may be present and may
incorrectly predict too much damage if the number of the small stress cycles is high
enough. To help control this, the user can set the infinite life value that will be used if
the alternating stress is beyond the limit of the SN curve. Setting a higher value will
make small stress cycles less damaging if they occur many times. The rainflow and
damage matrix results can be helpful in determining the effects of small stress cycles in
your loading history. The rainflow and damage matrices shown in Figure 13 illustrates
the possible effects of infinite life. Both damage matrices came from the same loading
(and thus same rainflow matrix), but the first damage matrix was calculated with an
infinite life if 1e6 cycles and the second was calculated with an infinite life of 1e9
cycles.
FIGURE
Model > Static Structural > Solution > goodman stress life rl
TABLE
Model > Static Structural > Solution > goodman stress life rl > Results
Object Name Life

State
Damage Safety Factor Equivalent Alternating Stress
Solved
Scope
Geometry
All Bodies
Definition
Type
Design Life
Life
Damage Safety Factor Equivalent Alternating Stress

1.e+009 cycles
Page93

Results
Minimum
1.e+012 cycles
8.895
4.7782 Pa
1.e-003
Maximum
6.4722e+007 Pa
Material Data
Structural Steel 2
TABLE
Structural Steel 2 > Constants
Structural
Young's Modulus
2.e+011 Pa
Poisson's Ratio
0.3
Density
7850. kg/m
Thermal Expansion
1.2e-005 1/C
2.5e+008 Pa
2.5e+008 Pa
4.6e+008 Pa
Compressive Ultimate Strength 0. Pa

Thermal
60.5 W/mC
Specific Heat
434. J/kgC
Electromagnetics
10000
Resistivity
1.7e-007 Ohmm
Page94
FIGURE
Structural Steel 2 > Alternating Stress
TABLE
Structural Steel 2 > Alternating Stress > Property Attributes
Interpolation
Log-Log
Mean Curve Type Mean Stress
Page95
TABLE
Structural Steel 2 > Alternating Stress > Alternating Stress vs. Cycles
Cycles
Alternating Stress Pa
10.
3.999e+009
20.
2.827e+009
50.
1.896e+009
100.
1.413e+009
200.
1.069e+009
2000.
4.41e+008
10000
2.62e+008
20000
2.14e+008
1.e+005 1.38e+008
2.e+005 1.14e+008
1.e+006 8.62e+007
FIGURE Structural Steel 2 > Strain-Life Parameters
Page96
TABLE
Structural Steel 2 > Strain-Life Parameters > Property Attributes
Display Curve Type Strain-Life

TABLE
Structural Steel 2 > Strain-Life Parameters > Strain-Life Parameters
Strength Coefficient Pa
9.2e+008
Strength Exponent
-0.106
0.213
Ductility Exponent
-0.47
Cyclic Strength Coefficient Pa
1.e+009
Cyclic Strain Hardening Exponent 0.2
Page97
Wind analysis
Contents
1. File
Table
2. Mesh
Table
3. Physics
Table
Table
4. Solution
Table
5. User
Figure
Figure
Figure 4
1 File
2 Mesh
Information
for
Information
for
3 Domain
4 Boundary
Physics
Physics
for
for
5 Boundary
Flows
for
Report
windanalysiscfx11_001
Report
Report
Report
Data
2
3
Fig: Wind analysis
Page98
1. File Report
Table 1. File Information for windanalysiscfx11_001
Case
File Path
D:/pressurevesselanalysis/windanalysiscfx11_001.res
File Date
15 March 2008
File Time
03:46:08 PM
File Type
CFX5
File Version 11.0

Fluids
Air at 25 C
Solids
None
Particles
None
Figure 2. pressure distributation on face of vessel

Page99
2. Mesh Report
Table 2. Mesh Information for windanalysiscfx11_001
Domain
Nodes
Elements
pressurevessel
7338
28308
Figure 3. streamline and pressure representation
Page100
3. Physics Report
Table 3. Domain Physics for windanalysiscfx11_001
Name
Location Type Materials
pressurevessel B4
Models
Heat Transfer Model = Isothermal

Turbulence
Model
=
SST
Fluid Air at 25 C Turbulent Wall Functions = Automatic
Buoyancy Model = Non Buoyant
Domain Motion = Stationary
Table 4. Boundary Physics for windanalysiscfx11_001
Domain
Name
pressurevessel inlet
Location
inlet
Type
Settings
Inlet
Flow Regime = Subsonic

Normal Speed = 47 [m s^-1]
Mass And Momentum = Normal
Speed
Eddy Length Scale = 0.1 [m]
Fractional Intensity = 0.05
Turbulence = Intensity and
Length Scale
Flow Regime = Subsonic
Mass And Momentum = Static
Pressure
Relative Pressure = 0 [Pa]
pressurevessel outlet
outlet
Outlet
pressurevessel symp
symp
Symmetry
pressurevessel body
body
Wall
Wall Influence On Flow = No

Slip
pressurevessel freewalls
freewalls
Wall
Wall Influence On Flow = Free

Slip
F41.4,
F45.4
Wall
Wall Influence On Flow = No

Slip
pressurevessel
pressurevessel
Default
Page101
4. Solution Report
Table 5. Boundary Flows for windanalysiscfx11_001
Mass Flow
Momentum
Location
Type
body
Boundary 0.0000e+00
-1.7561e+03 2.7605e+02
-8.3776e+01
freewalls
Boundary 0.0000e+00
-1.4953e+02 0.0000e+00
0.0000e+00
inlet
Boundary 1.7405e+02
-5.1811e-07 -8.5229e+03 1.5579e-06
outlet
Boundary -1.7405e+02 1.3129e+01
8.1929e+03
-2.3151e+00
pressurevessel Default Boundary 0.0000e+00
-1.9325e-02 5.4447e+01
8.5967e+01
symp
1.8922e+03
0.0000e+00
Boundary 0.0000e+00
0.0000e+00
By interpolation we get: for 41 m/s of

wind speed the wind pressure is 730
N/ m2
and from the standard wind
load table we compare the result

which is very accurate.
Page102
INTRODUCTION TO GLASS LINING
Introduction of Glass lining (Glasteel)

In recent years, because of the expansion of the chemical process and pharmaceutical
industries world-wide and increased concerns for safety and quality control, Pfaudler
began investigating new approaches in glass development that would lead to a glass
composition that could be made available to all users of glass-lined equipment.
Page103

Together with the chemical process industry and with the co-operation of Pfaudler
divisions around the world, Pfaudler established the criteria for a new composition:
A non-crystalline structure.
Increased resistance to acid and alkali corrosion.
High resistance to impact.
High resistance to thermally induced stresses.
A formulation that could be easily produced by all Pfaudler manufacturing plants.
The result is Glasteel 9100, Pfaudler's first "international glass", offering an unmatched
combination of corrosion resistance, impact strength, thermal shock resistance, nonadherence and heat transfer efficiency.
Now GMM Pfaudler customers, regardless of where their processing operations are
located, can purchase a single glass system and be assured of getting the same high
quality worldwide. With Glasteel 9100 , GMM Pfaudler sets a standard the world can
depend on.
glass. However, these are very recipe sensitive and general statements cannot usually be
made. An exception to this are chemistries that involve the element silicon (Si),
especially when ionised, e.g. Si, SiO. Relatively small amounts of dissolved SiO can be
highly effective in reducing the corrosion rate of the Glasteel 9100 system, thereby
greatly extending its usage range. It has also been shown that colloidal silica additions to
recipes containing the highly corrosive fluorine ion (F-) can drastically reduce the
corrosive rate.
Page104

Water
Pure Water
Pure water in the liquid phase is not very aggressive. Its behaviour resembles highly
diluted acid and corrodes only the surface layer of the glass ("ion exchange process"). At
170C, a corrosion rate of 0.1 mm/year can be expected.
But because this water is an unbuffered, pH-unstable system, even a slight alkalization
can change the situation. If there is a shift toward higher pH values, the isocorrosion
curves for diluted alkaline solutions have to be consulted for orientation purposes.
Glasteel 9100 is highly resistant to condensing water vapour. However, to counter the
possible danger of the condensate shifting to an alkaline pH, it is recommended that the
vessel contents be slightly acidified with a volatile acid, e.g. hydrochloric or acetic acid.
It is also highly recommended that the unjacketed top head be insulated or heat traced to
reduce condensation formation.
Agueous Neutral pHMedia
With these type media, e.g. tap water, salt solutions, corrosion rate depends greatly on the
type and quantity of the dissolved substance. Carbonates and phosphates usually increase
the rate while alcohols and some ionic species, e.g. A13+, Zn2+ Ca2+, may reduce it.
Alkalis
As alkali concentration rises, corrosion rate increases. Also, the temperature gradient for
alkaline glass corrosion, is steeper. The result is that concentrated alkalis require a more
definite setting of the temperature limits.
The corrosion rate of concentrated alkaline solutions cannot be expressed by the pH value
alone. For aqueous solutions of alkaline materials with a pH value of 14, the particular
concentration must also be considered to establish appropriate operating temperatures.
Other factors affecting alkaline corrosion are the specific reaction and the dissolving
ability of the chemical, the influence of the nature and amount of other dissolved
substances and agitation.
Page105

Isocorrosion curves for sodium hydroxide, potassium hydroxide, sodium carbonate and
ammonia take into account technically relevant parameters influencing the rate of
corrosion; for example, the volume/ surface area ratio, inhibition effects by calcium ions,
alkaline concentration and temperature.
Under actual operating conditions, even very slight contamination (tap water in sodium
hydroxide, for example) can cause major changes in the rate of corrosion. Other factors,
such as product velocity and splash zone, can affect the corrosion rate as well. Due to
these interactive complexities, meaningful testing is strongly advised.
To eliminate the influence of the testing equipment on the rate of corrosion, procedures
are carried out in polypropylene bottles. For solutions above the boiling point, autoclaves
with PTFE inserts were used. By comparing the results with control experiments, it is
proven that the testing equipment does not have an inhibiting effect.
Pfaudler Ultra-Glas 6500
1 . Extends the range of Glasteel applications.

2. Allows safe and easy handling of high temperature processes
never before approved for Glasteel equipment.
3. Provides potential for reduced cycle time compared to conventional
vessel glass.
4. Provides extended thermal shock protection for faster heating
and cooling.
5. Provides increased operating safety margin through its enhanced
thermal protection.
6. Is ideal for the higher temperatures required by today's chemical
process applications.
Page106

The features of GMM Pfaudler Ultra-Glas 6500 are the result of changes in glass
composition and material preparation, altered applications and firing procedures, as well
as changes in equipment design and materials of construction. These changes permit
trouble-free application of the required high-stress coating and provide the highly
corrosive-resistant glass-lined surface for which Pfaudler has been respected for years.
Technical details of corrosion rates in common chemicals and thermal operation limits
are available on request.
Temperature Limits
Although Ultra-Glas 6500 has a high degree of helpful compressive stress in the glass
layer there are definite limits to the level of thermal stress which the glass can withstand
without incurring damage:
Only two thermal conditions must be considered when determining the temperature
limits:
A. Introduction of media into a vessel.
B. Introduction of media into a jacket.
CAUTION: "Safe" operating temperatures vary with conditions. Because so many
variables are involved, temperature ranges are given only as a guide. Where in practical,
operation below the maximum and above the minimum is recommended. Contact
Pfaudler for details.
Type 4300 Glass Coatings
Type 4300 glass coatings represent a new aspect of this tradition and are designed to
bridge a perceived gap in the application range. GMM Pfaudler Type 4300 glass is still
an acidic type of glass, but its primary application is based on improved alkali resistance.
Type 4300 glass coatings are advisable wherever alkaline conditions prevail during the
Page107

cycle, or as a result of concentration and temperature, or where concentration and/or
temperature conditions exceed permissible limits for conventional glass.
In addition, Type 4300 glass coatings are advisable where any of the following
conditions exist:
Protection of alkaline products against metal contamination.
Danger of discoloration of alkaline products due to incorporation of metals.
Stabilization of high-molecular alkalis sensitive to metal contact.
Inadequate redox stability of the vessel material in the alkaline range.
Compared to our world renowned standard glass, Type 4300 has three times better
alkali resistance. This means that higher process temperatures can be used, or that, under
otherwise equal conditions, these glass coatings will have three times the life
expectations.
The Type 4300 glass does make a slight concession in the area of acid resistance.
Although it is adequate for mild service, it is not recommended for aggressive acid
conditions.
Corrosion Resistance
For pure acids and bases most commonly used in the chemical industry , technically
relevant parameters influencing the rate of corrosion (for example, the volume/surface
area ratio, inhibition effects, concentration, and temperature) are considered.
In practical operation these materials are always encountered with liquid additives,
dissolved substances or gases which may have positive or negative effects on resistance.
We therefore recommend performing corrosion tests or contacting a Pfaudler consultant
to assure material suitability for individual processes.
The Need For PPG
Page108

When the requirements of the Bulk Drug industry were studied recently, in context of the
stringent requirements of GMP and FDA, the need for a different glass was evident. Two
of the requirements of the pharmaceutical industry are increased purity in order to comply
with the FDA and GMP requirements and alternating alkali/acid operation.
The process equipment of the chemical and pharmaceutical industries has so far been
very similar - especially in terms of glasslined reactors and components. In light of the
survey, Pfaudler's response was a novel glass tailored to the needs of manufacturing
pharmaceutical products, vitamins and fine chemicals.
Page109
Appendix
Page110
Page111
Page112
Page113
BIBLOGRAPHY
Dennis Moss
Hiadri Farzdak
C.S Sharma
Somnath chatopadhay
For Ansys :
Tutorials of cfx 11.0
Page114

Design of Pressure Vessels PDF

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DESIGN AND ANALYSIS OF

JIMIT VYAS AND MAHAVIR SOLANKI

GUIDED BY : MR BHAVESH PATEL

I wish to express my deepest thanks and gratitude to my elite guide Mr Bhavesh

Jimit Vyas & Mahavir Solanki

conclusively, this modus operandi of design based on technical standard and

Unfired Cylindrical Pressure Vessels

a) category A: longitudinal welded joints within the main sheet, communicating

Definition and Examples

LOCAL PRIMARY MEMBRANE STESS, PL

equipment, ladders, platforms, piping and vessel contents.

FAILURE IN PRESSURE VESSELS

Plastic instabilityIncremental collapse; incremental collapse is cyclic strain

Mono-bloc- Solid vessel wall.

maintained at a margin below yield strength. The elastic deformation residual in

Fig : nozzle reinforcement

Normal reinforcement methods apply to

13. Re-pads over seams

is acceptable, provided the

efficiency of the ligaments between the holes is acceptable.

required for the two openings.

Multiple openings may be reinforced s an opening equal in diameter to that of a

circle circumscribing the multiple openings.

DESIGN OF PRESSURE VESSELS

Engineering Design Guidelines For Pressure Vessels

CODES AND STANDARDS

For Pressure vessels

For Pressure vessels (Selectively for high

ASME SEC. VIII DIV.2

For Storage Spheres

ASME SEC. VIII DIV.3

For Pressure vessels (Selectively for high pressure)

API 650 / IS: 803

For Storage Tanks.

For Low Pressure Storage Tanks,

Cryogenic Storage Tanks (Double Wall)

ASME SEC. VIIIDIV.1

For workmanship of Vessels not categorized under

ISO R831/ IBR

For Steam producing, steam storage catch water

IS: 9178 / DIN 1055

For Silos Hoppers and Bins

BS: 4994 / ASME SEC X

FRP vessels / tanks.`

Welded Aluminium Alloy Storage Tanks.

For material specification

For material specification (Tanks)

IS: 875 / SITE DATA

For wind load consideration

IS: 1893 / SITE DATA

For seismic design consideration

For Local load / stress analysis

MINIMUM SHELL/HEAD THICKNESS

Minimum thickness shall be as given below

Wall thickness = Dia/1000 +1.5 + Corrosion Allowance

Based on inside diameter

All Clad/Lined Vessels

Based on inside diameter

Vessels (Thickness>50mm) Based on inside diameter

All Other Vessels

Based on outside diameter

Tanks & Spheres

Based on inside diameter