High Pressure Vessel Thickness Calculations

Problem (1): A cylindrical shell of a vessel has an inside diameter 2 m and is subjected to an internal
pressure 5 kg/cm2. Calculate the thickness and corresponding deflection. Allowable tensile stress of the
material is 1020 kg/cm2.

Poissons ratio µ = 0.3 ; Young’s modulus of elasticity E= 2.09 × 106 kg/cm2

Given -: Di = 2 m 200 cm;  R1 = 100 cm

P = 5 kg/cm2

ft = 1020 kg/cm2

µ = 0.3

E= 2.09 × 106 kg/cm2

To Prove -: i) t = …………….cm

ii) w = ………… cm

Solution-: We know that

If the vessel is thick cylinder then

 f t  pi 
t  R1   1
 f t  pi 
 

 1020  5 
t  100    1
 1020  5 

t  0.4914 cm……………………………………Ans

We also know that t  R2  R1

 R 2  t  R1

 R2  0.4914  100

 R2  100 .4914 cm

And maximum radial deflection is given by

 p i R1 (2   )
3

w
E ( R2  R1 )
2 2

5  100 3 (2  0.3)
w
2.09  10 6 (100.4914 2  100 2 )

w  0.0413 cm ……………………………….Answer

Problem (2): The inside radius of a hydraulic cylinder vessel is 20 cm. Calculate the required
thickness if it operates at 500 kg/cm2. The permissible tensile stress of material is 2400 kg/cm2.

Given -: R1 = 20 cm D = 400 cm

P = 500 kg/cm2

ft = 2400 kg/cm2

To Prove -: i) t = …………….cm

Solution-: We know that

If the vessel is thick cylinder then

 f t  pi 
t  R1   1
 f t  pi 
 

 2400  500 
t  20    1
 2400  500 

t  4.7088 cm……………………………………Answer

If the vessel is thin then

pD
t
2 fJ

500  40
t
2  2400  1.0

t  4.1667 cm…………………………………….Answer
Problem (3): A high pressure vessel is to be operating at 100 MN/m2. The inside diameter of
vessel is 30.5 cm. Steel having yield stress 466 MN/m2 is selected for fabrication. Estimate the
wall thickness required by various theories with a factor of safety 1.6.

Given -: Di = 30.5 cm  R1 = 15.25 cm 0.1525 m

P = 100 MN/m2

fyp = 466 MN/m2

F.S. = 1.6

To Prove -: i) t = …………….cm (maximum principal stress theory)

ii) t = …………….cm(maximum shear stress theory)

iii) t = ……………..cm (maximum energy distortion)

Solution-: We know that

Permissible tensile stress ft = (fyp/F.S.) = (466/1.6) = 291.25 MN/m2

a) According to maximum principal stress theory, thickness can be calculated as

 f t  pi 
t  R1   1
 f t  pi 
 

 291.25  100 
t  0.1525    1
 291.25  100 

t  0.0656 m or 6.56 cm……………………………………Answer

b) According to maximum shear stress theory, thickness can be calculated as

f yp
K
f yp  3Pi

466
K
466  3  1.6  100

 K  1.5701
 But

R2
K
R1

1.5701  0.1525  R2

R2 = 0.2395 m………………………… Answer

And we know that

t  R2  R1

t  0.2395  0.1525

t  0.087 m………………………………..Answer

c) According to maximum energy distortion, thickness can be calculated as

 t  t 
Pi  2.31 f t  1  
 2 R2  2 R2 

 t  t 
Pi  2.31 f t  1    t  R2  R1
 2(t  R1 )  2(t  R1 ) 

 t  t 
100  2.31  291.25 1  
 2(t  0.1525)  2(t  0.1525) 

 t  t 
0.1486   1  
 2t  0.305)  2t  0.305) 

 t  2t  0.305  t 
0.1486    
 2t  0.305)  2t  0.305) 

 t  t  0.305 
0.1486    
 2t  0.305)  2t  0.305) 

 t 2  0.305t 
0.1486   
2 
 (2t  0.305) 
 0.1486 (2t  0.305 ) 2  (t 2  0.305 t )

0.1486 (4t 2  2  2  0.305 t  0.305 2 )  (t 2  0.305 t )

0.1486 (4t 2  1.22t  0.0930 )  (t 2  0.305 t )

t 2  0.5944 t 2  0.1813 t  0.305 t  0.01382  0

0.4056 t 2  0.1237 t  0.01382  0

t  0.0869 m or 8.69 cm …………………………………….Answer

Problem (4): A vessel is to be designed to withstand internal pressure of 150 MN/m2. An ID of

300 mm is specified and having a yield point of 450 MN/m2 has been selected. Calculate the
wall thickness required by various theories with F.S. is 1.5.

Given -: Di = 300 mm  R1 = 150 mm 0.15 m

P = 150 MN/m2

fyp = 450 MN/m2

F.S. = 1.5

To Prove -: i) t = …………….cm (maximum principal stress theory)

ii) t = …………….cm(maximum shear stress theory)

iii) t = ……………..cm (maximum energy distortion)

Solution-: We know that

Permissible tensile stress ft = (fyp/F.S.) = (450/1.5) = 300 MN/m2

a) According to maximum principal stress theory, thickness can be calculated as

 f t  pi 
t  R1   1
 f t  pi 
 

 300  150 
t  0.15    1
 300  150 

t  0.1098 m ……………………………………Ans
b) According to maximum shear stress theory, thickness can be calculated as
f yp
K
f yp  3Pi

450
K
450  3  1.5  150

 K  2.7321

But

R2
K
R1

 2.7321  0.15  R2

R2 = 0.4098 m………………………… Ans

And we know that

t  R2  R1

t  0.4098  0.15

t  0.2598 m………………………………..Ans

c) According to maximum energy distortion, thickness can be calculated as

 t  t 
Pi  2.31 f t  1  
 2 R2  2 R2 

 t  t 
Pi  2.31 f t  1    t  R2  R1
 2(t  R1 )  2(t  R1 ) 

 t  t 
150  2.31 300 1  
 2(t  0.15)  2(t  0.15) 
  t  t 
0.2164   1  
 2t  0.30)  2t  0.30) 

 t  2t  0.30  t 
0.2164    
 2t  0.30)  2t  0.30) 

 t  t  0.30 
0.2164    
 2t  0.30)  2t  0.30) 

 t 2  0.30t 
0.2164   
2 
 ( 2t  0.30) 

0.2164 (2t  0.30 ) 2  (t 2  0.30t )

0.2164 (4t 2  2  2  0.30t  0.30 2 )  (t 2  0.30t )

0.2164 (4t 2  1.2t  0.09 )  (t 2  0.30t )

t 2  0.8656 t 2  0.2596 t  0.30t  0.01947  0

0.1344 t 2  0.0404 t  0.01382  0

t  0.2038 m …………………………………….Answer

Problem (5): A thick walled (monobloc) high pressure vessel has 500 mm diameter. It is
subjected to an internal pressure of 600 bars. The yield strength of material is 5000 kg/cm2.
Ultimate tensile strength of material is 6500 kg/cm2. Calculate the thickness of vessel according
to the various theories of failure. F.S is 1.4. Also estimate the tangential stress and radial stress
variation along the vessel wall.

Given -: Di = 500 mm  R1 = 250 mm 25 cm

P = 600 bar 611 kg/cm2

fyp = 5000 Kg/cm2

ft = 6500 Kg/cm2

 = 1.4

To Prove -: i) t = …………….cm (maximum principal stress theory)

 ii) t = …………….cm(maximum shear stress theory)

iii) t = ……………..cm (maximum energy distortion)

Solution-: We know that

a) According to maximum principal stress theory, thickness can be calculated as

 f t  pi 
t  R1   1
 f t  pi 
 

 6500  611 
t  25    1
 6500  611 

t  2.4716 cm ……………………………………Answer

And we know that

t  R2  R1

 R2  25  2.4716

 R2  22.5284 cm

b) According to maximum shear stress theory, thickness can be calculated as

f yp
K
f yp  3Pi

5000
K
5000  3  1.4  611

K  1.1921

 K  1.1921

But

R2
K
R1
 1.1921  25  R2

R2 = 29.8025 cm………………………… Answer

And we know that

t  R2  R1

t  29 .8205  25

t  4.8025 cm………………………………..Answer

a) According to maximum energy distortion, thickness can be calculated as

 t  t 
Pi  2.31 f t  1  
 2 R2  2 R2 

 t  t 
Pi  2.31 f t  1    t  R2  R1
 2(t  R1 )  2(t  R1 ) 

 t  t 
611  2.31 6500 1  
 2(t  25)  2(t  25) 

 t  t 
0.0407   1  
 2t  50)  2t  50) 

 t  2t  50  t 
0.0407    
 2t  50)  2t  50) 

 t  t  50 
0.0407    
 2t  50)  2t  50) 

 t 2  50t 
0.0407   
 (2t  50)
2


0.0407 (2t  50 ) 2  (t 2  50t )

0.0407 (4t 2  2  2  50t  50 2 )  (t 2  50t )

 0.0407 (4t 2  200 t  2500 )  (t 2  50t )

t 2  0.1628 t 2  8.14t  50t  101 .75  0

0.8372 t 2  41 .86t  101 .75  0

t  2.3228 cm …………………………………….Answer

The tangential stress variation can be estimated by co-relation

 Pi R1 2  R2 2 
f t   1 
2 

2 

2
 2
( R R1 )  R1 

Use R1 = 25, 26, 27, 28, 29, 30 cm; R2 = 30 cm, Pi = 611 kg/cm2

 611 25 2  30 2 
f t   1  2
2 
 f t  3388.27 kg/cm2 R1 = 25 cm
 (30  25 )  25
2


 611 26 2  30 2 
f t   1  2
2 
 f t  4298.82 kg/cm2 R1 = 26 cm
 (30 2
 26 )  26 

 611 27 2  30 2 
f t   1  2
2 
 f t  5820.57 kg/cm2 R1 = 27 cm
 (30  27 )  27
2


 611 28 2  30 2 
f t   1  2
2 
 f t  8870.03 kg/cm2 R1 = 28 cm
 (30  28 )  28
2


 611 29 2  30 2 
f t   1  2
2 
 f t  18029.67 kg/cm2 R1 = 29 cm
 (30  29 )  29
2


 611 25 2  30 2 
f t   1  2
2 
 f t  0 kg/cm2 R1 = 30 cm
 (30  25 )  25
2


The radial stress variation can be estimated by co-relation

  Pi R1 2  R2 2 
f r   
2 
 1


2 2
 2
( R R1 )  1
R 
Use R1 = 25, 26, 27, 28, 29, 30 cm; R2 = 30 cm, Pi = 611 kg/cm2

  611 25 2  30 2 
f t    2  1
2 
f r  -600 kg/cm2 R1 = 25 cm
 (30  25 )  25
2


  611 26 2  30 2 
f t    2  1
2 
f r  -597.53 kg/cm2 R1 = 26 cm
 (30  26 )  26
2


  611 27 2  30 2 
f t    2  1
2 
f r  -588.31 kg/cm2 R1 = 27 cm
 (30  27 )  27
2


  611 28 2  30 2 
f t   
2 
  1 f r  -567.73 kg/cm2 R1 = 28 cm
 (30 2
 28 )  28 2


  611 29 2  30 2 
f t    2  1
2 
f r  -599.9 kg/cm2 R1 = 29 cm
 (30  29 )  29
2


  611 30 2  30 2 
f t    2  1
2 
f r  0 kg/cm2 R1 = 30 cm
 (30  30 )  30
2
