| | | | DESIGN OF TALL CYLINDRICAL SELF-SUPPORTING PROCESS COLUMNS 129 48. ILLUSTRATIVE EXAMPLE Detailed mechanical computations are to be prepared for the process column with the design data given below. 1, Design Data Shell inside diameter: $ ft 6 in. Shell overall length: 160 ft Support skirt height: 10 ft Operating hydrostatic head: 10 ft above the bottom t. Operating pressure: 180 psig Design pressure: 220 psig Operating temperature: top half,-45°F bottom, -10°F Design temperature: -50°F Corrosion allowance: in. Material: shell, SA 516 gr. 55 Sq = 55,000/4 = 13,750 psi, use S, = 13,700 psi skirt, top SA 516 gr.55 (Charpy V-notch impact tested) bottom SA 285 gr.C PWHT: yes X-ray: full Weld efficiency: 100 percent Trays: C.S. perforated, number 90, weir height 4 in. Cold insulation thickness: 5 in. Flange rating: 150 Ib min. Minimum hydrostatic test pressure: 330 psig Location: Houston, Texas. The design and fabrication shall comply with the requirements of the applic- able subsections of the ASME Pressure Vessel Code Section VIII, Division 1, 1977 Edition, up to and including 1977 Winter Addenda, 2. Shell Thickness Required for Internal Pressure Shell thickness: °R;|(SE - 0.6P) = (220 X 33.06)/(13,700 - 132) = 0,536 + C.A. 536 + 0.063 = 0.599 in. Use §-in.-thick plate. P= (13,700 X 0.5625)/(33.06 + 0.6 X 0.5625) = 230 psi Pune = (13,700 X 0.625)/(33.0 + 0.6 X 0.625) = 256 psiFrr—C—C— 60 mph. Equivalent load at top: F = 0.00086 X 35 X 6.38 X 170 X 12? = 4,685 Ib. Moment at bottom T.L.: FX 160 = 752,175 lb-ft.DESIGN OF TALL CYLINDRICAL SELF-SUPPORTING PROCESS COLUMNS — 139 Wind moment as computed is higher, no further stress check is required. Estimated cyclic lifetime: Longitudinal cyclic stress at BTL: 0.106 X 752,175/5.5? = 2,635 Ib/in. Stress range S, = 2 X 2,635/1.125 = 4,685 psi. Stress concentration factor 6 = 2.0. Number of cycles to failure: WV = (780,000/2 X 4,685)* = 4.06 X 10° cycles. S.F.=20; N/20 = 2.03 X 10° Safe vibration time: (2.03 X 10° X 1.8/3,600) x (1/24 X 356) = 12 years. 8. Field Hydrotest in Corroded Condition Maximum stress at any point in the vessel should not exceed 0.8 Sy during the hydrotest. Maximum allowable: S, = 13,700 psi Yield strength: Sy = 30,000 psi Maximum allowable ratio of hydrotest stress/design stress: 0.8 X 30,000 13,700 <1 Pressures in the vertical column during hydrotest (see Fig. 4.27): % +O140 PRESSURE VESSEL DESIGN HANDBOOK _Minimum test pressure at top: 1.5 X 220 = Liquid static head to section 2: 71.4 X 0.434 = Test pressure at 2 Liquid static head from 2 to 3: 50 X 0.434 = Test pressure at 3 Liquid static head from 3 to 4: 40 X 0.434 = Test pressure at 4 Liquid static head from 4 to bottom: 1.4 X 0.434 = Test at bottom Maximum allowable test pressure for 150-Ib flanges at bottom: 425 psig > 402 psig. Pressure stress ratios for shell: pra P Rit 0.60 _ Puli + 0.61) SE Et : _ 361 (33.063 + 0.6 X 0.5625) Atsection 2: RTs =""3 700 x 1.0 x 0.5625 ee _ 383 (33,063 + 0.6 X 0.8125) Atsection 3: RTS = 13700 x 1.0 X 08125 Atsecion4: RT, #4013063 +0.6x 1.125) 13,700 X 1.0X 1.125 PD; +0.28) fe age For head: 402 (66.125 + 0.6 X 1.125) At bottom: RT 9. Approximate Weights for Design (1) Operating weight Wo: To section 2 (Fig. 4.23) Top head, § in. thick, 2:1 ellipsoidal Shell, $ in. thick, 472 Ib/ft X 70 ft Top demister with support Tray supports, 2 in. X 4 in. thick, 35 Ib/ring X 45 Manholes, 2, 20-in., 750 Ib X 2 330 psig 31 361 2 383 _18 401 eat - 402 <175 =157<1.75 =1.452<1.75 =0.876< 1.75 ZK 13,700% 10K 1123 087 <1.75 1,200 Ib 33,000 200 1,600 1,500DESIGN OF TALL CYLINDRICAL SELF-SUPPORTING PROCESS COLUMNS 141 Nozzles (estimated) 500 Clips for platforms and ladder (estimated) 500 Insulation, cold, 5 in. thick, 90 Ib/ft X 70 ft (6300) Platforms 3, 3 X 25 ft? x 35 Ib/ft? (2,650) Piping (estimated) (6,000) Ladder 20 lb/ft X 70 ft (1,400) Operating liquid on trays, 1,482 Ib/ft X 45 X (4+ 1/12 (27,000) Trays, 310 Ib/tray X 45 (14,000) Wo at section 2 94,850 Ib Shell, J in. thick, 660 lb/ft X SO ft 33,000 Tray support rings, 25 X 35 Ib/ring 900 Manholes, 2, 20-in., 800 Ib X 2 1,600 Nozzles (estimated) 500 Clips (estimated) 500 Insulation, 50.ft X 90 Ib/ft (4,500) Platforms, 2 X 25 ft? X 35 Ib/ft? (1,750) Piping (estimated) (3,000) Ladder, 20 Ib/ft X SO ft (1,000) Operating liquid, 1,482 Ib/ft X () X 25 (15,500) Trays, 310 Ib/tray X 25 (7800) W, at section 3 164,900 Ib Shell, 1,3; in. thick, 900 1b/ft X 40 ft 36,000 Tray supports, 35 Ib/ring X 20 700 Manholes, 2, 20-in., 850 Ib X 2 1,700 Nozzles (estimated) $00 Clips (estimated) 500 Insulation, 90 Ib/ft X 40 ft (3,600) Platforms, 2 X 25 ft X 35 Ib/ft? (1,750) Piping (estimated) 3,000) Ladder, $0 ft X 20 Ib/ft (1,000) Operating liquid, 1,482 lb/ft X [(;) X 20 + 10] (27,000) Trays, 310 Ib/tray X 20 (6,200) W, at section 5 246,850 Ib Support skirt, flared to 11 ft, 1 in. thick 15,000 Base ring, top ring, stiffeners 3,000 Fireproofing, 4 in. thick (10,000) Operating liquid in bottom head (1,500) Bottom head, 2:1 ellipsoidal, 1 in. thick 2,400 We at base 6 278,750 Ib142 PRESSURE VESSEL DESIGN HANDBOOK (2) Erection weight: 134,800 Ib, no trays 162,800 Ib, with trays. (3) Shop test weight: Wr = 134,800 + 162 ft X 1,482 lb/ft = 375,000 Ib. (4) Field test weight: Wr = 278,750 Ib ~ ins. 14,400 Ib + 122 X 1,482 Ib/ft = 445,150 Ib 10. Remarks 1. When computations for shell thickness were first computerized, the ten- dency was to step up the shell wall by ;& in. to save on material as much as possible, The result was too many shell sections with different thicknesses. This did not prove to be most economical and practical for fabrication and deflection computations. Usually, to divide a. tall column into three to five sections has proved to be satisfactory. 2. For simplicity the standard ASA AS8.1-1955 was used in computing the unit wind load in Fig. 4.23. The unit load w can be computed by the standard ASA AS58.1-1972 without any effect on the computation procedure of the shell thickness. 3. These computations cover the general features of the design. It is expected that careful attention will be given to the preparation of the weld and other details, as well as to materials quality control, fabrication, inspection, and tests. 4, As previously mentioned under the skirt design, for support skirts lapped to the cylindrical shell above the tangent line, the localized bending stresses in the shell dueto the forces normal to the shell surface are small and are considered acceptable. The Code formulas can be used. For the support skirts butted to ellipsoidal, torispherical, or toriconical heads below the tangent lines, the longitudinal membrane stress, as in cylindrical and spherical shells, is readily calculated (pressure stress + longitudinal stress due to axial loads.) The tangential stress will consist of membrane and bending stress components due to the force component normal to the head surface. The com- putations become complex. However, for 2:1 ellipsoidal heads (also torispherical and toriconical heads with similar large knuckle radii) the tangential membrane stress is minimized and the Code formulas can be used if the connecting weld is, at or near the head tangent line and if the centerlines of the supporting skirt and the shell coincide. 5. The Code basic allowable stress S, in compression and in tension for loads in combination with wind loads has been increased (1983) by 20 percent. How- ever, the maximum allowable vessel deflection due to wind load will govern in most cases.