182 PROCESS EQUIPMENT DESIGN operation, since the edges cannot be formed to the deserved cur- yature by the method of rolling alone. It is advisable tu clamp together the two adjoining edges of the shell. The clamps can be removed as soon as these edges are tack welded. Finally the longitudinal seam of the shell is welded by any one of the fusion welding methods. For large diameter vessels and heavy sections, the submerged arc method is most suitable. This method is automatic, and gives a neat and regutar weld which is free from any defects. In the case of copper and some special steel shells, after the initial rolling and welding, the shells are rolled again to give a uniform circular shape. The rollers on such rolling machines are removable for insertion of the original shell. Vessels having wall thickness above 5 cm are fabricated by forging. The various types of dished heads are produced from blanks by either pressing them in a fydraulic press or by spinning them to the desired shape. m the second method the blank is made to rotate, while a pair of rollers are made to exert pres- sure on it. The blank is gradually moved in the radial direc- tion simultaneously. The pressure of the rollers is therefore, gradually transferred to concentric areas on the blank. This pressure gives rise to the dished shape as required. It may be necessary to form a bevel on the edge of the head, for welding it to the shell, This can be produced by oxy-acetylene torch, which can be attached to the tool post of a vertical boring machine. The head is slowly rotated with the table of: the machine, while the torch is being operated. The head is con- nected to the shell by welding and the assembly may be heat treated depending on the thickness. Holes in the shell or the head can be made by an oxy-acety- lene torch which is attached to a compass or @ pantograph mebhanism. The edges of the holes may be upset by a hydrau- lic press, by heating the area around the hole locally. The noz- zles are welded to these openings as required. It is desirable to tack weld these nozzles and check their correct position and alignments prior to the final welding. Nozzles may be fabricated from plates by the method of rolling and welding or may be formed to the desired shape byPRESSURE VESSELS 183 forging. Flanges are produced by forging with the help of a steam hydraulic press. After suitable heat treatment, these are machined to give the final shape and size. Post weld heat treatment is carried out in the case of carbon and low alloy ferritic steels either by normalising or by stress relieving. Special heat treatment is necessary in case of alloy steels and non-ferrous metals. Thermal stress relieving is neces- sary when the vessel is (a) intended for containing toxic or inflammable material ; (b) intended for operation below 0°C {c} intended for use with media liable to cause stress corrosion cracking (d) subject to excessive stress concentration or risk of fatigue due to changing loads (e) under risk of brittle fracture (f) to have dimensional accuracy and shape in. service (g) to be made of a plate thickness (including corrosion allowance) at any welded joint in the vessel shell or head, which exceeds the values given in Table 6.9. * The vessel is stress relieved as a whole in an enclosed fur- nace wherever practicable. Where it is not practicable to do so, special precautions will have to be taken to heat the vessel in sections. To obtain good finish the vessel is sand blasted, ground and polished. 6.13 Numerical Problem Data (Plate 1) (a) Shell Internal diameter (Approx.) 1200 mm Material—stainless steel (0.5 Cr 18 Ni 11 Mo 3) Permissible stress at 150°C 13.00 kg/mm? Tnternal pressure 3.00 kg/om® (b) Head-—Flanged and shallow dished External diameter 1200 mm Crown radius 1200 mm Kauckle radius 72mm Material—Same as shell {Continued on page 185)184 PROCESS EQUIPMENT DESIGN Table 6.9 Maximum Plate Thickness above which Post Weld Heat Treatment is Required Percentage Chemical Composition and i Mechanical Properties Plate Thickness Carbon 0.20 Max Manganese 1.00 Max Residual elements 0.80 Max Specified minimum yield strength 26 kef/mm* Max Carbon 0.25 Max Manganese 1.60 Max Residual elements 0.80 Max Specified minimum yield strength 38 kgf/mm* Max Carbon 0.30 Max Manganese 1.20 Max Residual element 0.40 Max Specified minimum yield strength 38 kgf/mm? Max Catbon 0.25 Max Manganese 1.60 Max Chromium 0.60 Max 30mm However, for fine grain- ed steel this may be increased to 38 mm subject to preheating ‘over 30 mm Molybdenum 0.60 Max Vanadium 0.12 Max Residual or other elements 0.80 Max Specified minimum yield strength 44 kgf/mm? Max Carbon 0.35 Max Manganese 1.20 Max Residual or other element 0.40 Max : Specified minimum yield strength 44 kefimm? Max Carbon, 0.25 Max Manganese 1.60 Max Chromium 1.50 Max Molybdenum 1.50 Max Vanadium 0.16 Max Residual or other element 0.80 Specified minimum yield strength 44 kefimm? Max All thicknesses All other ferritic steels All thicknessesPRESSURE VESSELS 185 (c) Flanges Materiai—carbon steel (IS—2002) grade I Permissible stress (upto 250°C)—9.5 kg/mm? Gasket asbestos (d) Bolts Material—Hot rolled carbon steel Permissible stress—upto 50°C 5.87 kg/mm? Permissible stress—upto 200°C 5.45 kg/mm? (©) Nozzle—(welded to head) Internal diameter—150 mm. Thickness — 3mm Material — same as shell 6.13.1 DestGNn or SHELI, From equation 6.3 (Internal design pressure is 340.3=— 3,3 kg/em’) PD. 3.3.x 1200 2fl-p 2xTSOXIO x0 853.3 =1.80 mm. 2 mm thickness will be satisfactory, However, for rigidity a minimum thickness of 4 mm is commonly used. No corrosion allowance is necessary for stainless steel, Combined loadings (based on 2 mm thickness): From equation 6.5 & £ fn LEED 35.1200) 99g kglem? (tensile O-FT Bx 10 From equation 6.6 3 A Lp 33 126 497 kgjem? (tensile) © O* 4B x10 From equation 6.7 W 3200x108 _ _— . LD ED EX MID 424 kg/em? (ccompressive) No wind lead A=0 Sr=f,t+h= 497 —42.4=454.6 kg/cm? (tensile) Torque due to offset piping ete.—50 kgm186 PROCESS EQUIPMENT DESIGN From equation 6.10 Tr 50x 108 x 10® LP By DEH 2K 1198 C100) 05 Ke lem fy is negligible as compared to other stresses From equation 6,11 Sr= [ossr—oss 454 6)-4-(454 | 3 ==860 kg/cm? (tensile) Both fr and f, are less than the permissible tensile stress (1300 kg/om*) 6.13.2 HEAD DESIGN—-FLANGED AND SHALLOW DisHED Heap From equation 6.23 (Internal design pressure 3.3 kgj/em*) = 3.3 x 1200 1.75, meen. 1300 % 1 =2.66 mm ; J=1 1 7206 W= 5 (3+/ 1200) _. 4 7] 1,75 Use 4mm thickness (No corrosion allowance is necessary) Straight flange length 3x4=12 mm Minimum specified 20 mm 6.13.3 FLANGES FoR Tor HEAD AND SHELL ‘The shell and top head are connected by a flanged joint. The vessel is made of stainless steel for which the flange may be selected from Indian Standard specification (IS-4868--Welded shell flanges for stainless steel pressure vessels and equipment) Table | of the specification gives a flange of 1200 mm nominal diameter. This requires a minimum shell thickness of 6 mm. The shell thickness as per design is only 4 mm. It is ‘therefore, necessary to weld an additional ring between the shell and the flange (see Fig. 6.24). .| | ! i PRESSURE VESSELS 187 The particulars of flange and bolts are as follows— Nominal diameter of flange — 1200 mm Inside diameter of flange — 1202 mm Outside diameter of flange — 1315 mm Outside diameter of stainless steel backing ring — 1240 mm Bolt circle diameter — 1270mm Thickness of flange _- 45 mm Number of bolts — Bier Nominal diameter M20 Tf a flange is not of the standard size, it is necessary to carry out a design procedure as follows: (a) Design of gasket and bolt size ‘The flange is made of carbon steel with a stainless steel lining (raised face) in the form of aring, A flat asbestos gasket of 1200 mm internal diameter and 1240 mm external diameter and 3 mm thickness is used, to cover the raised face. From Tables 6.7 and 6.8 Gasket factor m—2.00 Minimum design seating stress—1{2 kg/cm? L_ (1240-1200) 2 Basic gasket seating width b= =10mm Effective gasket seating width 6=2.5/b,=2.5V10=7.9 mm From equation 6.36 1.9, 1240-41200 Wm =® XT * 9x16 =34000 kg From equation 6,37 7.9 1240-41200 10 * 2x10 x12 (G=1220 mm) Wing =FK2% x2x3.3 + x/4x ( = 4000+ 38400-42400 kg From equation 6.38 An = 34000 "a 387 1240-41200 \# ~Tx10— ) x33 =57.9 cm®188 PROCESS EQUIPMENT DESIGN — 42400 2 my ggg 277.8 om e 1220 Number of bolts= TRE 49 Use 48 bolts From equation 6.39 + I78 4 Diameter of bolt = Vi 4s %h ss 1.435 em Use M 18 bolts Pitch diameter—16.376 mm Minor diameter— 14.480 mm Actual bolt area EP 16.3757 $14.48? _ . = 71 —aNtbo ]x4s=90 om From equation 6.40 ae 1220 20 Am Ber XID ax = 292 cm® The bolt area suggested is satisfactory. Pitch of bolts— 4.75 x 18==85.6 mm Pitch circle diameter (B) . 8.62048 =1310 mim 8=outside diameter of gasket 4-2 x diameter of bolt+12 mm =1240+2x18+12=1278 mm Outside diameter of flange Pitch circle diameter + 2 x diameter of the bolt =1278+2 x18 ==1314 mm {b) Flange thickness From equation 6.41 1 K= ——— 1.5 x42400 x. (310-1220) 2 03+ TEXTES I RIDPRESSURE VESSELS 189 = =2.74 33 y= 1220,f 33 ” 274x950 = 48 mm 6.13.4 Nozzie REINFORCEMENT DESIGN Nozzle is provided on the head (Fig. 6.17) Internal design pressure—3.3 kg/om® From equation 6.3 minimum nozzle thickness 3.3xX150 = FRisOx Tag 70189 mm No corrosion allowance, since the material is stainless steel, Actual thickness t,=3 mm Maximum horizontal distance for compensation (AB)—2150=300 mm Maximum vertical distance for compensation (AD) —~6 2.66-- 15.99 mm or (3.5X2.66-+2.5 x 3)=16.8 mm Area of compensation 150 2.66=400 num? @ Area of compensation Provided by the head A,=150 (3—2.66)=51 mm? (ii) Area of compensation provided by the nozzle A.=2 x2.5 x3 (30,189) =42 mm? (iii) The nozzle does not project inside the vessel H,=0 A,=0 Ayt do+Ay=514+424+0~93 mm! Area of compensation required==400—93— 307 mm’, This can be provided by a ting of 260 mm outside diameter, 156 mm inside diameter and 3 mm thick. Area of compensa- tion by ring =(260~156) 3=312 mm®. This is satisfactory.