182 PROCESS EQUIPMENT DESIGN operation, since the edges cannot be formed to the deserved cur- vature by the method of rolling alone. It is advisable to 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 regular 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 hydraulic press or by spinning them to the desired shape, {n 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 ty 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- jene torch which is attached to a compass or a pantograph methanism. 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 beat 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/cm? (b) Head--—Flanged and shallow dished External diameter 1200 mm Crown radius 1200 mm Knuckle 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 ; Mechanical Properties Plate Thickness Carbon 0.20 Max j Manganese 1.00 Max oo elements 0. fo Nan, b Specified minimum yield strengt 26 kafimm? Max 410.mm Carbon 0.25 Max Manganese 1.60 Max Residual elements 0.80 Max However, for fine grain- Specified minimum yield strength ed steelS this may be 38 kgf/mm? Max increased to 38 mm subject to preheating Carbon 0.30 Max over 30 mm Manganese 1.20 Max Residual element 0.40 Max Specified minimum yield strength 38 kgf/mm? Max Carbon 0.25 Max 7 Manganese 1.60 Max Chromium 0.60 Max Molybdenum 0.60 Max Vanadium 0.12 Max Residual or other elements 0.80 Max Specified minimum yicld strength 44 kgf/mm? Max 4 20 mm Carbon 0.35 Max Manganese 1.20 Max Residual or other element 0.40 Max - Specified minimum yield strength 44 kefimm?® Max J Carbon, 0.25 Max } Manganese 1.60 Max Chromium 1.50 Max . Molybdenum 1.50 Max All thicknesses Vanadium 0.16 Max Residual or other element 0.80 Specified minimum yield strength 44 kefimm? Max J All other ferritic steels All thicknessesPRESSURE VESSELS 185 (c) Flanges Material—carbon steel (IS—2002) grade | Permissible stress (upto 250°C)—9.5 kg/mm? Gasket asbestos (d) Bolts Material—Hot rolied 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 DESIGN or SHELL, From equation 6.3 (Internal design pressure is 3+0.3= 3.3 kgjem?) PD: _ 3,3 1200 2fl-p ~TXVSOx 1x0 8579.3 =1.80 mm. t= 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 min thickness): From equation 6.5 5 fen PDA 33 (1200) (200) _.993 kelem® (tensile) O-FTSx1O From equation 6.6 3 af Sf =P p33 SUES 497 kglem? (tensile) & OAR x10 From equation 6.7 W 3200x102 | 5 7 SPRD TH aia 74 kg/cm? (compressive) No wind load f,=0 So=f,tfy=497 ~ 42.4 = 454.6 kg/cm? (tensile) Torque due to offset piping etc.—50 kgm186 PROCESS EQUIPMENT DESIGN From equation 6.10 _ T 50x 10°x10@ Le PBA TR BR IIIS CD) 0 KBlem* Jy is negligible as compared to other stresses From equation 6.11 f at Fr= | (993° —(093 x 454.6)-+-(454 6) } ae J ==860 kg/cm’ (tensile) - Both fz and f, are less than the permissible tensile stress (1300 kg/em?) 6.43.2 HEAD DESIGN—-FLANGED AND SHALLOW DisHeD Heap From equation 6.23 (Internal design pressure 3.3 kgjem*) fp 331200 1.75. , me 2xT300%1 ? =2.66 mm 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 1 of the specification gives a lange of 1200 mm nominal diameter. This requires a minimum shell thickness of 6mm. The shell thickness as per design is only 4mm. It is therefore, necessary to weld an additional ring between the shell and the flange (see Fig. 6.24).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 i ring — 1240 mm Bolt circle diameter — 1270mm Thickness of flange — 4mm Number of bolts = 48 Nominal diameter M20 If 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 i is made of carbon steel with a stainless steel lining (raised face) i in the form of a ring. A flat asbestos gasket of 1200 mm internal dismeter 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—112 kg/cm? 1 (1240-1200) 2 Effective gasket seating width 6-2.5\/6)=2.5¥10=7.9 mm From equation 6.36 ' i Basic gasket seating width bay == 10mm 7.9, 1240-41200 _ Wen, =0X Bee Se x2 (G=1220 mm) =34000 kg From equation 6,37 Wray BX2% EE yp PPADS 1200 9 03,3 10 X~ 2x10 1240+ 1200 \* + nf4x (Sa ) x33 = 4000+ 3840042400 kg From equation 6.38 A, = 34000 "a 587 =57.9 cm?188 PROCESS EQUIPMENT DESIGN 42400 = 42400 2 Any = Sqg~ 77.8 om ; 1220 Number of bolts jy 257g 49 Use 48 bolts From equation 6.39 Diameter of bolt = al a = 1.433 om x Use M 18 bolts Pitch diameter—16,376 mm. Minor diameter— 14.480 mm Actual bolt area _ =f 16.375? 414,482 _ 2 =ab 2xto ‘]x48=90 cm’ From equation 6.40 Qn 1220 20 A= ar xX KU2x-Fy = 292 cm® The bolt area suggested is satisfactory. Pitch of bolts— 4.75 x 18-=85.6 mm. Pitch circle diameter (B) . .6 xa =1310 mm B=outside diameter of gasket-+-2 x diameter of bolt+12 mm = 1240-+-2 x 18+-12=1278 mm Outside diameter of flange Pitch circle diameter + 2x diameter of the bolt ==1278+2 x18 1314 mm (b) Flange thickness From equation 6.41 K= L a 1.5 x 42490 x, C310— 1220) 03> Sax RII xDPRESSURE VESSELS 189 =2.74 1 03.0635 3 t= 1220,f —33 , J 2.74 x950 = 48 mm 6.13.4 Nozz.z REINFORCEMENT DESIGN Nozzle is provided on the head (Fig. 6.17} Internal design pressure —3.3 kg/cm? From equation 6.3 minimum nozzle thickness 3.3150 ZxX1300x TFS ~0.189 mm No corrosion allowance, since the material is stainless steel. Actual thickness t,=3 mm Maximum horizontal distance for compensation (4B)—2 x 150=300 mm Maximum vertical distance for compensation (AD) —6 2.662 15,99 mm or (3.5 X2.66-+2.5 x 3)=16.8 mm Area of compensation 150 x 2.66=400 nun? @ Area of compensation provided by the head A= 150 (3—2.66)=51 mm? Gi) Area of compensation provided by the nozzle A,=2x2.5x3 (3—0.189)=42 mm? (iii) The nozzle does not Project inside the vessel H,=0 4,=0 Art Aot+-4y=51+42+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 3mm thick. Area of compensa- tion by ring=(260~156) 3=312 mm’. This is satisfactory.