Design of a Vertical Steam Pressure Vessel

MACHIN DESIGN PRESSURE VESSEL DESIGN PROJECT 1 B.
UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL AND INDUSTRIAL
ENGINEERING
DESIGN PROJECT- ONE
DESIGN OF VERTICAL STEAM PRESSURE VESSEL
SECTION TWO
TO INSTRUCTOR: MS KIRUBAL
NAME ID NO-
BELAYNEH ADMAS 00228/09
MACHIN DESIGN PRESSURE VESSEL DESIGN PROJECT 1 B.A
CHAPTER-1
1. Introduction
1.1 Definition of Pressure Vessel
A pressure vessel is a closed container designed to hold gases or liquids at a pressure
substantially different from the ambient pressure. It also defined as a container with a
pressure differential between inside and outside. The inside pressure is usually higher
than the outside, except for some isolated situations. The fluid inside the vessel may
undergo a change in state as in the case of steam boilers, or may combine with other
reagents as in the case of a chemical reactor. Pressure vessels often have a combination of
high pressures together with high temperatures, and in some cases flammable fluids or
highly radioactive materials. Because of such hazards it is imperative that the design be
such that no leakage can occur. The legal definition of pressure vessel varies from
country to country, but often involves the maximum safe pressure (may need to be above
half a bar) that a vessel is designed.
Fig1; pressure vessel sample

1.2 History of pressure vessel codes
Perhaps the earliest reference to the design of pressure vessel was made in about 1495 by
Leonardo da Vinci in his codex Madrid I. Quoting from a translation, Leonardo wrote
“we shall describe how air can be forced under water to left very heavy weights, that is,
how to fill skins with air once they are secured to weights at the bottom of the water. And
there will be descriptions of how to lift weights by tying them to submerged ships full of
sand and how to remove the sand from the ships.”
Leonardo’s pressurized bags of air, if implemented did not kill or injure large number of
people and did not force the need for a pressure vessel code.
Numerous boiler explosions took place through the late 1800s and early 1900s. This led
to the enactment of the first code for construction of steam boilers by the Commonwealth
of Massachusetts in 1907. This subsequently resulted in the development and publication
of the ASME Boiler and Pressure Vessel Code in 1914, which sought to standardize the
design, manufacturing, and inspection of boilers and pressure vessels. In 1921 the
National Board of Boiler and Pressure Vessel Inspectors was organized to promote
consistent inspection and testing. . The year 1928 saw the advent of welded pressure
vessels. For higher pressures the welded shells were made thicker than 70mm.
The rules for design, fabrication and inspection of pressure vessels are provided by codes
that have been developed by industry and government in various countries. The design
and construction codes all have established rules of safety governing design, fabrication
and inspection of boilers, pressure vessels and nuclear components. These codes are
intended to provide reasonable protection of life and property and also provide for margin
for deterioration in service
The rapid development of finite-element software has remarkably impacted the detailed
design of pressure vessel components. These developments along with continuing
increase in computing speed and storage capacity of the computer have really made the
design process extremely quick and at the same time have led to very accurate design
assessment. Initially in the early to mid-1970s, detailed finite-element analyses were
generally performed for confirmatory analyses.
Today these tasks are routinely accomplished in an interactive mode. The three
dimensional finite element analysis programs using solid elements are rapidly replacing
plate, shell, and two-dimensional programs for routine structural design analysis of
pressure vessels. In addition the concepts of Computer-aided design (CAD) and
computer-aided manufacturing (CAM) are being integrated.
1.3 Classification of pressure vessel

Pressure vessels can be classified in different categories as follows:-

a) According to the end construction
This can be classified in to two groups;
І. Open end construction pressure vessel-In this case, the hoop stress is induced by
the fluid pressure. Example-a simple cylinder with piston, Such as cylinder of press.
ІІ. Closed end construction pressure vessel-In this case, longitudinal stress in addition
to hoop stress are induced.
b) According to dimension
The pressure vessel, according to their dimension, may be classified as:
І .Thin-walled pressure vessel-if the ratio of is less than, then the pressure vessel is called thin-
walled vessel. In this case, the radial stress is small and it can be neglected and the longitudinal
and the circumferential stress are constant.
Fig 1.1 thin walled pressure vessel

ІІ. Thick-walled pressure vessel- if the ratio of is greater than or equal to, it is called
thick-walled vessel.in this case, the radial stress can’t be neglected and the other two stress are
not constant. Thick-walled pressure vessels are mostly used in case of high pressure such as
guns, barrels, high pressure cylinder etc.
Remark-The majority of the vessel used in the chemical and allied industries are classified as
thin-walled pressure vessel.
ro Po
Pi
ri
Fig 1.3Thick Walled Cylinders
c). According to geometrical shape
The pressure vessel, according to their geometrical shape, can be classified as follow
i. Cylindrical shape
ii. Conical shape
iii. Spherical shape with one or two cone
c) According to position arrangement
The pressure vessel, according to their position arrangement, may be classified as
follow:
i. Vertical pressure vessel
ii. Horizontal pressure vessel
iii. Spherical pressure vessel
A). Vertical pressure vessel:-

Vertical pressure vessels are used for a variety of operational needs, mainly as reservoirs of
compressed air - air chambers, as well as pressurized water tanks or expansion tanks to
compensate for the volume of hot water stations with air or steam cushion - aqua mat, and as
releasers called expanders.
Vertical pressure vessels consist of a cylindrical shell and dished bottoms. They are placed on
three welded legs. The size and positioning of the filler necks is adjusted according to the
customer requirements and accordance with the relevant European standards. The pressure
vessels can be produced from ferrous or austenitic steel.
Figure 1.4 vertical pressure vessels

b) Horizontal pressure vessel:-
The free horizontal pressure vessel in pressure vessel is a container designed to hold gases or
liquids at a pressure substantially different from the ambient pressure.
Figure1.5 horizontal pressure vessels
C) Spherical pressure vessel:-

This type of pressure vessels are known as thin walled vessels. This forms the most typical
application of plane stress. Plane of stress is a class of common engineering problems involving
stress in a thin plate. Spherical vessel have the advantage of requiring thinner walls for a given
pressure and diameter than the equivalent cylinder. Therefore they are used for large gas or
liquid containers, gas cooled nuclear reactors, containment buildings for nuclear plant,
Figure 1.6 spherical pressure vessels

1.4 Practical use of pressure vessel
Pressure vessel is the container for fluid under high pressure. It can store fluid such as liquid
vapor and gas under pressure .pressure vessel had been used in various water treatment
application like mixed bed exchanger, activated carbon filters ,sand filters, dual medical filters
etc. with internal rubber lining carbon steel internal including strainers and screen laterals
,ladders and plate form etc… Pressure vessel is the container for fluid under high pressure.
Pressure vessel has a variety of application. This includes the industry and the private sector.
They appear in this sector as-
 Industrial compressed air reservoirs

 Domestic hot water storage tank
 Autoclave
 Distillation tower
 Recompression chamber
 Diving cylinder
 Oil refineries and petrochemical plants
 Nuclear reactor vessels
 Submarine and space ship habitats
 Pneumatic reservoirs
 Hydraulic reservoirs under pressure

 Rail vehicle airbrake reservoirs
 Road vehicle airbrake reservoirs
 Storage vessels for liquefied gases such as ammonia, chlorine, propane, butane,
and LPG
N.B -Not only in the above sectors, pressure vessel are used almost in all industries and in
home.
1.5 Area of application of pressure vessel

Pressure vessels are used to store fluids, such as liquids, vapors and gases under pressure vessels.
That means used to for different human activities in modern worlds. Major uses of pressure
vessels are:-
 In brewery and soft drink factories

 power generation industry for fossil and nuclear power
 In pharmaceutical factories
 In oil refineries plant
 In dye factories
 In engine cylinders.
 In medical sterilization system.
 Food production facilities.
 in steam boilers
Generally speaking, pressurized equipment is required for a wide range of industrial plant
for storage and manufacturing purposes.
1.6 Component of pressure vessel
The major components of pressure vessel are listed below:

I. Head
II. Shell
III. Nozzle
IV. Support
I. Head
All pressure vessel shells must be closed at the ends by heads (or another shell section).Heads is
typically curved rather than flat.
There are four types of head:

 Flat Plates and Formed Flat Heads.
 Hemispherical Heads.
 Ellipsoidal Heads.
 Tori-spherical Heads.
Flat plates are used as covers for access ports or manholes, and as the channel covers of heat
exchangers.
Standard Tori-spherical heads are the most commonly used end closures for vessels up to
operating pressures of 15 bars. They can be used for higher pressures, but above 10 bars, their
cost should be compared with that of an Ellipsoidal head. Above 15 bars, an Ellipsoidal head will
usually prove to be the most economical closure to use.
A Hemispherical head is the strongest shape, capable of resisting about twice the pressure of a
Tori-spherical head of the same thickness. The cost of forming a hemispherical head will,
however, be higher than for a shallow Tori-spherical head. Hemispherical heads are used for
high pressures.
II. Shell
The shell is the primary component that contains the pressure. Pressure vessel shells are welded
together to form a structure that has a common rotational axis. Most pressure vessel shells are
cylindrical, spherical, or conical in shape. Horizontal drums have cylindrical shells and are
fabricated in a wide range of diameters and lengths.
III. Nozzle
A nozzle is a cylindrical component that penetrates the shell or heads of a pressure Vessel. The
nozzle ends are usually flanged to allow for the necessary connections and to permit easy
disassembly for maintenance or access.
Nozzles are used for the following applications:-
 Attach piping for flow into or out of the vessel.

 Attach instrument connections, (e.g., level gauges, thermos wells, or pressure
gauges).
 Provide access to the vessel interior at man-holes.
 Provide for direct attachment of other equipment items, (e.g., a heat exchanger or
mixer)
IV. Support
The method used to support a vessel will depend on the size, shape, and weight of the
vessel; the design temperature and pressure; the vessel location and arrangement; and the
internal and external fittings and attachments. Horizontal vessels are usually mounted on
two saddle supports. Skirt supports are used for tall, vertical columns. Brackets, or lugs, are
used for all types of vessel. The supports must be designed to carry the weight of the vessel
and contents, and any superimposed loads, such as wind loads. Supports will impose
localized loads on the vessel wall, and the design must be checked to ensure that the
resulting stress concentrations are below the maximum allowable design stress. Supports
should be designed to allow easy access to the vessel and fittings for inspection and
maintenance.
Typical kinds of supports are as follow:-
A. Skirt support
B. Leg
C. Saddle
D. Lug
A. Skirt Support
Tall, vertical, cylindrical pressure vessels are typically supported by skirts. A support skirt is a
cylindrical shell section that is welded either to the lower portion of the vessel shell or to the
bottom head (for cylindrical vessels). Skirts for spherical vessels are welded to the vessel near
the mid-plane of the shell. The skirt is normally long enough to provide enough flexibility so that
radial thermal expansion of the shell does not cause high thermal stresses at its junction with the
skirt.
Figure 1.7 skirt support
B. Leg support
Small vertical drums are typically supported on legs that are welded to the lower portion of the
shell. The maximum ratio of support leg length to drum diameter is typically 2:1. The number of
legs needed depends on the drum size and the loads to be carried. Support legs are also typically
used for spherical pressurized storage vessels. The support legs for small vertical drums and
spherical pressurized Storage vessels may be made from structural steel columns or pipe
sections, whichever provides a more efficient design.
Figure 1.8 leg support
C. Saddle support
Horizontal drums are typically supported at two locations by saddle supports. A saddle Support
spreads the weight load over a large area of the shell to prevent an excessive local stress in the
shell at the support points. The width of the saddle, among other design details, is determined by
the specific size and design conditions of the pressure vessel. One saddle support is normally
fixed or anchored to its foundation.
Figure 1.9 saddle support
D.Lug support
Lugs that are welded to the pressure vessel shell, which are shown on, may also be used to
support vertical pressure vessels. The use of lugs is typically limited to vessels of small to
medium diameter (1 to 10 ft.) and moderate height-to diameter ratios in the range of 2:1 to 5:1.
Lug supports are often used for vessels of this size that are located above grade within structural
steel. The lugs are typically bolted to horizontal structural members to provide stability against
overturning loads; however, the bolt holes are often slotted to permit free radial thermal
expansion of the drum.
Figure 1.10 lug support

1.7 Special Components of Pressure vessel
Flange: Flanged joints are used for connecting pipes and instruments to
vessels, for manhole covers, and for removable vessel heads when ease of
access is required. Flanges may also be used on the vessel body, when it is
necessary to divide the vessel into sections for transport or maintenance.
Flanged joints are also used to connect pipes to other equipment, such as pumps
and valves. Screwed joints are often used for small-diameter pipe connections,
below 40 mm. Flanged joints are also used for connecting pipe sections where
ease of assembly and dismantling is required for maintenance, but pipework
will normally be welded to reduce costs. Flanges range in size from a few
millimeters diameter for small pipes, to several meters diameter for those used
as body or head flanges on vessels.
 Types of flange, and selection
Several different types of flange are used for various applications. The principal
types used in the process industries are:
1. Welding-neck flanges.
2. Slip-on flanges, hub and plate types.
3. Lap-joint flanges.
4. Screwed flanges.
5. Blank, or blind, flanges.
Welding-neck flanges: have a long tapered hub between the flange ring and the
welded joint. This gradual transition of the section reduces the discontinuity
stresses between the flange and branch, and increases the strength of the flange
assembly. Welding-neck flanges are suitable for extreme service conditions;
where the flange is likely to be subjected to temperature, shear and vibration
loads. They will normally be specified for the connections and nozzles on
process vessels and process equipment.
Fig 1.11- Welding-neck flange
Slip-on flanges: slip over the pipe or nozzle and are welded externally, and
usually also internally. The end of the pipe is set back from 0 to 2.0 mm. The
strength of a slip-on flange is from one-third to two-thirds that of the
corresponding standard welding-neck flange. Slip-on flanges are cheaper than
welding-neck flanges and are easier to align, but have poor resistance to shock
and vibration loads. Slip-on flanges are generally used for pipe work.
Fig1.12- Slip-on flange

Lap-joint flanges: are used for piped work. They are economical when used
with expensive alloy pipe, such as stainless steel, as the flange can be made
from inexpensive carbon steel. Usually a short lapped nozzle is welded to the
pipe, but with some schedules of pipe the lap can be formed on the pipe itself,
and this will give a cheap method of pipe assembly. Lap-joint flanges are
sometimes known as “Van-stone flanges”.
Fig1.13- Lap-joint flange
Screwed-flanges: are used to connect screwed fittings to flanges. They are also
sometimes used for alloy pipe which is difficult to weld satisfactorily.
Fig1.14- Screwed flange

Blind flanges (blank flanges): are flat plates, used to blank off flange
connections, and as covers for manholes and inspection ports.
Fig1.15- Blind flange
Gaskets: are used to make a leak-tight joint between two surfaces. It is

impractical to machine flanges to the degree of surface finish that would be
required to make a satisfactory seal under pressure without a gasket.
Gaskets are made from “semi-plastic” materials; which will deform and flow
under load to fill the surface irregularities between the flange faces, yet retain
sufficient elasticity to take up the changes in the flange alignment that occur
under load.
A great variety of proprietary gasket materials is used, and reference

should be made to the manufacturers’ catalogues and technical manuals when
selecting gaskets for a particular application. The minimum seating stress y is
the force per unit area (pressure) on the gasket that is required to cause the
material to flow and fill the surface irregularities in the gasket face. The gasket
factor m is the ratio of the gasket stress (pressure) under the operating
conditions to the internal pressure in the vessel or pipe.
The internal pressure will force the flanges’ faces apart, so the pressure on the
gasket under operating conditions will be lower than the initial tightening-up
pressure. The gasket factor gives the minimum pressure that must be maintained
on the gasket to ensure a satisfactory seal. The following factors must be
considered when selecting a gasket material:
1. The process conditions: pressure, temperature, corrosive nature of the

process fluid.
2. Whether repeated assembly and disassembly of the joint is required.
3. The type of flange and flange face
Up to pressures of 20 bars, the operating temperature and
corrosiveness of the process fluid will be the controlling factor in gasket
selection. Vegetable fiber and synthetic rubber gaskets can be used at
temperatures of up to 100oC. Solid polyfluorocarbon (Teflon) and compressed
asbestos gaskets can be used to a maximum temperature of about 260 oC. Metal-
reinforced gaskets can be used up to around 450 oC. Plain soft metal gaskets are
normally used for higher temperatures.
Pressure gages: are instruments for measuring the condition of a fluid

(liquid or gas) that is specified by the force that the fluid would exert when at
rest on a unit area, such as N/c.m2.
Temperature gages: are instruments for measuring the condition of a fluid

(liquid or gas) that is specified by the temperature that the fluid would exert
when at rest on a unit area, such as N/c.m2.
1.8 PROBLEM STATEMENTS

In human life pressure vessels are the main important devices in different application for our life
in different areas like, house hold, factories, industries &other for storage of fluid and chemicals.
Even if they are essential in our survival, the occurrence not questionable task. The failure of
pressure vessel is very devastating &serious thing since it leads to several economic losses,
environmental pollution, and danger of life. If its failure leads to these effect the cause of the
failure is our focus to minimize it as much as possible. So the cause of failure is mostly design
problem which includes: - improper material selection (material defect), not considering external
factors (temperature, pressure, acidic rain etc…), not considering the type of fluid it store (water,
steam, alcohol, benzene or gaseous), and following improper design procedure.
These is not the only cause but corrosion and fatigue effect is also the major problem of failure
Corrosion fatigue is fatigue in a corrosive environment. It is the mechanical degradation of a
material under the joint action of corrosion and cyclic loading. Nearly all engineering structures
experience some form of alternating stress, and are exposed to harmful environments during their
service life. So such things are generally leads the pressure vessel to fail.
1.9 General objective

 The main objective of this project is to design an advanced, problem solving, long lived
vertical pressure vessel by considering the specification we are given with the pressure of
3Mpa and temperature of 3000c under the working fluid of steam.
1.10 Specific objective

Specifically, we would like to design vertical positioned pressure vessel with hemispherical
head closure and supported by skirt by considering the effect of internal pressure, temperature
and other real-timed design consideration based on the given design specification by using
currently used design codes and standards of designing pressure vessel.
Specifically, we would like to design support, head, shell and nozzle and it has its own
procedures to design each component and to design the hole assembled of pressure vessels.
The specific objective of the project is to design a vertical pressure vessel subjected to the
following parameters.
Fluid content----------------------------- steam
Design Pressure --------------------------3.5MPa
Design Temperature --------------------- 3000c

Internal Volume---------------------------1m3
Corrosion Allowance---------------------2 mm
Vessel Orientation ------------------------Vertical
1.11 SCOPE OF THE PROJECT
Pressure vessel used in various field and plays a significant role in our life. So the method of
construction, the serving time length, the factor which distort them and their causes are the main
things that we must observe critically.
We know that mostly pressure vessels fail in short time due to several factors like, corrosion,
design problem, variable environmental condition, and such a like. Considering these problem
we should construct vessel which serve the customer for long time as much as possible. These
can be done designing pressure vessel considering such problems and also giving greater factor
of safety (allowance) to the construction in order to avoid physical damage.
Generally our scope is producing advanced pressure vessel which is resistant to corrosion and
failure due to any other effect like temperature & pressure change by designing properly.
1.12 Limitation the Project

 However we design properly some factors may lead the work un-functional. From these
factors effect of corrosion play the great role due the reason that pressure vessel are all in
contact with water which give great opportunity for rusting, these is impossible prevent
completely. And other extremely variable factors change with time to time and place to
place are difficult to control easily in design. So this things would be the limitation of our
project.
2. CHAPTER TWO
2.1 LITRETURE REVIEW
1. M.A Khan et al [3] carried out his research on Stress distribution in horizontal pressure
vessel and saddle supports. Her quarter of the pressure vessel is modelled. After that
stress distribution is carried out for pressure vessel He concluded that highly stressed area
is the flange plate of saddle.
2. M. Javed Hyder et al [4] made research on optimization of location and size of opening
in a pressure vessel cylinder using ANSYS. Analysis is performed for three thick walled
cylinder with different internal diameters. From the research it is concluded that location
and size of the hole depends upon the size of the cylinder. The optimum location is where
von Misses stress is minimum and also the whole size should be such that von-Misses
stress should be minimum around the vicinity of the hole.
3. M. Giglio et al [5] presented his research on Fatigue analysis of different types of
pressure vessel nozzle. He carried out comparison of two different methods for the
construction of pressure vessel nozzle. He conclude that failure of nozzles was carried out
by crack passing through their thickness. Both designs (external and integral
reinforcement) give good fatigue life results but nozzle with external reinforcement is
easy to produce than with integral one. Choice of simply produced nozzle obtained with a
cylindrical tube and a reinforcement plate gives good results in terms of stress and fatigue
life.
4. Avinash R.Kharat et al [6] carried out his research on analysis of stress concentration at
opening in pressure vessel using ANOVA. The motivation for this research is to analyze
the stress concentration occurring at the openings of the pressure vessels and the means to
reduce the effect of the same. Finally conclusion shows that sudden change in strain flow
lines causes the strain and stress to rise abruptly. Strain increases with increasing the
opening size in the geometry.
5. Bandarupalli Praneeth et al [7] carried out research on finite element analysis of pressure
vessel and piping design. The stresses developed in solid layer pressure vessel and
multilayer pressure vessel are analyzed. Here, theoretical and ANSYS results are
compared. Finally they conclude that theoretical calculated values are very close to that
of the values obtained from ANSYS is suitable for multilayer stress concentration factor
(SCF) of a cylindrical vessel with lateral nozzle. Finally they conclude that when the
geometric parameters of the vessels are fixed, SCF of the structure will increase with
decreases in the lateral angle.
6. Shyam R. Gupta et al [8] presented their work on the design and analysis of pressure
vessel using PV Elite software. Due to mathematical calculation designing of pressure
vessel becomes tedious but by using software like PV Elite designing of pressure vessel
can be done easily. By using this software finally they conclude that Due to mathematical
calculation designing of pressure vessel becomes tedious but by using software like PV-
Elite designing of pressure vessel can be done easily.
7. M. Jeyakumar et al [9] researched on “Influence of residual stresses on failure pressure of
cylindrical pressure vessel. Here a main criterion is to study the effect of residual stresses
on the pressure vessel. Conclusion shows that there is a reduction in failure pressure due
to unfavorable residual stresses.
8. Z.ModiAJ,Jadav C.S[10] concluded that the radial stresses in case of hemispherical head
pressure vessel is low compared to other types of head, in this paper author study the
comparative structural behavior of different types of geometry of pressure vessel, the
head is under internal uniform pressure, the analytical and finite element method used for
finding stresses in pressure vessel, the aim is finding best head for specific parameter
with finite element analysis of thin cylindrical pressure vessel, here three types of
geometry consider like hemisphere, flat and ellipsoidal and computation result compared
with finite element analysis
9. Yogesh Borse and Avadesh K. Sharma [12] present the finite element modeling and
Analysis of Pressure vessels with different end connections i.e. Hemispherical,
Ellipsoidal & Toro spherical. They describes its basic structure, stress characteristics and
the engineering finite element modeling for analyzing, testing and validation of pressure
vessels under high stress zones. Their results with the used loads and boundary conditions
which remain same for all the analysis with different end connections shows that the end
connection with hemispherical shape results in the least stresses when compared to other
models not only at weld zone but also at the far end of the end-connection.
 From the literature review it is cleared that study of the different factors that affects the
design and overall life of pressure vessel and they have to be considered in different cases
of pressure vessel. Finite element analysis is an extremely powerful tool for the analysis
of pressure vessel. A structural analysis of the pressure vessel will be implemented. From
above literature review - Inclination angle, circular cross section with hemispherical ends,
fatigue analysis, stress distribution, fracture analysis, optimization of location and size of
opening in a pressure vessel cylinder are the main criteria among all that have to be
considered on the design and analysis of pressure vessel to avoid any failure of pressure
vessel.
3 .CHAPTER – THREE
3.1 Methodology
Methodology is a general guide line or procedure which are used to solve problems to design
our project which is, design of unfired pressure vessel. We will try to follow the following
procedure.
3.1.1 IDENTIFICATION OF THE NEED

The information in selection of pressure vessel is described and the application of selected
pressure vessel is been discussed. To design of pressure vessel the selection of Code are
important as a reference guide to achieve the secure pressure vessel. The selections of ASME
Code Section VIII div 1 are described. The standard of material selection used are explains in
this chapter. Beside of that, the design and analysis software to obtain the result are introduced.
Instead of that, design process methodology is also described
1) Volume of the fluid to be contain, the total volume or the volume of the fluid within the
pressure vessel either filled or partially filled.
2) Operating pressure, the pressure at which the vessel subjected, this means It is recommended
to design a vessel and its parts for a higher pressure than the operating pressure. A design
pressure higher than the operating pressure with 10 percent, whichever is the greater, will satisfy
the requirement. The pressure of the fluid will also be considering. The maximum allowable
working pressure (MAWP) for a vessel is the permissible pressure at the top of the vessel in
its normal operating position at a specific temperature. This pressure is based on
calculations for every element of the vessel using nominal thicknesses exclusive of corrosion
allowance. It is the basis for establishing the set pressures of any pressure-relieving devices
protecting the vessel.
3) Operating temperature, the temperature of the fluid at which it operates. Design temperature
is the temperature that will be maintained in the metal of the part of the vessel being
considered for the specified operation of the vessel. For most vessels, it is the temperature
that corresponds to the design pressure. However, there is a maximum design temperature and a
minimum design temperature (MDMT) for any given vessel. The MDMT shall be the lowest
temperature expected in service or the lowest allowable temperature as calculated for the
individual parts. Design temperature for vessels under external pressure shall not exceed the
maximum temperatures.
4) Nature of the fluid, can be volatile, reactive, flammable or not to the environment or to the
wall of the pressure vessel.
5) Major fluid connection, the values that connected and acts inlet and outlet.
6) Design of general shape (cylindrical, spherical, and conical) and orientation (if it is vertical or
horizontal).
7) External load: earth quick wind load
Failure of the vessel checked by the theory of the pressure vessel using the maximum shear stress
theory, analysis of these variables are design methodology for pressure vessel.
3.1.2 DEFINITION OF PROBLEMS
We are asked to design vertical pressure vessel which has a capacity to store steam without a
great failures of material or parts.
3.1.3 ANALYSIS AND OPTIMIZATION
Selecting suitable material, Geometric, force, cost and stress analysis for each component, Such
as: shell, head, nozzle, flange, bolt and skirt support, Checking the maximum principal and shear
stress with the permissible stress of material.
3.1.4 Selection of material

The selection of material for the design is the first requirement based on the design
specification.
There are many consideration to select the material for designing purposes based on considering
the fluid/ medium, the working pressure (internal pressure) and the temperature at the design
pressure vessel. To select the proper material the following criterion should be considered:-
Availability of the material

Suitability of the material for working consideration such as pressure,
temperature and strength.
Cost of the material
Table 3.1: typical design stress
(Table taken from Coulson & Richardson volume 6 chap 13- table 13.2)
We will select the materials based on the following criteria:-
1. performance characteristics (properties)
2. processing (manufacturing) properties
3. environmental profile
4. availability of the material
5. economical consideration
Material manufacturing process in pressure vessel can use many types of material as designed
and customer wants. In our pressure vessel data the working material is low alloy steel with a
strength data at a given working temperature.
Table 3.2: Selected material for pressure vessel
Material Tensile strength Design stress at temperature

3000
Low alloy steel 550 235
Many pressure vessels are made of steel. Some mechanical property of steel achieved by
rolling or forging could be affected by welding unless special precautions are taken. In addition
to mechanical strength current standard dictate the use of steel with high impact resistance
especially for vessel in low temperature. In application where carbon steel is used it would suffer
corrosion so special corrosion resistant material must be used
Pressure vessel may also be constructed from concrete (PVC) or other material which are
weak in tension Cabling wrapped around the vessel or with in the wall in the vessel itself provide
the necessary tension to resist the internal pressure .there is also a high order of redundancy tank
to the large number of individual cables resisting internal pressure.
Generally pressure vessel may be made from
 Steel on its alloys

 Aluminum and its alloy
 Other metals
 Carbon fibers
3.1.5 PRESENTATION
`Design part drawing and assembling drawing of vertical pressure vessel using auto CAD.
3.1.6 DESIGN SPECIFICATION

Table 3.3 design specification
Design of column vertical pressure vessel specification
Parameters Value Unit
Design pressure 3.5 MPa
Design temperature 300 °C
Total inside volume 1 m3

Corrosion allowance 2 M
Working fluid Steam
Vessel orientation Vertical
It also includes material selection for the construction of the vessel is low alloy steel.
3.1.7 DESIGN PROCEDURE
 Determine the minimum plate thickness to resist the internal pressure

 Select the size and shape of vessel head (ellipsoidal, conical…)
 Increase the basic plate thickness to allow for the bending stress induced by the wind
loading at the base of the vessel and due to wind loading.
 Check the maximum combination stress at the base area with the design stress and
check that for critical buckling stress
 Decide which opening need for compensation
 Use standard flanges
 Design of the support type leg, skirt, lug, saddle
 Design the base ring
3.2 Design at available condition

3.2.1 Design pressure –
From the internal pressure at the vessel the design pressure is calculated. - The design pressure
is taken from this given internal pressure of 5 to 10% above it.
PD = Pi + [5-to-10] %Pi
3.2.2 Design temperature

For the purpose of design of pressure vessel the temperature of the fluid and the given internal
temperature with the outside of the temperature must be balanced.
3.2.3 Design of stress

By considering the given temperature and the selected material the yield stress will be known.
We design by using yield stress of the material. In cylinder there are coordinate systems that
describe the state of stress
Figure 3.1 state of stress
The hoop stress circumferential/tangential ( σ H )
The radial stress
The longitudinal stress ( σ L)
*principal stress are the maximum or minimum order defined.
*analysis stress in the thine walled vessels; with internal pressure loading
A) Cylindrical (hoop/tangential/circumferential stress)
The total force acting on the longitudinal section
FT=intensity of pressure × projected area = (Pi) × (L × di)
The total resisting force acting on the cylinder wall
FR= (tangential stress) × (area resisting the force) =δ h (L.t) ×2
*for equilibrium equation (1) is equal to equation (2)

FT=FR (Pi) (L × di) = δ h (L.t) × (2)
Pi ×di
t=
2 σh
b) Longitudinal stress (σ L)
The total force acting on the transverse section due to pressure.
Pi × π × di 2
FT= (intensity of pressure) × (cross sectional area) =
4
The total resistive force due to the material strength
FR= (σ L) × (area resisting the force)
FR= (σ L) × (π dit)
At equilibrium
Pi ×di
FT=FR t=
4 σL
3.3 Design component of pressure vessel

3.3.1Design of shell
Consider the cylindrical shell and calculation or designing the parameter of the shell. Thus
design diameter, and thickness of shell.
The shell is the primary component that contains the pressure mainly. So, in order to design this
shell, it is necessary to determine the values of maximum allowable stress, tensile strength the
internal pressure, design temperature, material selection, welded joint efficiency and corrosion
allowance.
Internal pressure
First find internal pressure from design pressure:
10
 Pd =Pi + Pi ×( 100 )
Where:
Pi – Internal Pressure
pd – Design Pressure
Pd
F=
C×S×E
Where: Pd – Design pressure, psi
C– Corrosion allowance, in
S– Allowable stress, psi
E- Joint factor or efficiency
Then, calculate for design pressure, Pd
3.3.2 Design of head
From many type of pressure vessel head, select the preferable one and design using the formula.
Calculate head thickness, diameter and length. In these project we are ordered to design.
First let us find the thickness of the head.

Pd × D i × K
t h=
2× S × E−0.2 Pd
Where:
t h – Head thickness
Pd – Design pressure, psi
S – Allowable stress, psi
E – Joint factor or efficiency
K – Coefficient
Di – Inner diameter
K for ellipsoidal head is calculated by
2
1 a
K=
6[ ( )]
2+
b
Where:
a = 2 (major axis)
b = 1 (minor axis) ∴K=1
P d × Di
Substituting the values we get so far,t h becomes t h=
2× S × E−0.2 Pd
3.3.3 Design of opening and nozzle

The pressure vessel need many opening for different purpose. Among this for inlet and outlet of
fluid drain, sample, manhole, pressure and temperature gauge. Therefore for these components or
parts the opening is designed by compensation method, reinforcement of area from the shell or
head at the pressure vessel. We are going to design nozzle and reinforcement area under
considerations. We select our nozzle from the standard table listed below.
Table 3.4 selection of nozzle opening
Inside diameter of nozzle Inspection opening required

12 in – 18 in Two – half inch pipe size threaded opening.
Over 18 in- < 36 in Minimum 15 in I.D manhole or two inch
pipe size threaded opening.
Over 36 in Minimum 15 I.D manholes or 2-6 inch pipe
size nozzle.
Reinforcement of bottom product and feed Place of openings:

*Bottom product: At the center of vessel head.
*Feed: Mid - point of the vessel.
Diameter of openings: All have 50 mm inside diameter.
Calculation for area of reinforcement required.

It should not be less than the value of:
Ar =d ×t r Where: t r– minimum required thickness of the shell.
d – Diameter of the nozzle = 50.8 mm
First find the value oft r,

Ri × P D
tr = Where: P D– Design pressure
S∗E−0.6 P D
Di
Ri – Internal Radius of the shell, =
2
S– Allowable stress
E– Joint factor take 1.0 for 100% Radiography (the plate will be like virgin plate.)
3.3.4 Design of support

WE design skirt support and is designed by calculating the weight of fluid and the weight of
vessel. The contact angle should be less than 120o and will not normally greater than 150o. Wear
plate are often welded to the shell wall to reinforcement the wall over the area of contact with the
saddle. Design of bolt: -Design of bolting (bolt design) used for flanges to connect the support
with the ground. Design of skirt Support
The skirt support must be designed to withstand the load imposed by the weight of the vessel
and contents. They are constructed of bricks or concrete, or are fabricated from carbon steel
plate.
Longitudinal bending stress
There are two severe points that longitudinal bending stress appear.
Stress analysis of skirt support
σ s(Tensile) = σ bs – σ ws And σ s(compressive) = σ bs + σ ws
σ bs= Bending stress on the skirt
4 Mx
σ bs=
π (Ds+ t s) D s t s
The Dead weight stress in the skirt (σ ws) is calculated as:-

WT
σ ws=
π (Ds+ t s)t s
M s = Maximum bending moment evaluated at the base of the skirt (Due to wind loading)
Ds =Inside diameter of the skirt at the base

t s = Skirt thickness
W T = Total weight of the vessel and contents (WT =3886.47N)
WT
σ ws=
π (Ds+ t s)t s
To calculate the resultant tensile stress on the skirt:

σ s(Tensile) = σ bs – σ ws
To calculate the resultant compressive stress on the skirt:

σ s(Compressive) = σ bs + σ w s
3.3.5 Design of the bolt

In design materials the design of bolt is the basic thing because bolt is used to clamp or connect
two or more part together .in our design we use bolt for the attachment of flange with the nozzle
so in our design we have different nozzle with different internal diameter such as some 250mm,
600mm. then we will work our calculation on this two.
Then we will calculate the force acted on each indusial bolt
F
Pi=
A
F=Pi × A
FT
Then in single bolts can be calculated as follow F i=
n
3.4 Discussion and Conclusion
Discuss and explain the result on the design of each component and draw conclusion from the
design in different angle.
3.5 Cost analysis

Calculate the total amount of cost which are taken by the design of pressure vessel starting from
the material cost up to the manufacturing cost including the machining time, labor,...
3.6 Recommendation
The design is carried out in order to prevent problems due to improper design as well as
improper selection of material which results failure and economical as well as energy loss. So in
order to prevent these problems and increase customer’s satisfaction the designer must consider
proper design procedure starts from good time management.
3.7 Reference
Finally state the reference books or any material which are used for the design of pressure vessel
4. CHAPTER-FOUR
4.1 DETAILED DESIGN ANALYSIS
The give Specification and their corresponding values of our design
Parameter value
Design pressure …………………… …………………………….3.5MPa
Design temperature ………………..…. …………………………3000c
Vessel orientation ……………………………………………….vertical
Cover shape ……………………………......................................ellipsoidal
Support type ………………………………………………….skirt
Total inside volume…………………. ………………. …. …….1m3
Corrosion allowance ……………… …………………………….2mm
We have to give recommendation about the design of vessel. State the problems during
designing of the pressure vessel.
4.1.1 Design pressures

For vessels under internal pressure, the design pressure is normally taken as the pressure at
which the relief device is set. This will normally be 5 to 10 per cent above the normal working
pressure, to avoid spurious operation during minor process upsets. When deciding the design
pressure.
10
PD=Pi + Pi×
100
100 PI +10 Pi
PD= -------------------=100PD=110Pi
100
100 PD
Pi= -----------------------from the given parameter PD=3.5MPa
110
100×3.5MPa=110×PiMPa=350MPa
350
Pi= =3.18 MPawhere Pi=Internal pressure
110
PD=Design pressure
If internal is greater than 300psi or
PD > 0.385*SE then the wall of the cylinder is thick, otherwise

PD< 0.385*SE or less than 300psi, the wall of the cylinder is thin.
1 psi=6894.8 Pa
x=3.5 MPa
3.5 MPa∗1 psi
x= =507.6 psi> 300psi, therefore thick walled pressure vessel is employed.
6894.8 Pa
4.1.2 Design temperature

The strength of metals decreases with increasing temperature so the maximum allowable
design stress will depend on the material temperature. The design temperature at which the
design stress is evaluated should be taken as the maximum working temperature of the material,
with due allowance for any uncertainty involved in predicting vessel wall temperatures.
Then at T=300℃
From typical design stress table find the stress for low alloy steel:-
2
Design stress: - 235 N/mm
2
Tensile strength: - 550 N/mm
4.1.3 Design stress
For design purposes it is necessary to decide a value for the maximum allowable stress (nominal
design strength) that can be accepted in the material of construction. The design stress factor
allows for any uncertainty in the design methods, the loading, the quality of the materials, and
the workman ship.
For materials not subject to high temperatures the design stress is based on the yield stress (or
proof stress), or the tensile strength (ultimate tensile stress) of the material at the design
temperature.
Welded joint efficiency, and construction categories
The strength of a welded joint will depend on the type of joint and the quality of the welding.
The soundness of welds is checked by visual inspection and by non-destructive testing
(Radiography).The possible lower strength of a welded joint compared with the virgin plate is
usually allowed for in design by multiplying the allowable design stress for the material by a
"Welded joint factor" J. The value of the joint factor used in design will depend on the type of
joint and amount of radiography required by the design code.
Table 4.1: welded joint factor (table taken from Coulson & Richardson vol 6)
Table 4.1: welded joint factor (table taken from Coulson & Richardson vol 6)
In our design we use joint efficiency value E=1
The above table is above the maximum allowable joint efficiency .taking the factor as 1.0
implies that joint is equally as strong as a virgin plate. This is achieved by radio graphing
complete weld length. Cutting out and remarking any defects. The use of lower joint factor
factors in design through saving cost in radiography will result in any cost saving on inspection
and fabrication against the increased cost of materials.
4.1.4 Corrosion allowance

The additional thickness of metal added to allow for material lost by heat, corrosion and
erosion or scaling. The allowance to be used should be agreed between the customer and
manufacturer’s corrosion is complex phenomena, and it is not possible to give specific rules for
the estimation of corrosion allowance required for circumstances. The allowance should be based
on the experience with the material construction under similar surface conditions to those for the
purposed design. For carbon and low alloy steel with several condition are anticipated, this
should be increased to 4mm most design codes and standard specify a minimum allowance of
1mm.
For carbon and low alloy steel where sever corrosion is not expected the minimum allowance
given that 2mm should be used. I.e. CA=2mm
Two procedures are method 1 and 2 that determining the diameter and the length of vessel.
Method 1:
Where; Pi=internal pressure=3.18MPa
CA=corrosion allowance=2mm
E = Joint efficiency=1
S=allowable stress =235MPa
Pi
F1= F1&F2=vessel ratios
CSE
Method 2:
SE
F2=C [ -0.6]
PD
L
Table 4.2: diameter for different ratio
D
L
Diameter for different ratios
D
L D
D
3 6v
√
3
5π
4 12 v
√
3
13 π
5 3v
√
3
4π
We can select method is preferable then method one because it gives more accurate diameter and
length
Using method 2:-
SE 235 Mpa × 1
F2=C [ -0.6] = 2 [ -0.6] =146.6mm=14.66cm
Pi 3.18 Mpa
1 inch=2.54cm
x =14.66cm X×2.54cm=14.66cm×1inch
x=5.7716 inch
Therefore, F2=5.7716 inch
L
From graph 2 F 2 indicates ratio is
D
(From K. Abakan’s, Hydrocarbon Processing and Petroleum Refiner, June 1963.)

Figure 2-58. Method 1: fig 4.1 Chart for determining optimum diameter.
Vessel volume, ft3

(From S.P. Jawadekar, Chemical Engineering, Dec. 15, 1980.)
Figure 2-59. Method 2: fig 4.2 Chart for determining the optimum UD ratio
4.2 Design of components
4.2.1 Design of shell
According to geometrical shape of shell classified in to three thus are:-
 Cylindrical shell
 Conical wall
 Spherical vessel with one or two cones
We are select cylindrical shape because these vessels are:-
Fig 4.3 cylindrical shell

 Easy to manufacture and install economical to be maintain
 The cylindrical shall stress will be greater than that of the two principal stress
To calculate diameter, length and thickness of the shell use the following data and formulas
Table 4.3 L/D approximation table
Pressure(psi) L/D ratio
0-250 3
250-500 4
>500 5
L
To determine ratio we use both vessel ratio and total inside volume reading from chart:
Di
First let us change the unit of volume in to ft3 by using conversion factor.
1ft3=0.028317m3
L
F2=5.7716 inch from this take =3
Di
V=35.3145 ft3
Let us express L in terms of Di
L= 3 Di
2
π Di3 π D i L
V= + but L=3 Di
12 4
π D3 π D2
V= + L ……….From optimum vessel proportion for vessel with (2).
12 4
Where V = Volume of vessel in m3
D = Internal diameter of shell in m
L = Length in m
Our design pressure: - P = 3.5Mpa =507.6 psi since {1psi=6894.8pa)
Hence, P psi>500 (psi) we take the ratio approximately L/D = 3 therefore L = 3D
π D3 π D2
1 m3 = + L
12 4
π D3 9 π D3
1 m3 = +
12 12
12 3 12 3
1 m 3 × 12 = 10 π D3 D 3= m= m
10 π 31.4
D = ∛ ( 0.38217 m3 )
D = 0.72569 m=725.69mm
L = 3× 0.72569m L = 2.17707mm
D 0.72569
2 Hi 2 2×
Ls = L - 2.17707 - 4 Ls =¿ 2.17707 – 4 =
3
3 3
2.05612m=2056.12mm
2Hi = 6.53121-6.16836 = 0.36285 Hi = 0.181425m
Where Ls = length of the shell
H i = inner head of the ellipsoidal
2 2
V s = π D Ls = π 0.72569 × 2.05612 = 0.850003m3
4 4
Where V s =¿volume of shell
To calculate the thickness of shell use the following formula

SE+ Pi
If Pi> 0.385SE……………..use t s = R×[
√ SE−Pi
−1]
Pi × R
Pi<0.385SE……………….use t s =
SE−0.6 Pi
Where S = allowable design stress
E = joint efficiency……………..take E = 1
t s = shell thickness
D 0.72569
R = radius of shell……………….R = = =0.362845 m = 362.845mm
2 2
Design stress: - S=235 N / mm2
Tensile strength: - σ t=550 N /mm2
0.385SE = 0.385×235 Mpa × 1 = 90.475 MPa
Pi × R
Since P D(=3.5Mpa) < 90.475 M pa…………………….use t s =
SE−0.6 Pi
3.18× 362.845
ts = = 4.95mm which is without corrosion allowance so shell thickness
( 235× 1 )−0.6 × 3.18
will be
t =t s+ CA = 4.95 + 2 = 6.95 mm Where CA = Corrosion allowance
t
To check the cylinder is thin or thick use [ ] ratio
D
t 1
For [ ] < ………...………………… thin shell
D 10
t 1
For [ ]≥ ………………………….. Thick shell
D 10
t 6.95 mm 1
[ ]= = 9.57709−3∨0.00957709 <
D 725.69mm 10
Therefore the cylinder is thin shell
Outside diameter of shell DO
DO = D+2t
DO=725.69mm+2×6.95 =739.59mm = 0.73959m
Dm= Di + t where Dm= mean diameter of shell
D m= 725.69mm + 6.95mm
D m= 732.64mm
4.2.2 Stress analysis of cylindrical shell
Now let us find the circumferential or hoop stress:-
Circumferential or hoop stress is a tensile stress acting in the direction to the circumference or
hoop in finding stress analysis hoop stress and longitudinal stress are calculated.
Figure 4.4 stress analysis

First let us find both the hoop stress (σ H ) and longitudinal stress () by using a formula as
follows:
The hoop stress is given by
P i× D
σh = m
Where σ h = hoop stress
2t
Dm = mean diameter
. Dm = Di + t=725.69+6.95=732.64mm
3.18× 732.64
σ1 = σ h = = 167.611Mpa
2× 6.95
Know check hoop stress is less than design stress for safe design
σ h< S ………….. 167.611Mpa < 235Mpa therefore our design is safe
Radial stress: is the stress acting in the radial direction. It is given as follows:
Pi Di P i Di 3.18× 732.64
σ h= ∧σ l= σ =σ = =83.8056 MPa
2t 4t 2 l 4 ×6.95
Find the maximum shear stress (τ max)
σ 1 −σ 2
τ max=
2
167.611 MPa−83.8056 MPa

τ max= =41.9027 MPa
2
Then, check it is safe by comparing it with design stress.
σy
τ max <
2
41.902 MPa<235 MPa
∴Therefore the design of cylindrical shell is safe for longitudinal and hoop stress.
N.B:-Since all stress on the above is less than design stress 235Mpa; therefore the design is safe.
4.2.3 Design of Head
All pressure vessel shell must be closed at the end by heads. The ends of cylindrical vessel are
closed by head various shapes. This are:-
 Flat plates head
 Hemispherical head
 Ellipsoidal head etc.
But our design head is ellipsoidal head. Because of its smooth translation with cylindrical then
which ≈avoides stress concentration effect. For pressure vessel having an internal pressure above
15Bar, its proved that an ellipsoidal l head is used for economic benefit.
Most standard ellipsoidal are manufactured with a major and minor axis ratio of 2:1 the
following equation can be calculated required thickness.
Calculate the stress on the shell using lame’s equation
 Tangential stress: - is the maximum tensile stress and it is known as
circumferential stress.
 Radial stress: - is the maximum compressive stress and it is negative. The
negative sign indicates that the radial stress is opposite to design stress equal.
Since, if the stress is less than the maximum tensile strength of the material, then the design
is safe. Now to calculate the value of stress.
Our given head has ellipsoidal shape .so to design it we start from calculating its thickness by
using the following steps:
Pi × D
t h=
(2 × E × S−0.2 × Pi)
Where:
t h= thickness of the head
Pi – internal pressure
Di– internal diameter
S – Design stress:
@ 300 o c for low alloy steel S= 235MPa
J – Joint factor take 1.0 for 100%
Radiography (the plate will be like virgin plate .)❑
❑
th = 3.18× 725.69 = 4.95mm

¿¿
Therefore our total thick ness is:
T th =t h + corrosion allowance
T th =4.917 mm+2 mm=6.95 mm
Next find the stress analysis of the head by finding longitudinal ( σ l ) stress by the following
formulas:
 Stress analysis at the center of the head:
Let us find the outer head as follows:

Di
H i= where Hi is inner head for ellipsoidal head
4
725.69mm
Hi = = 181.42mm and
4
Do
Ho= but Do = Di+ 2×t total
4
Do = 725.69mm + 2×6.95mm
Do = = 739.59mm
739.59 mm
∴ Ho= = 184.881m
4
At center of head longitudinal stresses have greater effect
D=725.69 mm
725.69
R= = 362.845mm
2
Pi × R2 ( 362.845mm )2
σl= =3.18 Mpa × =162.5 MPa
2t×h 2× 6.95 mm× 184.881mm
To calculate ellipsoidal head volume
π D 2o
Vh = ×h
6
2
V h = π ×739.59 ×184.881 =
6
π × 0.73959× 0.184881
Vh ¿ = 0.053m3
6
So we are going to check that the factor of safety if the factor of safety greater than 1.5 our
design is safe:
design stress
F.s=
longitudinal stress
235
¿ =1.5 approximately grater or equal to 1.5Therefore our design safe
162.5
 Stress analysis at the tangent line of the head:
We use the following formulas to find the stress at the tangent line of the head.
D
σ l =P×
4 T th
725.69 mm
σ 2=¿ σ l =3.18 Mpa × =83 Mpa
4∗6.95 mm
D 725.69 mm
σ 1 =σ h=P × = 3.18 M pa× =166.02 MPa
2 Tt 2∗6.95 mm
Next find the maximum shear and compare it with the design stress.
σy
τ max ¿ σ h−σ l < , if this condition fulfill the design is safe.
2
166.813 Mpa−83.1066 Mpa 235 Mp
<
2 2
83.02 Mpa<235 Mpa
The design is safe. Sample for ellipsoidal head is shown below
Fig 4.5 ellipsoidal

type of head
4.2.4 Nozzle design (opening design)

A nozzle is a cylindrical component that penetrates the shell or heads of a pressure vessel. The
nozzle ends are usually flanged to allow for the necessary connections and to permit easy
disassembly for maintenance or access. Nozzles are used for the following applications:
 Attach piping for flow into or out of the vessel
 Attach instrument connections, (e.g., level gauges, thermos wells, or pressure
gauges)
 Provide access to the vessel interior at many ways
 Provide for direct attachment of other equipment items, (e.g., a heat exchanger or
mixer)
Nozzles are also sometimes extended into the vessel interior for some applications, such as for
inlet flow distribution or to permit the entry of thermos wells. Openings in pressure vessels in the
regions of shells or heads are required to serve the following purposes:
 Man ways for letting personnel in and out of the vessel to perform routine
maintenance and repair
 Holes for draining or cleaning the vessel
 Hand hole openings for inspecting the vessel from outside
 Nozzles attached to pipes to convey the working fluid inside and outside of the
vessel
 Instrument nozzles
 Compartment for other equipment’
Vessel components are weakened when materials is removed to provide the nozzle. High stress
concentration exits at the opening edge and require extra care to keep loadings acceptability of
opening in the pressure boundary for pressure loading only.
Reinforced opening or area replacement method

It is used when the area which was to carry the primary membrane stress is missing due to the
opening to replace this area, close in substitute areas are called up on carry the stress.
Efficiency method
The area of the metal remaining between adjacent openings compared with the area of the metal
that was there before the opening existed.
Area of reinforcement required

The nozzle and manhole internal diameter is not given on the specification, we can find the
diameter of nozzle and manhole from inspection of standard table.
Table 4.4 Inspection of standard table
4.2.5 Design of inlet and outlet pipes (openings)

Assume that inlet and outlet opening have the same dimension and its material is similar with shell and
head material, which make it suitable for good weld.
Since 1inch=25.4mm, the internal diameter of shell is 725.69 mm becomes 28.57inch.Therefore the
nozzle internal diameter 2 inch from standard table.
Internal diameter of the inlet and out let nozzle =𝑑𝑖= 2𝑖𝑛𝑐ℎ = 50.8 𝑚𝑚
Using the internal diameter of the nozzle we can calculate the thickness of the nozzle with corrosion
allowance:
Using the internal diameter of the nozzle we can calculate the thickness of the nozzle with corrosion
allowance:
In our design we take the inlet pipe diameter di=50.4 mm

D i 50.8 mm
Ri = = =25.4mm
2 2
Assume our inlet opening pipe is placed on the cylindrical shell.

The minimum thickness of the nozzle for inlet pipe is given by:-
PiRi
tn =
SE−0.6 Pi
PiR
t n= +CaWhere 𝑡𝑛=thickness of nozzle with corrosion allowance
SE−0.6 Pi
d=diameter of nozzles
Ca = Corrosion allowance
Pi = internal pressure
3.18 MPa× 25.4 mm

t n= +2 mm=2.4mm: Rn = internal nozzle radius = 25.4mm d=di + 2 × Ca
235× 1−0.6 × 3.18 MPa
= 50.8mm + 2 × 2mm = 54.8mm
Do = the outer diameter of nozzle
Do = d + 2tn = 54.8mm + 2 × 2.4mm = 59.6 mm
Where: - Ca = corrosion allowance = 2mm
E = joint efficiency = 1.0

S = design stress = 235Mpa
Pd = design pressure = 3.5Mpa
t rn= thickness of nozzle without corrosion allowance = 2mm

Area of reinforcement required
For vessels under internal pressure the total cross-section area required for reinforcement of opening shell
not be less than:
A = d × tr Where,
d=chord length at the mid surface of the thickness required excluding the excess
thickness available for reinforcement.
t r=minimum required thickness of shell

reinforcement area When the reinforcing limits do not extend outside of an area where the required
thickness and limits are available equally on each side of the opening centerline, the following equations
may be used to determine the area of reinforcement available:
Therefore, these are the same parameters that used to design opening.
A = d × tr Where, d=diameter of nozzle
d=di + 2 × Ca = 50.8mm + 2 × 2mm = 54.8mm

A = area of reinforcement require
t r=minimum thickness of shell is t-ca=6.95-2=4.95mm
A = 50.8mm × 4.95mm = 251.46mm2 Is the required area
 Area available in vessel wall, A1, is the larger of:

A1= d (t −t r) or
A1= 2(t −t r) (t n − t)
A1 = d (t −t r) = 54.8mm (6.95 – 4.95mm) = 109.6mm2 Take the larger area
A1= 2(t −t r) (t n − t)) = 2(6.95− 4.95) (2.4 – 6.95) = -18.2mm2
Take the larger area Therefore A1 = 109.6mm 2
 Area available in nozzle wall, A2, is smaller of:

Outward
A 2 = 5t (t n− ca) or
A 2 = 5 × 6.95(2.4 − 2) mm2 = 13.9mm2
A 2 = 5t n (t n − ca) = 5 × 2.4 (2.4 − 2) mm2 = 4.8mm2 is the smaller Inward
 Area available in inward nozzle

A3 = 5(t) (t n) = 5 × 6.95 × 2.4= 83.4mm2
 Area of welds, A4
A4= 2(0.5) (t2) = 2 × 0.5 × (6.95)2 = 48.3mm2
The total area of reinforcement is:
AT = A1+A 2+A3 + A4
AT =¿109.6mm2 + 4.8mm2 + 83.4mm2 + 48.3mm2 = 246.1mm2
Since AT < A that is 246.1mm2 > 251.46 mm2 therefore the opening is adequately not reinforced
for that reason our design is to safe.
We need additional reinforcement by taking t w= 4mm thickness of the pad for good welding.
Area available in an element

A1= ( Dp−d−2∗t n )∗t w But D p = 2d – 2 t w wheret w = thickness of pad.
D p = 2×54.8 – 2 ×4 D p = 101.6mm
In order to check weather our calculation is right since thin diameter does not extend beyond
the outer limit of the permitted reinforcement zone
2d=2×54.8=109.6, since 101.6 <109.6. Our design is acceptable
Since the required reinforcement area is less than the available area therefore it needs additional
reinforcement or filler material for welding. From fig c=t rn.
Fig 4.6 Reinforcement limits 1
Parallel to the shell surface the horizontal limits are greater of
x = d and x = 0.5d + t + t n
x= 54.8mm and x = 0.5 × 54.8mm + 6.95mm + 2.4mm = 36.75mm.

We can select greater x = 54.8mm.

Perpendicular to the shell surface the vertical limits are smaller of
Y = 2.5t and Y = 2.5tn
Y = 2.5 × 6.95mm and Y = 2.5 × 2.4mm
Y = 17.4mm and y = 6mm Select smaller Y = 6mm
t r 4.95
From the above figure tanθ= = =¿
x 54.8
Ѳ = 5.16°, by using this angle, read F from pressure vessel design manual-2-book figure 2-48.
Fig 4.7 angle of phase with longitudinal value of F

For the angle value of force will be
F≈ 0.98, F = 0.98 and f r 1= design stress of nozzel = 235 MPa =1 since

design stress of shell 235 MPa
uses same material for good welding take the angle of the fillet is 45° and t w = 1.5mm
Now read all area formulas from machine design data book .The area of reinforcement required is given
by:
A = d × t r× F + 2tntrF (1 − fr1)
A = 54.8 × 4.95 × 0.98 + 2 × 2.4× 4.95 × 1(1 – 0.98) = 266.32mm2

The area available in cylindrical shell is:
A1 = d (Ext − F×t r) − 2tn (Ext − Ft r) (1− fr1) or
A1 = 2(t −t n) (Ext − Ft r) − 2tn (Ext − Ft r) (1− fr1)
But F = 0.98 , fr1 = 0.98, E = 1
A1 = 54.8(1×6.95−0.98 × 4.95 ¿−2 ×2.4 (1× 6.95−0.98)(1−0.98)=114.5 mm 2 or
A1 = 2(t −t n) (t −t r) = 2(6.95 – 2.4) (6.95 – 4.95) = 18.2mm2

For safe design take the largest one A1= 114.5mm2 the area available in the nozzle projecting out ward:
A2 = 5(t n−t rn) × f r 1 ×t = 5(2.4-2) × 0.98 × 6.95mm2 = 13.622 mm2or
A2 = 5(t n−t rn) f r 1 t n = 5(2.4− 2) × 0.98 × 2.4mm2 = 4.704mm2
For safe design take the smaller oneA2 = 4.704mm2 . The area available in inward nozzle:
A3 = 2(t n− Ca) f r 1 × Y = 2 × (2.4 − 2) × 0.98 × 6= 4.704mm2
The area available in outward: we take t w=thickness of the pad 4mm.
A41 = tw2 × fr1 = (4)2 × 0.98mm2 = 15.68mm2
The area available inward weld: t w=4mm
A43 = tw2 × fr1 = (4)2 × 0.98mm2 = 15.68mm2

Now the total available area is given by:
AT = A1 + A2 + A3 + A41 + A43 = (114.5 + 4.704+ 4.704 + 15.68+ 15.68) mm2=155.268 mm2

AT < A………..155.268mm2<266.32mm2.
The area reinforcement is required A = 266.32mm 2
The area available in the cylinder shell A 1 = 114.5mm2
The area available in nozzle projecting out ward is changed and is given by
A2 = 5(t n−t rn)× f r 1t = 5(2.4 − 2) × 0.98 × 6.95) mm2 = 13.35mm2or
A2 = 2(t n− t rn ¿(2.5tn −t w) f r 1 = 2(2.4 − 2) (2.5× 2.4 - 4)× 0.98 = 1.568mm2
For safe design take smaller one A2 = 1.568mm2

The area available inward nozzle is the same as above A 3 = 4.704 mm2
The area available outward nozzle is given by
A41 = tw2 × fr1 = (4)2 × 0.98mm2 = 15.68mm2 but fr2=fr1. For the same material is added
The area available in outward weld is given by
A42 = tw2 × fr1 = (4)2 × 0.98 mm2 = 15.68mm2 but fr1 = fr2 = fr3
The area available in inward weld is given by
A43 = tw2 × fr1 = (4)2 × 0.98mm2 = 15.68 mm2
The area available in element is given by .A5
d p= 2x − 2tw = 2 × 54.8 − 2 × 4 = 101.6 mm. Where: - d p = diameter of pad (fillet material)
A5 = ((d p− d − 2tn) × t w× f r 3 = (101.6 – 54.8 − 2 × 2.4) × 4 × 0.98) mm2 = 164.64mm2
Now the AT = A1 + A2 + A3 + A41 + A42 + A43 + A5

Total available area is given by:

(114.5+1.568+4.704+15.68+15.68+15.68+164.64) mm2=332.452mm2
AT > A 332.452mm2>266.32 mm2
Therefore the opening is adequately reinforced for that reason our design is safe.
Since our total reinforcement area is less than area reinforcement required (195.742
mm2 <266.32 mm2). Therefore our design is safe.
Next find the stress analysis of the nozzle by finding of the hoop ( σ h) and longitudinal (σ l )
stresses by the following formulas:
P d Di pdDi
σ h= ∧σ l =
2 tn 4 tn
3.5∗50.8 N
σ h=σ 1= =52.81
2∗2.4 mm
2
3.5∗50.8 N
σ l =σ 2= =18.52
4∗2.4 mm2
Find the maximum shear stress (τ max)

σ 1 −σ 2
τ max=
2
52.81 N /mm2−18.52 N /mm 2 2
τ max= =17.145 N / mm
2
Then, check it is safe by comparing it with design stress.
σy
τ max <
2
17.145 N /mm 2 <240 N /mm 2
∴Therefore the design is safe and also we can know either the design safe or not by using factor
safety but, we take working stress is radial stress (hoop stress) in the nozzle, because hoop stress
is more affect in the nozzle.
design stress 235 N /mm 2
F s= = =4.45
working stress 52.81 N /mm2
Then our factor of safety is greater than 1.5 and less than 5 therefor our design is safe.
4.2.6 Design of circular handhold
Since in our design we get smaller shell diameter 0.73m we cannot design manhole but we can
design the hand hole should be used in order to do some operations on the pressure vessel. We
can take the diameter of hand hole as 0.2m.
Then the wall thickness of the handhold can be calculated as follows:
Pi × Rhandhole
t handhole =
ᵟ d E−0.6 Pi
Where P =deign pressure (3.18Mpa)
D
Rhandhole =radius of hand hole(R= =0.1m)
2
ᵟ d 0 r S= Design stress for the materials of hand hole (low alloy steel)
=235N/mm2
E =Joint efficiency factor (E =1)
Pi × Rhandhole
t handhole =
ᵟ dE−0.6 Pi
3.18× 100
t handhole = t handhole= 1.36mm
235× 1−0.6 × 3.18
Total thickness of the hand hole including the corrosion allowance calculated as follows
t thandhole= t handhole + C where C=corrosion allowance
t thandhole= 1.36mm + 2mm t thandhole= 3.36mm
Area for the hand hole will be:
π D handhole2
Ahandhole =
4
2
Ahandhole = π × 200
4
Ahandhole =31400mm2
Stress analysis for hand hole

Longitudinal stress (σ L ):
Pi × D
σL = handhole
4 × t handhole
3.18× 200
σL =
4 ×3.36
N
σ L= 47.32 and
mm2
The hoop (circumferential stress) or (σ H )
P
σ H = i×D handhole
2× t handhole
3.18× 200
σ H=
2× 3.36
N
σ H = 94.64
mm2
Since both longitudinal and circumferential stress less than the allowable or design stress
therefore our design is safe.
4.2.7 Design of vessel support

The vessel support is intended to support the pressure vessel on the support base. The support
has to be designed with stand the dead weight from the pressure vessel and to limit the heat
flow from the vessel walls to the base. The pressure vessel support should be able to with stand
the dead weight of the vessel and internals and the contained fluid without experiencing
permanent deformation 9.
In our case the support of the pressure vessel is straight skirt and we choose a 5.8(carbon steel)
material to design because of it has excellent fatigue resistance, good temperature resistance,
it is tougher and has high strength.
Table 4.5 standard material for support design
It carries all the loads at the pressure vessel. In order to design this three legs support we
consider the dead weight. The major sources of dead weight loads are
The vessel shell
The vessel head
The vessel fitting, manhole and nozzle

Wind load
Weight of fluid
Weight of shell: is the sum of the weight of shell material and the fluid stored on it.
Weight of shell material
The material is low alloy steel we take ρ=7850 kg/ m3
W s=π D m t s ρ L g where: - D m = mean diameter of shell
g= acceleration due to gravity taken as 9.81m/s2

t s=thickness of shell
L= vessel length, tangent to tangent
But L= Ls + 2 Ho
Do
L= Ls + 2 but Do= outside diameter of the shell
4
739.59
L=2056.12 + 2 × L= 2426mm
4
Dm= Di + t where Dm= mean diameter of shell
Dm= 725.69mm + 6.95mm
Dm= 732.64mm
W s= π Dm t s ρ L g
W s= π×0.73264 ×0.00495×7850 ×2.426 × 9.81
W s=2127.4N
Weight of shell fluid

W sf=m f ×g but mf= ρ× v f where v f =volume of the fluid on the shell
2
V f = Ls π × Di
msf = ρ × v f but ( 4 )
2
V f = 2.05612 × (π ×0.72569 )
4
V f = 0.85m 3
ms f = 1000 ×8.5×10−10
msf =8.5×10−7 kg
W sf = m s f ×g
W sf = 8.5×10−7 ×9.81
W sf = 8.34×10−6 N
Weight of head: is the sum of the weight of head material and the fluid stored on it.
Weight of head material
W h = 1.084 Dm2×t h×ρ×g
Where: - Dm = mean diameter of ellipsoidal head
g= acceleration due to gravity taken as 9.81m/s2

t h=thickness of head
W h = 1.084Dm2×t h×ρ×g
W h = 1.084×0.73264 2 × 0.00495×7850×9.81
W h =221.8N
Weight of head fluid

3
V hf = π Di where Vh=volume of the fluid on the head but Di= 0.72569m
8
3
V hf = π × 0.72569
8
V hf = 0.15m3
m hf = ρ× v f
m hf = 1000×1. 5× 10−10
m hf =1. 5× 10−7kg
w hf =m hf ×g
W hf =1. 5× 10−7×9.81
W hf = 1.47×10−6 N
Weight of Nozzle: is the sum of the weight of nozzle material and the fluid stored on it.
Weight of nozzle material

W n = m n×g where: - m n = mass of nozzle
But m n = ρ× v n where: - v n= volume of nozzle matreial

2 2
V n= π ( do −di ) L where: - d o = outlet nozzle diameter
4
d i= inlet nozzle diameter
L= length of nozzle
di 54.8 mm Di 725.69mm
r i= = = 25.4mm and Ri = = =362.85mm
2 2 2 2
C= Ri -√ Ri2−r i2 where: - C=length of part of the nozzle entering to shell
C=362.85-√ 362.852−25.4 2
C=0.89mm
L= C+ t s+ length of part of the nozzle leaving the shell
Let's take the value of length of the nozzle leaving the shell 239mm then
L= 0.89mm+4.95mm + 239.16mm
L=245mm
2 2
V n= π ( do −di ) L
4
2 2
V n= π 59.6 −50.8 × 245
( )
4
V n= 186847.6 mm3
m n= ρ×V n
m n= 7850×1.868476−4
m n= 1.47kg
W n =m n×g
W n = 1.47×9.81
W n = 14.42N
Weight of nozzle fluid

W nf =m f ×g but m f = ρ×V f where: - V f =¿ volume of the fluid on the nozzle

2
V f = π di L
4
2
V f = π 50.8 ×245
4
V f = 496321.6mm3
We take ρ of water =1000kg/m3

mf = ρ× v f
mf = 1000×0.0004963216m3
mf = 4.96×10−1 kg
W fn=m f ×g
W fn= 4.96×10−1×9.81
W fn= 4.87N
Weight of Wind (wind load)

The atmospheric pressure is varies from place to place then we take the mean atmospheric
pressure in aids Ababa as Patm= 1012N/m2.
W wn= Patm × A f where Patm= mean atmospheric pressure
A f = projected area
But A f = D0× H total

DO 739.59
H head = = =184.9mm
4 4
But H total= Lshell + 2 H head + Lskirt we take length of the skirt ( Lskirt ) = 500mm
H total= 2056.12mm + 2 ×184.9mm + 500mm
H total=2925.92mm =~2.93m
A f = D0× H total
A f = 0.73959m×2.05612m
A f =1.52 m2
W wn= 1012N/m2×1.5m2
W wn= 1518N
The wind effect has its own role in pressure vessel design. When we design pressure vessel with
greater height, we have to consider this effect on the vessel. The moment on the vessel due to
2
wind is calculated as: Mx = w x ;
2
Where M x = moment due to wind X is the distance measured from the free end (approximately
equal to Total height of the vessel = 1.5m) and ' w ' the load per unit length (Newton Per meter)
and calculated as follows:
D m= Di + t where: - D m= mean diameter of vessel
D m= 725.69mm + 6.95mm
D m= 732.64mm = 0.73264m And
w = D m× Patm = 0.73264m×1012N/m2
w = 741.43N/m And
2
Mx = w x
2
2
M x = 741.43× 2.93
2
M x = 3182.6Nm
Figure 4.8 wind load pressure the vessel

Now we can find the total weight as follows:
Wt material=W s+ W h +W n
Wt material=2127.4N+221.8N+14.42N
Wt material=2363.6N
Wt fluid =W sf + W hf + W nf
Wt fluid =8.34 × 10−6 N +1.47 ×10−6 N + 4.87N
Wt fluid =4.87N
∴ W net =Wt material+Wt fluid + W wn

W net = 2363.6N+ 4.87N+1518N
W net = 3886.47N
Then we find the design weight as follows:

W d = W net +W net × 10%
10
W d = 3886.4N + 3886.4N ×
100
W d =4275.04N
Now let us find the loading on each leg: -

Wd
Q= where n= number of legs let n=3
n
Q= load
W d = design weight
4275.04 N
Q=
3
Q=1425.01N
The area of legs calculated as follows: - ᵟ d=¿ Q ¿ where ᵟ d = design or allowable

A
stress=510N/mm2 for 5.8(carbon steel) material
Q 1425.01
A= A= A=2.8mm2
ᵟd 510
Skirt thickness
The skirt thickness must be sufficient to withstand the dead-weight loads and bending
Moments imposed on it by the vessel; it will not be under the vessel pressure. Mostly it sets
from the horizontal80° .
We can give the thickness and diameter of skirt by its standard by considering shell diameter.
2L
Internal diameter of skirt at lower part ( Ds ) = 739.59+2×4.95+
tan 80
2× 500
Ds =739.59+2×4.95+ =925.82mm
tan 80
Thickness of skirt (t s) = 30mm = 0.03m
Stress analysis of skirt support

σ s(Tensile) = σ bs – σ ws And σ s(compressive) = σ bs + σ ws
σ bs= Bending stress on the skirt
4 Mx
σ bs= (Mx= 3182.6Nm)
π (Ds+ t s) D s t s
4 ×3182.6 Nm
σ bs=
π ( 0.92582+0.03 m ) × 0.92582 m×0.03 m
σ bs=152642.69 N/m
The Dead weight stress in the skirt (σ ws) is calculated as:-

WT
σ ws=
π (Ds+ t s)t s
M s = Maximum bending moment evaluated at the base of the skirt (Due to wind loading)
Ds =Inside diameter of the skirt at the base

t s = Skirt thickness
W T = Total weight of the vessel and contents (WT =3886.47N)
WT
σ ws=
π (Ds+ t s)t s
3886.4 N
σ ws=
π ( 0.92582 m+ 0.03 m) ×0.03 m
σ ws= 43182.22N/m
To calculate the resultant tensile stress on the skirt:

σ s(Tensile) = σ bs – σ ws
σ s(Tensile) =152642.69 N/m2–43182.22 N/m2
σ s(Tensile) = 109460.47N/m2
To calculate the resultant compressive stress on the skirt:

σ s(Compressive) = σ bs + σ ws
σ s(Compressive) =152642.69 N/m2–43182.22 N/m2
σ s(Compressvie) = 195824.91N/m2
Since both σ s(Tensile) and σ s(Compressive) are less than the allowable or design stress that is
ᵟ d=¿ ¿510 * 106 N/m2 therefore our design is safe.
4.2.8 Design of welded joint

A welded joint is a permanent joint which is obtained by the fusion of edge of two parts to be
joined together with or without the application of pressure and filler material. Electric arc
welding is extensively used because of greater speed of welding [2].
The main considerations involved in the selection of weld type are:
 The shape of welded component required
 The thickness of the plates to be welded
 The direction of force to be applied
We Select butt joint especially square butt joint for the connection of both head and shell but
for the connection of nozzle to the shell part select corner joint.
Stresses for Welded Joints:
The stresses in welded joints are difficult to determine because of the variable and
unpredictable Parameters like homogeneity of the weld metal, thermal stresses in the welds,
changes of physical Properties due to high rate of cooling etc. The stresses are obtained, on the
following assumptions [2]:
 The load is distributed uniformly along the entire length of the weld, and
 The stress is spread uniformly over its effective section.
The following table shows the stresses for welded joints for joining ferrous metals with mild
steel electrode under steady and fatigue or reversed load.
Table 4.6 standard for weld design
Since the stress in the weld material is to be 81Mpa our electrode is mild steel electrode. The
recommended minimum size of weld is 14mm size of weld between 25mm- 55mm
π ( d o2−d i2 ) ×ᵟ m
F= where: - d o = outside diameter of the nozzle
4
d i= inside diameter of the nozzle
π ( d o2−d i2 ) ×ᵟ m
F=
4
π ( 59.6 2−54.82 ) × ᵟ m
F=
4
F= 431.06ᵟ m …………………… (1)
And
P D × π × d i2
F R=
4
2
F R= 3.18× π × 54.8
4
F R=7496.45N …………………… (2)
By equating equation 1 and 2 we calculate ᵟ m as follows:
Since F R= F
7496.45
∴ ᵟ m= = 17.39 N/mm2
431.06
4.2.9 Design of bolted flange joints

Bolt joints are one of the most common elements in construction and machine design. They
consist of fasteners that a capture and join other part and are secure with the mating of bolt
joints designs or screw threads [2].
There are two main type of bolted joint design:
1) Tension joint
2) Shear joint
In the tension joint the bolt and clamped component at the joint are designed to transfer the
external tension load through the joint by away of clamped component through the design of
proper balance of joint and bolt stiffness. The second type of bolted joint transfer the applied
load in a shear on the bolt shank and relies on shear strength of the bolt, tension loads on such
joints are only identically 2.
We select mild steel material to design bolted flange joints because of easily workable, very
hard, yet malleable, good for construction, easy to shape and machine and very flexible and can
be harden.
Table 4.7 material selection for bolt design
Steel grade Measured Yield strength Tensile strength

direction
( MP a) ( MP a)
HT50 A 542 591
HT80 A 693 830

Mild steel A 452 497
HT50 B 501 562
HT80 B 657 799
Mild steel B 439 471
HT50 C 531 587
HT80 C 665 811
Mild steel C 447 478
Use the following formula important to find the size and number of bolt.
Let Di = internal diameter of cylinder

D p = design pressure in the cylinder
d c = core diameter of the bolt
σ tb= permissible tensile stress of the bolt
n = number of bolt
Here we know that the upward force acting on the cylinder cover is:
π D i2∗P D
F= ……………………………….. (1)
4
This force is resisted by n number of bolt and the resisting force offered by n number of bolts
π dc 2∗σ tb∗n
F p= …………………………………………. (2)
4
From equation (1) the upward force acting on cylinder cover is
π D i 2 × PD
F=
4
π ×725.69 2 ×3.18
F=
4
F=1314616.4N
From equation (2) the resisting force by the bolt
π dc 2 ×σ tb × n
F R=
4
In our design we select the material for the bolt is mild steel. So, σ tb= 497N/mm2 the core
diameter is from the table by taking standard M 16 size.
From the table we take d c=¿13.546 ¿mm
π dc 2 ×σ tb × n
F R=
4
π ×13.546 2 × 497× n
F R=
4
F R=71589.3n since F= F R
1314616.4
∴ n= = 18.36≈19
71589.3
Nominal or major diameter of nut and bolt (d=D) = 16mm
Table 4.8 standard bolt dimension
Table standard bolt dimension
The total length of bolt and thread length of bolt can be calculated as follows:
Let us take L<125mm, d<50.8mm
Lt =216+ 6 mm
Lt =2× 16+6 mm
Lt =¿38mm
Lunthreaded =L−Lthreaded
Lunthreaded =100−38 mm
Lunthreaded =62 mm
Table 4.9 standard bolt and nut dimension

Stress analysis of bolt

F=448104.01N is the total force acted in the whole 12 bolts. Then in single bolts can be
calculated as follow
F 1314616.4 N
F i= = =69190.34N
n 19 bolts
Then we will calculate the stress on the bolt. Let us take standard bolt size of M 16
F i bolt π D 2i π ( 16 )2
Stress on a bolt = but Abolt = = =200.96 mm2
A bolt 4 4
69190.34 N
¿ =344.3 MPa
200.96 mm2
The tensile strength of M 16 bolts is σ tb= 497N/mm2
Since 344.3Mpa<497MPa hence our design is safe.
4.2.10 Design of Nut

We select mild steel material to design nut the same as bolt flange joint because of easily
workable, very hard, yet malleable, good for construction, easy to shape and machine and very
flexible and can be harden.
Table 4.10 material selection for the nut design
Steel grade Measured Yield strength Tensile strength

direction
( MP a) ( MP a)
HT50 A 542 591
HT80 A 693 830
Mild steel A 452 497
HT50 B 501 562
HT80 B 657 799
Mild steel B 439 471
HT50 C 531 587

HT80 C 665 811
Mild steel C 447 478
By reading from the above standard table we get:
 minor or core diameter of nut (d c ) = 13.835mm

 effective or pitch diameter of nut (d p) = 14.701mm
 nominal or major diameter of nut and bolt (d=D) = 16.000mm
Table4.11nut standard dimension
4.2.11 Flange design

Flanged joints are used for connecting pipes and instruments to vessels, for manhole covers,
and for removable vessel heads when ease of access is required. Flanges may also be used on
the vessel body, when it is necessary to divide the vessel into sections for transport or
maintenance. Flanged joints are also used to connect pipes to other equipment, such as pumps
and valves. Standard flanges will be specified for most applications. Special designs would be
used only if no suitable standard flange were available; or for large flanges, such as the body
flanges of vessels, where it may be cheaper to size a flange specifically for the duty required
rather than to accept the nearest standard flange, which of necessity would be over-sized 9.
Standard flanges
Standard flanges are available in a range of types, sizes and materials; and are used extensively
for pipes, nozzles and other attachments to pressure vessels. The proportions of standard
flanges are set out in the various codes and standards. A typical example of a standard flange
design is shown below. The relevant British Standards are BS 1560, Part 3 and BS 4504, Part 3,
which cover flanges for pipes, valves and fittings; in carbon and alloy steels [9].
Figure 4.9 standard flange
Table4.12 flange standard dimension
Now as we design the bolt before our bolt is Bolt M 1 6 standard size
For this reason our flange design parameters are in the first row of the table above that means
d1= 200mm
d2= 18mm
d3= 240mm
d4=258mm
h=44mm
b= 20mm
D= 320mm
f= 3mm
K= 280mm
Bolt M 1 6
4.2.12 Cost analysis

It is the total amount of money and man power which is used or consumption during
manufacturing of horizontal pressure vessel. Basic costs we spend in manufacturing are:-
I. Material cost
II. Labor costs Machine costs
Material cost
It is the total cost of shell materials that are:
Shells
Head
Opening
Nozzle
Support
Any design when he or she design a new material the cost analysis is the basic objective in the
design. The cost material most the of the packing is pound on dollar prices is an indication of
the cost of the some commonly used material is the table
 Our material selected is as follow
 Shell- low allow steel
 Head-low alloy steel
 Support-carbon steel
Cost analysis of shell

W=2127.4N
Since W=mg
m=216.9kg
1ton=1000kg
m=216.9kg m=0.2169ton
1ton=1000$
0.2169ton=cost of shell then we can change its dollar value in to birr by using relation
1 dollar=20.25 birr.
Cost of shell=216.9$=4392.225birr
Cost analysis of head
W=221.8N
Since W= mg
m=22.61kg
1ton=1000kg
m=22.61kg m=0.02261ton
1ton=1000$
0.02261ton=cost of head
Cost of head=22.61$=457.85birr
We have two head
Cost of head=2×457.85birr=915.7birr
Cost analysis of nozzle (opening)
W=14.42N
Since W= mg
m=1.47kg
1ton=1000kg
m=1.47kg m=0.00147ton
1ton=1000$
0.00147ton=cost of nozzle
Cost nozzle=1.47$=29.77birr
We have two nozzles
Cost nozzle=2×29.77birr=59.54 birr
Cost analysis of support
ρcarbonsteel =8300kg/m3
v=w × d × L=0.03×0.92582×0.5=0.0138873m 3
m=ρ × v=8300×0.0138873= 115.27kg
1kg=20.25
115.27kg=cost of support
Cost of support=2334.2birr
We have three skirts from the above calculation so:-
So cost support=3×2334.2birr=7002.6birr
Cost of other material
Cost of other material is like welding, labor, ladder and other assistants to o be pressure vessel
be 100$
Cost of other material=2025birr
The total cost of the pressure vessel is the summation of all the above value.
Cost of pressure vessel=cost of shell+ cost of head + cost of nozzle + cost of support +
cost of other material
Cost of pressure vessel = 4392.225+915.7+59.54+7002.6+2025
Cost of pressure vessel =14395.065 birr
CHAPTER 5
5.1 Result and discussion:
The following table shows the overall geometry of vertical pressure vessel. That we have
calculate and analysis in the project.
Table 5.1 result

components dimensions
1) shell Do= 739.59mm
Di=¿ 725.69mm
t s= 4.95mm
D m =732.64mm
Ls = 2056.12mm
V s = 0.850003m3
Di= 725.69mm
2) head Do= 739.59mm
H i= = 181.42mm
H o= 184.881mm
t h= 4.95mm
V h= 0.053m3
Sf = 43.75mm
d i= = 50.8mm
3) Inlet and outlet nozzle t n= = 2.4mm
d o = 59.6mm
t rn= 2mm
t r= 4.95mm
d c =9.858mm
4) Bolt flanged joint M12
n= 12
Lthreadedpart =76mm
Lunthreaded part=24mm
D=d= 12mm
5) Nut d c =10.106mm
d p= 10.863mm
D=d= 12mm
d1=60.3mm
5) Flange d2= 14mm
d3= 80mm
d4= 90mm
h= 28mm
b= 14mm
D= 140mm
f= 3mm
K= 110mm
M12
6) hand hole t handhole= 1.36mm
Ahandhole = 31400mm2
V= 1.00019m3
7) vessel support Lskirt = 500mm
Ds = 925.82mm
t s= 30mm
In this pressure vessel design report we have designed a total inside volume (V= 1.00019m3)
Pressure vessel for steam storing application. In this process we have designed shell, head, inlet
and outlet nozzle, bolt flanged joint, flange, hand hole and vessel support .All of these
components are designed by using appropriate formulas for each and their factor of safety are
checked for strength to avoid failures.
CHAPTER 6
6.1 Conclusion and recommendation
6.1.1 CONCLUSION
We conclude from this pressure vessel design the pressure with nominal volume 1 m3which is
used to store steam at 3.5 MP aand 300℃ designed above is designed to satisfy all the required
requirements to be able to work under the above parameters. A corrosion allowance of 2mm is
applied during the design to prevent failure due to corrosion and fatigue conditions. Our pressure
vessel is made with the material called low alloy steel for all part and carbon steel for skirt
design due to have higher than to those of the plain carbon steels for given applications. This
means it has higher strength, hardness, hot hardness, wear resistance, toughness, and more
desirable combinations of these properties.
During designing of this project we have so, many problems are happened like in calculating of
area of reinforcement actually in the required area of the nozzle. In our design of pressure vessel
the required area less than available area. So, we can use the reinforcement pad.
The design of pressure vessel in initialized with the specification requirements in terms of
standard technical specifications along with numerous requirements that lay hidden from the
market.
The storage of fluid at higher pressure in the pressure vessel is at the heart of its performance
and it is the first step towards the design. The pressure vessel components are merely selected,
but the selection is very critical. A slight change in selection will lead to a different pressure
vessel altogether from what is aimed to be designed.
It is observed that all the pressure vessel components are selected on basis of available ASME
standards and the manufactures also follow the ASME standards while manufacturing the
components.
Selection of pressure vessels components should be according to standards rather than
customizing the design:-the standards lead to;
 A universal approach
 Less time consumption
 Easy replacement
 So less overall cost.
6.1.2 Recommendation:
.The length of the vessel and the diameter of the vessel is very small so it is difficult to design
the man hole .there for we recommended that for the future designs the diameter of the vessel
and the length should be comfortable.
.In our design project we are design that hand hole because of a very small diameter of the vessel
and this hand hole is design at the two side of head .
When we design some part we have to collect information from different source. This means
the design is performed by using many references and web sites. So the materials needed for
design case must be fulfilled in order to perform applicable design for all users.
We recommended that the pressure vessel design should include the earthquake loading,
vibration, loading from piping and external equipment and wobble effect in which the pressure
vessel delivered with. More try to study the load analysis by recent software and it is our
suggestion to test the pressure vessel in laboratory before use.
REFERENCES:
 [1]. Coulson & Richardson’s Chemical Engineering volume- 6 .
 [2]. Pressure vessel hand book -10th edition.
 [3]. M.A Khan, “Stress distribution in horizontal pressure vessel and saddle supports”,
International Journal of Pressure Vessels and Piping 87 (2010).
 [4]. M. Javed Hyder, K, Asif,” “Optimization of location and size of opening in a
pressure vessel cylinder using ANSYS”, engineering Failure Analysis 15 (2008).
 [5].M. Giglio, “Fatigue analysis of different types of pressure vessel nozzle”, revised 19
November 2002; accepted 20 November 2002
 [6]. Avinash R.Kharat, V. V. Kulkarni,” Analysis of stress concentration at opening in
pressure vessel using ANOVA”, IJRET: International Journal of Research in
Engineering and Technology, eISSN: 2319-1163.
 [7]. Bandrupalli Praneeth, T.B.S.Rao, “Finite Element Analysis of Pressure Vessel and
Piping Design “, International Journal of Engineering Trends and Technology-
Volume3Issue5- 2012
 [8]. Shyam R. Gupta, Ashish Desai, Chetan P. Vora, “Optimize nozzle location for
minimization of stress in pressure vessel”, Volume 1, Issue 6, June 2014, e-ISSN: 2348 -
4470
 [9]. M. Jeyakumar, T.Christoper, “Influence of residual stresses on failure pressure of
cylindrical pressure vessel”, Chinese journal of aeronautics, (2013).
 [10]. Modi A J, Jadav C.S, “Structural Analysis Of Different Geometry Heads For
Pressure Vessel Using Ansys Multiphysiscs”, The 5th International Conference On
Advance In Mechanical Engineering. 2011.
 [11].Machine element one and machine element two.
 [12]. Strength of material.
 [13]. Pressure vessel design manual-10th edition.
 [14] http://www.google.com.
 [15] GUIDEBOOK FOR THE DESIGN OF ASME SECTION VIII PRESSURE VESSELS Second Edition by
James R. Farr
 [2] a text book of machine design, R.S. KHURMI & J.K. GUPTA , [A Textbook for the Students of
B.E. / B.Tech., U.P.S.C. (Engg. Services); Section ‘B’ of A.M.I.E. (I)] EURASIA PUBLISHING HOUSE
(PVT.) LTD. RAM NAGAR, NEW DELHI-110 055

Design of a Vertical Steam Pressure Vessel

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Design of a Vertical Steam Pressure Vessel

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MACHIN DESIGN PRESSURE VESSEL DESIGN PROJECT 1 B.

DESIGN PROJECT- ONE

DESIGN OF VERTICAL STEAM PRESSURE VESSEL

Fig1; pressure vessel sample

1.3 Classification of pressure vessel

Pressure vessels can be classified in different categories as follows:-

This can be classified in to two groups;

The pressure vessel, according to their dimension, may be classified as:

Fig 1.1 thin walled pressure vessel

Fig 1.3Thick Walled Cylinders

c). According to geometrical shape

A). Vertical pressure vessel:-

Figure 1.4 vertical pressure vessels

Figure1.5 horizontal pressure vessels

C) Spherical pressure vessel:-

Figure 1.6 spherical pressure vessels

 Industrial compressed air reservoirs

 Hydraulic reservoirs under pressure

1.5 Area of application of pressure vessel

 In brewery and soft drink factories

1.6 Component of pressure vessel

The major components of pressure vessel are listed below:

There are four types of head:

Nozzles are used for the following applications:-

 Attach piping for flow into or out of the vessel.

Typical kinds of supports are as follow:-

Figure 1.7 skirt support

Figure 1.8 leg support

Figure 1.9 saddle support

Figure 1.10 lug support

 Types of flange, and selection

Fig 1.11- Welding-neck flange

Fig1.12- Slip-on flange

Fig1.13- Lap-joint flange

Fig1.14- Screwed flange

Fig1.15- Blind flange

Gaskets: are used to make a leak-tight joint between two surfaces. It is

A great variety of proprietary gasket materials is used, and reference

1. The process conditions: pressure, temperature, corrosive nature of the

Pressure gages: are instruments for measuring the condition of a fluid

Temperature gages: are instruments for measuring the condition of a fluid

1.8 PROBLEM STATEMENTS

1.9 General objective

1.10 Specific objective

Fluid content----------------------------- steam

Design Pressure --------------------------3.5MPa

Design Temperature --------------------- 3000c

1.12 Limitation the Project

2.1 LITRETURE REVIEW

3.1.1 IDENTIFICATION OF THE NEED

3.1.2 DEFINITION OF PROBLEMS

3.1.3 ANALYSIS AND OPTIMIZATION

3.1.4 Selection of material

Availability of the material

Table 3.1: typical design stress

Material Tensile strength Design stress at temperature

Low alloy steel 550 235

Generally pressure vessel may be made from

 Steel on its alloys

3.1.6 DESIGN SPECIFICATION

Design of column vertical pressure vessel specification

Parameters Value Unit