Professional Documents
Culture Documents
UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL AND INDUSTRIAL
ENGINEERING
Section 03
Page
Design I, Design of Vertical Pressure Vessel
ABSTRACT
In this project there are five chapters are included here; in chapter one discuses about
the general over view of the project; chapter two tells about literature review and chapter
three
is focus on complete analysis of the design of a pressure vessel basis on several design
consideration. Geometrical analysis, wind load analysis, and stress analysis are conducted on
this design and select the proper material for components of the pressure vessel through
taking
some standard tables and standard machine element components. After all, dimensions and
materials are decided for the design component, on the last two chapters result discussion
conclusion and recommendation as well as the part and assembly drawing also provided for
complete description. The main thing here is that the designed pressure vessel can hold the
required fluid of 1.6m3 as we have checked after we designed the vessel.
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Design I, Design of Vertical Pressure Vessel
ACKNOWLEDGEMENT
First of all we would like to thank our GOD for the successful completion of our project. We
would like to express our deepest gratitude and sincere appreciation to Mr. Andebet Tilahun
(Msc.) for his guidance, follow-up, and advice throughout the project period. . We would like to
extend our thanks to those who helped us with different ideas and motivation which inspire us
for the successful completion of this project. . Last but not the least; we would like to thank our
beloved family, for giving birth to us at the first place and supporting us spiritually throughout
our life.
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Design I, Design of Vertical Pressure Vessel
Table of Contents
Abstract.......................................................................................................................................................ii
Acknowledgement......................................................................................................................................iii
Table of Contents………………………………………………………………………..…………………iv
List of Table……………………………………………………………………………….…………….…vi
List of Figure……………………………………………………………………………………………...vii
Chapter -1....................................................................................................................................................1
1. Introduction.............................................................................................................................................1
1.1. Over view of the project...................................................................................................................1
1.1.1 definition of pressure vessel........................................................................................................2
1.1.2 Back ground of pressure vessel...................................................................................................3
1.1.3. Application................................................................................................................................5
1.1.4. Use.............................................................................................................................................5
1.1.5. TYPES OF PRESSURE VESSEL.............................................................................................6
1.1.6. Working principle....................................................................................................................10
1.1.7 Main Components of Pressure Vessel.......................................................................................10
1.2 Statement of the problem.................................................................................................................21
1.3 Objective.........................................................................................................................................21
1.3.1 General objective......................................................................................................................21
1.3.2 Specific objective......................................................................................................................22
1.4. Scope of the project........................................................................................................................22
1.5. Methodology...................................................................................................................................22
Chapter- 2..................................................................................................................................................24
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Design I, Design of Vertical Pressure Vessel
Literature review.......................................................................................................................................24
Chapter- 3..................................................................................................................................................25
Design and analysis…………………………………………………………………………………….…25
3.1. Introduction....................................................................................................................................25
3.2. General Design Considerations:......................................................................................................26
3.3. Detail design and analysis of a column (vertical layout) pressure vessel........................................28
3.3.1. Design of shell:........................................................................................................................28
3.3.2. Design of Head:.......................................................................................................................36
3.3.3. Design of inlet and outlet nozzle..............................................................................................43
3.3.4. Design of Skirt Support...........................................................................................................47
3.3.5. Design of bolted flange joint....................................................................................................58
3.3.6. Design of Nut...........................................................................................................................62
3.3.7. Flange design:..........................................................................................................................64
3.3.8. Design of circular handhold:....................................................................................................67
3.3.9. Design of welded joint:............................................................................................................68
3.3.10. Design of Gaskets..................................................................................................................70
Chapter-4………………………………………………………………………………………..…………72
4.1. Result and discussion:.........................................................................................................................72
4.1.1. Result.......................................................................................................................................72
4.1.2 Discussions...............................................................................................................................74
Chapter - 5.................................................................................................................................................74
5. Conclusion and recommendation...........................................................................................................74
5.1. Conclusion......................................................................................................................................74
5.2. Recommendation:...........................................................................................................................74
Chapter- 6..................................................................................................................................................75
6. 3D Part and Assemble Drawing.......………………………………………………….……….………..75
Reference...................................................................................................................................................81
Appendix...................................................................................................................................................78
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Design I, Design of Vertical Pressure Vessel
List of table
Table 3.1. Given specification data............................................................................................................26
Table 3.2.Joint factor table .......................................................................................................................28
Table 3.3. Appropriate standard material ..................................................................................................29
Table 3.4. Appropriate material for shell ..................................................................................................30
Table 3.5. Optimum vessel proportion ......................................................................................................32
Table3.6. stress analysis for head .............................................................................................................39
Table 3.7. Material selection for bolt design .............................................................................................58
Table 3.8. Material selection for the nut design ........................................................................................62
Table 3.9. Nut standard dimension ...........................................................................................................63
Table 3.10.material selection for the nut design .......................................................................................65
Table 4.1.result table ................................................................................................................................72
Table 6.1. Standard bolt and nut dimension ..............................................................................................81
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Design I, Design of Vertical Pressure Vessel
List of Figure
Page
CHAPTER-1
INTRODUCTION
1.1. Overview of the project
Pressure vessel are probably one of the most wide spread equipment with the different industrial
sector .in fact ,there is no industrial plant without pressure vessels ,steam boilers, tanks
autoclaves,collectors,pipe,heat exchangers etc…
The pressure vessel which are either cylindrical or tanks are used to store fluid under pressure.
Pressure vessel and tanks are in fact essential to the chemical, petroleum, petro chemical and
nuclear industry.it is in the class of equipment that the reaction. Separation and storage of raw
material occur. Similarly pressurized equipment is required for a wide range of industrial plant
for storage and manufacturing purpose, Also It has a container with pressure differential between
inside and outside. The inside pressure is usually higher than the outside. Pressure vessel has a
combination of high pressure together with high temperature and in some case highly radioactive
material or flammable fluid. Due to such hazards it is imperative that the design be such that no
linkage can occur.
A pressure vessel is not an easy structure. Actually it is characterized by a regular and simple
shape but requires special care, especially when modern approach to structural design is
concerned.
In the case of shell, opening requiring reinforcement in vessel under internal pressure the metal
removal must be replaced by the metal of reinforcement. In addition to providing the area of
reinforcement, adequate welds must be provided to attach the metal of reinforcement and the
induced stress must be evaluated. material used for reinforcement shall have an allowable stress
value equal to or greater than of the material in this vessel wall except that, when such material
is not available, lower strength material may be used ;provided, the reinforcement is increased in
inversed proportion to the ratio of the allowable stress values of the two material to the ratio of
the two materials to compensate for the allowable stress value of any reinforcement having a
higher allowable stress value than that of the vessel wall [1].
Figure 1.1 Pictorial view of vertical pressure vessel [2].
Design involves parameters such as maximum safe operating pressure and temperature, safety
factor, corrosion allowance and minimum design temperature (for brittle fracture). Construction
is tested using nondestructive testing, such as ultrasonic testing, radiography, and pressure
tests. Hydrostatic tests use water, but pneumatic tests use air or another gas. Hydrostatic testing
is preferred, because it is a safer method, as much less energy is released if a fracture occurs
during the test (water does not rapidly increase its volume when rapid depressurization occurs,
unlike gases like air, which fail explosively).
1.1.3. Application
Pressure vessel is the container for fluid under high pressure. They are used in variety of
industries like:
Petroleum refining
Chemical plant
Power plant
Food and beverage
medical application
LPG tanks and many more
In addition it also 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…
1.1.4. Use
Pressure vessels are used in a variety of applications in both industry and the private sector. They
appear in these sectors as
recompression chambers,
distillation towers,
pressure reactors,
autoclaves,
nuclear reactor vessels,
submarine and space ship habitats,
pneumatic reservoirs,
or the outer skin carries both the aircraft maneuvering loads and the cabin
pressurization loads.
a) Welded
b) Cast
c) Brazed, and
a) Storage vessels
b) Reactors
c) Boilers
d) Mixers, and
e) Heat exchangers.
The size and geometric form of pressure vessels diverge greatly from the large cylindrical
vessels used for high-pressure gas storage to the small size used as hydraulic units for aircraft.
Some of the vessels are buried in the ground or deep in the ocean, but most are positioned on
ground or supported in platforms. There are four types of pressure vessels. But mainly two types
of pressure vessels usually available in industry:
a. Cylindrical.
b. Spherical
c, Conical, and.
d. Combined
This type of a vessel designed with a fixed radius and thickness subjected to an internal gage
pressure. This vessel has an axial symmetry. The cylindrical vessels are generally preferred,
since they present simpler manufacturing problems and make better use of the available space.
Boiler drums, heat exchangers, chemical reactors, and so on, are generally cylindrical.
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 vessels 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, and so on.
For the same internal design pressure, a spherical vessel will require only half the wall
thickness as a cylindrical vessel.
Spherical vessels have the advantage of holding the largest volume per unit surface area
of the container [7].
Vertical
Horizontal and
Thin walled (t/D<1/10) and, Thick walled (t/D≥1/10) pressure vessels. Where; t and D are the
thickness and diameter of the shell respectively [4].
Industry
alcohol and
poisenes fliuid
realesed from
industry
pressure vessel
store alcohols
and convert to
neuteral fluid
finally realese to
the river
a) Shell
b) Head
c) Nozzle
d) Support
e) Flanges
\a) Shell
The shell is the main component of any vessels that contains the pressure. Material of shell
normally come in plate or rolled steel. Commonly, some pressure vessel shells has a rotational
axis and be welded together to form a structure. Most pressure vessel shells are cylindrical,
spherical, or conical in shape [6].
b) Head
All pressure vessel shells must be closed at the ends by heads. Heads that usually used are
typically in curved rather than flat.
Configurations of curved shape stronger and let the pressure vessel's heads to be thinner, lighter
and less expensive rather than flat heads. Inside a vessel, heads can also be used.
Elliptical, hemispherical, and tore spherical are the most commonly used head types.
Note that; all head types have a straight flange (sf) section, which simplifies welding the head to
the adjacent cylindrical shell section.
The elliptical and tori spherical heads have an indicated head
depth (h), which is measured from the straight flange to the maximum point of curvature on the
inside surface.
This is also called a 2:1 elliptical head. The shape of this head is more economical and
not exposed to wind loading, because the height of the head is just a quarter of the
diameter. Its radius varies between the major and minor axis. As our vessel is vertically
oriented it’s merely exposed to wind loading, if so the elliptical head can withstand the
wind load in a slight extent when compared with others. Even if an elliptical head is
exposed to snow loading and the edge between the straight flange (sf) and the curved
head became crack easily, whenever this condition are present we select it as a best head
by fabricating from carbon and low alloy steel as it is hard and strong with a moderate
ductility properties as well as low cost and availability.
Figure 1.5 Ellipsoidal (or) elliptical head [2].
Ellipsoidal would be the most common type of heads, which is used during the designing of a
new pressure vessel.
2) Hemispherical
A sphere is the ideal shape for a head, because the pressure in the vessel is divided
equally across the surface of the head. The radius (r) of the head equals the radius of the
cylindrical part of the vessel. The required thickness of a hemispherical head is normally
one-half the thickness of an elliptical or tori spherical head for the same design
conditions, material, and diameter. Hemispherical heads are normally fabricated from
segmented sections that are welded together, spun, or pressed.
Tall towers may have sections with different diameters along their length. The transition
between the different diameters is made in a conical section. The most common design
for a conical transition does not have formed knuckles at the ends of the cone. The
cylindrical sections of different diameter are welded to each end of the cone. Formed
knuckles are sometimes used at the cone-to-cylinder transition in order to reduce
localized stresses. When knuckles are used, the transition is called Tori conical. The use
of knuckles is 106 mandatory when the cone half-apex angle exceeds 30°. Knuckles are
also sometimes used for smaller angles when there is concern about potentially high local
stresses at the cone-to-cylinder junction. The ASME Code has design procedures for tori
conical sections.
Figure 1.8 Tori conical head [2].
Reinforcement of openings
The philosophy is based on providing additional material in the region of the opening by
thickening the shell or adding a pad material. The additional material is deemed effective
in carrying the higher loads. On most vessels, is provided on the outside of the vessel. In
some vessels, the reinforcement appears inside, while in others both inside and outside
regions are reinforced. On many vessels, however, the arrangement is such that no
reinforcement can be placed on the inside because of interfering components [7].
c) Nozzles
A nozzle is a cylindrical component that penetrates and mounts whether at the shell or
heads of a pressure vessel surface. The nozzle ends are generally flanged.
Flanges function is to allow the necessary connections. Flanges also use to permit easy
disassembly for routines maintenance or easy access. Nozzles commonly are used for the
following applications [2].
Conical head
d) Support
The type of support that is designed and used depends on the orientation of the pressure
vessel whether horizontally or vertically.
In any situation, the pressure vessel support must be enough to support the applied weight
and other loads.
Design pressure of the vessel is not being considered in the design of its support because
the support is not be pressurized. But, design temperature should be considered for
support design.
It should be considered from the perspective of material selection and provision for
differential thermal expansion.
There are different types of supports which are used depending upon the size and
orientation of the pressure vessel.
These are;-
Skirt support
Leg support
Saddle support
Lug support
Skirt support
This type of support generally been used for tall, vertical, cylindrical pressure vessels.
The skirt is normally design long enough to provide flexibility so that radial
thermal expansion of the shell does not cause high thermal stresses at its junction
with the skirt.
Base ring/flange
Base ring is a part of skirt support which is used to distribute the vertical load over a sufficient
area of the concrete foundation. In addition it serves also to accommodate the anchor bolts [7].
Small vertical drums are normally supported by legs that are welded to the bottom of the
pressure shell.
The maximum ratio of support provides for leg length to drum diameter is typically 2:1.
The number of legs is designed depends on the drum size and the loads to be carried.
Support legs are also usually designed for spherical pressure vessels.
The support legs for small vertical vessels and spherical storage vessels normally made from
high carbon material such as structural steel columns or pipe sections, which provides a more
efficient and perfect design.
Figure 1.10 Pictorial view of vertical pressure vessel with leg support [2].
Saddle support
This type of support divides the weight load over a large area of the shell to avoid an
unnecessary stress in the shell at two different locations.
The width of the saddle is considered by the specific size and design conditions of the pressure
vessel.
Figure 1.11. Pictorial view of horizontal pressure vessel with saddle support [2].
Lug support
Vertical pressure vessels may also be supported by lugs.
Diameter (1 to 10 ft) Also moderate height to diameter ratios in the range of 2:l1 to 5:1
the lugs are typically bolted to the use of lugs is typically limited to pressure vessels of
small and medium horizontal structural members in order to provide stability against
overturning loads [7].
Figure 1.12 Pictorial view of vertical pressure vessel with lug support [3].
1.3 Objective
1.3.1 General objective
The main objective of our project is to design a column (vertical layout) pressure vessel that has
an ability to store diesel a within the given specification of
Those components which are design at the end of the project are, shell, nozzle, and standard
flange, Columns supporting skirt and base ring/flange .An ellipsoidal head and others.
Since our project is to design a column (vertical layout) pressure vessel based on the given
specification that is design pressure(160mpa), design temperature(300 0C), total inside
volume(1.8m3), corrosion allowance(2.4),and working fluid is diesel but we are limited to apply
the schedule time for the design purpose since we have taken other courses parallel. And also
there is no sufficient material in our workshop to manufacture the design.
1.5. Methodology
For this particular design project we follow the following project design methodology to solve
the design problem
IDENTIFICATION OF NEED
Design of a column (vertical layout) Pressure vessel
DEFINITION OF PROBLEM
PRESENTATION
Part drawing and assembling drawing of the column (vertical layout) pressure
vessel using Auto CAD software.
CHAPTER- 2
LITERATURE REVIEW
Prof. Sha Husain S.Maghrabi et al [6] presented their work on Elastic behavior of Cylindrical
Vessels with Lateral Nozzle under internal pressure. The objective of this work is to study the
elastic stress distribution, deformation, characteristic and 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.
M. Giglio et al [6] 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 concludes that failure of nozzles was carried out by crack passing through their
thickness. Both designs (external and internal 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.
DiCarlucci et al [7] in year 2008 has done the work on ASME norms should be considered for
designing. Seismic loads should be considered while designing a pressure vessel. Wind load and
seismic load creates moment at lug. The greater moment should be consider for design to avoid
accidents.
E. 0. Bergman [8] states that the external loads applied to vertical pressure vessels produce axial
loading and bending moments on the vessel. These result in axial tensions and compressions in
the shell, which must be combined with the effects of the pressure loading to give the total
longitudinal stress acting in the shell. The design method to be used depends on whether the
longitudinal stress in the shell is tension or compression, and on whether the vessel is subjected
to internal or external pressure.
From the above journals we conclude that a column (vertical layout) pressure vessel is fail due to
certain factors such as: External loading, Wind loading, Crack passing through the thickness of
nozzle, Effect of residual stress.
In order to improve the life and efficiency of vertical or column pressure vessel. When we design
vertical or column pressure vessel, we must consider external loads such as wind load and
seismic load, and also we should select material.
CHAPTER- 3
Design pressure
A vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation. 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 [9]. When
deciding the design pressure, the hydrostatic pressure in the base of the column should
be added to the operating pressure, if significant. Vessels subject to external pressure should
be designed to resist the maximum differential pressure that is likely to occur in service. From
the equation of design pressure we can get the normal working pressure (or) internal pressure”
Pi” as shown below:-
PD =P+ P*10%
Since, PD = P+ P*10%
PD = Pi (1+10%)
Pi= PD/1.1
Pi= 160Mpa/1.1
Pi= 145.45Mpa.
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 [9].
TD = 300°c
Corrosion allowance
The corrosion allowance is the additional thickness of metal added to allow for material lost by
corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer. Corrosion is a complex phenomenon, and it is not possible to give
specific rules for the estimation of the corrosion allowance required for all circumstances. The
allowance should be based on experience with the material of construction under similar service
conditions to those for the proposed design [9].
Degree of radiography
Type of joint 100 % Spot None
Double-welded butt or 1.0 0.85 0.7
equivalent
Single-weld butt joint 0.9 0.80 0.65
with bonding strips
3.3. Detail design and analysis of a column (vertical layout) pressure vessel
The design procedures in pressure vessel codes for cylindrical shells are mostly based on linear
elastic assumption, occupationally allowing for limited in elastic behavior over a localized
region. The shell the thickness is the major design parameter and usually controlled by internal
pressure and sometimes by external pressure which can be produce bucking. Now to determine
the thickness and diameter of shell first categorized our pressure vessel according to its design
pressure compared to standard. Therefore check for which non opposition that our pressure is
safe.
From the above table we select the material, design stress and tensile strength for shell based on
the design temperature, and design pressure.
ᵖd∗R
PD <0.385ᵟd* E t
…………………………. use s = ……equation 2
ᵟ d∗E−0.6 PD
= 0.385ᵟd* E
0.385*240N/mm2*1=92.4mpa
But Pd =160mpa
To calculate the thickness of the shell, first find the diameter .from the given volume 1.8m 3 and
also find vessel ratio
E= joint factor
F1¿ 2.4∗(240∗1¿¿ 160−0.6)¿
F1=2.16mm
Now convert the unit in to inch by using conversion factor
1inch=25.4mm
X? =2.16mm
X = F1=0.085inch
L
To know ratio we use the vessel ratio and total inside volume.
Di
First let us change the unit of volume in to ft3 by using conversion factor
1ft3=0.028317m3
1ft3=0.028317m3
V? = 1.8m3
V=63.566ft3
By using V=63.566ft3 and
F1=0.085inch, then to find the diameter change the design pressure unit to PSI.
1mpa =145.04PSI
160mpa=pd
pd=23206.4PSI
Di 754.62
R= =
2 2
377.31mm =0.37731m
Ts =466.381mm.
But for safe design we consider corrosion allowance.
ttotal=t s +c =466.381+2.4 = 468.781mm
Do =754.62 + 2* t total
Do =754.62+2(468.781) =1692.182mm
Dm= Di + t
Dm= 754.62mm + 468.781mm
Dm= 1223.4mm
And length of the cylinder can be found by:
L
=5
Di
L= 5 Di
L=5*754.62mm
L=3773.1mm
From this the length of the shell is given by:
2∗Hi
Ls = L-( ) but
3
Di
Hi=
4
Where Hi is inner head for ellipsoidal head
754.62
Hi= = 188.655mm
4
Ls = L-¿)
2∗188.655 mm
Ls = 3773.1mm - ( )
3
Ls = 3647.33mm
2
V s =Ls ( π∗Di )
4
2
V s = 3.64733 ( π∗0.754 .62 )
4
V s = 1.63125m3
❑H = Pd ¿ Dm
2∗t
(b)Longitudinal stress (¿ L )¿
Consider a closed thin cylindrical shell subjected to internal pressure tensile stress acting in the
direction of the axis is called longitudinal stress. In other words, it is tensile stress acting on the
transverse or circumferential section Y-Y (or on the ends of the vessel).
❑L= pd∗Dm
4t
Calculate the design stress analysis of the shell thickness to know whether it is safe or not.
Figure 3.1 Stress analyses [2].
As we know
And
H =2l
Since both hoop and longitudinal stress are less than the allowable (Design) stress our design is
safe.
Figure 3.2 2D shell structures [2].
3.3.2. Design of Head:
Heads are one of the important parts in pressure vessels and refer to the parts of the vessel that
confine the shell from below, above, and the sides. The ends of the vessels are closed by means
of heads before putting them into operation. The heads are normally made from the same
material as the shell and may be welded to the shell itself. They also may be integral with the
shell in forged or cast construction. The head geometrical design is dependent on the geometry of
the shell as well as other design parameters such as operating temperature and pressure.
The heads may be of various types such as:
Ellipsoidal
Tori spherical
Hemispherical
Conical
ASME equation for Ellipsoidal heads
The design thickness of an Ellipsoidal head is given by:
P D DK
t=
2 δE−0. 2 PD Where: D– shell diameter
S-allowable Stress
k – Stress intensity
1 a
K=
6 [
2+( )2
b ] a-semi minor axis
b-semi major axis of the Ellipsoidal head
which is 2:1
1 2
K=
6 [
2+( )2 =1
1 ]
P D DK 160 MPa∗754 . 62mm∗1
t= = ==269 . 507 mm
2 δE−0. 2 PD 2∗240 MPa∗1−0. 2∗160 MPa
For safe design we should consider corrosion allowance.
t total = th+2.5 = 269.507+2.4= 271.907 271.9mm
D 754 . 62 mm
Hi= = =188 . 655 mm
4 4
Do
ho= , but
4
Do=di+2ttotal
=754.62mm+2(271.9)mm
=1298.42mm
D0
Ho¿ = 1298.42/ 4
4
=324.605mm
2
V h= 2* ( π∗Di ∗Sf π∗Di2 2∗hi
+ * ) but
4 4 3
Di
Hi= and
4
hi Di
Sf= =
3 12
2
V h= 2* ( π Di ∗Di π∗Di2 2∗Di
+ * )
4∗12 4 3∗4
3
V h= 2* ( π Di π∗Di3
+ )
48 24
3 3
V h = 2* π Di +2∗π Di
( 48 )
3
V h = 2* 3 π Di
( 48 )
3
V h = π Di but Di= 0.75462m
8
3
V h= π∗0.75462
8
V h= 0.16875m3
V t= V s+ V h
V t = 1.63125m3 + 0.16875m3
V t = 1.8m3
x =maridinal stress .
There are two types of stress in head due to internal pressure. This are
At any point x
At the center and,
At the tangent
di
h=
4
754.62mm
h= = 188.655mm
4
Di 754.62mm
R= = = 377.31mm
2 2
Figure 3.4 Head stress analysis [2].
Let x=250mm
4 2
h √
RL= R2 + X 2 1− R2
h( )
377.314 377.312
RL=
√ 188.655
2
+250 (
2
1−
188.655
2 )
= RL= √ 569451+(−187500)
= RL= √ 381951
RL=618.02mm
RL3∗h2
Rm=
R4
618.023∗188.6552
Rm=
377.314
Rm =414.52mm
Pd∗Rl PDRRL
∴x = and = (1-RL /2Rm)
2t t
160∗618.02
x = =160.659MPa< 240 MPa
2∗468.781
PD∗RL RL
∅=
t
1− (
2 Rm )
160∗618.02 618.02
∅ =
468.781
1−(2∗414.52 )
= 210.93(1-0.7454)
=53.689MPa <240MPa
R 377.31
= =2.0which is>1.42
h 188.655
R
ratio exceeds 1.42,hoop stress in the knucle become compressive.
h
PD∗R2
x =
2∗t∗h
160∗377.312
x =
2∗468.781∗188.655
∴x =128.78N/mm2<240MPa
PD∗R
x =
2t
160∗377.31
x =
2∗468.781
x =64.39 N/mm2
PD∗R R2
∅=
t
1−(2∗h 2 )
160∗377.31 377.312
∅ =
468.781
1−(2∗188.655 2 )
∅ = -123.51N/mm2 MPa<240MPa
∴As we see from the above result the negative sign shows the presence of compressive stress.
When we see from the above three cases stress is maximum at the center of head and this stress
is less than the allowable or design stress, so our design of head is safe.
3.3.3. Design of inlet and outlet 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 [9].
All process vessels will have openings for connections, man ways, and instrument fittings. The
presence of an opening weakens the shell, and gives rise to stress concentrations. The stress at
the edge of a hole will be considerably higher than the average stress in the surrounding plate. To
compensate for the effect of an opening, the wall thickness is increased in the region adjacent to
the opening. Sufficient reinforcement must be provided to compensate for the weakening effect
of the opening without significantly altering the general dilation pattern of the vessel at the
opening. Over-reinforcement will reduce the flexibility of the wall, causing a hard spot, and
giving rise to secondary stresses [9].
We select low alloy steel material to design inlet and outlet nozzles because it is suitable for
welding, has high atmospheric corrosion resistance capacity. The standard table is found at the
above table 3.3.
Nozzle attached to pipes to convey the working fluid inside and outside of the vessel.
Like shell design we select low alloy steel for design of inlet and out let nozzles because it is
suitable for welding has high atmospheric corrosive resistance capacity.
For opening in cylindrical shell are limited to that sizes
In shell 60inch and less in diameter ,the opening shell not exceed 0.5 diameter or 2inch
In shell over 60inch in diameter, the opening shell not exceed 0.33diameter or 4inch
where di=inner diameter of the shell, so diameter of shell=28.56inch which is less than
60 inch so the opening diameter =0.5 diameter or 2 inch
Dn=1inch=25.4mm
Therefore 2inch is 50.8mm because of internal diameter the nozzle is over 18inch and
less than 36inch so
Rn= Dn/2 =25.4mm
Do=55.8mm
Assume our inlet opening pipe is placed on the cylindrical shell.
PDRi
t r=
δ dE−0 . 6 PD
160 MPa∗377 . 31mm
¿ =419 .23 mm
240 MPa∗1−0 .6∗160 MPa
t=tr+c = 419.23+2.4=421.63mm
PD n 160 MPa∗50. 8 mm
σ H= = =144 . 01 MPa
2∗tm 2∗28. 22 mm
tr = 419.23mm
tn =8.5699mm from standard table
t = 421.63mm
trn =28.22mm
A=
A 1 + A 2 + A3 +A
2
Take the smaller A2= 842 mm
Inward
A 3 =5∗t∗t n=5∗421.63∗8.56996=18066..76 mm2
A 4 =2∗0. 5∗t 2
=2*0.5*421.632=177771.85mm2
(2053.44+842+18066.76+177771.85)mm2=mm2
At=198734.05mm2
The available area > the required area, it means the design is safe.
Figure 3.5. 2D of inlet and outlet nozzle [2].
Weight of shell material: is the sum of weight of shell material and fluid
W S=W SF +W SM
Where; Wsm=weight of shell
Wsf = weight of shell fluid
W sf=mf*g but mf= ρ*Vf where Vf=volume of the fluid on the shell
Mf=mass of fluid
2
V f = Ls π∗Di
But ( 4 )
2
V f = 3.50699 ( π∗0.75462 )
4
Vf =1,568m3
msf = 1.568 m3*849kg/m3=1331.64kg
W sf = ms f *g
W sf = 1331.64*9.81=13063.44N
Wsm=πDmtsgLg
But L=Ls+2Hd
L=3506+2(Do/4), Do=outside diameter of shell
L=3506.9mm+2(1298.42/4)
=4156.11mm=4.15611m
Dm =Di+ts
=754.62+421.63=1176.25mm=1.176m
Wsm=πDmtsLg
Wsm =π*1.176*0.42163*7850*4.15611*9.81
Wsm =498556.5N
is the sum of the weight of head material and the fluid stored on it.
th=thickness of head
W h m= 1.084 Dm2*th*ρ*g
W hm = 1.084*1.1762∗0.42163*7850*9.81
W hm =48675.9N
Weight of Nozzle: is the sum of the weight of nozzle material and the fluid stored on it.
W nf =m f *g but m f = ρ*V f
2
V f = π di L
4
2
V f = π 50.8 ∗635.286
4
V f = 0.0012876m3
m f = ρ*Vf
m f = 849 kg /m3*0.0012876m3
m f = 1.0932kg
W fn=m f *g
W fn=10.724N
( 2 2)
V n= π do −di L where d o = outlet nozzle diameter
4
L= length of nozzle
m n = mass of nozzle
di 50.8 mm Di 754.62mm
r i= = = 25.4mm and Ri= = =377.31mm
2 2 2 2
l=377.31-√ 37 7.312−25.42
l=0.856mm
L=635.286mm
=50.8+2(2.4) = 55.56mm
=do=55.56*2(421.63)=46851.5mm
2 2
V n= π ( do −di ) L
4
2 2
V n= π ( 46851.5 −50.8 )∗635.286
4
m n= ρ*V n
m n= 7850*1095.23
m n= 8597561kg
W n =m n*g
W n = 8597561*9.81
W n = 84342082N
2
V f = π di L
4
2
V f = π 50.8 ∗635.286
4
V f = 0.001287m3
m f = ρ*Vf
m f = 849 kg /m3*0.001287m3
m f = 1.0932kg
W fn=m f *g
W fn= 10.724N
Weight of Wind
The atmospheric pressure is varies from place to place then we take the mean atmospheric
pressure in BAHIR DAR.
The wind effect has its own role in pressure vessel design. When we design pressure vessel with
pressure height we have to consider the effect of wind on the vessel.
A f = projected area
But H total= Lshell + 2 H head + Lskirt we take length of the skirt ( Lskirt ) = 114mm
H total=4189.68mm
A f = 1298.42*4189.68
A f = 5.44m2
W wn= 1009N/m2*5.44m2
W wn= 5488.92N
2
Mx = w x Where M x = moment due to wind
2
’w’ the load per unit length (Newton Per meter) and calculated as follows:
Dm= 1.17625m
And
w = 1186.83N/m
And
2
Mx = w x
2
2
M x = 1186.83* 1.8139
2
M x = 1952.47Nm
.
Figure 3.6. Wind load pressure vessel [2].
For material;
Wt material=Wsm+Whm+Wnm
Wt material=84889314.4N
For fluid
Wt fluid =13063.44 N + W hf + W nf
Wt fluid =14196.424N
W net = 84908999.74N
W d = 93399899.714N
P= load
W d = design weight
93399899.714 N
P=
3
P=31133299.9N
In our design the support of pressure vessel is straight skirt and we choose 5.8 (carbon steel)
material to design because of it has excellent fatigue resistance, good temperature resistance it is
tougher and has high strength.
P
ᵟ d= where ᵟ d= design or allowable stress=510N/mm2 for 5.8(carbon steel)
A
material
Q
A=
ᵟd
31133299.9
A=
510
A=61045.68mm2
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.
σ s(Tensile) = σ bs – σ ws And
σ s(Compressive) = σ bs + σ ws
4 Ms
σ bs= ( M s= 1952.47Nm)
π (Ds+ t s) D s t s
4∗1952.4 Nm
σ bs=
π ( 0.06 m+0.03 m )∗0 .06 m∗0.03 m
σ bs=15344894N/m2
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)
t s = Skirt thickness
WT
σ ws=
π (Ds+ t s)t s
84908999.74 N
σ ws=
π ( 0.06 m+0.03 m )∗0.03 m
σ ws= 1*1010N/m2
σ s(Tensile) = σ bs – σ ws
σ s(Tensile)= 15344894N/m2-1*1010N/m2
σ s(Tensile) =- 9994793.64052N/m2
by
considering the standard units m
σ s(Compressive) = σ bs + σ ws
Since both σ s(Tensile) and σ s(Compressive) are less than the allowable or design stress that is ᵟd=
510 * 106 N/m2 therefore our design is safe.
Use the following formula important to find the size and number of bolt.
n = number of bolt
Here we know that the upward face acting on the cylinder cover is:
π D i2∗D p
F= ……………………………….. (1)
4
This force is resisted by n number of bolt and the resisting force offered by n number of bolts i
π dc 2∗σ tb∗n
F p= …………………………………………. (2)
4
π D i2∗D p
F=
4
π∗754.622∗160
F=
4
F=22778053N
π dc 2∗σ tb∗n
F R=
4
σ tb=497N/mm2 for mild steel and we take the core diameter from the table by taking standard
M30 then dc=25
π dc 2∗σ tb∗n
F R=
4
π ¿ 25.7062∗497¿ n
F R=
4
F R=257937.96n
FR=F
257937.96n= 22778053N
22778053
∴ n= = 88
257937.96
Nominal or major diameter of nut and bolt (d=D) = 30.000mm
F T 22778053 N
F i= = =¿ 258841.5N
n 88 bolts
π D 2i π ( 30 )2
Abolt = = =706.8 mm 2
4 4
F i bolt
Stress on a bolt =
A bolt
258841.5 N
¿ =366.21 MPa
706.8mm 2
Then we will calculate the total length and thread length of bolt
LT =2∗30+ 6 mm
LT =66 mm
Lunthreaded =L−Lthreaded
Size Pitch Major Effective Minor or Depth Stress Base Heigh Helix
or or pitch core of area of nut t of thicknes
nomina diameter diameter thread nut s
l of nut of nut
diamete
r of nut
M30 3.5m 30mm 27.727m 26.211m 2.147m 561mp 44m 24m 1.5
0 m m m m a m m
Figure 3.8. Schematic diagram of nut [2].
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 steel [9].
For this reason our flange design parameters are in the first row of the table above that means
d1= 914.4mm
d2= 33mm
d3= 950mm
d4=1005mm
h1=95mm
h2=20mm
b= 34mm
D= 1115mm
f= 5
K= 1050mm
Bolt M30
Since in our design we get smaller shell diameter the hand hole should be used in order to do
some operations on the pressure vessel. We take the diameter of hand hole as 0.20m.
Then the wall thickness of the handhold can be calculated as follows:
t handhole = (PD * Rhandhole )/ (ᵟ d E-0.6PD)
t handhole= 166.6mm
t handhole= t handhole + C
π D handhole2
Ahandhole =
4
2
Ahandhole = π ¿ 200
4
L=Longitudinal stress
H=hoop stress
L = (PD * Dhandhole)/ (4*t handhole )
L= (160Mpa*200mm)/ (4*169mm)
L= 47.33N/mm2
H=2*L
H = (PD * Dhandhole)/ (2*t handhole)
H= (160Mpa*200mm)/(2*169mm)
H=94.67N/mm2
Since both longitudinal and circumferential stress less than the allowable or design stress
therefore our design is safe.
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.
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.
Since the stress in the weld material is to be 81Mpa our electrode is mild steel electrode. The
recommended minimum size of weld is 20mm size of weld over 58mm.
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
And
P D∗π∗d i2
F R=
4
2
F R= 160∗π∗50.8
4
Since F R= F
625775.9m=324292N
324292 N
∴ ᵟ m= = 5.2 N/mm2
625775
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 low 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. In addition to that the operating temperature, pressure and
corrosiveness of the process will be the controlling factor in gasket selection. i.e.
Vegetable fiber and synthetic rubber gaskets can be used at temperatures of up to 100°C.
Solid polyfluorocarbon (Teflon) and compressed asbestos gaskets can be used to a maximum
temperature of about 260°C.
Metal-reinforced gaskets can be used up to around 450°C.
Plain soft metal gaskets are normally used for higher temperatures.
For our case Solid polyfluorocarbon (Teflon) and compressed asbestos gaskets is desirable
because it can resist the operating temperature. Then the total moment (M op) acting on the flange
is given by:
CHAPTER- 4
4.1. Result
The following table shows the overall geometry of vertical pressure vessel.
6) Nut
d c =26.211mm
Miled steel d p= 27.727mm
D=d= 30mm
4.2. Discussions
the pressure vessel is designed as the shell will have shell thickness of 466.381mm and a
diameter of 1692.182mm with a total or overall length of 3.647m so as to with stand to hold
1.8m3of diesel under 160MPa and a temperature of 3000C.
The ellipsoidal head designed variety of shell thickness because of it has high resistance
for the same value of stress with the cylindrical shell so to compensate with its costive we have
considered.
CHAPTER -5
5.2. Recommendation:
We recommend that 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. And also in our pressure vessel design we don’t consider the earthquake loading,
vibration, loading from piping and external equipment but in actual case must be considered.
CHAPTER- 6
6.1.5. Nut
[2] Chirag H. Panchigar PG student of mechanical department A Review Paper on Design and
Analysis of Pressure vessel.
[3]Dennis Moss, “Pressure vessel design manual”.
[4] David Heckman, “Finite element analysis of pressure vessels”, MBARI 1998.
[5] International Journal of innovative Research in Technology & science (IJIRTS).
[7] 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.
[8] M. Giglio, “Fatigue analysis of different types of pressure vessel nozzle”, revised 19
November 2002; accepted 20 November 2002.
[9]Bergman, Alhambra, Calif. The Design of Vertical Pressure Vessels Subjected to Applied
Forces. University of new south wates, Sydney, Australia, Welding technology institute of
Australia, Austral.
[10]WWW.Google.com: Web sites.
APPENDIX
Appendix B:
Table 6.1. Standard bolt and nut dimension [1].