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ACKNOWLEDGEMENT
Frist we would have great thanks for the ALMIGTY GOD who gives power and strength to do this
kind of project work.
Our instructor M.r Kirubel give us this project, thanks to him, and many individuals contribute their
knowledge and ideas for the accomplishment of this project work, therefore we want to confess that
we never do anything entirely by ourselves without any need of assistance from other personalities.
We would like to take this opportunity to express our great gratitude to our instructor M.r
Dhayanidhi. For his great effort and contribution to help us to did our project by giving different
helpful material that we need for our project and also he tried to answer every questions that we
ask and gave us guidelines on the way how to handle this basic and essential project. Beside of this
he has shown a great enthusiast in order to give us the desired knowledge and finally we get a better
knowledge Therefore, the knowledge that we get from him is very helpful in our future life. Finally,
our Special thanks goes’ to for all of our group members for their great effort while doing the
project.
ABSTRACT
This paper present design and analysis of vertical pressure vessel. A detailed study of various parts
of pressure vessels like shell, closure (Head), support, flanges, nozzles, types of vessels etc. Design is
carried out according to rules of ASME code section VIII, The Second chapter deals with detailed
study of pressure vessel i.e. types of pressure vessels like open vessels, closed vessels, vertical and
horizontal vessels etc, and components of horizontal pressure vessel also mentioned like shell, head,
nozzle and supports and flange, type of flange used in horizontal pressure vessel are also included,
welding-neck flange ,slip-on-flange, lap joint flange etc ,The third chapter included, the general
design procedure of horizontal pressure vessel, which include design of shell, design of Head, design
of nozzles and design of Anchor bolt. Chapter four deals with the material specification of Horizontal
pressure vessel and the material fabrication of horizontal pressure vessel also discussed on chapter
five,
NOMENCLATURES AND ABBREVIATION
T : design temperature, °C
C : corrosion allowance, mm
Di: inside diameter of the vessel, mm
Do: outside diameter of the vessel, mm
Ri: inside radius of the vessel, mm
Ro: outside radius of the vessel, mm
S: maximum allowable stress, kg/cmA2
E : Joint efficiency, %
T : required the thickness, mm
tn : minimum thickness provided for the nozzle, mm
trn: selected thickness for the nozzle, mm
fr : strength reduction factor
Fe : seismic coefficient
N : Number of bolts
Ab : Area within the bolt circles, mmA2
Cb : circumference of bolt circle, mm
Ba : required area of one bolt, mm
Cs : circumference on outer diameter of skirt, mm
Dso : outer diameter of the skirt, mm
Dsi: inside diameter of the skirt, mm
Fb : safe bearing load on the concrete, kg/cm A2
I : width of the base plate, mm
t = minimum required thickness of the shell exclusively of Corrosion allowance
P=design pressure, or maximum an allowable working Pressure welded -joint efficiency
S=maximum allowable stress
Ri=inside radius of the shell
Ro=outside radius of the shell
ASME: American Society of Mechanical Engineers
ASTM:American Society for Testing and Materials
ASNT:American Society for Nondestructive Testing
SA: Ferrous Material
SB: Non-ferrous Materials
MAWP : Maximum Allowable Working Pressure at Maximum Allowable Temperature
CHAPTER ONE
OVERVIEW OF PRESSURE VESSEL
1.1 INTRODUCTION
The pressure vessels are used to store fluids under pressure. Pressure vessel is defined
as a container with a pressure differential between inside and outside. The inside pressure is
usually higher than the outside. The fluid inside the vessel may undergo a change in state as
in the case of steam boiler or may combine with other reagent as in the case of chemical
reactor. Pressure vessel often has a combination of high pressure together with high
temperature and in some cases flammable fluids or highly radioactive material. Because of
such hazards it is imperative that the design be such that no leakage can occur. . Pressure
vessel and tank are in fact essential to the chemical, petroleum, petrochemical and nuclear
industry. It is in the class of equipment that the reaction, separation and storage of raw
material occur. In the same word, pressurized equipment is required for a wide range of
industrial plant for storage and manufacturing purpose. In the case of shell, opening requiring
reinforcement in vessel under internal pressure the metal removed 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 stresses must be
evaluated. Materials 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 materials to the ratio
of the two materials to compensate for the lower allowable stress value of any reinforcement
having a higher allowable stress value than that of the vessel wall.
The gas or fluid that being stored may be through change of state inside the pressure
vessel, for example case of steam boilers or it might combine with other reagents, such as a
chemical plant.
The pressure vessels must design with a perfect care because crack of pressure vessels
will cause an explosion which may cause of death and loss of property. The material that be
used to construct pressure vessels may be ductile such as mild steel or brittle such that cast
iron.
ASME Section VIII is the section of the ASME Boiler & Pressure Vessel Code (BPVC)
that covers pressure vessels. It gives detailed requirements for the design, fabrication,
testing, inspection, and certification of both fired and unfired pressure vessels.
API 510, "Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and
Alteration" is an inspection code, written and published by the American Petroleum
Institute, that covers the in-service inspection, repair, alteration, and rerating activities
for pressure vessels and the pressure relieving devices protecting these vessels.
When it comes to inspections, most pressure vessels should be examined once before
being placed into service and again every 5 years after every alteration or major repair. An
inspection can be internal, external, or both and should involve a thorough examination, a
thickness evaluation, a stress analysis, an inspection of the vessel’s pressure release valves,
and a hydrostatic pressure test. It is also important to perform a surface inspection, examine
the insulation and any structural connections, and finally inspect any welds or joints.
Pressure vessels are used in a variety of applications. These include the industry and
the private sector. They appear in these sectors respectively as industrial compressed air
receivers and domestic hot water storage tanks, other examples of pressure vessels are: diving
cylinder, recompression chamber, distillation towers, autoclaves and many other vessels in
mining or oil refineries and
petrochemical plants, nuclear reactor vessel, habitat of a space ship, habitat of a submarine,
pneumatic reservoir, hydraulic reservoir under pressure, rail vehicle airbrake reservoir, road
vehicle airbrake reservoir and storage vessels for liquefied gases such as ammonia, chlorine,
propane, butane and LPG.
According to the dimensions pressure vessels may be of thin shell or thick shell.
The deciding factor among thin and thick shells is its wall thickness and shell diameter if the
ratio t/d is less than 1/10 the vessel is said to be thin shell and if the ratio is greater than 1/10
it is said to be a thick shell. Thin shell are used in boilers, tanks and pipes whereas thick
shells are used in high pressure cylinder, tanks gun barrels.
According to the end construction, the pressure vessels are may be open end or closed
end.
A simple cylinder with a piston is an example of open-end vessel whereas a tank is an
example of closed end vessel. Due to the fluid pressure circumferential or hoop stresses are
including in case of open ended vessels whereas longitudinal stresses in addition to
circumferential stresses are induced in case of closed ended vessels.
This particular type of pressure vessel is ideal for storing high-pressure liquids. A spherical
structure is a very strong one because the stresses are evenly distributed on its surface, both
externally and internally. Thus, it eliminates any weak points, but it is also true that
manufacturing them can be a lot more expensive than their cylindrical counterparts.
A great benefit of spherical pressure vessels is that they possess a smaller surface area for
every unit of volume, as compared to any other shape. This means that the amount of heat
transferred to liquid within the sphere from warmer surroundings will be a lot less as opposed
to rectangular or cylindrical storage vessels.
Conical transitions are really usual in several industrial sectors so that people minimally
related to design or manufacturing of pressure vessels are used to deal with them. The shape
or these conical sections is mainly imposed by the process in which vessel is immersed. In
order to satisfy properly the process needs, the conical part could take different forms. The
principal classification criterion is established by the external configuration of the cone,
which could be either concentric or eccentric.
Figure 1.4: conical pressure vessel
I. Storage Vessels
Storage vessels are mostly cylindrical in shape, boasting flat bottoms and are perpendicular to
the ground. They have a floating or fixed frangible roof.
These pressure vessels are primarily used for storing liquids and can be found in a wide range
of sizes. Depending on the product that has to be stored or the purpose they have to serve,
these pressure vessels are constructed with various materials, with the most common material
being carbon steel.
Storage vessels are available in a variety of shapes, including horizontal and vertical
cylindrical, closed top and open top, cone bottom, flat bottom, dish bottom, and slope bottom.
The large ones tend to be vertical cylindrical, but there are also some spherical storage
vessels used as well.
There are different types of storage vessels that are used these days, which include
atmospheric, thermal storage tanks, high pressure, septic tanks, milk tank, water tanks, and
mobile ‘storage’ tanks.
II. Heat Exchangers
The second most common type of pressure vessels, and almost as prolific as storage vessels,
is called the heat exchanger. Modern processing and manufacturing have been made possible
by these heat exchangers and they can be found in almost every aspect of our lives.
It is a widely known fact that heat, due to its nature, can prove to be very destructive in many
industrial processes. Therefore, it has to be reused or removed to handle this concern. This is
where heat exchangers come in because they are used for transferring heat between two fluids
or more.
Heat exchangers can actually be used for both heating and cooling processes. A solid wall
may be used for separating the fluids to prevent mixing or they will come into direct contact.
Thus, it is crucial that the material chosen for making the heat exchanger ensures that this
vessel operates at peak optimization for extended periods.
The most commonly used material for making these heat exchangers is carbon steel, but it is
also common to use stringent alloys for ensuring proper functioning and longevity.
Common applications of heat exchangers can be seen in space heating, power stations,
petrochemical plants, chemical plants, natural gas processing, petroleum refineries, sewage
treatment, and air conditioning. Classic examples of heat exchangers include a heat sink that
uses a passive heat exchanger and an internal combustion engine.
The most versatile type of pressure vessels, process vessels are essential components in
which different processes are performed. These vessels are designed to handle temperature
and pressure and are used in almost all industries and in conjunction with the other two types
of pressure vessels as well.
In simple terms, a process vessel is a container that’s created and equipped with the
accessories and controls for completing different processes, as part of an overall process. The
material used for making the process vessel, along with its control and accessories, depends
on the intended purpose.
Some of the process industries that make use of these process vessels include food and drug
manufacturing, paint, refineries, and other similar operations manufacturing products in huge
quantities. Listed below are some of the common types of process vessels:
Pressure vessels used for separating components from the process input or raw
materials, such as benzene splitter in an oil refinery.
Pressure vessels used in reactors for processes that need pressure to occur or to
create pressure that results from the process.
Lined process vessels that are widely used in the chemical, pharmaceutical,
paper, and food industries for processing substances that may cause corrosion
or rust to the equipment.
Jacketed process vessels that are needed for processes that require the
temperature to be maintained at a specific level.
The use of autoclaves for processes that need high pressures and high
temperatures in a sterile environment.
The pressure vessel considered here is a single unit when fabricated. However, for the
Convenience of design, it is divided into the following parts.
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.
Figure 1.5: Model of shell
Head
The head is the part that closes the end of a pressure vessel. Curved heads are ideal–and the
most common shape in pressure vessels–because they are lighter, cheaper and stronger than
flat heads.
Heads can also be used inside a vessel. These “intermediate heads” separate sections of the
pressure vessel to permit different design conditions.
In each section Heads are usually categorized by their shapes. Ellipsoidal, hemispherical,
torispherical, conical, toriconical and flat are the common types of heads.
Since the nozzle is designed to penetrate the shell casing to serve as an opening, it is
always considered to be the weakest point of a pressure vessel. So, it is critical that the nozzle
design is strong enough to maintain the pressure inside of the vessel safely. As a result, these
forged nozzles often use flanges to reinforce the strength of the nozzle based on the function
of the pressure vessel
Supports
The type of support that is used depends primarily on the size and orientation of the pressure
vessel. In all cases, the pressure vessel support must be adequate for The applied weight,
wind, and earthquake loads calculated base loads are used to design of anchorage and
foundation for the pressure vessels Typical kinds of supports are as follow:
a) Leg
Small vertical drums are typically sup-ported 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. Cross bracing between the legs,
as shown in is typically used to help absorb wind or earth-quake loads
b) Saddle
Horizontal drums are typically sup-ported 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 the other support is normally free to
permit unrestrained longitudinal thermal expansion of the drum.
c) Skirt
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.
d) Lug
Lugs that are welded to the pressure vessel shell, 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
Objectives of the project
General objective
The main objective of our project is to design Vertical Pressure Vessel position with Conical
and Hemispherical head by the given design temperature and pressure on its effect and
having a material of vessel carbon steel and low alloy steel with a medium or working fluid
of steam at the design temperature of 300◦C, design pressure3.5Mpa, total inside volume 10
m^3, corrosion allowance=2mm and with vertical vessel orientation.
Specific objective
The specific objective of this project is concerned with the design and analysis of the
components of vertical pressure vessel like shell, heads, nozzles, flanges of nozzles, supports,
supports as they have their own procedures to design each component and to design the
whole assembly of vertical unfired pressure vessel.
Problem statement
The industrial pressure vessels design is carried out using various softwares. The values and
the design data obtained is further used for manufacturing of the vessel. The designer utilizes
considerably higher values of the dimensions as per the code in order to make vessel safer
during operation and intern increasing fatigue life. But the dimensions used for the
construction and manufacturing result in heavier construction. This increases the amount of
material utilized, overall cost and the transportation cost of the vessel. This paper focuses on
minimizing the overall weight and cost of vessel by determining the optimum wall thickness
for the vessel construction
Literature review
A. V.N. Skopinsky, A.B. SMETANKIN[1]
Presented work on modeling and stress analysis of nozzle connection in Ellipsoidal head
of pressure vessel under external loading, in this paper he used Timoshenko shell theory and
the finite element method, the effect of stress concentration in external loading has more
effect than in the internal pressure, there is an appreciable increase of the maximum stress for
shell in the interaction region even at the small level of nominal stress, non-radial and offset
connection have non-uniform distribution of stress on the interaction curve between the
nozzle and the head, the influence of angular parameter α for non-radial nozzle connection is
shown in this paper, a decrease of maximum effective stress as an angle α increase is more
significant for non-central connection, and in case of torsionalmoment loading, the angle
affects the stressin opposite manner, the stress in the shell increase as alpha angle increase.
B. Hardik B nayak, R R Trivedi[2]
Had worked on stress analysis of reactor nozzle to head junction, in this paper stress
analysis is carried out for nozzle to head junction subjected to applied external load, internal
pressure and moments under different loading condition, the stress will occur at the nozzle to
head or shell junction area due to discontinuity of geometry defect will occur and the junction
region will be the failure source of the whole structure, stresses at reactor nozzle to head
junction are obtained by welding research council(WRC) 107 and PVcode cal software 2008
with and without stress indices and they found that general solution obtained for nozzle to
head junction have not given the result in allowable limits for WRC 107 and PVcode cal
software because it does not take pressure into account while calculating the local and general
primary membrane equivalent stress and the stress calculated by nozzle to head junction
using ANSYS software give more accurate data than 107.
C. M J Mungla[3]
Had conducted design and analysis of various components of pressure vessels like shell,
heads, flanges, and nozzle and support structures along using ASME code. Design of base
ring and skirt sections has not been covered under ASME code and their dimensions are
calculated with general design principles. Stress analysis of these components has been
carried out with combined load cases.
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.
Presented work on Modeling of Pressure Vessels with different End Connections using
Pro Mechanica, author used here only three types head hemispherical, elliptical and
torispherical In this paper authors, describes its basic structure and the engineering finite
element modeling for analyzing, testing and validation of pressure vessels under high stress
zones, Analysis results do not suggests the use of Toro spherical end connection with the
same thickness due to more displacement occurs in this type of head.
G. Pavo Baličević[7]
Proposed method for stress analysis in cylindrical pressure vessels with ellipsoidal heads,
based on the ax symmetric shell theory. The starting point were the approximate solutions of
the differential equation system that were used to get mathematical expressions for
determining internal forces, moments and displacements in the vessel walls. Application of
the method was shown on a selected numerical example, while a special computer
programmed was created for calculation purposes.
Had did work on local pressure stress on lateral pipe-nozzle with various angle of
interaction, this paper report variation of local pressure stress factor at the junction of pipe-
nozzle when its angle varies from 90 to 30 degree, the circumferential and longitudinal stress
at four symmetric points around the pipe nozzle junction are plotted as function of an angle,
the ALGOR finite element software was employed to model for the true pipe-nozzle
geometry, the numerical stress result come from parameters beta and gamma which are the
nozzle mean radius and pipe thickness, at angle 90 degree at this angle result had low value
local stress, these stress increase as angle of interaction is decrease from 90 degree and stress
value more decrease when angle is decrease from 45 degree, the inside crotch point B has
worst circumferential stress value, and concluded that angle 90 degree local pressure stress
are same at point A and B as same as point C and D due to symmetry. And it had low stress
value than other angle.
Methodology
Design of shell