DESIGN OF VERTICAL PRESSURE VESSEL 2015

AKNOWLEDGE

First we would like to acknowledge our teacherSenshawFikadu, that he advice or help us how to
design this project. second we like to say thanks to our friends, that helping us by share lap top,
and ideas.

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 DESIGN OF VERTICAL PRESSURE VESSEL 2015

DIRE DAWA UNIVERSITY

Institute of technology
Mechanical Engineering Department

MEng- Machine Design II Project I

A/Y 2015 SEMESTER. II CR.HR 3
Project-I Design of a Pressure Vessel
Name of Students: MEDHN……………………….R/767/04
TSEGAY ………………….R/1259/04
Issued Date: _________________________
Due Date: _________________________
A. SPECIFICATION
1. Main Parameters

i. Medium:

Oil product CO + H2 Acidic Helium Alkaline Ethane + Methane

ii. Inner Service Pressure: [MPa]

0.4 0.6 1 1.6 2.5 6.3 10 16 25

0.25

iii. Nominal Volume: [m3]

0.5 1 1.6 2.5 4

0.25

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 DESIGN OF VERTICAL PRESSURE VESSEL 2015

iv. Service Temperature: [0C]

200 250 300 350 400 450

v. Position

Horizontal Vertical

2. Supporting Element

Lateral legs Bottom legs Saddle frame Supporting Bracket

3. Connecting Pipes:
a. Two longitudinal, One lateral, with

Nominal 25 40 65 80 100 125 150

Diameter, [mm] X

b. One pipe for safety valve nominal diameter 25mm (flange)

c. One sample opening nominal diameter 25mm (flange)
d. One bottom discharge pipe, if necessary with flanges,

Nominal 25 40 65 80 125 150

Diameter, [mm] x

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 DESIGN OF VERTICAL PRESSURE VESSEL 2015

Contents
CHAPTER ONE..........................................................................................................................................2
1.1 Introduction.......................................................................................................................................2
1.11 Uses of pressure vessel....................................................................................................................2
1.12 Shape of pressure vessels.................................................................................................................2
1.13 Classification of pressure vessel......................................................................................................3
1.2Pressure vessel components................................................................................................................3
1. Vessel shell..............................................................................................................................................3
2. Heads.......................................................................................................................................................4
3. Lateral leg support...................................................................................................................................5
4. Nozzle.....................................................................................................................................................5
5. Flanges....................................................................................................................................................6
6. Manholes.................................................................................................................................................6
7. Bolt and nut.............................................................................................................................................6
1.3 Determine the diameter and length of pressure vessel.......................................................................7
CHAPTER TWO.........................................................................................................................................8
2.1 Material selection..............................................................................................................................8
A: Strength..................................................................................................................................................8
B: Corrosion resistance................................................................................................................................9
C: Resistance to hydrogen attack...............................................................................................................10
C: Fabric ability.........................................................................................................................................11
2.11 Conclusion about material selection..............................................................................................12
2.2: Welding type.................................................................................................................................12
1: aspect of economy.................................................................................................................................13
2: The circumstances of welding...............................................................................................................13
3: The code requirement............................................................................................................................13
2.21Types of welded joint.................................................................................................................14
Categories of welding............................................................................................................................14
A) Category A:......................................................................................................................................14
B) Category B:.......................................................................................................................................14

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 DESIGN OF VERTICAL PRESSURE VESSEL 2015

c) Category c:........................................................................................................................................14
d) Category d:........................................................................................................................................15
2.22 Conclusion about welding selection...........................................................................................15
CHAPTER THREE...................................................................................................................................15
3.1: Calculate shell thickness for internal pressure................................................................................15
(a)CIRCUMFERNTIAL STRESS (LONGITUDINAL JOINTS).........................................................16
(b) LONGITUDINAL STRESS (CIRUMFERENTIAL JOINTS)........................................................16
3.2: Review different type of head.........................................................................................................17
CHAPTER F0UR......................................................................................................................................19
Identify of Head-to-Shell transitions.........................................................................................................19
4.1: SELECTION OF FLANGE BASED ON THE TEMPERATURE AND PRESSURE RATING R
[2]..........................................................................................................................................................19
4.3: FLANGE AND GASKET DESGINR [1].......................................................................................20
4.31 FLANGE APPLIED LOAD AND FALNGE MOMENT........................................................20
4.32 Flange stress R[2] and R[3]...................................................................................................23
CHAPTER FIVE.......................................................................................................................................28
5.1 CALCULATING WALL THICKNESS OF THE NOZZLE R [2.................................................28
5.2 REINFORCMENT OF OPENING..................................................................................................29
5.3 DESIGN OF MANHOLE OR INSPECTION R[9].............................................................................31
5.4 SUPORET DESIGNAND CHECK OF PRESSURE VESSLE R[2]............................................31
STRESSES IN RESPONSE TO DIFFERENT LOADS........................................................................32
a) DUE TO INTERNAL PRESSURE...................................................................................................32
b) STRESS DUE TO WEIGHT OF VESSEL & ATTACHMENT..................................................32
ERECTION WEIGHT.......................................................................................................................33
C) STRESS DUE TO WIND LOAD:...................................................................................................34
d) STRESS DUE TO SEISMIC LOAD............................................................................................38
(a) PERIOD OF VIBRATION..............................................................................................................38
(e)STRESS DUE TO EARTHQUAKE.............................................................................................39
COMBINATION OF STRESSES.........................................................................................................41
COMPARISON.....................................................................................................................................42
5.5 FABRICATION AND WELDING METHOD................................................................................42

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CHAPTER ONE
1.1 Introduction
A Pressure vessel is a closed container designed to hold gases or liquids at a pressure
substantially different from the ambient pressure. It is generally a cylindrical or spherical in
shape and is a metallic container which can with stand pressures exerted by the fluid material in
closed. The pressure differential is dangerous and fatal accidents have occurred in the history of
pressure vessel development and operation. Consequently, pressure vessels design, manufacture,
and operation are regulated by engineering authorities backed by legislation. The pressure
vessel must be designed with a great care because of if the explode will hurt the works
and loss of property.

1.11 Uses of pressure vessel

Pressure vessels are used in a variety of application in both industry and the private sector
.they appear in this sector as industrial compressed air receivers and domestic hot water storage
tanks. Other example of pressure vessels are diving cylinder, recompression camper, distillation
tower ,autoclaves ,and many other vessels in mining or oil refiners and petro chemical plant
,nuclear reactor vessels ,habitat of a space ship ,habitat of a submarine ,pneumatic reservoir
,hydraulic reservoir under pressure, rail vehicle air break reservoir ,road vehicle airbrake
reservoir and storage vessels for liquefied gasses such as ammonia,chlorine,propane,e.t.c

1.12 Shape of pressure vessels

Pressure vessels may be of almost any shape, but shapes consisting of portion of spheres,
cones, and cylinders are most used. A very common design is cylinder having end caps called as
heads. Theoretically the optimal shape of pressure vessel is sphere. Unfortunately, it is difficult

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to manufacture spherical shape, hence more expensive, so usually pressure vessel are cylindrical
in shape with 2:1 end caps or semi elliptical heads on each end.

1.13 Classification of pressure vessel

1) Based on the thickness and its diameter ratio

I:THIN CYLINDER:

If the ratio of the thickness to the internal diameter i.e. t/d is less than about 1/20,
the cylinder is assumed to be thin cylinder.
And also the thickness (t) of the shell less than 1/10 of the diameter (D) of the
shell.

I:THICK CYLINDER:

If the ratio of thickness to the internal diameter i.e. t/d is greater than 1/20, the
cylinder is assumed to be thick cylinder. And also the thickness(t) of the shell
greater than 1/10 the diameter(D) of the shell grater.

2) Based on the end of constriction

I) CLOSED END: its end is closed. E.g. tank

II) OPEN END:Its end is open such as piston.

1.2Pressure vessel components

Pressure vessels have many components there are;
1. Vessel shell
2. Heads
3. Supporting leg
4. Nozzle
5. Flanges
6. Manhole
7. Bolt and Nut

1. Vessel 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 and conical in shape.

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2. Heads
Is part or component used to close both ends the shell. Heads are typically curved rather
than flat. Curved configurations are stronger and allow the heads to be thinner, lighter, and less
expensive than flat heads. Heads are typically ellipsoidal, tori spherical, hemispherical, and
conical and tori conical.

 Elliptical Heads- The 2:1 semi-elliptical head is the most commonly used head type.
Half of its minor axis (i.e. the inside depth of the head minus the length of the straight
flange section) equals one-fourth of the inside diameter of the head. The thickness of this
type of head is normally equal to the thickness of the cylinder to which it is attached

 Hemispherical Heads: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. Hemispherical heads are an
economical option to consider when expensive alloy material is used. As elliptical or tori
spherical heads because of higher fabrication in carbon steel construction, hemispherical
heads are generally not as economical cost. Carbon steel hemispherical heads may be
economical for thin, very large-diameter vessels, or in thick, small-diameter vessels. The
thickness transition zone between the hemispherical head and
Shell must be contoured to minimize the effect of local stress.

 Tori spherical Heads- A tori spherical (or flanged and dished) head is typically
somewhat flatter than an elliptical head and can be the same thickness as an elliptical
head for identical design conditions and diameter. The minimum permitted knuckle
radius of a tori spherical head is 6% of the maximum inside crown radius. The maximum
inside crown radius equals the outside diameter of the head.

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  Conical Sections: 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.

3. Lateral leg support

It is component which is used to support the pressure vessel. And it depends primarily on
the size and orientation of the pressure vessel. In all cases, the lateral leg support of pressure
vessel must be resist for the applied weight, wind, and earthquake loads.

4. 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, thermo 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).

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* Nozzles are also sometimes extended into the vessel interior for some applications, such as for
inlet flow distribution or to permit the entry of thermo wells.

5. Flanges
Used to coupling the pipe which the fluid enter or exit the pipe to the pressure
vessel. 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.

6. Manholes
A manhole is an opening using for the inspection of the vessel during operation. They are
using for regular maintenance such as painting if corrosion occurs cleaning and examination if
same un-wanted dust exist inside the vessel. Manholes are not to be less than 300 x 400 mm or
400 mm in inside diameter. Where the neck height of a manhole is excessive, the size of the
manhole is to be suitably increased

7. Bolt and nut

 A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a
mating bolt to fasten a stack of parts together. The two partners are kept together by a
combination of their threads' friction, a slight stretch of the bolt, and compression of the
parts.
 A bolt is a form of threaded fastener with an external male thread. Bolts are thus closely
related to, and often confused with, screws.

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1.3 Determine the diameter and length of pressure vessel
We can calculate length & diameter of vessels by using nominal vessel volume for
typical ratio of length to diameter is given by table as follows. Therefore volume of pressure
vessels is as follows.

L/D Psi MPa

3 0-250 0.000-1.724
4 250-500 1.724-3.448
5 >500 >3.448

Table 1.1.used to fined L/D ratio

We know that the volume of a pressure vessel is 2.5 m3 and the volume is equal to the
sum of the volume of the head and bottom (hemispherical) and the volume vessel shell (which is
in cylindrical in shape).

L/D=3 L=3D

V=V s + 2V h where V=total volume

Vs=shell volume
V s= πD2L/4
V h= πD3/12 Vh=head volume
L=length of pressure vessel
D=diameter
V=V s + 2V h r=radius

V= πD2L/4 + 2 ( πD3/12)

2.5=πD2L/4 + πD3/6

2.5=3(πD2L) + 2(πD3)
12

30=3(πD2 × 3D) + 2(πD3)

30= 9πD3 + 2πD3

30=11πD3

30/34.56=D3

D=0.954m

The standard diameter is 0.8m

The radius r=D/2=0.4m

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The length of the pressure vessel L=3D

L=3*0.954m

L=2.86m

CHAPTER TWO
2.1 Material selection
For best design the material should be selected appropriately. The mechanical and
physical properties are very important for the selection of the material. The materials will be
strong and toughness, control high pressure and high temperature, resistance to hydraulic Attack
and corrosion. Selection of material based on the following factors.

A: Strength
The strength of the martial are based on the mechanical propriety of the material that
used for the most easy ,fast ,strong and low cost of production some of the mechanical
properties are(yield strength ,ultimate tensile strength ,creep strength and rupture strength).

 Yield strength
Yield strength is the region which a material changes from plastic to elastic
deformation. The stress level at which the plastic deformation begins.

 Ultimate tensile strength(UTS)

The ultimate tensile strength (tensile stress) is a measure of the basic strength of the
material .It is the maximum stress that the material will stand and measure by a standard
tensile test.

 Creep strength
Material are often pleased in a service at elevated temperature and exposed to static
mechanical stress the deformation under such circumstance is termed creep .The time
dependent and permanent deformation of material when subjected to a constant lode and
stress.

 Rupture strength
Is the material resistance to the fracture caused by the internal pressure of the fluid
that was present inside the tank. And it is proportional to tensile strength(UTS) which
Table 2.1means the martial have high UTS and it have good Rupture strength

Metal alloys Aluminum Copper Nickel Cast Stain less

iron steel18Cr/8Ni(304)

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 Yield 35 69 138 197 205
strength(MPa)

UTS(MPa) 90 200 520 414 510

B: Corrosion resistance
 Corrosion is the disintegration of an engineered material in to its constituent atom due to
chemical reactions with its surroundings. In the most common use of the world, this means
electrochemical oxidation of metals in reaction with an oxidant such as oxygen. Rusting, the
formation of iron oxides is a well-known example of electrochemical corrosion.
 Corrosion is the deterioration of metals by chemical action. A material's resistance to
corrosion is probably the most important factor that influences its selection for a specific
application. The most common method that is used to address corrosion in pressure vessels is
to specify a corrosion allowance. A corrosion allowance is supplemental metal thickness that
is added to the minimum thickness that is required to resist the applied loads. This added
thickness compensates for thinning (i.e., corrosion) that will take place during service.
 The corrosion resistance of carbon steel could be increased through the addition of alloying
elements such as chromium, molybdenum, or nickel. Alloy materials, rather than carbon
steel, are often used in applications where increased corrosion resistance is required in order
to minimize the necessary corrosion allowance. Corrosion is one of the most prevalent
conditions found in pressure vessels. The following types of corrosion are commonly found:
1. Pitting Shallow:isolated, scattered pitting over a small area that does not substantially weaken
the vessel. It could, however, eventually cause leakage.
2. Line corrosion:this is a condition where pits are connected, or nearly connected, to each other
in a narrow band or line. Line corrosion frequently occurs in the area of intersection of the
support skirt and the bottom of the vessel and at the liquid-vapor interface.
3. General corrosion: this is corrosion that covers a considerable area of the vessel. When this
occurs, consider the safe working pressure of the vessel that is directly related to the remaining
material thickness.
4. Grooving: this type of corrosion is a form of metal deterioration caused by localized
corrosion. It may be accelerated by stress concentration. Grooving may be found adjacent to
riveted lap joints or welds and on flanged surfaces, particularly the flanges of unstained heads.
5. Galvanic corrosion: Occurs when two different metals have physical or electrical contact
with each other and are immersed in common electrolyte, or when the same metal is exposed to
electrolyte with different concentrations. (i.e., a film of water containing dissolved oxygen,
nitrogen, and carbon dioxide). This corrosion mechanism is most active when there are large
differences between the electrode potentials of the two metals, but galvanic corrosion may also
exist with relatively minor changes of alloy composition (i.e., between a weld metal and the base
metal).
Neutral (i.e., an oxide coating on aluminum) or protective coatings may inhibit galvanic
corrosion, but in most instances, the metals or alloys must be selected on the basis of intrinsic
resistance to corrosion. In pressure vessels, the effects of galvanic corrosion are most noticeable
at rivets, welds, and flanged and bolted connections.

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C: Resistance to hydrogen attack
At temperatures from approximately 300°F to 400°F, monatomic hydrogen diffuses into
voids that are normally present in steel. In these voids, the monatomic hydrogen forms molecular
hydrogen, which cannot diffuse out of the steel. If this hydrogen diffusion81 continues, pressure
can build to high levels within the steel, and the steel can crack. At elevated temperatures, over
approximately 600°F, monatomic hydrogen not only causes cracks to form but also attacks the
steel.
Hydrogen attack differs from corrosion in that damage occurs throughout the thickness of
the component, rather than just at its surface, and occurs without any metal loss. In addition,
once hydrogen attack has occurred, the metal cannot be repaired and must be replaced. Thus, it is
not practical to provide a corrosion allowance to allow for hydrogen attack. Instead, materials are
selected such that they are resistant to hydrogen attack at the specified design conditions.
Hydrogen attack is a potential design factor at hydrogen partial pressures above approximately
100 Pisa.

The tensile strength (UTS) and elastic modulus of metals decrease with increasing
temperature. The temperature that give for this presser vessel is 4000C (752F) above 600F,
hydrogen attack cause irreparable damage through the component thickness & can damaged
carbon and low alloy steel.

Table 2.2

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C: Fabric ability
Fabric ability refers to the ease of construction and to any special fabrication practices
that are required to use the material. Of special importance is the ease with which the material
can be rolled or otherwise shaped to conform to vessel component geometry requirements.
Pressure vessels commonly use welded construction. Therefore, the materials used must be
wieldable so that individual components can be assembled into the completed vessel. The
material chemistry of the weld area must be equivalent to that of the base material so that the
material properties and corrosion resistance of the weld area will be the same as those of the base
material. A guide to the fabrication properties of common metals and alloys are shown blow. S –
satisfactory

D -Difficult, special techniques needed.

U - Unsatisfactory.

Martial Mashing Cold Hot Casting Welding Annealing

work work temperate(oC)
Cast iron S U U S U/D _
Stainless S S S D S 1050
steel(18Cr,8Ni)304

Nickel S S S S S 1150

Aluminum S S D S S 550
Copper(dioxides) D S S S D 700

Table 2.2

2.11 Conclusion about material selection

We select to our design Stainless steel 18Cr/8Ni(304)because it has good yield
strength(205MPa), tensile(UTS) strength(510MPa), good fracture toughness, good resistance
of temperature, good corrosion resistance and it can fabricate in different mated except
casting.

Material Tensile( UTS)strengt Modulus of Hardness Brinell Specific gravity

h, MPa elasticity, GPa

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 Stainless steel 510 210 160 8.0
18Cr/8NI
(304)

Table 2.3

2.2: Welding type

Welding is a way of heating of heating pieces of metal using electricity or a flame so that
they melt and stick together.
There are several methods to make welded joints. In a particular case the choice of a type
from the numerous alternatives depends on:

A: aspect of economy
B: the circumstance of welding
C: the requirement of the code

1: aspect of economy
If the two preceding factors allow free choice, then the aspect of economy must be the
deciding factor. Some consideration concerning the economy of welding:

 V-edge preparation, which can be made by torch cutting, is always more

economical than the use of J or U preparation.
 Double V preparation requires only half the deposited weld metal required for
single V preparation.

Increasing the size of a fillet weld, its strength increases in direct proportion, while the
deposited weld metal increases with the square of its size. Lower quality welding makes
necessary the use of thicker plate for the vessel. Whether using stronger welding and thinner
plate or the opposite is more economical, depends on the size of vessel, welding equipment, etc.
this must be decided in each particular case.

2: The circumstances of welding

In many cases the accessibility of the joint determines the type of welding. In a small
diameter vessel (under 18-24 inches) from the inside, no manual welding can be applied. Using
backing strip it must remain in plate. In larger diameter vessels if a man way is not used, the

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 last (closing) joint can be welded from outside only. The type of welding may be determined
also by the equipment of the manufacturer.

3: The code requirement

Regarding the type of joint the Code establishes requirements based on service, material
and location of the welding. The welding processes that may be used in the construction of
vessels are also restricted by the Code.The Code

Regulations are tabulated on the following pages under the titles:

Tabl
e 2.4
2.21Types of welded joint

Categories of welding
A) Category A: longitudinal welded joints within the main sheet, communicating Chambers,
nozzles and any welded joints within a formed or flat head.
B) Category B:circumferential welded joints within the main shell Communicating chambers,
nozzles and transitions in diameter Including joints between the translations and a cylinder at
either The large of small end, circumferential welded joints connecting from heads to main shells
to nozzles and to communicating chambers.
c) Category c: welded joints connecting flanges, tubes sheets and flat heads to main shells, to
formed heads, to nozzles or to communicating chambers and any welded joints connecting one
side plate to another side plate of a flat sided vessel.

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d) Category d:welded joints connecting communicating chambers or nozzles to main shells, to
heads and to flat sided vessels and those joints connecting nozzles to communicating chambers.

2.22 Conclusion about welding selection

we select butt joint because joint efficiency is (E=1).

Table 2.5

CHAPTER THREE
3.1: Calculate shell thickness for internal pressure
To find the thickness of the pressure vessel which subjected to internal design pressure
of P=0.4MPa there are different equations and its corrosion allowance for stainless steel
18Cr/8Ni is (2mm) from the table. There will be a minimum wall thickness required to ensure
that any vessel is sufficiently rigid to withstand its own weight, and any incidental loads.

Where t = min. required thickness of shell, mm

P = internal design pressure, Pa

Ri = inside radius of shell, mm

Ro=outside radius of shell, mm

S = max. Allowable stress, Pa

th=thickness of head, mm

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 E = joint efficiency (min)

C.A=corrosion allowance, mm

(a)CIRCUMFERNTIAL STRESS (LONGITUDINAL JOINTS)

It means that the governing stress will be the circumferential stress (hoop stress)
in the long seam. For this it has to satisfy that P does not exceed 0.385SE .In which case we
shall use the following formulae for thickness of shell t = PR/ (SE -0.6P) +
C.A

(b) LONGITUDINAL STRESS (CIRUMFERENTIAL JOINTS)

It means that the governing stress will be the longitudinal stress in the
circumferential joint. For this it has to satisfy that P does not exceed 1.25SE. OR if the
circumferential joint efficiency is less than ½ the longitudinal joint efficiency. In which case we
use the formula for thickness is

t = PR/ (2SE +0.4P) + C.A

Given: P=0.4MPa

R=0.4m

S=110 MPa

E=1

C.A=2mm=0.002m

Case1 using
Circumferential stress (longitudinal joint)
P ≤ 0.385SE
P ≤ 0.385*110MPa*1
0.4MPa ≤ 42.35MPa …………………… (Satisfied)

There for t=PR/ (SE-0.6P) + C.A

t= (0.4MPa*0.4m)/ (110MPa*1 - 0.6*0.4MPa) + 0.002m

t=0.003457m or3.457mm

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 standared tickness is 8mm........................ (ans)

case 2 using
Longitudinal stress (circumferential joint)
P ≤ 1.25SE
P ≤ 1.25*110MPa*1
0.4MPa ≤ 137.5MPa……………………….. (Satisfied)

There for t=PR / (2SE+0.4P) + C.A

= (0.4MPa*0.4m)/ (2*110MPa*1 + 0.4*0.4MPa) + 0.002m

t= 0.0027m or 2.7mm............................. (ans)

And the smallest value is t=0.0027mmm and for standard value let’s take t=0.005m or
5mm.

 Let’s find the external radius and diameter

Ro =R+t=0.4m+0.005m

Ro =0.405m ---------------------------- (ans)

And

Do=2*Ro=2*0.405m

Do=0.81m ------------------------- (ans)

3.2: Review different type of head

There are different kinds of pressure vessel closed heads.

Some of them are

 Flanged head:
 Hemispherical head :The design thickness of hemispherical head is given by

t=PRi/ (2SE-0.2P)
 Elliptical head: The design thickness of elliptical head is given by

t=PDK / (2SE-0.2P) where D-shell diameter,

K-stress intensity factor

2
K= [1/6 + (a/b) ] a and b semi-major, semi-miner axes of ellipse
 Tori spherical head: The design thickness of Tori spherical head is given by
t=PLM/ (2SE-0.2P) where L-spherical cross radiuses
M=1/4[1/3 + (L/r) 1/2] M-shear intensity factor

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 r-knuckle radiuses
 Conical head : The design thickness conical head is given by
t=PD/2cosα (SE-0.6P)where α-semi-apex angel
 Tori conical head: The design thickness tori conical head is given by
For conical region tc=PD/2cosα (SE-0.6P)
For Tori spherical region tk=PLM/ (2SE-0.2P)
1/2
M=1/4[1/3 + (L/r) ]
L=D1/cosα
Where M=shear intensity factor

3.21 Thickness of head

 Our pressure vessel is hemispherical head shape and 0.4MPa internal design pressure is
applied on it and its thickness is given blow

Given values Ri=0.4m

Ro=0.405m

P=04MPa

t=5mm=0.005m

E=1

C.A=2mm=0.002m

 According on the two theory

1) thin-shell theory
S= (PR)/ (2t)

S= (04MPa*0.4m)/ (2*0.005m)

S= 16MPa ---------------------------- (ans)

2) Exact theory
S= [PRi3/ (R30-R3i)] [1+R30/2R3i]

S= [(0.4MPa*(0.4m) 3)/ (0.4033-0.43) m3] *[1 + (0.4033/2*0.43)]

S=26.67MPa ------------------- (ans)

 There for let’s find the head thickness and take the largest value for S=26.67MPa.

t=PRi/ (2SE-0.2P) + C.A

t= (0.4MPa*0.4m)/ (2*26.67MPa*1 – 0.2*0.4MPa) + 0.002m

DESIGNE BY MEDHANE & TSEGAY Page

 t=0.005m or 5mm---------------------------------- (ans)

CHAPTER F0UR

Identify of Head-to-Shell transitions

4.1: SELECTION OF FLANGE BASED ON THE TEMPERATURE AND
PRESSURE RATING R [2]
For selecting the standard dimension and material for the flange by applying the
American National Standard ANSI B16.5-1981 of temperature and pressure rating. The
given temperature is 400oC (752oF) and pressure is 0.4MPa (58.015PSi). And we can’t find the
Mach value there for design pressure lets change in to standard value which is
3.1026MPa(450Psi).

Class 150lb.
Hydrostatic test/design pressure MPa(PSi) 0.4(58.015)
Temperature ,oC(oF) 400(752)
Maximum allowable non-shock pressure, 1.21(175.4)
MPa(PSi)
Table 4.1.Temperature pressure rating R [2]

We know that the flange is class 150lb and the material is Forged steel SA105 R [2].We
select Welding-neck flanges, because 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. The process will normally be specified for the connections and nozzles
on vessels and process equipment. R [1]

There are 2 flange that used for our pressure vessel design. The value is shown below.

 Two longitudinal pipe with D=65mm (2.56in).

 One lateral pipe D=65mm (2.56in).
 One bottom discharge D=40mm (1.575in)

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 Table.150lb. Flanges standard ANSI B16.5

Nom Diamete Diamete Diamete Outside Thickne Outside bolting Length

inal r of the r of the r of the diameter ss of the diameter through
pipe bore, hub at hub at flange flange the the hub.
size, mm(in) the point the base mm(in) mm(in) raised mm(in)
mm( [A] of mm(in) [H] [J] face(in) [C]
in) welding( [G] [K]
in) [E]
65 76.1 100 110 160 14 130 M12 71.4375
(2.56 (2.99) (3.94) (4.33) (6.3) (0.55) (5.11) (2.8)
)
40 52.578 60.452 77.7875 152.4 19.05 92.075 M12 63.5
(2) (2.07) (2.38) (3.0625) (6) (0.75) (3.625) (2.5)

Table 4.2

4.3FLANGE ANDGASKAT DESGINR [1]

4.31 FLANGE APPLIED LOAD AND FALNGE MOMENT
The load on the flange can be given as fallow

m=gasket factor

y=min design seating stress (N/mm2)

Pi=internal pressure of flange; =0.4Mpa

B=inside diameter of a flange for each pipe; =A/2

b=effective gasket selling width

2b=effective gasket pressure width

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 tf=thickness of flange; =J

hd= (G + H – 2E)/4

hg= (H - G)/4

ht= (G + H)/4

G’=mane diameter of gasket

=B + (ht-hg)

Hg=gasket reaction forces (pressure forces)

=πG’ (2b) mPi

H=total pressure

= (π/4)G’2Pi

Hd=pressure force of area inside the flange

= (π/4) B2Pi

Ht=pressure for a flange face

=H - Hd

The moment on the flange is,Mop=Hd*hd + Ht*ht + Hg*hg

Let’s calculate the lode and moment

 There gasket factor width and internal pressure for the flange are the same
m=3R [1], b=10mm and Pi=1.21MPa
 hd= (G + H – 2E)/4
 For 40mm: hd = (77.7875 + 152.4 - 2*60.452) mm/4 = 27.32mm
 For 65mm: hd = (110+ 160-2*100)mm/4=33.73mm

 hg= (H - G)/4
 For 40mm hg = (152.4 - 77.7875)mm/4 =18.65mm
 For 65mm hg= (160– 110)mm/4=12.5mm

 ht=(G+H)/4
 For 40mm ht= (77.7875 + 152.4)mm/4=57.55mm
 For 65mmht= (110+ 160)mm/4=67.5mm

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  tf=J
 For 40mmtf=19.05mm
 For65 mmtf=14mm

 B=A/2
 For 40mm B =52.578mm/2=26.3mm
 For 65mm B =76.1mm/2=38.055mm

 G’=B + (ht - hg)

 For 40mm G’=26.3mm + (57.55 – 18.65) mm=65.2mm
 For 65mm G’=38.055+ (67.5– 12.5) mm= 93.055mm
 H= (π/4) G’2Pi
 For 40mm H = (π/4)(65.2mm)2*1.21MPa=4039.898N
 For 65mm H = (π/4)(93.055mm)2*1.21MPa=8229.14N
 Hd= (π/4) B2Pi
 For 40mm Hd= (π/4)(26.3mm)2*1.21MPa=657.33N
 For 65mm Hd= (π/4)(38.055mm)2*1.21MPa=1376.25N
 Ht=H-Hd
 For 40mmHt= (4039.898 – 657.33)N=3382.27N
 For 65mmHt= (8229.14– 1376.25)N=6852.89N
 Hg=πG’ (2b)m pi
 For 40mm Hg =π(65.2mm)(2*10mm)3*1.21MPa=14870.8N
 For 65mmHg =π (93.055mm) (2*10mm) 3*1.21MPa=6755.8N

The moment is

 Mop=(Hd*hd)+ (Ht*ht)+ Hg*hg

 For 40mm pipe

Mop= (657.33N) (27.32mm) + (3382.27N) (57.55mm) + (14870.8N) (18.65mm)

Mop =489948.3Nmm=489.948N

 For 65mm pipe

Mop= (1376.26N) (33.73mm) + (6852.89N) (67.5mm) + (6755.8N) (12.5mm)

Mop =593438.82Nmm=593.438Nm

The minimum load required bolt load under the operating condition given by

 Wm1=H + Hg
 Wm1, 40mm=4039.898N + 14870.8N=18910.7N=18.9KN
 Wm1, 65mm=8229.14N + 6755.8N=14984.94=34.9KN

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 The force and the momentum must be checked under the bolting up conditions. The
moment is given by

 Matm=Wm2*hg
Matm: moment

Where Wm2is the bolt load required setting the gasket, given by

 Wm2=yπG’b

Gasket material Gasket factor Min design Min gasket

m seating stress y width b(mm)
(N/mm)

Rubber with 1.25 2.8 10

cotton fabric
insertion
Table 4.3

y=gasket setting pressure (stress) =2.8MPa

 Wm2, 40mm=2.8Mpa *π*65.2mm*10mm =5735.3N=5.73KN

 Matm, 40mm =5735.3N *18.65mm=106963.345Nmm=106.963Nm
 Wm2, 65mm=2.8Mpa *π*93.055mm*10mm=2605.54N=2.60554KN
 Matm, 65mm=593Nm*14mm=83020Nmm=83.02Nm

4.32 Flange stress R[2] and R[3]

Flange stress are given by

Longitudinal hub stress Radial flange stress Tangential flange stress

σhb=F1M σrd=F2M σtg=F3M - F4σrd

Table 4.4
where M is taken as Mop/B’ or Matm/B’, whichever is the greater; and the factors F1, F2, F3
and F4 are functions of the flange type and dimensions, and are obtained as followed

o F1= 1/λ gt2gt= (G-A)/2

λ=δ + γδ=t3/d and γ=α/T α=te+1
d= (u/v)hogo2go=J and ho= (B’go)1/2=(B’J) 1/2
=(u/v) (B’J)1/2J2B’= (G-A)/2
o F2=β/λt2t=thickness of the flange=J
β=1.333te+1

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 o F3=y/t2y=(1-v2)u

o F4=z z=k-factoer
K=A’/B’ A’= (H-G)/2 and B’= (G-A)/2
K =(H-G)/(G-A)
Take H, G and A values from above table 4.2

K40mm=(152.4–77.7875)mm/ (77.7875 – 52.578)mm

=2.98
K65mm=(160-110)mm/(110-76.1)mm
=1.47
And from R [3] we find this table

Nominal pipe K T Z Y, MPa(Psi) U

Dia.(mm)
40 2.98 1.21 1.25 0.018(1.88) 2.07
65 3.97 1.01 1.27 0.0101(1.45) 1.6
Table 4.5 value of (K, T, Z, Y and U) R [3]
Y-gasket seating design stress
 Let’s find the value of (e)
e=F/ho =F/(B’J)1/2
Let’s find the value of F (in y-axis) by using ASME code, section viii, Dev. 1.in x-axis g1/go(or
B’/J) and (**)
h/ho(or (C-J)/(B’-J)1/2)
After calculating of this value we fined F for each flange and the values are shown blow.
F40mm=0.6
F65mm=0.65
e40mm=0.6/15.495mm=0.038/mm
e65mm=0.65/15.4mm=0.042/mm
And let’s find (α and β)
α40mm=19.05mm (0.038/mm)+1=1.723
α65mm=14mm (0.042/mm)+1=1.588
β40mm=1.333*19.05mm (0.038/mm)+1=1.96
β65mm=1.333*14mm (0.042/mm)+1=1.784
And γ will be
γ40mm=1.96/1.21=1.62
γ65mm=1.784/1.22=1.46
Let’s find the value of v from ASME code Viii Div. 1 using by the value of (**) and it will be
v40mm=0.09
v65mm=0.07
d will be
d40mm=(2.07/0.09)(15.49)(19.05mm)2

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 =129,291.273mm3
D65mm=(1.6/0.07)(19.54mm)(14mm)2
=6252.8mm3
The value of δ will be
δ40mm= (19.05mm) 3/129291.273mm3
=0.0534
Δ65mm= (14mm) 3/6252.8mm3
=0.044
Let’s find the value of λ
λ40mm=1.0475
λ65mm=1.0201
Y will be
y40mm= (1-0.092)2.07=2.05
y65mm= (1-0.072)1.6=1.59
gt will be
for 40mm gt=12.6mm for mm gt=16.95mm

Nominal Dia. F1(1/mm2) F2 (1/mm2) F3(1/mm2) F4

(mm)
40 0.00601 0.005156 0.00564 1.25
65 0.00383 0.00354 0.0037 1.27
Table 4.6.value of the constant
To find the stress on the flange divided the value of the moment Mand it is the largest of them
(Mop/B’ or Matm/B’). And it is given blow
Nominal diameter(mm) Mop, Nm(KNmm) Matm(Nm) M(KN)
40 489.948 106.963 38.88
65 1374.322 218.63 85.89
Table 4.7. There for M=Mop/B’ the stress is

σhb=F1M
For 40mm=0.00601(1/mm2) (38.88KN)
=233.66MPa
For 65mm=0.00383(1/mm2) (85.89KN)
=328.9MPa

σrd=F2M
For 40mm=0.005156(1/mm2) (38.88KN)
=200.4MPa
For 65mm=0.00354(1/mm2) (85.89KN)
=304MPa
σtg =F3M-F4σrd
For 40mm=0.00564(1/mm2) (38.88KN) - 1.25*200.4MPa
=31.22MPa

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For 65mm=0.00354(1/mm2) (85.89KN) - 1.27*304MPa
=82Mpa
The flange must be sized so that the stresses given by equations satisfy the following
criteria: when ffo=102.04MPa (14.8KPSi) is the maximum allowable design stress for the flange
material at the operating conditions. R[1] and [2]
σhb> 1.5ffo
For 40mm 233.66MPa > 153.06MPa----- (satisfied)
F0r 65mm 328.9MPa > 153.06MPa------- (satisfied)
σrd>ffo
For 45mm 200.4MPa > 102.04MPa ------ (satisfied)
For 65mm 304MPa > 102.04MPa --------- (satisfied)

0.5(σhb+σrd) >ffo
For 45mm 217.03MPa8 > 102.04MPa --- (satisfied)
For 65mm 316.45MPa > 102.04MPa --- (satisfied)

0.5(σhb+σtg) >ffo
For 45mm 132.44MPa > 102.04MPa --- (satisfied)
For 65mm 205.45MPa > 102.04MPa --- (satisfied)
The bolt spacing must be selected to give a uniform compression of the gasket. It will
not normally be less than 2.5 times the bolt diameter, to give sufficient clearance for tightening
with a wrench or spanner. The following formula can be used to determine the maximum bolt
spacing:
From the table R[1] and R[2] the material [SA-193-B7] and maximum allowable stress
(fb) for the bolt is 172.37MPa (25KPSi).
The minimum bolt area is given by
Abf=Wm/fb
Where Wmgreatest of Wm1or Wm2
Nominal Dia.(mm) Wm1(KN) Wm2(KN)
40 18.91 5.735
65 34.9468 9.343
Table 4.8
Abf=Wm/fb
For 40mm =18.91KN/172.37MPa=109.7mm2
For 65mm =34.9468KN/172.37MPa=202.74mm2
The bolt spacing must be selected to give a uniform compression of the gasket. It will
not normally be less than 2.5 times the bolt diameter, to give sufficient clearance for tightening
with a wrench or spanner. The following formula can be used to determine the maximum bolt
spacing:

Pb=2db+6tf/ (m+0.5)
Where Pb-bolt pitch (spacing), mm
db-bolt diameter, mm
tf-flange thickness, mm
m-Gasket factor, 1.25
Pbwill be

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For 40mm
=2*15.875mm+6*19.05mm/ (1.25+0.5) =83.46mm
For 65mm
=2*15.875mm+6*23.8125mm/ (1.25+0.5) =99.8mm

CHAPTER FIVE
5.1 CALCULATING WALL THICKNESS OF THE NOZZLE R [2 ]

To find the thickness of the nozzle

tn=PR/ (SE-0.6P) + C.A

Where:tn-thickness of the nozzle

P-maximum allowable
E-joint efficiency (E=1)
S-maximum allowable stress
R-internal radius of the pipe
C.A-corrosion allowance
For nozzle design we selects SA-106-B from the table and S=83.63MPa (13.0KPSi). R
[2]

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Given
Nominal Dia. (mm) P, MPa(PSi) C.A, mm(in) Radius(mm)
40 16.188 (2348) 3.175 (0.125) 20
65 17.6(2552.66) 1(0.04) 38.05
Table 5.1
E=1
S=15000Psi =103.421MPa
tn will betn=PR/ (SE-0.6P) + C.A

tn,40mm=[(16.188MPa*20mm)/(103.421MPa*1- 0.6*16.188MPa)]+3.175mm
=6.63mm
tn,65mm=[(17.6MPa*38.05mm)/(103.421MPa*1-0.6*17.6MPa)]+1mm
=7.22mm

5.2 REINFORCMENT OF OPENING

The “equal area method” is the simplest method used for calculating the amount of
reinforcement required, and is allowed in most design codes and standards. The principle used is
to provide reinforcement local to the opening, equal in cross-sectional area to the area removed
in forming the opening. If the actual thickness of the vessel wall is greater than the minimum
required to resist the loading, the excess thickness can be taken into account when estimating the
area of reinforcement required. Similarly with a branch connection, if the wall thickness of the
branch or nozzle is greater than the minimum required, the excess material in the branch can be
taken into account. Any corrosion allowance must be deducted when determining the excess
thickness available as compensation. The standards and codes differ in the areas of the branch
and shell considered to be effective for reinforcement, and should be consulted to determine the
actual area allowed and the disposition of the various types of reinforcement. For branch
connections of small diameter the reinforcement area can usually be provided by increasing the
wall thickness of the branch pipe. Some design codes and standards do not require compensation
for connections below 89 mm (3 in.) diameter. If anything, the equal area method tends to over-
estimate the compensation required and in some instances the additional material can reduce the
fatigue life of the vessel. More sophisticated methods for determining the compensation required
have been introduced into the latest editions of the codes and standards. The equal-area method
is generally used for estimating the increase in thickness required to compensate for multiple
openings. R [1]
First calculate the reinforcement area R [3]

A=D*t*F

Where:tr-shell thickness=0.64((D+tn) tn) 1/2 (,)

F-correction factor=1

D-diameter of the pipe

DESIGNE BY MEDHANE & TSEGAY Page

tn-nozzle material thickness

E-joint efficiency=1

T-Shell material thickness= (for shell 5mm or for head 5mm)

A=D*t*F

A40mm=40mm*5mm*1=200mm2

A65mm=65mm*5mm*1=325mm2

By taking A1 as the largest of the A11 or A12 calculating the reinforcement area of the
vessel

A11= (Et-F*tr) D and A12=2(E*t-F*tr)*(t + tn) from (,)For

40mm tr=39

For 65mm tr=64

A11, 40mm = (1*5mm-1*39mm) 40mm=1360mm2

A12, 40mm =2(1*5mm-1*39mm) (5mm+6.63mm) =790.84mm2

A11, 65mm = (1*5mm-1*64mm) 65mm=3835mm2

A12, 65mm =2(1*5mm-1*64mm) (5mm+7.22mm) =1441.96mm2

There for A1 (reinforcement in shell) will be the largest value of (A11 or A12)

A1, 40mm=1360mm2

A1, 65mm=3835mm2

By taking A2 as the smaller of A21 or A22 and calculate the available nozzle wall.

For 40mm tr n=0.8362

For 65mm tr n =1.46

A21= (tn-trn) 5t and A22=2(tn-trn) (2.5tn-te) , te=0(no pad)

A21, 40mm= (6.63mm-0.8362mm) 5*5mm=144.845mm2

A22, 40mm=2(6.63mm-0.8362mm) (2.5*6.63mm-0) =192.06mm2

A21, 65mm= (7.22mm-1.46mm) 5*5mm=144mm2

A22, 65mm=2(7.22mm-1.46mm) (2.5*7.22mm-0) =207.94mm2

DESIGNE BY MEDHANE & TSEGAY Page

 A2 will be

A2, 40mm=144.845mm2

A2, 65mm=144mm2

Total Atotal=A1+A2

A40mm, total = 993.72mm2+144.845mm2=1138.565mm2

A65mm, total = (3835+144) mm2=3979mm2

Nominal Dia.(mm) Atotal(mm2) A(mm2)

40 1138.565 200
65 3979 325
Table 5.2

Atotal>A it is adequately reinforced.

5.3 DESIGN OF MANHOLE OR INSPECTION R[9]

All pressure vessels for use with compressed oil and those subject to internal corrosion,
erosion or mechanical abrasion, shall be provided with suitable manhole, hand hole, or other
inspection openings for examination and cleaning. The required inspection openings shown in
the table below are selected from the alternatives allowed by the Code, UG46, as they are
considered to be the most economical. The inside diameter of the pressure vessel is 0.8m
(31.496in).
According to the diameter its manhole recommended is 381mm (15in).
Di mm(in) Inspection opening required, mm(in)
800(31.496) 381(15)
Table 5.3

5.4 SUPORET DESIGNAND CHECK OF PRESSURE VESSLE R[2]

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STRESSES IN RESPONSE TO DIFFERENT LOADS
a) DUE TO INTERNAL PRESSURE
As we are treating methanator as a thin cylinder so the values of hoop stress &
longitudinal stress are calculated as under .Therefore radial stresses are ignored (very small)
so we consider the following primary membrane stresses

(a)Hoop Stresses and (b) Longitudinal Stresses

 HOOP STRESSES (S 1)

S1= PiDi /2t

= (1.6MPa) (800mm) / 2(5mm) = 128MPa

 LONGITUDINAL STRESS (S 2)

S2= PiDi/ 4t

= (1.6MPa) (800mm) / 4(5mm) = 64MPa

As hoop stress is greater so design is based on hoop stress.

b) STRESS DUE TO WEIGHT OF VESSEL & ATTACHMENT

It is assumed that weight of the vessel and its attachments results in compressive stress
only & eccentricity doesn’t exist and the resulting force coincides with the axis of the vessel. ()
The weight shall be calculated for the various conditions of the tower as follows.

A. Erection weight
B. Operating weight
C. Test weight
The compressive stress due to the weight is given by

S = W / ct --------------------------------------------- (a)

Where: S = unit stress, MPa

W = weight of vessel above the section under consideration, N

DESIGNE BY MEDHANE & TSEGAY Page

 c = circumference of shell or skirt on the mean diameter, mm

t = thickness of shell or skirt, mm

The weights of different vessel elements are given in the tables attached.

WEIGHT

ERECTION WEIGHT
Vshell=πD2L/4=2.0443m3
Vhead=2(πD3/12=0.227m3)

1) SHELL=ρshell*Vshell*g
=1.2922Kg/m3*2.0443m3*9.82m/s2=30.97KN
2) HEADS = ρhead*Vhead*g
=1.2922Kg/m3*0.227m3*9.82m/s2=2.88KNmultiply by 2
3) FLANGES (6) = n* (SIZE) = 3*mflange*g=3*4350Kg*9.82m/s2
=128.45KN
ERECTION WEIGHT=162.3KN--------------- (ANS)

B) OPERATING WEIGHT

Which include the weight of the erection + operating liquid

ERECTION WEIGHT = 162.3KN

WEIGHT FOR OPERATING LIQUID = ρliquid*vpressure vessel*g our liquid is oil (take Olive Oil)
then the density=800-920Kg/m3

take 800 ,the temperature is 4000c

= 800Kg/m3*1m3*9.81m/s2

=7.848KN

Total weight=7.848KN + 145.46KN=153.3KN------ (ans)

STRESS DUE TO WEGHT

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 Putting values in the formula (a)

Where, c = π * D mean = π*800 mm =2513.27mm

t = 5mm

Sw = 312.31KN/ (2513.27mm*5mm) =24.8MPa (compressive) ---------- (1)

C) STRESS DUE TO WIND LOAD:

Towers under wind pressure are considered as uniformly loaded cantilever beams. The
computation of wind is based on standard ANSI A58.1-1982. Where terrain features and local
records indicate that 50 years at standard height are higher than those shown in the map, those
higher values shall be the minimum basic wind speed.

The minimum basic wind speed for determining design wind pressure shall be taken
from the map of wind speed. Design wind pressure shall be determined by the following
formula:-

F=wind load=q*G*Cf* A

P = qs*G*CfA/A=q*G*Cf

Where, P= Design wind pressure, MPa

q = Wind stagnation pressure at the standard height of 9.144m (30 feet) as tabulated:

Basic wind speed, 70 80 90 100 110 120 130

mph, V

Pressure PSf, q 13 17 21 26 31 37 44

Table 5.4.Windpressure R[2]

Cf = Pressure coefficient (shape factor):

Round or elliptical towers----------------------------0.8

G = Combined height, exposure and gust factor coefficient as tabulated:

Coefficient G

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Height above ground, ft. Exposure C Exposure B

0-20 1.2 0.7

20-40 1.3 0.8

40-60 1.5 1.0

60-100 1.6 1.1

100-150 1.8 1.3

150-200 1.9 1.4

Table 5.5 Coefficient of C and B R[2]

Exposure C---------------------The most severe exposure

Exposure B ---------------------Intermediate exposure

For the methanator we will take a wind speed of 112.7Km/hr(70mph), so the value of

qs =0.089MPa (13psf)

Cf= 0.8-------------------------For circular vessel

G = 1.2---------------Intermediate exposure & vessel height of 3.924m(12.87ft)

There for the value of wind pressure using the above formula will be;

P = 0.085MPa

We will take the wind pressure 0.085MPa.

QUANTITIES FORMULAS

Shear V= Pw*D1*H

Moment at base M=Pw*D1*H*h1

Moment at height h(t) Mt = M- ht{V-0.5PwD1ht}

Stress S= 12M / R2*π*t

DESIGNE BY MEDHANE & TSEGAY Page

Table 5.6 Formula R [2]

Where, D1= width of the vessel with insulation, 0.814m=814mm

E = Efficiency of the welded joints = 1.0

h1= lever arm, ft = H / 2 = 1.962m=1962mm

ht= distance from base to section under consideration, 1.524m=1524mm

H = length of vessel section, 3.924m=3924mm

M = Maximum moment (at the base), Nm

Mt= Moment at height h t, Nm

Pw= Wind pressure, 0.089MPa

R = Mean radius of vessel, 0.4m=400mm

S = Stress due to wind, MPa =?

V = Total shear, N

t = Thickness of shell excluding corrosion, 5mm

The values of shear, moment at base & moment at skirt joint are calculated as under and then the
stress developed in response to the moment M(t) using the formulae listed in the table above. By
putting the values of the parameters listed above for methanator

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 Shear V = 0.089MPa*0.814m*3.294m

V =0.2386MPa=238.6 KN

Moment (at base) M = 0.089MPa*0.814m*3.294m*1.962m =0.4682MPa=468.2 KNm

Moment at head to skirt joint

Mt = 0.4682 – 1.524m{0.2386 – 0.5*0.089MPa*0.814*1.524m}

Mt = 0.1575MPa=157.5KNm

Stress due to wind = 12*M / (R)2*π*t

=12*0.4682MNm/ (0.4m)2*π*0.005m

= 2235.5MPa------------ (tensile)

d) STRESS DUE TO SEISMIC LOAD

(a) PERIOD OF VIBRATION

As a result of wind tall towers develop vibration. The period of vibration should
be limited, since large natural periods of vibration can lead to fatigue failure. The allowable
period has been computed from the maximum permissible deflection.

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 QUANTITIES FORMULAS

Period of vibration, T sec T=0.0000265(H / D)2*(w*D /t)½

Maximum allowable period of vibration, Ta Ta=0.80(WH /Vg) ½s

sec

Table 5.7Formula for time of vibration R [2]

Where, D = Outside diameter of vessel, 0.81m=810m

H = Length of vessel including skirt, 3.924m=392.4mm

g = 9.81m / sec2 gravitational acceleration

t = Thickness of skirt at the base, 5mm

V = Total shear = ZICW/Rw (calculated ahead)=1038.6N

W= Weight of tower =158.13KN

w= weight of tower per mater of height, = 40.29KN

Putting values to get period of vibration for methanator

T = 0.0000265(3.924/0.81) 2*(158.13*0.81/0.01) ½

T = 0.07sec

Now allowable period of vibration

Ta = 0.80 {W*H / V*g} ½=0.8{(158.13*3.924)/(9.82*1038.6)}1/2

Ta = 0.2sec=0.2

As ‘T’ is less than ‘Ta’ hence the condition is satisfied

(e)STRESS DUE TO EARTHQUAKE

The loading condition of the tower under seismic forces is similar to that of the
cantilever beam when the load increases uniformly towards the free end

FORMULAS

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 Shear Moment

V=ZICW/Rw M=[FtH+(V-Ft)(2H /3)]

Mx= M(x/H)

Table 5.9

Where

Rw=Numerical coefficient (use 2.9 for vessels)

E = Efficiency of welded joints = 1.0

Ft= Total horizontal seismic force at the top of the vessel, 0N (because T < 0.7)

= 0.07TV (Ft shall not exceed 0.25V)

= 0, for T < 0.7

H =Length of vessel including skirt, 3.924m=392.4mm

I = Occupancy importance coefficient (use 1.0 for vessels)

K = Horizontal force factor (use 2.0 for vessels)

M = Maximum moment at the base, Nm

Mx= Moment at distance x, Nm

S = Numerical coefficient for site structure resonance

= 1.0

The product CS shall not exceed 0.14

W = Weight of the vessel, 153.3KN

Z = Seismic factor

= 0.15

Shear = (0.15*1*0.126*158.13KN)/2.9

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 V = 1038.6N

Ft = 0.07*T*V =0.07*0.07*1038.6N=5.1N

0.25V = 259.65N

As condition is that Ft should not exceed 0.25V so it is satisfied for methanator

Therefore Moment

M = [5.1*3.924 + (1038.6-5.1)*(2*3.924/3)]

M =2723.6Nm

Moment at skirt to head joint

Mt = M(x/H) where x=H/3=3.924m/3=1.308m

=2723.6Nm*(1.308m/3.924m)

=907.8Nm

Therefore stress due to earthquake

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Seq = 12* Mt / R2 *π* t

= 12*907.8/ (0.4)2*π*0.005

=4.33MPa

COMBINATION OF STRESSES
The stresses induced by the previously described loadings shall be investigated in combination to
establish the governing stresses.

It is assumed that wind and earthquake loads do not occur simultaneously

Thus the tower should be designed for either wind or earthquake load

Whichever is greater?

In case of methanator the stress due to internal pressure is the hoop stress (membrane stresses),
the stress due to earthquake (greater) & stress due to weight (compressive) is considered

Combination of stresses will be as follows

+stress due to earthquake

+stress due to internal pressure

-stress due to weight

From the previous calculations putting the values of stresses

+4.33MPa

+128MPa

-40.3MPa

Combined stress at the head to skirt joint on the vessel in operating conditions =92.03MPa

COMPARISON
The governing stress will be tensile as shown by the positive sign, which is lesser than allowable
stress of the given material at that particular temperature

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Therefore the design is safe.

5.5 FABRICATION AND WELDING METHOD

Fabrication and welding method of the pressure vessel is based on the economic aspects of the
shell and the head. We used for the fabrication of the head and the shell by using but joint
welding for the contacting of the shell and head. We know that the martial for the pressure vessel
is stainless steel 18Cr/8Ni type 304 and its length is 2.4m by 1m and this stainless steel are
joining by but welding joint.

Shell fabrication

Shell is fabricated by rolling the sheet of stainless steel and welds it together to get the
cylindrical shape of the vessel by using but weld joint.

Head fabrication

Head shall is fabricated by making it in to different parts and by using but weld joint. And
finally support joining with the shallby using but joint welding.

Reference

R [1]-Coulson and Richardson’s, CHEMICAL ENGINEERING, Volume 6

R [2]-PREESURE VESSL HANDBOOK, 11th Editions

R [3]-PRESSURE VESLL DESIGN MANUAL,3rd Edition, BY Dennis Moss

R [4]-CHEMICAL ENGNEER’S HANDBOOK, Robert H.Berry and Don W.Geern

R [5]-Material science and Engineering,7th Edition, By William D.callister Jr.

R [6]-STANDARED HANDBOOK OF MACHINE DESIGN, by (JosephE.shigey, Charles

R.mischke and Thomass H.brown)

R [7]-PRESSURE VSSLE DESIGNE AND PRACTICE

R [8]-TEXTBOOK OF MASI

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