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THE MERCIFUL
I.D:-3209119
(2015-2016)
A horizontal storage drum feeding tower is to be design the drum
holds liquid methane at -110 C° and methane flow rate 1500 kg/hr
pressure 0.45 gf/Cm3 the drums is assumed as to be fully in
instrumented and operator of in experience . design this storage
drums.
I
CHAPTERS Contents Page
Number
1.Introdaction: 2
1.1:- Objective: 2
1.2:- The Pressure vessel: 3
1.2.1:- Classification of Pressure Vessels 4
1.2.1.1:-According to the dimensions 4
1.2.1.2:-According to the end construction. 4
1.2.2:-Types of The Pressure Vessels . 4
1.2.2.1:-Horizontal Pressure Vessel. 4
1.2.2.2:- Vertical Pressure Vessel. 5
1.3:- The Carbon Stee. 6
Chapter 1.3.1:- The Difference Between Carbon Steels. 6
One 1.3.2:- Types of Carbon-Steel. 7
1.3.2.1:- Low carbon steel. 7
1.3.2.2:- Medium carbon steel. 7
1.3.2.3:- High carbon steel. 8
1.4:- The Methane. 8
1.4.1:- Chemical properties of methane. 8
1.4.2:- Sources of methane. 9
1.4.3:- Uses of methane. 9
1.5:- Insulation by glass wool fibers. 10
1.5.1:- Glass wool fibers. 10
1.5.2:- Thermal insulation. 10
2.1:- Calculation of vessel inside dimeters Di 12
Chapter 2.2:- Calculation of vessel long L 12
Two 2.3:- Calculation of vessel thickness tv 12
2.4:- Calculation of vessel Meam dimeters Dm. 12
2.5:- Calculation of vessel weight Wv. 12
Chapter 3.1:- physical properietes of carbon steel. 18
3.2:- physical properietes of glass wool fibers. 18
Three 3.3:- physical properietes of air. 19
3.4:-physical properietes of methane. 19
II
CHAPTERS Contents Page
Number
4. Mechanical Design. 21
4.1. Head thickness. 21
4.2. Thickness of Insulation. 23
4.3. Weight of ladders. 27
4.4. Weight of insulation. 27
4.5. Dead Weight. 27
4.6. Life Weight. 28
4.7. Total Weight. 28
4.8. Wind Loads. 28
4.9. Bending Moment. 29
4.10. Analysis of stress. 29
4.11. Dead weight stress. 30
Chapter 4.12. Bending stress. 30
Four 4.13. The Resultant of longitudinal stresses. 31
4.14. The Maximum Operating stresses. 31
4.15. Elastic Stability. 32
4.16. Vessel Support(Skirt Support). 32
4.16.1. Skirt Thickness. 34
4.16.2. Skirt Diameter. 34
4.16.3. Skirt Lenght 34
4.16.4. Bending Moment at Base of the Skirt. 34
4.16.5. Bending Stress in the Skirt. 34
4.16.6. Dead Weight Stress in the Skirt. 34
4.16.7. The Resultant Stress on the Skirt. 35
4.17. The Optimum Pipes Diameter and Flange Design for
36
Carbon steel.
III
Page
CHAPTERS Table of Figure Number
Chapter 1.2.2.1 Horizontal circular cylindrical tank.
One 5
Chapter
Two
Chapter
Three
4.1. Domed heads (a) Hemispherical (b) Ellipsoidal (c)
21
Torispherical
4.2. Horizontal cylindrical vessel on saddle supports. 32
4.3. Typical skirt-support designs. (a) Straight skirt.
33
Chapter (b) Conical skirt.
4.4. Bracket supports. (a) Supported on legs.
Four 33
(b) Supported from steelwork.
4.5. Flange types. (a) Welding-neck. (b) Slip-on. (c) Lap-joint.
36
(d) Screwed.
4.6 Typical standard flange design (All dimensions mm)
37
IV
Page
CHAPTERS List of Equation Number
4.1.1.Head thickness tn 22
V
Page
CHAPTERS List of Equation Number
VI
Page
CHAPTERS List of Equation
Number
VII
1.INTRODUCTION:-
1.1. Objective:-
High pressure rise is developed in the pressure vessel and pressure vessel has to
withstand severe forces. So the selection of pressure vessel is most critical.
That’s why we can say that pressure vessel is the heart for storage of fluid.
Pressure vessel must pass series of Hydrostatic tests.
These tests examine the ability of the structure to withstand various pressures to
see if protective zone around the operator station remains intact in an overturn.
Plant safety and integrity are of fundamental concern in pressure vessel design
and these of course depend on the adequacy of design codes.
Vessels, tanks, and pipelines that carry, store, or receive fluids are called
pressure vessels.
1
ASME : The American Society of Mechanical Engineers
2
and property damage. Plant safety and integrity are of fundamental concern
in pressure vessel design and these of course depend on the adequacy of
design codes. When discussing pressure vessels we must also consider
tanks. Pressure vessels and tanks are significantly different in both
design and construction: tanks, unlike pressure vessels, are limited to
atmospheric pressure; and pressure vessels often have internals while most
tanks do not (and those that do are limited to heating coils or mixers).
Pressure vessels are used in a number of industries; for example, the power
generation industry for fossil and nuclear power, the petrochemical industry
for storing and processing crude petroleum oil in tank farms as well as
storing gasoline in service stations, and the chemical industry (in chemical
reactors) to name but a few. Their use has expanded throughout the world.
Pressure vessels and tanks are, in fact,essential to the chemical, petroleum,
petrochemical and nuclear industries. It is in this class of equipment that the
reactions, separations, and storage of raw materials occur. Generally
speaking, pressurized equipment is required for a wide range of industria l
plant for storage and manufacturing purposes. The size and geometric form
of pressure vessels vary greatly from the large cylindrical vessels used for
high-pressure gas storage to the small size used as hydraulic units for
aircraft. Some are buried in the ground or deep in the ocean, but most are
positioned on ground or supported in platforms.
The pressure vessels (cylinders or tanks) are used to store fluids under pressure.
The fluid being stored may undergo a change of state inside the pressure vessel
as in case of steam boilers or it may combine with other reagents as in a
chemical plant. The pressure vessels are designed with great care because
rupture of a pressure vessel means an explosion which may cause loss of life and
property. The material of pressure vessels may be brittle such as cast iron, or
ductile such as mild steel.
3
1.2.1. Classification of Pressure Vessels.
The pressure vessels may be classified as follows:
On the other hand, if the wall thickness of the shell is greater than 1/10 of the
Thin shells are used in boilers, tanks and pipes, whereas thick shells are used in
high pressure cylinders, tanks, gun barrels
The purpose of this paper is to indicate the approximate stresses that exist in
cylindrical vessels supported on two saddles at various locations. Knowing
4
these stresses, it is possible to determine which vessels may be designed
for internal pressure alone, and to design structurally adequate and economical
stiffening for the vessels which require it.
Information about the seismic design of horizontal circular cylindrical tanks are
contained in the Eurocode 82 , but they are not actually exhaustive. In particular,
EC8 suggests that horizontal tanks need to be analyzed both along the
longitudinal and the transverse axis and that an approximate values for
hydrodynamic pressures induced by horizontal excitation in either the
longitudinal and transversal direction can be obtained from solutions for the
rectangular tank of equal dimension at the liquid level and in the direction of
motion, and ofdepth required to give equal liquid volume.
This approximation is sufficiently accurate for design purposes over the range of
H/R
(see Fig. 1) between 0.5 and 1.6. When H/R exceeds, 1.6, the tank should be
assumed to behave as if it were full with the total fluid mass rigidly connected to
the tank.
2
Eurocode 8: Design of structures for earthquake resistance
5
these variations in flow and maintain a constant flow rate out. When a vertical
process vessel is used as a knock out drum, a mixture of gas and liquid flows
into the vessel and this mixture is separated into its gas and liquid components
within the vessel. The gas then flows out the top of the vessel and the liquid
flows out the bottom .
Vertical process vessels, as their name indicates, are erected in the vertical
position. They are cylindrical in shape with each end capped by a domed cover
called a head. The length to diameter ratio of a vertical vessel is typically 3:1
The term steel is usually taken to mean an iron-based alloy containing carbon in
amounts less than about 2%. Carbon steels (sometimes also termed plain carbon
steels, ordinary steels, or straight carbon steels) can be defined as steels that
contain only residual amounts of elements other than carbon, except those (such
as silicon and aluminum) added for deoxidation and those (such as manganese
and cerium) added to counteract certain deleterious effects of residual sulfur.
However, silicon and manganese can be added in amounts greater than those
required strictly to meet these criteria so that arbitrary upper limits for these
elements have to be set; usually, 0.60% for silicon and 1.65% for manganese are
accepted as the limits for carbon steel.
6
When looking at the big picture, there are three distinctions between carbon
steels: low, medium, and high.
Medium carbon steels have good machining characteristics, and one of the more
popular grades used in machined steel product is AISI 1045.
7
AISI 1045 can also be hardened by heating the material too approximately 820-
850C (1508 -1562 F) and held until the material reaches a uniform temperature.
It should be soaked for one hour per 25 mm section of material and subsequently
cooled in still air.
8
methane content between 5 and 14 percent by volume, are explosive. Explosions
of such mixtures have been frequent in coal mines and collieries and have been
the cause of many mine.
The production and combustion of natural gas and coal are the major
anthropogenic (human-associated) sources of methane. Activities such as the
extraction and processing of natural gas and the destructive distillation of
bituminous coal in the manufacture of coal gas and coke-oven gas result in the
release of significant amounts of methane into the atmosphere. Other human
activities that are associated with methane production include biomass burning,
livestock farming, and waste management (where bacteria produce methane as
they decompose sludge in waste-treatment facilities and decaying matter in
landfills).
9
1.5. Insulation by glass wool fibers:-
1.5.1. Glass wool fibers.
Glass wool fibers are synthetic or man-made, very small finely spun fibers of
glass that form a mass resembling wool. There is considerable variation in the
properties of individual fibers within this class, depending on the manufacturing
process and end use. They are commonly used for insulation or filtration.
There are generally two categories of glass wool fibers that consumers might
use:
Glass wool is a thermal insulation that consists of intertwined and flexible glass
fibers, which causes it to "package" air, resulting in a low density that can be
varied through compression and binder content ( these air cells are the actual
insulator). Glass wool can be a loose fill material, blown into attics, or, together
with an active binder sprayed on the underside of structures, sheets and panels
that can be used to insulate flat surfaces such as cavity wall insulation, ceiling
tiles, curtain walls as well as ducting. It is also used to insulate piping and for
soundproofing.
10
11
2.Chemical Design :-
2.1. Calculation of vessel dimensions:-
2.1. Calculation of vessel inside dimeters Di.
4∗𝑉
𝐷𝑖 = 3√𝐿 ( Eq:2.1 )
⁄ 𝐷∗𝜋
2.2. Calculation of vessel long L.
𝐿 = 𝐿⁄𝐷 ∗ 𝐷 (Eq:2.2)
2.3. Calculation of vessel thickness t v.
𝑃0 ∗𝐷𝑖∗103
𝑡𝑣 = 2∗𝐽∗𝑓−𝑃0
+C (Eq:2.3)
2.4. Calculation of vessel Meam dimeters Dm.
12
Design stress (nominal design strength)
13
Welded joint efficiency, and construction categories
14
The calculation:-
Timprature -110°C
Time =8min
P= 34kgf/Cm2 = 3.334 N/mm²
Po=P*1.1=3.6674 N/mm²
flow rate m’=1500 kg/hr
density ρ =0.45 g/Cm3
m’ 1500
Q= = = 3.333𝑚3 /ℎ𝑟
ρ 450
8
𝑉 = 𝑄 ∗ 𝑡 = 3.333 ∗ = 0.445𝑚3
60
3
4∗𝑉 3 4 ∗ 0.445
𝐷𝑖 = =√ = 0.61𝑚
√ 𝐿⁄ ∗ 𝜋 2.5 ∗ 𝜋
𝐷
=397.274N
15
L/D Di (m) L tv (mm) Do (m) Wv (N)
(m)=Hv
2.5 0.610 1.524 11.898 0.621 397.274
3 0.574 1.721 11.315 0.585 385.093
3.5 0.545 1.907 10.848 0.556 376.892
4 0.521 2.085 10.463 0.532 371.144
4.5 0.501 2.255 10.137 0.511 367.008
5 0.484 2.419 9.856 0.494 363.980
Table 2.5 Calculation of vessel dimensions
From the table , the less wight when the ratio L/D=5
Then:- Diameter of vessel is 0.484m
Lenght of vessel is 2.419m
16
17
3.physical properietes:-
3.1. physical properietes of carbon steel:-
density ρ(kg/m³) 24
18
3.3. physical properietes of air:-
19
20
4.Mechanical Design:-
4.1. Head thickness:-
Heads are formed steel plates for pressure vessels and heat
exchangers. The heads are usually found at the ends of an
equipment, top or bottom for vertical vessels and left right for
horizontal vessels. There are only a few shapes used for the heads
that have proven to be useful. If the head is cut in half over the
diameter of the head, the shapes follow more or less an ellipse, see
also the figure 4.1.
21
4.1.1.Head thickness tn:-
𝑃𝑜 ∗𝑅𝑐∗10 3 ∗𝐶𝑠
𝑡ℎ = +C (Eq.4.1)
2∗𝑓∗𝐽+𝑃0 (𝐶𝑠−0.2)
.Cs:stress concentration factor for torispherical:-
1
𝐶𝑠 *(3+ 2√𝑅𝑐⁄𝑅𝑘 (Eq.4. 2)
4
Rc=Di=0.484m
Rk=6%Rc=0.029m
1
𝐶𝑠 = *(3+ 2√0.484⁄0.029 = 1.7706
4
3.6674∗0.484∗10 3∗1.7706
𝑡ℎ = + 2 =15.35mm
2∗135∗0.85+3.6674(1.7706−0.2)
𝐷𝑖
4.1.2:-depth of heat= = 0.484
4
= 0.121𝑚
4
4.1.3:-weight of head:-
𝐷
𝜋∗(𝐷0 + 0+𝑎+𝑡ℎ )2 ∗𝑡ℎ
𝑊𝐻 = 𝜌𝑚 [ 24
] (Eq.4.3)
4
0.494
𝜋 ∗ (0.494 + + 2 + 15.35 ∗ 10−3 )2 ∗ 15.35 ∗ 10−3
𝑊𝐻 = 7833 [ 24 ]
4
𝑊𝐻 =604.427N
22
4.2. Thickness of Insulation:-
4.2.1. Heat without Insulation .
The general eqution of heat flow is:-
∆𝑇
𝑞= ∑𝑅
(Eq.4.4)
Where:
q:amount of heat transfer
∑ 𝑅 total resistance of heat transfer
𝑇𝑚𝑎𝑥 +𝑇𝑚𝑖𝑛
𝑇𝑓 = (Eq.4.7)
2
Assume:-
23
60+0
𝑇𝑓 = = 30°C =303.15°K
2
1 1
𝛽= = = 3.29 ∗ 10−3 °K −1
𝑇𝑓 303.15
1
𝑁𝑢 = 0.15𝑅𝑎 3 107 ≤ 𝑅𝑎 ≤ 1011 (Eq.4.9b)
𝑅𝑎 = 𝐺𝑟 ∗ 𝑃𝑟 (Eq.4.10)
Ra Reynolds number
Pr Prandtl number from (Table:3.3). Pag-19
Gr Grashof number.
𝑔∗𝐷𝑖 3 𝛽(𝑇𝑠−𝑇)
𝐺𝑟 = (Eq.4.11)
𝑣
Where:
g = acceleration of gravity = 9.81, m/s²
24
Di = longer side of the vessel
25
9.81∗(0.484)3 (3.29∗10−3)∗(30−(−110))
𝐺𝑟 = = 3.803 ∗ 106
0.13471∗10−6
(−110 − 30)
−186.971 =
ln ( 0.252⁄0.242) ln(𝑟3⁄0.252)
1 1
1.1261 ∗ 3.678 + 2𝜋 ∗ 54 ∗ 2.419 + 2𝜋 ∗ 0.038 ∗ 2.419 + 0.3639 ∗ 3.67
𝑟3 = 0.3234𝑚
𝑡𝑖𝑛 = 𝑟3 − 𝑟2 = 0.3234 − 0.252 = 0.0714𝑚 = 71.4𝑚𝑚
26
4.3. Weight of ladders:-
𝑊𝑙 = 150 ∗ 𝐻 (Eq.4.15)
𝐻 = 𝐷𝑜 + 1.5
Assume the support of vessl=1.5m
27
4.6. Life Weight:-
𝑊𝑓 = 𝜌𝑓 + 𝑉𝑓 + 𝑔 = (Eq.4.18)
28
4.9. Bending Moment (Mx):-
𝐹𝑤 +𝑋 2
𝑀𝑥 = (Eq.4.23)
2
𝑀𝑥 = 184005.7𝑁/𝑚𝑚
4.10. Analysis of stress:-
𝑃𝑜 +𝐷𝑖
𝜎ℎ = (Eq.4.24)
2𝑡𝑣
𝑃𝑜 +𝐷𝑖
𝜎𝑙 = (Eq.4.25)
4𝑡𝑣
29
4.11. Dead weight stress:-
𝐷 𝑊
𝜎𝑤 = (𝜋∗ (𝐷 +𝑡 (Eq.4.26).
𝑖 𝑣 )∗𝑡𝑣
1905.7803
𝜎𝑤 = = 0.1246N/mm²
(𝜋 ∗ (484 + 9.856) ∗ 9.856
𝜋
𝑙𝑣 = (𝐷04 + 𝐷𝑖4 ) (Eq.4.28).
64
30
4.13. The Resultant of longitudinal
stresses:-
𝜎𝑧 = 𝜎𝑙 + 𝜎𝑤 ± 𝜎𝑏 (Eq.4.29).
31
4.15. Elastic Stability:-
𝑡
𝜎𝑐 = 2 ∗ 104 ∗ 𝐷𝑣 (Eq.4.31).
𝑜
𝜎𝑐 = Elastic Stability .
For check must be (𝜎𝑏 + 𝜎𝑤 < 𝜎𝑐 ).
9.856
𝜎𝑐 = 2 ∗ 104 ∗ = 399.028𝑁/𝑚𝑚²
494
(0.1408 < 399.028) .
Then that is it acceptable.
4.16. Vessel Support(Skirt Support):-
32
Figure 4.3. Typical skirt-support designs. (a) Straight skirt. (b)
Conical skirt.
33
4.16.1. Skirt Thickness (ts) .
Assume 𝑡𝑠 = 𝑡𝑣 = 9.856𝑚𝑚.
4.16.2. Skirt Diameter (Ds) .
Assume 𝐷𝑠 = 𝐷𝑖 = 0.484𝑚 .
4.16.3. Skirt Lenght (Ls) .
𝐿𝑠 = 1.5𝑚 .
4.16.4. Bending Moment at Base of the Skirt (Mxs) .
𝐹𝑤
𝑀𝑥𝑠 = ∗ (𝐿 + 𝐿𝑠 )2 (Eq.4.32).
2
362.16
𝑀𝑥𝑠 = ∗ (2.419 + 1.5)2 = 2781.128𝑁/𝑚
2
4.16.5. Bending Stress in the Skirt (𝜎 b.s) .
4∗𝑀𝑥𝑠
𝜎𝑏𝑠 = (Eq.4.33).
𝜋∗(𝐷𝑠𝑘 +𝑡𝑠 )∗𝑡𝑠 ∗𝐷𝑠𝑘
1905.7803
𝜎𝑤𝑠(𝑡𝑒𝑠𝑡) = = 0.1246𝑁/𝑚𝑚²
𝜋 ∗ (484 + 9.856) ∗ 9.856
34
𝑊𝑓
𝜎𝑤𝑠(𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 ) = 𝜋∗(𝐷 (Eq.4.35).
𝑠𝑘 +𝑡𝑠 )∗𝑡𝑠
344.8𝑁
𝜎𝑤𝑠(𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 ) =
𝜋 ∗ (484 + 9.856) ∗ 9.856
= 0.0225𝑁/𝑚𝑚²
4.16.7. The Resultant Stress on the Skirt.
35
From the Young Modulus of Elasticity for Metals and
Alloys from( Engineering ToolBox.com)=201956.4N/mm².
9.856
= 0.125 ∗ 201956.4 ∗ ( ) ∗ 𝑠𝑖𝑛90
484
= 514.071𝑁/𝑚𝑚²
1.3784 < 514.071 Then that is it acceptable.
4.17. The Optimum Pipes Diameter and
Flange Design for Carbon steel:-
𝑑𝑜𝑝𝑡 = 293 ∗ 𝐺 0.53 ∗ 𝜌𝑚
−0.37
(Eq.4.38).
Figure 4.5. Flange types. (a) Welding-neck. (b) Slip-on. (c) Lap-
joint. (d) Screwed.
36
STEEL SLIP-ON BOSS FLANGE FOR WELDING
Nominal pressure 6 bar
37
38
5.1. Storag Tank Cost Estimation:-
39
Vessel lenght =2.419m
Inside diameter =0.484m
Design pressure =3.6674 N/mm²=36.674bar
Presser factor =1.6 from (Figure 5.1)
Material factor for Carbon steel =1.0
Bare cost from (Figure 5.1) =2000$.
Purchase cost=(bare cost from figure)*Material factor*Pressur factor (Eq.5.1)
=2000*1*1.6=3200$
40
41
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SINNOTT.
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steam. Peacesoftware.de ,email: webmaster@ peacesoftware.de
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