Professional Documents
Culture Documents
UNIVERSITY
NAME ID NO
1.
SUBMITTED TO:-Mr
SUBMITTED DATE:-
ACKNOWLEDGEMENT
First of all we would like to thanks for my Advisor Mr for that he has given us all
the information and the procedure, all the data and for he has given the reference books.
ACRONYM
ABSTRACT
Pressure vessel is a device which is used to store pressurized fluid. the current
existed pressure vessels has different problems, thus if there is changing of
operating service conditions, bursting of materials due to over pressurized force,
improper material selection and also poor machining operations and installations
during manufacturing process.
To prevent bursting of pressure vessel due to pressurized sulfuric acid we already
design a relief valve which operates by means of spring and ball mechanism
.generally in this document, the vessel designed to prevent the cause of failurity
related to design construction by selecting the available engineering materials and
also by considering other design requirements using the given design specifications
and requirements.
CONTENT PAGE
Acknowledgement
Acronym
Abstract
1. Background overview
1.1 introduction
1.2 statement of the problem
1.3 objective
1.3.1 general objective
1.3.2 specific objective
1.4 significance of the project
1.5 methodologies
1.5.1 Method
1.5.2 Procedure
2. Literature review
3. Detail design
3.1 design of shell
3.2 design of head
3.3 design of support
3.4 design of nozzle
4. Conclusion
5. Recommendation
6. Reference
.
Background Overview
Developments in pressure vessels during the nineteenth and twentieth centuries were
accompanied by all-too-frequent catastrophic pressure vessel explosions.
Disastrous accidents such as the SS Sultana (1865) and the Grover Shoe Factory explosion
(1904) led to the development of basic standards for manufacturing of pressure vessels. Further
improvements in metallurgy, welding technology and non-destructive testing helped, but a real
understanding of the science and mechanics of pressure vessel failure did not finally arrive until
the latter part of the twentieth century. The failure of the Cockenzie steam drum in 1966 during
hydraulic testing is described. A description is given, from personal experience, of testing the
overpressure safety valves in a nuclear power station. Even in the twenty-first century, the
catastrophic failure of a boiler pressure vessel in the SS Norway in Miami harbor in 2003, which
killed eight crew , was a reminder that pressure vessels remain hazardous unless carefully
designed, operated and inspected.
1.1 Introduction
Vessels tanks and pipelines that carry, store or receive fluids at high pressure are
called pressure vessels. A pressure vessel is designed as a container with a
pressure differential between inside and outside. The inside pressure is always
higher than the outside, except for some isolated situations. The fluid inside the
vessels may undergo a change in state as in the case of steam boilers, or may
combine with other reagents as in the case of a chemical reactor.
Pressure vessels often have a combination or high pressure together with
high temperature and in some case flammable fluids or higher radioactive
materials because or such hazards it imperative that the design be such that no
leakage can occur. In addition these vessels have to be designed carefully to care
with the operating temperature and pressure. It should be born in mind that the
rupture of a pressure vessel has a potential to cause extensive physical injury and
property damage. Plant safety and integrity are of fundamental concern in
pressure vessels design and these of course depend on the adequacy of design
cases
When discussing pressure vessels we must also consider thanks. 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 make internals where most tanks do not land those that do are limited to
heating coils or mixosl.
Pressure vessels are used in a number of industries for example the power
separation industry for fossil and nuclear power, the petrochemical industry for
storing and processing crude petroleum oil in tank forms 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
in fact, essential to industrial compressed air receivers, domestic not water
storage tanks, diving cylinders , recompression chambers , distillation towers ,
autoclaves ,oil refineries and petrochemical plants , nuclear reactor vessels
,pneumatic and hydraulic reservoirs , storage vessels for liquefied gases such as
ammonia ,chlorine ,propane , butane ,and LPG. Generally speaking pressurized
equipment is required for a wide range of industrial plant or storage and
manufacturing purpose.
The size and geometric form of pressure vessels vary greatly from the large
cylinder vessels used for high pressure gas storage to the small size used as
hydraulic units for aircraft. Some are buried in the ground or supported in
platforms.
Pressure vessels are usually spherical or cylindrical with domed ends. The
cylindrical vessels and generally proffered, since they pressure simpler
manufacturing problems and make better use of the available space. boiler
drums , heat exchangers , chemical reactors , and so on , are generally cylindrical
spherical vessels have the advantage of requiring thin or walls for a given
pressure than the equivalent cylinder therefore they are used for large gas or
liquid containers, gas – cooled , nuclear reactors for nuclear plant , and so on.
Classification of pressure vessels
Pressure vessels can be classified in different categories as follows:-
The pressure vessels according to their dimensions may be classified as thin shell or thick shell
the ratio of equal thickness (t) of the shell to its diameters (D) deciding factor.
t 1
a) Thin shell: - if the ratio of D is less than 10 is called a thin shells.
t 1
b) Thick shell:- if the ratio of D is equal or greater than 10 is called thick shell used in
high pressure cylinders, gun, barrels and other equipments where as thin shell are used in
boiler, tanks and pipes.
1.2.2. According to the end construction
This can be classified in to two groups:-
a) Open end construction pressure vessels
b) Closed end construction pressure vessels
1.2.3. According to the geometrical shapes
b) Conical and
A. head
B. shell
C. nozzle and
D. support
A. HEAD
All pressure vessel shells must be closed at the ends by heads (or another shell section).
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 can also be used inside a vessel. Head are
usually categorized by their shapes. Ellipsoidal, hemispherical, torispherical, conical, toriconical and flat
are the common types of heads.
B. 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.
C. 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:-
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 [3]. Calculated base loads are used to design of anchorage and foundation for the
pressure vessels.
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
ii. Leg support
Small vertical drums are typically supported on legs that are welded to the lower portion of the
shell. The maximum ratio of support leg length to drum diameter is typically 2:1. The number of legs
needed depends on the drum size and the loads to be carried. Support legs are also typically used for
spherical pressurized storage vessels. The support legs for small vertical drums and spherical pressurized
Storage vessels may be made from structural steel columns or pipe sections, whichever provides a more
efficient design.
shell
head
nozzle
support
1.5 METHODOLOGY
The main methodologies are:
Format interview
Meeting with teachers and senior students
Internet
Searching the standard mechanical data
Reference books
2. LITRATURE REVIEW
B.S. Azzam, M.A.A. Muhammad, M.O.A. Mokhtar et a1 (1996) was proposed a
new design technique that enables rapid and efficient design calculations. This
design method enables the designer of the composite pressure vessel to get readily
the ultimate failure pressure of these vessels depending on the number of
reinforced layers, layer thickness, fiber orientations, and materials. In this work a
numerous of aluminum tubes have been wrapped by different number of composite
layers made from different fibrous materials (glass, graphite and kevlar fibers).
Then, these tubes have been used as pressure vessels which tested till the explosion
failure. A comparison between the results of the experimental testing and the
theoretical proposed design for these composite pressure vessels has been
presented. This comparison has shown a good agreement between the theoretical
and experimental analysis.
Shu-Ho Dai (1998) explain that the prediction of the occurrence of failure events
for pressure vessels used in the process industry is a newly developing technology
in the field of modern technical management of facilities. It is of great significance
for ensuring safe and high efficiency operations in modernized large-scale and high
parameter facilities of chemical, petrochemical, nuclear and electric power plants.
Changheui Jang et al. (1999) describes the pressure vessel integrity under a
pressurized thermal shock using transient histories such as temperature, pressure
and heat transfer coefficient, the stress distribution is calculated and then stress
intensity factors are obtained for a wide range of crack sizes. The stress intensity
factors are compared with the fracture toughness to check if cracking is expected to
occur during the transient. Critical crack depth diagrams are prepared for each
transient which is expected to initiate a pressurized thermal shock accident. Plant-
specific analyses of the most limiting plant in Korea are performed to assure the
structural integrity of the reactor vessel and the results are discussed.
Specification:
Table 1: specification of pressure vessel
Fluid type H2SO4(Sulfuric acid)
Pressure 1.5 bar=0.15Mpa
temperature 41˚C
Layout Vertical
Support type Leg
End head shape Flat
Volume 9.5 m3
Material selection:
Geometric analysis:
To design our pressure vessel, we select cylinderical shell. To determine the
geometrical analysis of the pressure vessel, First find the diameter and
thickness of the cylindrical of shell.
To determine the above two unknowns use the formula of cylinder.
Vc = A×h A= πr2
D
=πr2×h r= 2
D
=π( 2 )2×h
π
= 4 D 2h
The given volume of the pressure vessel is 9.5m3and the pressure is 1.5Mpa, to
determine the dimension of both diameter and height use the following
relation.
If,
e 1
< , becomes thin walled pressure vessel
Di 10
e 1
> , becomes thick walled pressure vessel
Di 10
Now,
e 0.007519 m 7.519mm
Di
= 1.6 m = 1600mm
e
Di
=0.0047
e 1
Hence, the ratio of =0.0047 and it is less than we use thin cylindrical vessel for our
Di 10
sulfuric acid storage.
Figure 1: cylindrical shell
Design of head:
We are used flat head for our pressure vessel because the fabrication coast is low, flat ends are
not a structurally efficient form, and very thick plates would be required for high pressures or
large diameters. The thickness of flat head can be calculated as:
Pi
e = C p De
√ f
where, Pi= Design pressure
Cp= a design constant, dependent on the edge constraint,
De= nominal plate diameter,
f= design stress
Values for the design constant Cp and the nominal plate diameter De are given in the design codes
and standards for various arrangements of flat end closures.
For plates welded to the end of the shell with a fillet weld, angle of fillet 45˚and depth
equal to the plate thickness, take Cp as 0.55and De= Di.
1.65 Mpa
e =0.55×1.6×103
=72.966mm
√
240 Mpa
mm
Design of Drainage
The function of Drainage is to clean dirty part of the materials like unwanted fluids from the
pressure vessel as well as from other materials.
Now, we assume the nominal diameter of the Drainage as 80mm and we get the other
dimension by using standard flange table.
d1
Face
D B H d4 F No. d2 K d3
80 88.9 190 16 34 128 3 M16 4 18 150 110
Cylindrical shell:
The cylindrical shell of the pressure vessel subjected to external pressure can be expressed by:
t 3
Pc = 2.2 E ( ) where, Pc: external pressure acting on the
Do
Cylinder
E: young modulus
Do: outer diameter
Do= Di+2t t=e –thickness of the shell
=1600mm+ (2×7.519mm)
=1600mm+15.038mm=1615.038mm
Then, the critical pressure becomes;
7.519 3
Pc = 2.2×240×109( ¿
1615.038
=2.2×2.4×1011×1.0091×10-7
=53,280.48Pa=53.28Kpa
Design of vessels subject to combined loading
Primary stress:
i. The longitudinal and circumferential stresses due to internal pressure can be calculated
using the formula.
Circumferential stress/δh
PdDi
δh =
2t
1.65 Mpa × 1600 mm
=
2× 7.519 mm
2640
= Mpa
15.038
=175.55Mpa
Longitudinal stress/ δL
PdDi
δL =
4t
1.65 Mpa × 1600 mm
=
4 ×7.519 mm
2640
= Mpa
30.076
=87.77Mp a
ii. the direct stress (δw) due to the weight of the vessel and its media can be calculated:
W
δw = where, w-total weight
π ( Di+t ) t
T-thickness of the cylinder
Di-internal diameter
The total weight of the vessel is H SO
2 4
flat head) + weight of man hole + weight of inlet and outlet + weight of pressure and
temperature gauge + weight of drainage
FAILURE THEORIES
Theories of failure are used to predict failurity. There are four theories of failure these are,
1. Maximum nominal stress theory
2. Monr theory
3. Maximum shear stress theory
4. Maximum distortion energy theory
Now, our material is low alloy steel and it is ductile so, it is recommended to use Maximum
shear stress theory and Maximum distortion energy theory to predict the failurity of our vessel.
Maximum Shear Stress Theory:
This theory states that; yields begun whenever Maximum shear stress in any element
equals or exceeds the Maximum shear in a tension test that specimens of the same materials
when that specimens begun to yield.
Maximum shear stress is obtained by:
δ 1−δ 3
max=
2
But, the δ3 – is negligible because there is no radial stress on the material, since the vessel is thin
walled pressure vessel therefor the Maximum shear stress is
δ1
max=
2
51.7647 Mpa
=
2
=25.88Mpa
δy
Now, max= where, δy- yield strength of material
2n
n- Factor of safety
δy
n=
2❑max
430 Mpa
=
2× 25.88 Mpa
430 Mpa
=
51.7647 Mpa
= 8.3
VESSEL SUPPORT:
Leg support
Vertical vessels are normally supported by means of suitable structure. For our pressure vessel
we use bracket leg as a suitable support.
Vessels supported by bracket leg support are subjected to:
1. Longitudinal bending stress
2. Tangential (bearing) stress
3. Circumferential stress
For any component (contact members), there is a development of bearing stress, i.e.
Bearing stress – is the stress resulted from the contact of two members. In the bracket leg support
design there is a bearing stress between the vessel and the supporter.
Where, W= weight of vessel
n = number of legs
W
Q= load on one leg
n
R= Radius of head
H= lever arm of load
2A, 2B= Dimensions of wear plate
S= stress
t= wall thickness of head
K= factors (using charts)
C= √ AB
C= radius of circular wear plate
C R
D=1.82
√
R t
Now, assume there are four legs (n=4) and the total weight equally supported by each leg:
W
Q= , w= 181,354.9N
n
n= 4
181,354.9 N
=
4
= 45,338.7N, load on one leg
Assumption:
A=B=50mm=0.05m
Now, C= √ AB
= √ 0.05 ×0.05
= 0.05m
C R
D=1.82
√
R t
0.05 0.8
, R=0.8m
= 1.82×
= 2.015
√
0.8 0.00255
,D≈ 2
Using D=2 from the chart weight, the value of K1,K2,K3,K4,K5,K6,K7,K8 as;
D=2 K1=0.05
K2=0.025
K3=0.07
K4=0.01
K5=0.02
K6=0.015
K7=0.02
K8=0.04
H=0.025m
For computing the maximum tensile stresses in formula for S1and S2,K1,K3,K5 and K7 denote
negative factors and K2,K4,K6 and K8 denote positive factors.
For computing the maximum compression stresses, in formulas S1and S2, K1,K2,K3,K4,K5, K6,
K7andK8 denote negative factors.
1.Longitudinal stress:
a.Maximum tensile stress:
Q H R
S1= 2 [cosα (-k1+6k2)+
t
45,338.7 N
√
R t
(-k3+6k4)]
0.025 0.8
=
(0.025 m)
2 [cos0° (-0.05+6×0.025)+
=72,541,920N/m2(-0.22301)
S1=-16,177,573.6Pa
The stress due to internal pressure:
PR 0.165 MPa × 0.8
=
2t 2× 0.025
=+2.64×106Pa
The sum of stresses:
=-16,177,573.6Pa +2,640,000Pa
=-13,537,573.6Pa
=-13.5MPa
Also, 13.5MPa<630MPa
Therefore it is safe.
2. Circumferential stress:
a.Maximum tensile stress:
Q H R
S2= 2 [cosα (-k5+6k6) +
t
45,338.7 N
√
R t
(-k7+6k8)]
0.025 0.8
=
(0.025 m) 2 [cos0° (-0.02+6×0.015)+
=72,541,920N/m2(0.10894)
S2=+7,902,716.8Pa
The stress due to internal pressure:
PR 0.165 MPa × 0.8
=
2t 2× 0.025
=+2.64×106Pa
The sum of tensile stresses:
=7,902,716.8Pa+2,640,000Pa
=10,542,716.8Pa
=10.5MPa
Now 10.5MPa<430MPa therefore it is safe.
B.Maximum compressional stress:
Q H R
S2= 2 [cosα (-k5-6k6) +
t
45,338.7 N
√
R t
(-k7-6k8)]
0.025 0.8
=
(0.025 m)2
[cos0° (-0.02-6×0.015)+
=72,541,920N/m2[1× (-0.11)+0.177× (-0.26)]
√
0.8 0.025
(-0.02-6×0.04)]
=72,541,920N/m2(-0.15602)
S2=-11,317,990.36Pa
The stress due to internal pressure:
PR 0.165 MPa × 0.8
=
2t 2× 0.025
=+2.64×106Pa
The sum of stresses:
=-11,317,990.36Pa +2,640,000Pa
=-8,677,990.36Pa
=-8.67MPa
Which is less than 630MPa, therefore it is safe.
RECOMENDATION
Don’t use these pressure vessel above a pressure of 0.15 Mpa and a temperature of 41˚C.