University of Gondar Institute of Technology Department of Mechanical Engineering

UNIVERSITY OF GONDAR
INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
[UNFIRED HORIZONTAL PRESSURE VESSEL DESIGN]
Project done by:

1. Shemels Belayneh………………. ID No.03260//11
2. Getachew Setargew………. ID No.03344/11
Advisor:
Misganaw Abebaw
Month, Year
Mechanical and Engineering, Institute of Technology, University of Gondar, Ethiopia

Unfired horizontal pressure vessel design
DECLARATION
We declare that we have independently authored the present project work with the title [Unfired
horizontal pressure vessel design]. We have not used any other than the declared sources or
resources, and we have explicitly marked all material which has been quoted either literally or by
content from the used sources. This paper has not been submitted either in whole or part, for a
degree at this or any other university or institution.
NAME: Shemels Belayneh Signature: ____ _____
NAME: Getachew Setargew Signature: __ _______
TITLE OF THE DESIGN PROJECT: Unfired Horizontal Pressure Vessel

Design
ADVISOR: _______________________________________________________
Signature: ________________________________________________________
I
Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

CONTENTS OF THE PROJECT WORK

Acknowledgement ………………………………………………………………….…...… .[ii]
Abstract..................................................................................................................................... [ iv]
Table of contents…………………………………………………………………………...... [v ]
List of Figures ……………………………………………..………………………………. [vii ]
List of Tables ……………………………………………………..………………………....…[ix ]
Abbreviations and Acronym...………………...…………………………………………....... [x ]
II

Acknowledgement
First, we would have great thanks for the almighty God who gives power and strength to do this
kind of project work, our instructor Mr. Misganaw Abeam give us this project, thanks to him,
and many individuals contribute their knowledge and ideas for the accomplishment of this
project work, finally our special thanks goes to for all of our dormitory friends and classmate
students for their great effort doing the project
III

Abstract:
Vessels tanks and pipelines that carry, store or receive fluids are called pressure vessels. A
pressure vessel is defined as a container with a pressure differential between inside and outside.
The inside pressure is usually higher than the outside, except for some isolated situation. The
fluids inside the vessel way undergo a change in a state as in the case of a chemical reactor. The
main objective of this designing project is to design a pressure vessel that can work under the
specified working conditions such as: pressure, temperature and to analyze each component of
the vessel geometrical and theoretical analytical data and at the end to design with Auto-Cad. In
this project we have designed a pressure vessel that can store water as working fluid with 3 Mpa
of internal pressure and 127.2345m3 of storing capacity as it’s specified by our client, this
project work deals with a detailed study and design procedure of horizontal pressure vessel with
elliptical head, saddle support, flange, nuts, bolts, hand hole and pipe hole and openings. A
detailed study of various parts of pressure vessels like, shell, support, head, nozzle.
The detailed study of pressure vessel with properly selected material from various materials used
in pressure vessel construction is discussed. Not also this but also design criteria like,
temperature, pressure, corrosion allowance, stresses etc.… are clearly shown and we have got
acceptable quantitative result that does not oppose the required value to be.
IV

Contents
CHAPTER ONE............................................................................................................................1
1.Introduction.............................................................................................................................1
1.2. Background of the Study............................................................................................1
1.3. Problem of the Statement.............................................................................................2
1.4. Objectives of the Study...................................................................................................3
1.4.1.General Objective of the Study....................................................................................3
1.5. Scope and Limitations of the Study...............................................................................3
1.5.1. Scope of the project......................................................................................................3
1.5.2. Limitation of the Project..............................................................................................4
1.6.Organization of Project Work.........................................................................................4
CHAPTER TWO...........................................................................................................................5
2.Literature Review...................................................................................................................5
CHAPTER THREE...................................................................................................................6
3. Methodology of project work................................................................................................6
3.1 Classification Of Pressure Vessel....................................................................................6
1.2.2 Application of Pressure Vessel...................................................................................11
1.2.3 Components of Pressure Vessel..................................................................................11

Methodology of project work..................................................................................................15

CHAPTER FOUR.......................................................................................................................17
4.Analyses and solutions of project work...............................................................................17
4.1 Material Selection...........................................................................................................17
4.2Design Stress (nominal design strength).......................................................................19
4.3 Design Pressure.............................................................................................................20
4.4 Design Temperature.......................................................................................................20
4.5 Corrosion Allowance......................................................................................................21
4.6 Shell Design.....................................................................................................................21
4.6.1 Design of volume in pressure vessel...........................................................................22
4.6.2 Stress Analysis for the Shell.......................................................................................23
4.7 Vessel Head Selection and Sizing..................................................................................25
4.8 Design of Nozzle (opening).............................................................................................30
4.8.3 Design of Circular Handhold.....................................................................................36
4.9.1.1 Stress Analysis of Bolt...............................................................................................42
4.9.2 Design of Nuts..............................................................................................................42
4.9.3 Design of Flanges.........................................................................................................43
4.9.3.1 Standard Flanges.......................................................................................................43
4.10.1 Longitudinal Bending Stress....................................................................................52
4.10.2 Tangential Stress.......................................................................................................54
4.10.3 Circumferential Stress..............................................................................................54
4.11 Design of Welding.........................................................................................................56
4.11.1 Selection of Welding..................................................................................................56
4.11.2 Stress Analysis for Welding......................................................................................57
4.12 Cost Analysis.................................................................................................................59
4.12.1 Cost Analysis of Shell................................................................................................60
4.12.2 Cost Analysis of Head...............................................................................................60
VI

4.12,3 Cost Analysis of Nozzle (opening)............................................................................61

4.12.4 Cost Analysis of Support..........................................................................................61
CHAPTER FIVE.........................................................................................................................62
5. Results and Discussions.......................................................................................................62
5.1 Results..............................................................................................................................62
5.2 Discussions......................................................................................................................63
CHAPTER SIX........................................................................................................................64
6. Conclusion and Recommendation......................................................................................64
6.1 Conclusion.......................................................................................................................64
6.2 Recommendation............................................................................................................64
REFERENCE...............................................................................................................................64
Appendices....................................................................................................................................66
Appendix A: material properties............................................................................................66
Appendix B: Charts.................................................................................................................67
Appendix C: Constant Tables.................................................................................................70
List of Figures
List
VII

Figure: 2D cylindrical shell model……………………………………………………..21

Figure: Dimensional data for head…………………………………………………….22
Figure: 2D model nozzle(opening)……………………………………………………..34
Figure: 2D model Bolt………………………………………………………………….37
Figure :2D model nut……………………………………………………………………39
Figure :2D standard flange dimensions…………………………………………………….40
Figure: Standard saddle steel dimensions……………………………………………………45
Figure :2D model saddle……………………………………………………………………. 50

Figure :3D cylindrical shell…………………………………………………………………57
Figure :3D model head………………………………………………………………………57
Figure :3D Model Nozzle……………………………………………………………………58
Figure :3D Model Flange……………………………………………………………………58
Figure 3D Model Saddle…………………………………………………………………….59
Figure: Assembly Drawing of Horizontal Pressure Vessel…………………………………59
VIII

List of Tables
List Pages
Table 1: Given Design Data parameter……………………………………………………….13
Table 2: typical design stress for plate………………………………………….……………15
Table 3: inspections of opining……………………………………………………………….28
Table 4: standard bolt and nut dimension…………………………………………………....36
Table 5: dimension measurement for bolt…………………………………………………...37.
Table 6: standard flange dimensions…………………………………………………………40
Table 7: Standard saddle parameter………………………………………………………….45
Table 8: Cost of the material given by $/ton………………………………………………....55
Table 9: project result…………………………………………………………………………59
IX
Mechanical and Engineering, Institute of Technology, University of Gondar,Ethiopia

Abbreviations and Acronym

ASME Association Society of Mechanical Engineering
ts thickness of shell .
Pd Design pressure
R internal radius of the shell
C corrosion allowance
S Material stress
E Joint efficiency
di internal diameter
σh hoop stress
σ lLongitudinal stress
th thickness of head
h depth of head
Rm meridional radius of curvature
tn thickness of nozzle in in.
Rn internal radius of the nozzle
Mechanical and Engineering, Institute of Technology, University of Gondar,Ethiopia

CHAPTER ONE
1.Introduction
Vessels tanks and pipelines that carry, store or receive fluids are called pressure vessels. A
pressure vessel is defined as a container with a pressure differential between inside and outside.
The inside pressure is usually higher than the outside, except for some isolated situation. The
fluids inside the vessel way undergo a change in a state as in the case of a chemical reactor.
Pressure vessels often have a combination of high pressure with high temperature and in some
cases flammable fluids or highly radioactive materials. Because of such hazards it is imperative
that the design be such that no leakage can occur, in addition these vessels have to be design
carefully to cope with the operating temperature and pressure.
It should be borne in mind that the rupture of pressure vessels has a potential to cause
physical injury and property damage plant safety and integrity have 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 vessel and tanks are
significantly different in design: 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 mixtures).
Generally, pressure vessel are refers to those reservoirs and apparatus which work under
internal and external pressure and operate under the pressure.
1.2. Background of the Study
Perhaps the earliest reference to the design of pressure vessel was made in about 1495 by
Leonardo da Vinci in his
Codex matrix quoting from translation, Leonardo wrote <we shall describe how air can be forced
under water to lift very heavy weights that is how to fill skins with air once they are secured to
weight at the bottom of the water. And there will be description of how to lift weight by trying
them to sub merged ships full of sands and how to remove the sand from the ships>.
Leonardo’s pressurized bags of air if implemented did not kill or injury large number of people
and therefore did not force the need for pressure vessel code. That distinction must go to the
early model steam generators.
Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Before 1963 all pressure vessels were designed using systematic design by formula approach
which was based on experience and simple mechanics what was mostly described was how to
keep loop stress low with respect to yield and how to use ductile material to accommodate local
peak stress.
In the design by formula, the vessel geometry and major dimensions such as radius, length, etc.
are specified and the required thickness is then calculated for a given load using equation and
graphical data.
In 1963 ASME published the B and PV code section 8; nuclear vessels based on the principle of
limit analysis and stress analysis were used to determine higher allowable loads and more
consistent margin of safety.
This improvement in the code permitted two approaches for design.
⇛ improved design by formula, providing more accurate formula for sizing common component
and higher allowable Stress was intended for standard configuration.
⇛ design by analysis, in which designer performs stress analysis and evaluate results against
code limits, was intended for configuration net cover by the design by formula.
The new ASME boiler and pressure vessel code, section 8, division 2 was published on July 1,
2007. This 2007 edition became mandatory for pressure vessel design in July 2009, the new
section 8, division code 2 include a complete re-organization of a text, introduce consistent and
user friendly format style, and provides a number of new and enhanced pressure vessel design
procedures. Familiarity with the new organization and the application of these rules is essential
to both the new and experienced vessel engineering to ensure proper vessel design. From the
beginning of students’ project work, there are opening paragraphs, students should briefly
introduce their project work topic, explain its relevance, and tell readers why they should be
interested in it. State their clear research question or problem. In the end they can put to include a
short summary of how they’re going to answer or solve it in further their study.
Students’ project work demonstrates their mastery of a particular subject area and your ability to
independently create new, adopt, modification of scientific knowledge. When writing your
project work, your information retrieval skills are developed and their facility for critical and
analytical thinking, problem solving and argumentation is strengthened. All of which are skills
required for success in their future working life.
Classification of Pressure Vessel
Pressure vessels classified in different categories as follows:
According to the dimension:
The pressure vessels, according to their dimensions, may be classified
As thin shell or thick shell

a) thin shell: - If the wall thickness of the shell (t) is less than 1/10 of the diameter of the shell
(d), then it is called a thin shell
b) thick shell: if the wall thickness of the shell is greater than 1/10 of the diameter of the shell,
then it is said to be a thick shell. Thin shells are used in boilers, tanks and pipes, where as thick
shells are used in high-pressure cylinders, tanks, and gun barrels
According to the end construction:
This can be classified in to two groups: -
a) Open end construction pressure vessels: A simple cylinder with a piston, such as cylinder of a
press is an example of an open-end vessel. In case of vessels having open ends, the fluid pressure
induces the circumferential or hoop stresses.
b) Closed end construction pressure vessels: A tank is an example of a closed end vessel. In case
of closed ends, longitudinal stresses in addition to circumferential stresses are induced
According to the geometrical shapes:
a) Cylindrical geometrical shapes

b) Conical and
c) Spherical vessel with one or two cones.
According to the position arrangement
a) Horizontal pressure vessel:

The free horizontal pressure vessel in pressure vessel is a container designed to hold gases or
liquids at a pressure substantially different from the ambient pressure
b) Vertical pressure vessel
Vertical pressure vessels are used for a variety of operational needs, mainly as reservoirs of
compressed air - air chambers, as well as pressurized water tanks or expansion tanks to
compensate for the volume of hot water stations with air or steam cushion - aqua mat, and as
releasers called expanders.
Vertical pressure vessels consist of a cylindrical shell and dished bottoms. They are placed on
three welded legs. The size and positioning of the filler necks is adjusted according to the

customer requirements and accordance with the relevant European standards. The pressure
vessels can be produced from ferrous or austenitic steel
c) Spherical pressure vessel:
This type of pressure vessels are known as thin walled vessels. This forms the most typical
application of plane stress. Plane of stress is a class of common engineering problems involving
stress in a thin plate. Spherical vessel have the advantage of requiring thinner walls for a given
pressure and diameter than the equivalent cylinder. Therefore, they are used for large gas or
liquid containers, gas-cooled nuclear reactors, containment buildings for nuclear plant, and so
on…
According to the materials:
The pressure vessels are according the material classified as

a) Brittle material pressures vessels
b) Ductile material pressure vessels
Under the above consideration, there is also another classification
1) steel vessel
2) none ferrous vessel
3) none metallic vessel
According to the direction of force acting on the wall of vessels
a) Subjected to internal pressure
Vessel where the median pressure inside the vessel is larger than that of outside
1) low pressure vessel 0.1p
2) medium pressure vessel1.6p
3) high pressure vessel10<p
4) ultra- high pressure vessel P
c) Subjected to external pressure

These types of pressure vessel is a Vessel where the median pressure inside the vessel
is lower than the outside (gauge pressure). When the internal pressure is less than
0.1Mpa (absolute pressure) such vessel are called vacuum vessel.
According to the temperature
1) Normal temperature vessel -20
2) Medium temperature vessel is between normal temperature and high temperature
3) Low temperature vessel
4) High temperature vessel where the wall temperature is above the creep temperature
Application of Pressure Vessel
Pressure vessel is the container for fluid under high pressure. They used in variety of industries like:
o Petroleum refining
o Chemical plant
o Power plant
o Food and beverage
o Medical application
o LPG tanks and many more
In addition, it also can store fluid such as liquid vapor and gas under pressure. pressure vessel
had been used in various water treatment application like mixed bed exchanger , activated carbon
filters ,sand filters, dual medical filters etc. with internal rubber lining carbon steel internal
including strainers and screen laterals ,ladders and plate form etc.
Components of Pressure Vessel
Following are the main components of pressure Vessels in general
a) Shell
b) Head
c) Nozzle
d) Support
a) 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
b) 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, tori spherical, conical, tori conical and flat are the common types of
heads.
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: -
 Attach piping for flow into or out of the vessel.
 Attach instrument connections, (e.g., level gauges, thermos 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)
d) Support:
The type of support that is used depends primarily on the size and orientation of the pressure
vessel. In all cases, the pressure vessel support must be adequate for the applied weight, wind,
and earthquake loads. Calculated base loads are used to design of anchorage and foundation for
the pressure vessels
 There are four types of support:

 Saddle support
 Skirt support
 Leg support

 Lug support
1) Saddle support:
Horizontal drums typically supported at two locations by saddle support.
It spreads over a large area of the shell to prevent an excessive local stress in the shell at support
point.
One saddle support anchored whereas the other is free to permit unstrained longitudinal thermal
expansion of the drum [1].
2) Skirt support:
Tall vertical cylindrical pressure vessels 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).
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 [1]
3) Leg support:
Small vertical drums typically supported on legs that welded to the lower portion of the shell.
The maximum ratio of support leg length to drum diameter is typically 2:1 Reinforcing pads
welded to the shell first to provide additional local reinforcement and load distribution. The
number of legs depends on the drum size and loads to be carried. Support legs also used for
Spherical pressurized storage vessels. Cross bracing between the legs used to absorb wind or
earth quake loads [1].
4) Lug support:
Vertical pressure vessels may also supported by lugs. The use of lugs is typically limited to
pressure vessels of small and medium diameter (1 to 10 ft.). Also moderate height to diameter
ratios in the range of 2:1 to 5:1
The lugs typically bolted to horizontal structural members in order to provide stability against
overturning loads [2]

1.3. Problem of the Statement

Pressure vessel as one of the most desirable device it faces several defects created by different
causes. Those defect includes bending moment due to unbalanced load on the components,
corrosion resistance failure, mechanical failure, cracks on different parts of the pressure vessel,
mechanical deformation etc. These defects are causes for the pressure vessel to perform its
function improperly. So, in order to improve the function, the device I have to solve these defects
as much as possible by different mechanisms. For example: proper material selection, proper
consideration in placement of the device, proper manufacturing process etc. Then I would like
design my project by considering the above-mentioned problems. Problems may not remove
completely but it can be reduced. So, I would like to design a horizontal layout pressure vessel
with a minimum problem as much as possible.
1.4. Objectives of the Study
1.4.1. General Objective of the Study
Designing an horizontal un fired pressure vessels position with some ellipsoidal head by the
given internal pressure and temperature on its effect and having some material properties that can
be functional under the given temperature of 120°c and pressure 3MPa
1.4.2. Specific Objectives of the Study
Specifically, we would like to design different components of pressure vessel that can give the
proper function. And also the project has its own procedures to design each component and to
design the hole assembled of pressure vessels. This project used to design the components such
as support, head, shell and nozzle and it has its own procedures to design each component and to
design the hole assembled of horizontal presser vessel.
 Select material
 Design of cylindrical shell
 Design of curved or ellipsoidal head
 Design of nozzle and manhole
 Design of saddle support
1.5. Scope and Limitations of the Study
1.5.1. Scope of the project
Pressure vessel used in various field and plays a significant role in our life. So the method of construction,
the serving time length, the factor which distort them and their causes are the main things that we must
observe critically.
We know that mostly pressure vessels fail in short time due to several factors like, corrosion,
design problem, variable environmental condition, and such a like. Considering these problem

we should construct vessel, which serve the customer for long time as much as possible. These
can be done designing pressure vessel considering such problems and giving greater factor of
safety (allowance) to the construction in order to avoid physical damage.
Generally, our scope is producing advanced pressure vessel, which is resistant to corrosion and
failure due to any other effect like temperature & pressure change by designing properly. The
scope of this design project was on the detail design and analysis of each component of
horizontal pressure vessel and to draw out the detail drawing of each component using Auto
CAD software with the help of optimization concept and design procedure.
1.5.2. Limitation of the Project
The design is only horizontal pressure vessel because of time no others such as vertical.
The developed pressure vessel can only withstand below 3 M pa, and120°c of pressure, and
temperature respectively. In our design case, the designing fluid is water. The designing fluid
water play great role for corrosion due to the reason that pressure vessel are all in contact with
water which give great opportunity for rusting, these is impossible to prevent completely.
We have taken out most care while working on this project, but that doesn’t mean we were
perfect. There were limitations due to various factors. The major limiting factors in this projects
are listed below.
o Time shortage.
o Even though there are numerous works and journals done on pressure
vessel it is hard to find them since they are not properly documented and it
is inevitable that we might have missed some important information’s
digging into thousands of journals abut pressure vessel.
o The doers of this project were amateurs.
1.6. Organization of Project Work

Our project is about horizontal unfired pressure vessel and it composed from six chapters.
Chapter one: Introduction about pressure vessel, its background history, its general and specific
objectives, and its limitations.
Chapter two: Literature review about pressure vessel.
Chapter three: Detail design and methodology, how and why we choose the materials, the
formulas and other things that we used to design our pressure vessel.
Chapter four: Analyses and proposes of our design basically it has all the calculation for our
individual parts of our pressure vessel.

Chapter five: Results and Discussion we state our results and all of our key points at this chapter
Chapter six: Conclusion and recommendations in this chapter we conclude our design by the
results we had and we will state all of the things that we want to recommend for others who will
see this design project. Eventually, we state our references and appendix to let our audience or
viewer of this to let them know what are the sites or the tools we used to work this project and at
end of this we put some information that clarify our work on the appendix.
CHAPTER TWO
2.Literature Review
Pressure vessels are used as ammonia converter; urea reactor and supercritical fluid extractor at
higher level are widely used in chemical, oil refining, energy industries, and so on. Such vessels
are key equipment’s in various processes industries and have potential hazards. Much
attention has been paid to using them safely and to lowering their costs, with great progress
being made in the last century. For example:
⇔Analysis of Pressure Vessel junction by the Finite element Method written by
Mahadeva Siva Ramakrishna lyre not only tells the use of method to solve such high tension
zone problems but also gives a way to predict results for stresses and optimize the design [1];
⇔finite element analysis of Pressure vessel by David Heckman also tells the use of
computer programs instead of hand calculations for analyzing the high stress area’s and
different end connections[1] ;
⇔The different types of stresses and modeling of pressure vessel joints are also depicted in
ASME code in section Design by analysis Nishant M. Tandel, Jignesh M Parmar had
presented work on a review on pressure vessel design and analysis, the project deal with vessel
are subjected to various applied forces acting in combination with internal or external pressure
and some design principle, design of pressure vessel is governed by ASME pressure vessel
code, design of different pressure Vessel concerned with element such as shell, dish end,
operating man hole, support leg, based on standard and code and evaluation of shell and dish end
analyzed by means of analysis, and this paper they concluded that the design method to be
used in pressure vessel are depend upon stresses and internal or external pressure[1];
Chirag H. Panchigar and Vijay Parekh[9] wrote their review paper about “A Review Paper on
Design and Analysis of Pressure Vessel” and concluded that there are different factors that
10

affects the design and overall life of pressure vessel and they have to be considered in different
cases of pressure vessel.
⇔E. 0. Bergman states that the external loads applied to pressure vessels produce axial
loading and bending moments on the vessel. These result in axial tensions and compressions in
the shell, which must be combined with the effects of the pressure loading to give the total
Longitudinal stress acting in the shell. The design method to be used depends on whether the
longitudinal stress in the shell is tension or compression, and on whether the vessel is
subjected to internal or external pressure[1];
M. A Khan et al [8] carried out his research on “Stress distribution in horizontal pressure vessel
and saddle supports”. Here quarter of the pressure vessel is modeled. After that stress distribution
is carried out for pressure vessel. He concluded that highly stressed area is the flange plate of
saddle.
⇔Some of the presented work on Modeling of Pressure Vessels with different End
Connections using Pro Mechanical, author used here only three types head
hemispherical, elliptical and tori spherical In this paper authors, describes its basic
structure and the engineering finite element modeling for analyzing, testing and validation of
pressure vessels under high stress zones, Analysis results do not suggests the use of Toro
spherical end connection with the same thickness due to more displacement occurs in this type
of head [1];
From the above literature we have conclude that when we design a pressure vessel we have
to consider different loads. The pressure vessel faced both internal and external pressure. The
axial loading and bending moments are exerted on the pressure vessel.
There are also circumferential, axial, longitudinal stresses exerted to the pressure vessel. So in
order to design a good pressure vessel we have to consider the above conditions. And also we
have to consider problems stated at the problem statement.
A thorough literature is the foundation of any scientific paper and should always be the first step
of the writing process. There is no correct or standard number of references to be used. Not
quantity but quality and relevance of the references you use are important.
11

CHAPTER THREE
3. Methodology of project work
Methodology of project work

The methodology of this study can be further break down to 4 steps
1. Data collection: collecting design data from different journals, pressure vessel
manufacturing companies websites and review them
2. Numerical analysis: design shell, design head, design nozzle (openings), design support
and other data’s using stress analysis.
Design procedure of shell

 Select materials of shell
 Select the working fluid that means water
 Calculate thickness of the shell
 Calculate outer diameter of shell
 Find stress analysis of shell
Design procedure of heads

 Select materials of head
 Calculate the thickness of heads
 Calculate outer diameter of head
 Find the depth of heads
 Find the stress analysis stress of head
12

Design procedure of openings

 Select type of openings
 Select materials for openings
 Find the inner and outer diameter of openings
 Calculate the thickness of the openings
Design procedure of saddle support

 Select the material for saddle support
 Calculate the load on saddle support
 Calculate the stress of saddle support
 Calculate the total volume in vessel
3. Detail drawing of the main parts and assembly.

4. Report: write the final thesis, draw conclusion from what we get from above steps
CHAPTER FOUR
4.Analyses and solutions of project work

Design of horizontal layout pressure vessel specification
Table 1 Given Design Data
Parameters Value Unit

Design pressure 3 Mpa
Design temperature 120 °c
Internal diameters of 3 m
cylindrical section
Length of the cylinder 17 m
section
Corrosion allowance 1.8 m
13

Working fluid Water

Vessel orientation Horizontal
4.1 Material Selection

Many factors have to be considered when selecting engineering materials, but for chemical
process plant the overriding consideration is usually the ability to resist corrosion. The process
designer will be responsible for recommending materials that will be suitable for the process
conditions. We must also consider the requirements of the mechanical design properties; the
materials selected must have sufficient strength and be easily worked. The most economical
material that gives satisfied both process, this will be the material that gives the lowest cost over
the working life of the plant, allowing for maintenance and replacement. Other factors, such as
product contamination and process safety must also be considered.
The most important characteristics to be considered when selecting a material of constructions

are:
A. Mechanical properties:
Include the following properties.
 Strength:- Tensile strength required
 Stiffness: - The material should have high Elastic modulus (Young’s
modulus).
 Toughness: - Fracture resistance needed.
 Hardness: - high wear resistance required.
N.B: Also the material fatigue and creep resistances are needed.
B. The effect of high and low temperature on the mechanical properties.

C. Corrosion resistance
D. Any special properties required such as thermal conductivity, electrical résistance, and
magnetic properties.
E. Case of fabrication: forming, welding, casting etc.
F. Availability in standard sizes: plates, sections, tubes etc.
G. Cost of the material
14

The important materials generally accepted for construction of pressure vessels are indicated
here. Metals used are generally divided into three groups based on market cost as:-
1. Low cost: - for example: Cast iron, Cast carbon and low alloy steel, wrought carbon and
low alloy steel.
2. Medium cost: - for example: High alloy steel (12%chromium and above), Aluminum,
Nickel, Copper and their alloys, Lead.
3 High cost: - for example: platinum, Tantalum, Zirconium, Titanium silver
In our design Preferred Material Low alloy Steel (Ni, Cr, Mo, V) for all parts of pressure vessel
We selected Low alloy Steel because of its: -low cost and better strength
Material properties at the given design pressure and design temperature i.e.3 MPa and 120◦C
respectively
4.2Design Stress (nominal design strength)

For design purposes it is necessary to decide a value for the maximum allowable stress
(nominal design strength) that can be accepted in the material of construction. This is determined
by applying a suitable “design stress factor” (factor of safety) to the maximum stress that the
material could be expected to withstand without failure under standard test conditions. The
design stress factor allows for any uncertainty in the design methods, the loading, the quality of
the materials, and the workmanship. For materials not subject to high temperatures the design
stress is based on the yield stress (or proof stress), or the tensile strength (ultimate tensile stress)
of the material at the design temperature. Typical design stress values for some common
materials are shown in the table below. These may be used for preliminary designs. The
standards and codes should be consulted for the values to be used for detailed vessel design.
Table 2 typical design stress for plate (source Coulson_&_Richardson's_Chemical_Engineering,
_Volume_6)
Material Tensile Design stress at temperature℃ (N/mm2)
Strength
(N/mm2)
0 to 50 100 150 200 250 300 350 400 450 500
Carbon- 450 180 170 145 140 130 120 110 100
Molybd
15

enum
steel 0.5
percent
Mo
Low 550 240 240 240 240 240 235 230 220 190 170
alloy
steel(Ni
,Cr,Mo,
V)
Stainles 510 165 145 130 115 110 105 100 100 95 90
s
steel(18
Cr/8Ni)
From the above table find tensile strength and yield strength of low alloy steel at temperature of
120◦C
Parameter Value Unit
Tensile strength 550 Mpa
Yield strength 240 Mpa
In English units
T.S =550 MPa = 79770.9 psi
S=240 MPa = 34809.12 psi
4.3 Design Pressure

A pressure vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation. Vessels subject to external pressure should be designed to resist the
maximum differential pressure that is likely to occur in service. Vessels likely to be subjected to
vacuum should be designed for a full negative pressure of 1 bar, unless fitted with an effective,
and reliable, vacuum breaker. The pressure use in the design of a vessel is called design pressure.
It is recommended to design a vessel and its parts for a higher pressure than the operating
pressure. A design pressure higher than the operating pressure with 10 percent, whichever is the
greater, will satisfy the requirement. The pressure of the fluid will also be considering. The
design pressure, pi is given by:
Pd=3Mpa = 435.114 psi
16

Pi = Pd/1.1 =3/1.1= 2.72727 MPa = 395.558 psi
Where, Pi=internal pressure

4.4 Design Temperature
The strength of metals decreases with increasing temperature. So the maximum allowable design
stress will depend on the material temperature. Design temperature is the temperature that will be
maintained in the metal of the part of the vessel being considered for the specified operation of
the vessel. For most vessels, it is the temperature that corresponds to the design pressure.
However, there is a maximum design temperature and a minimum design temperature for any
given vessel. This minimum temperature shall be the lowest temperature expected in service or
the lowest allowable temperature as calculated for the individual parts. Design temperature for
vessels under external pressure shall not exceed the maximum temperatures.
My given temperature as a design temperature is
T=120°C
By using the given temperature there exist allowable stress(s) and tensile strength
Allowable stress=240Mpa
Tensile strength=550Mpa.
4.5 Corrosion Allowance
The corrosion allowance is the additional thickness of metal added to allow for material lost by
corrosion and erosion, or scaling. Corrosion is a complex phenomenon, and it is not possible to
give specific rules for the estimation of the corrosion allowance required for all circumstances.
The allowance should be based on experience with the material of construction under similar
service conditions to those for the proposed design. For carbon and low-alloy steels, where
severe corrosion is not expected, a minimum allowance of 2.0 mm should be used; where more
severe conditions are anticipated this should be increased to 4.0 mm. Most design codes and
standards specify a minimum allowance of 1.0 mm. Corrosion occurring over the life of a vessel
is catered for by a corrosion allowance, the design value of which depends upon the vessel duty
and the corrosiveness of its content. A design criterion of corrosion allowance is 1.8 mm for our
design since it is given in which corrosion due to moisture of water is expected. This corrosion
allowance is more than the minimum standard corrosion allowance.
4.6 Shell Design
Shell is one of the main components of pressure vessel and they came with three main
classifications based on their geometry, namely spherical, cylindrical, and conical.
17

In this section we will be selecting a material and computing/designing each part dimension
Given design Conditions in English units
1Mpa = 145.038 Psi
YMpa=x
Pd=3Mpa = 435.114 psi
Pi = 2.72727 MPa = 395.558 psi
1mm=0.0393701inch
Ymm
=x
C= 1.8 mm = 0.07086618 in.
4.6.1 Design of volume in pressure vessel

The total inside volume for a cylindrical shell with two semi ellipsoidal head with 2:1 major
axis to minor axis ratio pressure vessel is given by:
3 2
π d i π di
V= + L Equation , Volume
12 4
Where V = volume in m3
di = internal diameter in m
L = length
V=π33/12+π3217/4
V=7.068583471+120.165919
V=127.2345m3
Finding the shell thickness
18

Pd R
t s= +C Equation, shell thickness
SE−0.6 Pd
Where ts = thickness of shell in in.

Pd=Design pressure in psi
R= internal radius of the shell in in.
C = corrosion allowance in in.
S=Material stress in psi
E=Joint efficiency
di = internal diameter in mm
di
Where, R= =3000mm/2=1500mm=59.05515in
2
435.114∗59.05515
t s= +0.07086618
34809.12∗1−0.6∗435.114
ts = 0.814633812 in = 20.69168766 mm≈ 21 mm
∴ Do= Di +2t s=3000mm + 2(20.69168766) mm
Do=3041.383375mm=119.7395676 in
4.6.2 Stress Analysis for the Shell
 Find stress analysis of shell
Calculate the stress on the shell using lame’s equation
 Hoop stress: - is the maximum tensile stress and it is known as circumferential

stress.
Tangential stress: - is the maximum compressive stress and it is negative. The
negative sign indicates that the radial stress is opposite to design stress equal.
In order to proceed with our findings, we should check the induced hoop and longitudinal stress
and check whether they are less than the material design stress.
19

Hoop stress is given by
Pd R
σ H oop = Equation, Hoop stress
ts
Longitudinal stress is given by
Pd R
σ longt= Equation , Longitudinal stress
2t s
Where ts= thickness of shell in in.

Pd= Design pressure in psi
R=internal radius of the shell in in.
σ hoop = hoop stress
σ longt=¿ Longitudinal stress
The two stresses will be

435.114∗59.05515
σ hoop= =31542.66636 Psi
0.814633812
435.114∗59.05515
σ longt= =15774.63328 psi
2∗0.814633812
Find the maximum shear stress (τ max)
σ h−σ l
τ max=
2
31542.66636−15774.63328
τ max= =7884.01654 psi
2
Then, check it is safe by comparing it with design stress.
20

σy
τ max <
2
7884.01654 psi<17404.56 psi
∴Therefore the design is safe.
Or we can cheek our design either safe or not by using factor of safety.
Factor of safety=design stress/working stress where design stress S=34809.12 psi
Working stress σ h=31542.66636 psi
34809.12
F= =1.1
31542.66636
Then, factor of safety is greater than one the design is safe
Both the two stresses are less than the design stress value, which is 34809.12 psi, the design is
safe, therefore we can proceed with the shell thickness we found
Finally, the designed shell model will look like:
Figer 2D cylindrical shell model

4.7 Vessel Head Selection and Sizing
All pressure vessel shells must be closed at the ends by heads (or another shell section).
21

 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,
 tori spherical,
 conical,
 tori conical and
 Flat are the common types of heads.
Vessel head selection elliptical or Semi ellipsoidal (2:1 S.E. head)
Why elliptical head? Because
 They are more economical since the height of the head is just a quarter of the
diameter.
 Compared with flat heads a minimum thickness is achievable with the elliptical
head, which in turn cuts the manufacturing cost
. Figure Dimensional data for head (sourceCoulson_&_Richardson's_Chemical_Engineering,

Volume_6 )
22

Thickness computation
PDK
t h= +C Equation 1 Head thickness
2 SE−0.2 Pd
Where th= thickness of head in in.

Pd=Design pressure in psi
R= internal radius of the head in inch.
C =corrosion allowance inch.
K = head constant
S= Material stress in psi
E=Joint efficiency = 1
D =internal diameter of the cylinder section
h = depth of head, in
Where, D=3000mm=118.1103in
1
K= ¿Equation Head coefficient
6
[ ( )]
2
1 a a D 3000
K= 2+ = = =2
6 b b 2h 1500
Where:
- a = 2(major axis)
23

b = 1 (minor axis)
∴K = 1
PDK
th= +C = ( 435.144∗118.1103)/¿ =0.81003in=20.57475089mm
2 SE−0,2 Pd ¿¿
but Do= Di+ 2 * th=118.1103in+2¿ 0.81003∈¿
Do=119.73in
Before proceeding, we should check whether the head stress is less than the materials stress
value at center of the head at the tangent line.
At the center
2
Pd R
σ ϕ=σ x = Equation Latitudinal and meridonial stresses at center
2 t hh
di 118.1103
, h= = =29.527575in
4 4
Latitudinal and meridonial stresses at center
Where th = thickness of head in in.
R= internal radius of the head in in.
D=internal diameter of the cylinder section
2
435.114∗59.05515
σ ϕ=σ x =
2∗29.527575∗0.81003
σ ϕ=σ x =31721.93936 psi
The stress at center is less than the design streess34809.12 psi so the design is safe
At the tangent line
24

di 118.1103
Where, h= = =29.527575in
4 4
Pd R
σ x= Equation Latitudinal stress
2th
σ ϕ=
Pd R
th (
R2
1− 2 Equation
2h ) meridonial stress
435.114∗59.05515 59.055152
σ x= σ ϕ=¿ (435.114*59.05515)/0.81003(1− )
2∗0.81003 2 ¿ 29.5275752
σ x =15860.96968 psi σ ϕ=−31721.93936 psi
Thenσ x positive sine shows that the stress is tensile andσ ϕ negative sine shows that the stress is
compressive
the stress at the tangent in Latitudinal and meridonial is less than the design stress 34809.12
psi so the design is safe
At any point given x
Meridional stress and latitudinal stress
P d∗R L P d∗RL RL
σ x= σϕ = (1- ¿
2∗th th 2∗Rm
Notations: RL = latitudinal radius of curvature, in in.
Rm= meridional radius of curvature, in in.
Calculating for, R L
D
Ri = =1500mm=59.05515 in
2
√ ( )
4 2
R L = R i + x 2 1− Ri
2 2
h h
25

Substituting the values,

Since the value of x is bounded by h≤ x ≥ Ri.
Let us take x=1000 mm=39.3701 in. Since it is between h=29.527575∈¿ and Ri=¿59.05515 ∈¿¿
√ ( )
4 2
R L= 59.05515i +39.37012 1− 59.05515i
29.5275752 29.5275752
RL=96.43665612 in
RL 3∗h
Rm= " ”
Ri 4
96.436656123∗29.527575
Rm=
59.055154
Rm=2.177324216 in
P d∗R L 435.114∗96.43665612
σ x= = =16994.8 psi
2∗th 2∗0.81003
P d∗RL RL 435.114∗96.43665612 96.43665612

σϕ = (1- ¿= (1− )
th 2∗Rm 0.81003 2∗2.177324216
σ ϕ=¿¿ -1095382.449 psi
∴As we observe from the result the negative sign shows the presence of compressive stress.
When we observe from the above three cases stress is maximum at the center of head. Now for
the design to be safe let us compare the maximum stress to the allowable or design stress.
-1095382.449 <34809.12psi
∴ Our design of head is safe.
Finally, the designed head 3D model will look like
26

4.8 Design of Nozzle (opening)

Presence All process vessels will have openings for connections, man ways, and instrument
fittings. Then of an opening weakens the shell, and gives rise to stress concentrations. The stress
at the edge of a hole will be considerably higher than the average stress in the surrounding plate.
To compensate for the effect of an opening, the wall thickness is increased in the region adjacent
to the opening. Sufficient reinforcement must be provided to compensate for the weakening
effect of the opening without significantly altering the general dilation pattern of the vessel at the
opening. Over-reinforcement will reduce the flexibility of the wall, causing a hard spot, and
giving rise to secondary stresses. There are three compensation for opening: welded pad; inset
nozzle; and forged ring.
Openings in pressure vessels in the regions of shells or heads are required to serve the following
purposes:
 Man ways for letting personnel in and out of the vessel to perform routine maintenance
and repair
 Holes for draining or cleaning the vessel
 Hand hole openings for inspecting the vessel from outside
 Nozzles attached to pipes to convey the working ﬂuid inside and outside of the vessel
Because of removal of material at the location of the holes, there is a general weakening of the
shell. The amount of weakening is of course dependent on the diameter of the hole, the number
of holes, and how far the holes are spaced from one another.
For vessels under internal pressure the wall thickness of opening necks shall not be less than the
thickness computed for the applicable loadings in UG-22 on the neck (Pressure, reaction of
piping, etc.), plus corrosion allowance.
4.8.1 Design of inlet opening pipe
27

Where external piping is connected to the vessel, the scope of the Code includes:
(a) The welding end conduction for the first circumferential joint for welded Connections.
(b) The first threaded joint for screwed connections.
(c) The face of the first flange for bolted, flanged connections.
(d) The first sealing surface for proprietary connections or fittings.
Shape of opening:
Openings in pressure vessels shall preferably be circular, elliptical or orotund .An
Orotund openings one which is formed by two parallel sides and semicircular ends.
The opening made by a pipe or circular nozzle, the axis of which is not perpendicular
To the vessel wall or head, may be considered an elliptical opening for design purposes.
Openings maybe of shapes other than the above.
Size of opening:
Properly reinforced openings are not limited as to size, but, when the opening in the
Head of a cylinder shell is larger than one half the inside diameter of the head, it is
Recommended to use in place of heads, shell reducer sections as shown in the Code
FigureUG-36, then the required nozzle wall thickness is given by
Table 3 inspections of opining (source pressure vessel hand book 10th edition)
Inside diameter of pressure vessel(in) Inspection opening required
Over 12 in less than 18 in I.D. 1

two-1 in pipe size threaded opening
2
28

18 in to 36 in. inclusive I.D. min. 15 in I.D manhole or two-2 in pipe size

threaded opening
Over 36 in. I.D. Min .15 in I.D man hole or two-6 in pipe size
hole
In our design we take the inlet and outlet pipe diameter di=6∈¿152 mm (6 inch from the table)
di 6
Rn= = =3 in
2 2
Pd∗Rn
tn = +C Equation nozzle thickness 152.4
E∗S−0.4 Pd
Where tn = thickness of nozzle in in.
Rn= internal radius of the nozzle in in.
S= Material stress in psi
E=Joint efficiency = 1
C = corrosion allowance in in.
435.114∗3
tn = +0.07086618
34809.12∗1−0.6∗435.114
tn=0.1086396561∈¿ 2.75944 ≈ 3 mm
4.8.2 Stress analysis for pipe hole
Longitudinal stress (𝜎L ):
29

Pi∗Rpipehole
𝜎L =
2× t n
435.114∗3
𝜎L=
2∗0.10864
𝜎L= 70.9 psi
The hoop (circumferential stress)
Pi∗Rpipehole
𝜎h =
tn
435.114∗3
𝜎h =
0.10864
𝜎h = 12015.298 psi
Since both longitudinal and circumferential stress less than the allowable or design stress
(34809.12 in) therefore our design is safe.
The required minimum thickness of nozzle for inlet pipe is given by:-
The outer diameter of nozzle is given by:-
d o =d +2 t n………..but d=d i +2C =6+2*0.07086618 =6.1417 in
= (6.14173236+2*0.1086396561) in
do =6.359in=161.51881mm≈ 162mm
d=6.14173236 in=155.999≈ 156mm
d i=6∈¿(Nozzle diameter)
D i=118.1103∈(3000mm)Diameter of vessel
(A=length out side shell)
L=C+t s+A (L=total length of nozzle)
C=Ri -√ ¿ ¿²) (C=inside length of nozzle)
C=59.05515-√ 59.055152−32 C=0.076in
L=0.076in+0.814633812 in+5 in= 5.89in
The required minimum thickness of nozzle for inlet pipe was found by
30

P d Rn d
trn = But, Rn =
E S−0.6 Pd 2
6.14173236 435.114∗3.07086618
Rn = =3.07086618 in trn =
2 34809.12∗1−0.6∗435.114
trn=0.038675896in
The required minimum thickness of shell is given by:-
Pd R Di 118.1103
tr = But, R = = =59.05515 in
E∗S−0.6 Pd 2 2
435.114∗59.05515
tr =
34809.12∗1−0.6∗435.114
tr=0.7437676322418
The horizontal and vertical limit are as follows;
Vertical limit
h = 2.5𝑡𝑠ℎ𝑒𝑙𝑙 = 2.5 ×0.814633812 = 2.03658453 in
h1 = 2.5𝑡𝑛 = 2.5 ×0.1085546222110 = 0.2713865555275 in ℎ𝑖𝑠 𝑜𝑛𝑒 𝑖𝑠 𝑡ℎ𝑒 𝑠𝑚𝑎𝑙𝑙𝑒𝑟 𝑠𝑜 𝐼𝑤𝑖𝑙𝑙

𝑡𝑎𝑘𝑒 𝑡ℎ𝑖𝑠 𝑜𝑛𝑒.
Horizontal limit;
𝑥1 = d =6.14173236 in
𝑥2 = 0.5d + 𝑡 + 𝑡𝑛 = 0.5 ×6.14173236 + 0.814633812 + 0.1086396561=3.994 in
𝑥2 = 6.14173236, 𝑠𝑖𝑛𝑐𝑒 𝑡ℎ𝑖𝑠 𝑜𝑛𝑒 𝑖𝑠 𝑙𝑎𝑟𝑔𝑒𝑟 𝑜𝑛𝑒 𝐼 𝑤𝑖𝑙𝑙 𝑡𝑎𝑘𝑒 𝑡ℎ𝑖𝑠 𝑜𝑛𝑒
Area of reinforcement required as:
A = d*tr
31

A= 6.14173236∗0.7437676322418 tr = Minimum required thickness of a

shell
A=4.568 in2
. Area available in the cylindrical shell
𝐴1 = (𝑡 −tr) d or A1=2(t+tn) (t-tr) use the largest
A1= (0.814633812-0.7437676322418) ¿ 6.14173236 =0.435241109 in2
A1=2(0.814633812+0.1086396561 ) (0.814633812-0.7437676322418) =0.131 in2
For safe design Largest of the two value A1=0.435241109 in2

Area available in outward nozzle wall –
𝐴2 = 5t (𝑡𝑛 − 𝑡r𝑛), =5¿ 0.814633812 ( 0.1086396561−0.038675896 )=0.284974∈¿2
A2=5tn (tn-trn) =5¿ 0.1086396561 ( 0.1086396561−0.038675896 )=0.038∈¿ 2
We take smallerA2=0.038∈¿2
Area available in inward nozzle
𝐴3 = 2 (tn-c) h1=2(0.1086396561-0.07086618 ¿∗0.2713865555275
A3=0.0205 in2
Area of weld
A4=2te2 where te=thickness of reinforcing pad (assume, teType equation here .=0.787402
in=20mm)
A4=1.24 in2
Area available in Reinforcing pad or element
A5= (Dp-d-2tn) te where, DP=2(Rn+tn+t)=2¿( 0.1086396561+3.07086618+ 0.814633812)
Dp=7.988≈ 8 in
A5=1.29191 in
32

 The Total available area of the reinforcement is :
∴ At = A1 + A2 + A3 + A 4+A5
At=0.435241109+ 0.038+0.0205+ 1.24+1.29191 in2
At=3.02565 in2
 We use two pipe holes the total area is At=6.0513 in2>Ar=4.568 in2 therefore the opening
is adequately reinforced for that reason our design is safe
4.8.3 Design of Circular Handhold

Since in our design we get smaller shell diameter 3m the hand hole should be used in order to do
some operations on the pressure vessel. We take the diameter of hand hole as 16 inch (0.4064m).
Then the wall thickness of the handhold can be calculated as follows:
We used low alloy steel to design the hand hole:
( PD∗Rhandhole)
thandhole =
(ᵟdE −0.6 PD)
Where PD =deign pressure (3Mpa)=435.114 in
D
Rhandhole=
2
16
Rhandhole= =8 in
2
S = Design stress for the materials of hand hole
=34809.12 psi
E =Joint efficiency factor (E =1)
( PD∗Rhandhole)
thandhole =
( SE−0.6 PD)
435.114∗8
thandhole =
(34809.12∗1−( 0.6∗3∗435.114 ) )
=0.1 in
Total thickness of the hand hole including the corrosion allowance calculated as follows:
thandhole= thandhole + C
= 0.1+0.07086618
=0.171 in
Where C=corrosion allowance
C= - where C=length of part of the nozzle entering to shell
33

di 3000
Ri = = =1500mm=59.05515 in where, di=internal diameter of shell
2 2
16
ri= =8 in where, ri= inlet nozzle diameter
2
C=59.05515-√ 59.055152−82
C=0.5in
L= C+ + length of part of the nozzle leaving the shell
L= 0.5in+ 0.814633786 in + 5 in
L=6.359 in
Area for the hand hole will be:

2
π D handhole
Ahandhole =
4
2
π 16
=
4
=201.06 in2
Ahandholes=201.06 in2
Stress analysis for hand hole
Longitudinal stress (𝜎L ):
Pi∗Rhandhole
𝜎L =
2× thandhole
435.114∗8
𝜎L=
2∗0.171
𝜎L= 10178.105 psi
The hoop (circumferential stress)
Pi∗Rhandlehole
𝜎h =
thandhole
435.114∗8
𝜎h =
0.171
𝜎h = 20356.21 psi
34

Since both longitudinal and circumferential stress less than the allowable or design
stress(34809.12 in) therefore our design is safe.
Figer 2D model nozzle
4.9 Design of bolts, nuts and Flanges
4.9.1 Design of Bolts
Bolt joints are one of the most common elements in construction and machine design. They
consist of fasteners that a capture and join other part and are secure with the mating of bolt joints
designs or screw threads.
There are two main type of bolted joint design:
1) Tension joint
2) Shear joint
In the tension joint the bolt and clamped component at the joint are designed to transfer the
external tension load through the joint by away of clamped component through the design of
proper balance of joint and bolt stiffness. The second type of bolted joint transfer the applied
load in a shear on the bolt shank and relies on shear strength of the bolt, tension loads on such
joints are only identically.
35

Use the following formula important to find the size and number of bolt.
Let D i = internal diameter of cylinder
D p = design pressure in the cylinder
d c = core diameter of the bolt
σ tb= permissible tensile stress of the bolt
n=number of bolt
From equation (2) the resisting force by the bolt
Here
we know that the upward face acting on the cylinder cover is:
π Di2∗D p
F=
4
This force is resisted by n number of bolt and the resisting force offered by n number of
bolts is
2
π dc ∗σ tb∗n
F R=
4
From equation (1) the upward force acting on cylinder cover is
π Di2∗D p
F=
4
= π∗¿ ¿
F=21205750.41 N
In our design we select the material for the bolt is low alloy steel. So, σ tb= 550N/mm2 the
core diameter is from the table by taking standard M36 Size.
Table 4 standard bolt dimension
36

Designation Pitch Major or Effective Minor or Minor or Depth of Stress

nominal core core
mm Or pitch Thread area
diameter diameter
Diameter
Diameter (bolt)mm mm2
(dc)mm (dc)mm
(d=D)mm
Nut and
Nut and bolt(dp)mm
bolt bolt Nut
(1) (2) (3) (4) (5) (6) (7) (8)
M 33 3.5 33 30.727 28.706 29.211 2.147 694
M 36 4 36 33.402 31.093 31.670 2.454 817
M 39 4 39 36.02 34.093 34.670 2.454 976
From the table we take d c=¿16.933 ¿mm
π dc 2∗σ tb∗n
F R=
4
2
π ¿ 31.093 ∗550 ¿n
F R=
4
F R =417616.66855909n since F= F R
21205750.411731
∴ n= =50.778=51
417616.66855909
Nominal or major diameter of nut and bolt (d=D) =36mm

Units: mm
NOMINAL BODY
HEAD THICKNESS ACROSS THE FLATS ACROSS CORNERS
SIZE (D) DIAMETER
D D H H F F (MIN) C C (MIN)
(MAX) (MIN) (MAX) (MIN) (MAX) (MAX)
m10 10.00 9.78 6.63 6.17 17.00 15.73 18.48 17.77
m12 12.00 11.73 7.76 4.24 19.00 17.73 20.78 20.03
37

m14 14.00 13.73 9.09 8.51 22.00 20.67 24.25 23.35

m16 16.00 15.73 10.32 9.68 24.00 23.67 27.71 26.75
m20 20.00 19.67 12.88 12.12 30.00 29.16 34.64 32.95
m24 24.00 23.67 15.44 14.56 36.00 35.00 41.57 39.55
m30 30.00 29.67 19.48 17.92 46.00 45.00 53.12 50.85
m36 36.00 35.61 23.38 21.63 55.00 53.80 63.51 60.79
m42 42.00 41.38 26.97 25.03 65.00 62.90 75.06 71.71
Table: 5 dimension measurement for bolt

Nomina Body diameter Head thickness Across the flats Across the corners
l size(D)
D(max) D(min) H(max) H(min) F(max) F(min) C(max) C(min)
M 36 36.00 35.61 23.38 21.63 55.00 53.80 63.51 60.79
38

Figure 2D bolt model
4.9.1.1 Stress Analysis of Bolt

F=21205750.41173N is the total force acted in the whole 36 bolts. Then in single bolts can be
calculated as follow
F T 21205750.41173
F i= = =¿415799.03N
n 51 bolts
Then we will calculate the stress on the bolt. Let us take standard bolt size of M 20
F i bolt π D 2i π 36 2
Stress on a bolt = but Abolt = = =1017.876 mm2
A bolt 4 4
415799.03 N
Stress on a bolt = =408.4967 MPa
1017.876 mm 2
The tensile strength of M 36 bolts is σ tb= 550N/mm2
Since408.4967 MPa <550MPa hence our design is safe.
The total length of bolt and thread length of bolt can be calculated as follows:
Lt =2 d+ 6 mm
Lt =2× 36+6 mm
Lthre =¿78mm
The total length of bolt and thread length of bolt can be calculated as follows:
Let us take 125<L< 200, d < 150mm letus take L=140mm
Lunthreaded =L−Lthreaded
Lunthreaded =(140−78) mm
Lunthreaded = 62mm
39

4.9.2 Design of Nuts

We select low alloy steel material to design nut the same as bolt flange joint because of easily
workable, better strength, low cost, good for construction, easy to shape.
By reading from the nut standard table we get:
 minor or core diameter of nut (d c ) =31.093 mm
 effective or pitch diameter of nut (d p ) =33.402 mm
 Nominal or major diameter of nut and bolt (d=D)=36mm
Figure 2D model nut
4.9.3 Design of Flanges

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. Flanges may also be used on the
vessel body, when it is necessary to divide the vessel into sections for transport or maintenance.
Flanged joints are also used to connect pipes to other equipment, such as pumps and valves.
Standard flanges will be specified for most applications. Special designs would be used only if
no suitable standard flange were available; or for large flanges, such as the body flanges of
vessels, where it may be cheaper to size a flange specifically for the duty required rather than to
accept the nearest standard flange, which of necessity would be over-sized.
4.9.3.1 Standard Flanges
Standard flanges are available in a range of types, sizes and materials; and are used extensively
for pipes, nozzles and other attachments to pressure vessels. The proportions of standard flanges
are set out in the various codes and standards. A typical example of a standard flange design is
shown below. The relevant British Standards are BS 1560, Part 3 and BS 4504, Part 3, which
cover flanges for pipes, valves and fittings; in carbon and alloy steels.
40

Figure 2D standard flange dimensions
Table 6 standard flange dimensions
Nominal Pipe o.d Flange Raised face bolting Drilling neck

size d1
D b H1 d4 f No d2 k d3 h2 r
900 914.4 1115 34 95 1005 5 M30 28 33 1052 950 20 12

1000 1016 1230 34 95 1110 5 M33 28 36 1160 1052 20 16
1200 1220 1455 38 115 1330 5 M36 32 39 1380 1255 25 16
1400 1420 1675 42 120 1535 5 M39 36 42 1590 1460 25 16
1600 1620 1915 46 130 1760 5 M45 40 48 1820 1665 25 16
1800 1820 2115 50 140 1960 5 M45 44 48 2020 1868 30 16
41

As we’re designing nut and the bolt and we have selected M 36 from standard size, and our
flange design parameters are selected from the above table that means
From the table standard flange we take the value at Nomi. Size 1200mm it gives the
values
Parameters
d1 d2 d3 d4 h b D f k Bolt
1220mm 39mm 1255mm 1330 115 38 1455mm 5mm 1380mm M36
4.10 Design of Vessel Support
Support:
The type of support that is used depends primarily on the size and orientation of the pressure
vessel. In all cases, the pressure vessel support must be adequate for the applied weight, wind,
and earthquake loads. Calculated base loads are used to design of anchorage and foundation for
the pressure vessels
 There are four type of support:

 Saddle support
 Skirt support
 Leg support
 Lug support
When designing a horizontal pressure vessel, a saddle support is more preferable than other
forms of support. We will also be using a saddle support for our design
In order to design a Vessel, support one should first determine the loads therefore before
we design the supports we will compute the loads.
The major sources of dead weight loads are:
1. The vessel shell.
2. The vessel fittings: man ways, nozzles.
42

3. Internal fittings: plates (plus the fluid on the plates); heating and cooling coils.
4. External fittings: ladders, platforms, piping.
5. Auxiliary equipment which is not self-supported; condensers, agitators.
.As result of those factors mention above the total weight would be
W t =W v +W h +W f Where:- W v , is weight of vessle
W h , is weight of head
W f , weight of the fluid
Since our arrangement is horizontal and the effect of wind loading is small, we do not take wind
load in effect. The weight of the vessel and fittings can be calculated from the preliminary design
sketches. The weights of standard vessel components: heads, shell plates, man ways, branches
and nozzles, are given in various handbooks. For preliminary calculations the approximate
weight of a cylindrical vessel with domed ends, and uniform wall thickness, can be estimated
from the following equation
−3
W v =C v πρ m D m g ( H v +0.8 Dm ) t∗10
Where
W v = total weight of the shell, excluding internal fittings, such as plates, N,
Cv = a factor to account for the weight of nozzles, man ways, internal supports, etc. which can be
taken as
=1.08 for vessels with only a few internal fittings,
= 1.15 for distillation columns, or similar vessels, with several man ways, and with
plate support rings, or equivalent fittings,
43

Hv = height, or length, between tangent lines (the length of the cylindrical section), m,
g = gravitational acceleration, 9.81 m/s
t = wall thickness, mm
ρm = density of vessel material, kg/m3
D m = mean diameter of vessel = ( D i +t∗103) m.
For a steel vessel, the weight of vessel reduces to:
W v =240 C v D m g ( H v + 0.8 Dm ) t . Then since our material is low alloy steel we use this formula to
calculate weight. But before weight calculation we need to find the mean diameter.
Dm =( D i +t∗10−3 )
D m =( 3+0.020691687 )
D m =3.02m
In our design we take the C v value as 1.08. And we are have length of vessel =17m
W v =7850∗1.08∗3.02∗9.81 ( 17 m+0.8∗3.02 m)∗0.02069168766 m
W v =¿100907.867¿ π N=317011.4137N=317.011KN
Then calculating for the weight of the head W h
kg
W h =ρgVh Since the head is low alloy steel we obtain the density=7850 3
m
π di3 π∗3 3 kg
Vh= = =2∗7.068583471m3 where, ρm=7850
12 12 m3
W h =7850× 9.81 ×2∗7.068583471
44

W h =1088682.0 N =1088.682KN
Then calculating for the weight of the fluid W f which is the maximum of all weight
mf
W f =mf∗g Since ρ f = then
vf
W f =v f ∗ρf ∗g Where: - v f =volume of the fluid =127.2345m3
ρ f =density of fluid =1000kg/m3
g= gravity =9.81m/s2
To calculate the weight of the fluid or in our case water
Now we can calculate weight of the fluid
W f =v f∗ρf ∗g
Wf = 127.2345 * 1000 * 9.81
W f =1248170.445 N
W t =W v +W h +W f
W t =317011.4137 N +1088682.0 N + 1248170.445 N
W t =2653.863 KN is thetotal weight
Where: - Q= load on one side
R= radius of the shell
S= stress
45

t s= wall thickness of shell
t h=wall thickness of head
K=constant
θ =constant angle of saddle
We know that our total weight is 2653.863 kN .so
WT
Q= Number of support in our design case is 3
3
2653.863 KN
Q=
3
Q=884.621KN
Figure Standard saddle steel dimensions

Table 7 standard saddle steel dimensions (source Coulson & Richardson. Chemical engineering
volume 6)
46

Vessel Maximum Dimension(m) mm

diameter(m) weight(KN)
V Y C E J G t2 t1 Bolt Bolt
diameter holes
3 1750 1.68 0.25 2.64 1.18 0.665 0.150 16 12 27 33
3.2 2000 1.78 0.25 2.82 1.26 0.730 0.150 16 12 27 33
The saddles must be designed to withstand the load imposed by the weight of the vessel and
contents. They are constructed of brick or concrete, or are fabricated from steel plate. The
contact angle should not be less than120 °, and will not normally be greater than150 °. Wear
plates are often welded to the shell to the shell wall to reinforce the wall over the area of contact
with the saddle.
Thin welded vessel with average diameter is best supported near the head so as to utilize the
stiffing effect of the head. Long thick welded vessel are best supported where the maximal
longitudinal bending stress as the mid span. This point varies with the contact angle of saddles.
The distance between the head tangent line and the saddle shell is no case be more than 0.2time
the length of the vessel( L )
4.10.1 Longitudinal Bending Stress

Contact angle(θ)Contact angle suggested by the ASME (Association Society of Mechanical
Engineering) is120 °, for very small vessel.
Using as the contact angle we get the values of constants as follows
K1= 0.335 K2= 1.171
K3= 0.319 K4= 0.880
47

K5= 0.401 K6= 0.013
K7= 0.760 K8= 0.603
A= 0.2 * L = 0.2 * 17m = 3.4 m

H = Di/4 = 3/4 = 0.75 m
K1=0.335
( )
2 2
A R −H
1− +
L 2 AL
QA 1−
4H Equation, longitudinal bending
1+
3L
S1=± 2
K R ts
( )
2 2
3.4 1.5 −0.75
1− +
17 2∗3.4∗17
884.621 KN∗3.4 1−
4∗0.75
1+
3∗17
S1=± 2
0.335∗1.5 ∗0.02069168766
( )
2 2
3.4 1.5 −0.75
1− +
17 2∗3.4∗17
3007.7 KN . m 1−
4∗0.75
1+
3∗17
S1=±
0.0155963595737
S1=±
3007.7 KN . m 1− (
0.81459775
1.0588235294117 )
0.0155963595737 m3
S1=± 44481.645 kpa =6451.53 psi
Stress at mid span (center)
48

( )
R 2− H 2
1+2 2
QL L 4A
−
4 4H L Equation, longitudinal bending at mid span
1+
3L
S1=±
π R2 t s
( )
2 2
1.5 −0.75
1+2 2
884.621 KN∗17 m 17 4∗3.4
−
4 4∗0.75 17
1+
3∗17
S1=±
π 1.52∗0.02069168766
3759.639 ( 0.0562−0.8 )
S1=±
π 1.52∗0.02069168766
S1=−41.441 KPa =-0.04144Mpa=-6.01 psi
In order for the saddle to not fail the stress due to internal pressure (PR/2ts) plus S1 shall not
exceed the allowable stress value of shell material.
-6.01+31542.66636 Psi =31536.7 psi <34809.12 psi

⸫ the design is safe to proceed
4.10.2 Tangential Stress
Since A> R/2 3.4>1.5/2 we choose the following formula
Since our saddle is away from load we use the following formula
( )
K 2 Q L−2 A
S2 = Equation, Tangential stress in shell
R t s L+4 / 3 H
Taking from the above table K 2=1.171
49

( )
1.171∗884.621 KN 17−2∗3.4
S2=
1.5∗0.02069168766 4
17+ ∗0.75
3
S2=33375.437 KN /m2∗0.566666
S2=18912.7 KPa =18.912Mpa=2743.06psi
In order for the saddle not to fail the value of S2 should be less than 0.8 times the allowable stress
value of vessel material.
0.8 *34809.12 psi = 27847.296 psi
2743.06psi <27847.296 psi
⸫ the design is safe to proceed.
4.10.3 Circumferential Stress

At the horn of the saddle L>8R 17>8¿ 1.5 we use this formula
−Q
S4 = Equation Circumferential stress at horn of saddle we take
4ts ¿¿
k6=0.013 and b= the length of saddle from the side=0.25m
−884.621 KN 3∗0.013∗884.621 KN
S4 = −
4∗0.02069168766(0.25+0.0395335798135) 2∗0.020691687662
−884.621 KN
S4 =
4∗0.02069168766 ¿ ¿
−884.621 KN
S4 = −43117.657677175 KPa
0.043438685
S4 =22752.83768Kpa=22.75283768Mpa=3300.026psi
50

In order for the saddle not to fail the S4 shall not exceed 1.5 times the allowable tensile stress
value of shell material.
1.5*34809.12 psi=52213.68 psi
3300.026psi<52213.68 psi
⸫ the design is safe to proceed
Stress at the bottom of the shell
−K 7∗Q
S5 =
ts¿ ¿
−0.760∗884.621 KN
S5=
0,02069168766 ¿ ¿
−672.312 KN
S 5=
0.010859671 m2
S5=−61909.057883 Kpa=−61.91 Mpa=−8979.16593 psi
In order for the saddle not to fail shall not exceed the compression yield point of shell material?
-8979.16593 Psi < 32809.12 psi
o The design is safe to proceed.
51

Figure 2D model saddle
4.11 Design of Welding

There are several methods to make welded joints. In a particular case the choice of a type
from the numerous alternatives depend on:
 The circumstances of welding
 The requirements of the Code
 The aspect of economy
1. The circumstance 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 place. In larger diameter vessels if a man-way is not
used, the last (closing) joint can be welded from outside only. The type of welding may be
determined also by the equipment of the manufacturer.
2. Code requirements.
52

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.
3. The economy of welding,
If the two preceding factors allow free choice, then the aspect of economy must be the
deciding factor. Some considerations 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 increasing in direct
proportion, while the deposited weld metal increasing with the square 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.
4.11.1 Selection of Welding

 Shell to shell and welded Head connection: for this kind of connections Category A
butt welding is recommended.
 Head to shell connections: for this kind of connections Category B butt welding is
recommended.
 Openings and flange: for this kind of connections Category B butt welding is
recommended.
 Support: for support and support to vessel connection use E80XX electrode and for all
contacting edges fillet welding is recommended.
4.11.2 Stress Analysis for Welding

 Stress of welding shell to head connections
The force of design pressure
Pi∗π 2
F D =PD∗Ai = ∗Di
4
where PD =3 MPa=435.114 Psi
53

D i= (3000) mm118.1103 in
Pi∗π 2 3∗π 2
F D =PD∗Ai = ∗D i = ∗3000 =21205.75 KN
4 4
The resisting force weld is
σ w∗π 2
F R =σ w ∗A w = ∗( D o ¿¿ 2−Di )¿
4
Where σ w =¿welding stress
Do=outside diameter of shell =Di+2t

Do=3041.383375mm=119.7395676 in
Do=3041.383375≈ 3042 mmmm
Di=3000mm
Aw=welding area
σ w∗π 2 2
F R =σ w ∗A w = ∗(3041.38 −3000 )=196343.5 σ w
4
Let FD=FR,
21205.75 KN =196343.5 σ w
Thus, σ w =108 MPa<240 MPa , the design is safe .

 Stresses of Welding of nozzle to shell
The force on the design pressure is.
P D∗π 2
F D =Pi∗Ai = ∗d i
4
54

Where di=internal diameter of nozzle=152.4mm=6in

Pd=design pressure
do =6.359in=161.51881mm≈ 162mm
P D∗π 2 3∗π 2
F D =Pi∗Ai = ∗d i = ∗( 152.4 ) =54724.41 N
4 4
The resisting force weld is
σ w∗π 2
F R =σ w ∗A w = ∗(d o ¿¿ 2−d i )¿
4
Where σ w =stress∈the weld
Let FD=FR , A w =Area of welding around the weld
σ w∗π 2
F R =σ w ∗A w = ∗( 161.52¿ ¿ 2−152.4 )=2248.6 σ w ¿
4
Let FD=FR
54724.41 N =2248.6 σ w
Thus, σ w =24.337 MPa<240 MPa , the designis safe .
 Stresses of Welding of Saddle support

Let take E80XX electrode with the following specification: Sut = 551 MPa
Sy = 462 MPa
nd = 1.5
Where: Sut = Ultimate strength

Sy = Yield strength
nd = design factor
3
From this since t is less than 38.1mm we select h= ∗t , ¿ table at shigley .
8
Thus, find AL, area
55

0.707∗3 0.707∗3
A L= ∗t∗D i2= ∗( 20.69168766∗10−3 )∗3 2=0.05 m2
8 8
Next find normal stress:
F 2653.863 KN
σ= = =53077.26 kPa=53.07726 Mpa
AL 0.05m 2
The allowable normal stress is for butt – fillet welding.

σ all=0.6∗S y =0.6∗462 MPa=277.2 MPa
From this we can conclude σ all >σ . so the factor of safety

σ all 277.2
n y= = =5.2
σ 53.07726
Thus, n y > nd means 5.2>1.5 ,
Therefore the design is safe.
4.12 Cost Analysis
Any design when he or she design a new material the cost analysis is the basic objective in the
design. The cost material most the of the packing is pound on dollar prices .It is the total amount
of money and man power which is used or consumption during manufacturing of horizontal
pressure vessel. Basic costs we spend in manufacturing are:-
 Material cost
 Labor costs Machine costs
In our pressure vessel design the shell, head is made of low alloy steel and support is made up
of carbon steel.
The cost is given by $/ton.
Table 8 cost of the material given by $/ton

Material $/ton
56

Low alloy steel 800

Carbon steel 500
I Material cost
The total cost of pressure vessel materials that are:
Shells
Head
Opening
Nozzle
Support
4.12.1 Cost Analysis of Shell
W=317.011KN
Since W=mg
m=32315.0866kg
m=32315.0866kg, m=32.3150866ton where 1ton=1000kg
Low Alloy Steel Price -$ 800/ton (40,720ETB/ton)
1ton=$800
32.3150866ton=?
Cost of shell then we can change its dollar value in to birr by using relation 1 dollar=50.9 birr.
800∗32.3150866
Cost of shell= =$25852.1
1
Cost of shell=1315871.89ETB
4.12.2 Cost Analysis of Head
W=544.341KN
Since W= mg
m=55488.38kg
m=55488.38 kg, m=55.48838ton
1ton=$800
55.48838ton =?
800∗1.867761
Cost of head= =$44390.7
1
Cost of head=2259486.8336 ETB
We have two head
Cost of head=2×2259486.8336 =4518973.6672 ETB
4.12,3 Cost Analysis of Nozzle (opening)
Pipe hole
W=25.6N
Since W= mg
m=2.6073 Kg
57

m=2.6073kg m=0.00261ton
1ton=$800
0.00261ton
Cost pipe hole=2.08583$=106.1687ETB
We have two pipe holes
Cost pipe hole=2×106.1687=212.337ETB
Hand hole
W=162.35N
Since W=mg
M=16.55kg m=0.01655ton
1ton=$800
0.01655ton?
800¿0.01655/1
$13.24
673.91ETB
We have two hand holes
Cost hand hole=2×673.91=1347.82ETB
Cost of nozzle=212.337ETB+1347.82ETB=1560.16ETB
4.12.4 Cost Analysis of Support
𝜌𝑐𝑎𝑟𝑏𝑜𝑛𝑠𝑡𝑒𝑒𝑙=7.85 g/cm3 =7850kg/m3
v=w × d × L=2.64×1.68×0.25=1.1088m3
m=ρ × v=7850×1.1088=8704.08kg=8.704ton
Carbon steel price
1ton=$500
8.70408ton =?
500∗8.70408
Cost of support= =$4352.04
1
Cost of support=221518.836ETB
We have three saddle support used
So cost support=3×221518.836ETB=664556.508ETB
Cost of other material
Cost of other material is like welding, labor, ladder and other assistants to o be pressure vessel be
2000$
Cost of other material=101,800ETB
The total cost of the pressure vessel is the summation of all the above value.
Cost of pressure vessel=cost of shell+ cost of head + cost of nozzle + cost of support + cost of
other material
Cost of pressure vessel = 1315871.89+4518973.6672
+1560.16+664556.508+101,800
58

Cost of pressure vessel =6602762.225 birr

3D Part Drawing
1.Shell
Figure 3D cylindrical shell
2, Head
Figure 3D model head
59

3,Nozzle
Figure 3D Model Nozzle
4.Flange
Figure 3D Model Flange
60

5.Saddle
Figure 3D Model Saddle
Assembly Drawing of Horizontal Pressure Vessel
Figure 3D Model Assembly
61

CHAPTER FIVE
5. Results and Discussions

5.1 Results
Table 5.1 Project results
Part Quantity Dimensions
Shell 1 Di=3000mm
Do=3041.38mm
ts=20.692≈ 21 mmmm
Dm=3020mm
Ls=17m
Head 2 Di=3000mm
th=20.57475≈ 21mm
Do=3041.15mm
Ho=760.3mm
Hi=750mm
Openings 2 hand-holes Hand hole
Di = 406.39978mm =16 in
tn = 0.1 in=2.54 mm
H = 6.359 in =161.5185mm
2 pipe holes pipe hole
Di = 152.4mm=6 in
tn = 0.1086 in 2.758mm
H = 5.891in =149.63mm
Bolt Flanged Joint 51 M 36
dc=31.093mm
Threaded part=78mm
Unthreaded part=62mm
D=d=36mm
Nut 51 dc=31.093mm
dp= 33.402mm
(d=D)= 36mm
Flange 4 M 36 D=1455mm
d1=1220mm h=115mm
62

d2=39mm f=5mm
d3=1255mm k=1380mm
d4=1330mm b=38mm
Saddle support 3 Vessel diameter=3m t2=16mm
V=1.68 m t1=12mm
Y=0.25m
C=2.64m
E=1.18m
J=0.665m
5.2 Discussions
In this pressure vessel design project we have designed Pressure vessel for water storing
application a total inside volume of (V=127.2345m3). In this project we have designed shell,
head, inlet and outlet nozzle, bolt flanged joint, flange, hand hole ,pipe hole and vessel support
.All of these components are designed by using appropriate formulas for each and their factor of
safety are checked for strength to avoid failures.
When we compare this pressure vessel with the previous pressure vessel as much as possible this
design of pressure vessel try to consider all failures, which can be occurred on, pressure vessel.
In addition, try to solve this problem to the minimum position.
CHAPTER SIX
6. Conclusion and Recommendation

6.1 Conclusion
We have successfully designed the horizontal pressure vessel with data’s administered to us by
our Instructor. We have analyzed the stability and strength of the pressure vessel under different
mechanical conditions; stresses (hoop, longitudinal and others), loads (dead weight of Pressure
vessel and fluid, wind load). From the analysis, we have concluded that if a pressure vessel is
manufactured for the conditions administered to us using our results, it can surely be a success.
In addition, of course we assure the pressure vessel is safe.
6.2 Recommendation
From the result we obtained we can recommended several points. When we are designing
horizontal vessel we allowed that the pressure vessel has a volume of 127.2345m3 of water.
63

Since these is small relatively the diameter as well as thickness of the vessel is also small.
However, such too small value obtained in analysis is can be over dimensioned and design it to
get acceptable vessel. However, when we see this in economical point of view, there is wastage
of economy for extra material involvement. Different source we used are not internationally
uniformed so selection of them and used in calculation are challenging requires critical thinking.
REFERENCE
[1] Pressure vessel design manual third edition by Dennis R. moss.
[2] R.S. Khurmi and J.K. Gupta, A Text Book of Machine Design, Fourteenth Edition
[3]MahidaAbhiraj (130450119043), Mehta Divyang(130450119047),Bharuch
ShriSa’dVidyaMandal Institute Of Technology Bharuch
[4] www.wikipedia
[5]pressure vessel design and practice 2 , somnath chattopadhyay
[6] Pressure vessel design manual third edition by Dennis R. moss.
[7]www.volvo.com
[8]https://d2t1xqejof9utc.cloudfront.net/screenshots/pics/
dee30d427a475446b58a7798e949c084/large.jpg
[9] www.wikipedia
[9] M.A Khan, “Stress distribution in horizontal pressure vessel and saddle
supports”, International Journal of Pressure Vessels and Piping, 87 (2010).
[10] Chi rag H. Panchigar, Vijay Parekh“A Review Paper on Design and Analysis of Pressure
Vessel” Afro - Asian International Conference on Science, Engineering & Technology, 2015
[11]Prof.Sha Husain S.Maghrabi, “Elastic behavior of Cylindrical Vessels with Lateral Nozzle
under internal pressure”, Vol. 2, Issue 1, Jan-Feb 2012, pp. 1029-1034.
[12] M. Jeyakumar, T.Christoper, “Influence of residual stresses on failure pressure of
cylindrical pressure vessel”, Chinese journal of aeronautics, (2013).
[13] M. Giglio, “Fatigue analysis of different types of pressure vessel nozzle”, revised 19
November 2002; accepted 20 November 2002.
64

[14] Pallavi Pudke, Prof. S. B. Rane, “Design and Analysis of Saddle Support: a case study in
vessel Design and Consulting Industry”, International Journal of Mechanical Engineering and
Technology (IJMET) Vol. 4, Issue 5, Sept-Oct 20
Appendices
Appendix A: material properties
Adapted from coulson & Richardson’s, chemical engineering, volume 6
Appendix B: Charts
65

Adapted from Eugene F. Megyesv, pressure vessel handbook, Eleventh Edition
66

Chart for determining constant K6
67

Appendix C: Constant Tables
68

Appendix D: Design dimension of screw thread, bolts and nuts according to IS:4218 (part III)
1976 (Reaffirmed 1996)
69

70

71

72

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UNIVERSITY OF GONDAR

[UNFIRED HORIZONTAL PRESSURE VESSEL DESIGN]

Project done by:

Mechanical and Engineering, Institute of Technology, University of Gondar, Ethiopia

NAME: Shemels Belayneh Signature: ____ _____

NAME: Getachew Setargew Signature: __ _______

TITLE OF THE DESIGN PROJECT: Unfired Horizontal Pressure Vessel

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

CONTENTS OF THE PROJECT WORK

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Methodology of project work..................................................................................................15

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

4.12,3 Cost Analysis of Nozzle (opening)............................................................................61

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Figure: 2D cylindrical shell model……………………………………………………..21

Figure: 2D model Bolt………………………………………………………………….37

Figure :2D model nut……………………………………………………………………39

Figure :2D standard flange dimensions…………………………………………………….40

Figure: Standard saddle steel dimensions……………………………………………………45

Figure :2D model saddle……………………………………………………………………. 50

Mechanical Engineering Department, Institute of Technology, University of Gondar, Ethiopia

Mechanical and Engineering, Institute of Technology, University of Gondar,Ethiopia

Abbreviations and Acronym

Mechanical and Engineering, Institute of Technology, University of Gondar,Ethiopia

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

a) Cylindrical geometrical shapes

a) Horizontal pressure vessel:

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

c) Spherical pressure vessel:

According to the materials:

The pressure vessels are according the material classified as

According to the direction of force acting on the wall of vessels

a) Subjected to internal pressure

c) Subjected to external pressure

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

According to the temperature

1) Normal temperature vessel -20

2) Medium temperature vessel is between normal temperature and high temperature

3) Low temperature vessel

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

 There are four types of support:

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Horizontal drums typically supported at two locations by saddle support.

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

1.3. Problem of the Statement

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

1.6. Organization of Project Work

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

3. Methodology of project work

Methodology of project work

Design procedure of shell

Design procedure of heads

Mechanical Engineering Department Institute of Technology, University of Gondar, Ethiopia

Design procedure of openings

Design procedure of saddle support

3. Detail drawing of the main parts and assembly.

4.Analyses and solutions of project work

NAME: Shemels Belayneh Signature: _

NAME: Getachew Setargew Signature: _____