UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL

ENGNEERING

DEPARTMENT OF INDUSTRIAL ENGINEERING

DESIGN OF HORIZONTAL PRESSURE VESSEL

PROJECT BY

NAME ID NO

MEKDELAWIT TEWODROS 03674/11

MEKETE NIGAT 03056/11

SELAM BIRUK 03099/11

Instructor: Mr.Andebet

Academic year: Mar,2022

Acknowledgement

First, we would like to give great gratitude to our almighty GOD for Every opportunity that
we got in life through his endless mercy. We would like to give special thanks for our
Instructor Mr. ANDEBET for his willingness to advices, comment and support us during the
whole project and makes us to be well coordinated and be on time. Then we would like to
express our sincere appreciation for all individual who invested their time, energy and
resources to help us.

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Abstract

In this project we have try to see about the design of horizontal pressure vessel. We have
discussed in five chapters. In chapter one we tried to explain about the background history
and make brief explanation on pressure vessel; chapter two includes literature review and
chapter three is focus on the detailed design analysis of a pressure vessel basis on several
design consideration. Starting from the proper material selection for components of the
pressure vessel to Geometrical analysis (head, shell, nozzle...), wind load analysis, and stress
analysis are conducted on this design to check the safety of our design using some standard
tables and standard machine element components. After all, dimensions and materials are
decided which fits for the given design specifications. On the last two chapters four and five
shows the result, discussion conclusion and recommendation

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Table of Contents
DESIGN OF HORIZONTAL PRESSURE VESSEL ........................................................... 1
CHAPTER ONE ...................................................................................................................... 1
1.1Introduction .................................................................................................................................... 1
1.2 Background of pressure vessel ...................................................................................................... 2
1.3 Statement of the problem .............................................................................................................. 3
1.4 Objective of the project ................................................................................................................. 4
1.4.1 Main objectives..................................................................................................................... 4
1.4.2Specific objectives ................................................................................................................. 4
1.5Scope and limitation of the study................................................................................................... 5
1.5.1Scope of the project ............................................................................................................... 5
1.5.2 Limitations of the project .................................................................................................... 5
1.6 Significance of the project ............................................................................................................ 5
1.7 Methodology ................................................................................................................................. 5
CHAPTER TWO ..................................................................................................................... 7
2.1 Definition of pressure vessel ......................................................................................................... 7
2.3 Classification of pressure vessels .................................................................................................. 8
2.3.1 According to the material .................................................................................................... 8
2.3.2According to the dimension.................................................................................................. 9
2.4 Component of pressure vessels ................................................................................................... 10
2.5Application of pressure vessel ..................................................................................................... 17
CHAPTER THREE ............................................................................................................... 18
3.1Detailed Design and Analysis ...................................................................................................... 18
3.2General design specification ........................................................................................................ 18
3.3 Material selection ........................................................................................................................ 18
3.4 Design pressure ........................................................................................................................... 19
3.5 Design temperature ..................................................................................................................... 20
3.6 Design of Shell............................................................................................................................ 20
3.6.1Stress Analysis For The Shell ............................................................................................. 23
3.7 Design of head ............................................................................................................................ 24
3.7.1 Stress analysis of ellipsoidal head ..................................................................................... 25
3.8 Design of Nozzle and Reinforcement ......................................................................................... 26
3.9 Design Manhole .......................................................................................................................... 29
3.10 Design of Support ..................................................................................................................... 31
3.11Dead weight of vessel and contents ........................................................................................... 32

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 3.11.1Weight of the shell ............................................................................................................. 33
3.11.2 Weight of head.................................................................................................................. 33
3.11.3Weight of Nozzle................................................................................................................ 34
3.12Wind loading.............................................................................................................................. 35
3.13 Design Flange (Standard flanges) ............................................................................................. 37
3.14Design of bolted and nut flange joints ....................................................................................... 38
2D assembly drawing ........................................................................................................................ 40
3.16 3D Design of the Model ............................................................................................................ 41
3.17 Cost analysis for the components.............................................................................................. 43
3.17.1Cost of Shell ....................................................................................................................... 43
3.17.2cost of head ........................................................................................................................ 44
3.17.4 Cost of the longitudinal and lateral material of the nozzle .......................................... 44
CHAPTER FOUR.................................................................................................................. 46
4.1Result and discussion ........................................................................................................ 46
4.1.2Result.................................................................................................................................... 46
4.2 Discussion ................................................................................................................................... 48
CHAPTER FIVE ................................................................................................................... 50
5.1Conclusion and Recommendation ............................................................................................... 50
5.2 Recommendation ........................................................................................................................ 50
Bibliography ........................................................................................................................... 51
APPENDIX A ......................................................................................................................... 52
APPENDIX B ......................................................................................................................... 53
APPENDIX C ......................................................................................................................... 54
APPENDIX D ......................................................................................................................... 55

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List of Figure

Figure 1. 1Horizontal pressure vessel [4] ............................................................................................... 1

Figure 2. 1vessel head at different cross section [2] ............................................................................. 11

Figure 2. 2Types of Nozzles [2]............................................................................................................ 11
Figure 2. 3Skirt Support [2] .................................................................................................................. 12
Figure 2. 4Leg Support [2].................................................................................................................... 13
Figure 2. 5Saddle Support [2] ............................................................................................................... 13
Figure 2. 6Lug Support [2] ................................................................................................................... 14
Figure 2. 7Welding-neck flange [2] ...................................................................................................... 15
Figure 2. 8Slip-on flange [2] ................................................................................................................. 15
Figure 2. 9Lap-joint flange [2].............................................................................................................. 16
Figure 2. 10Screwed flange [2] ............................................................................................................. 16
Figure 2. 11Blind flange [2].................................................................................................................. 16

Figure 3. 1Cylindrical shell [4] ............................................................................................................. 20

Figure 3. 2 2D drawing of shell ............................................................................................................ 24
Figure 3. 3 2D drawing of head ............................................................................................................ 25
Figure 3. 4nozzles [2] ........................................................................................................................... 27
Figure 3. 5 2D drawing of saddle support ............................................................................................. 32
Figure 3. 6 Flange [2]............................................................................................................................ 37
Figure 3. 7 2D drawing of flange .......................................................................................................... 38
Figure 3. 8 2D drawing of bolt.............................................................................................................. 40
Figure 3. 92 D assembly drawing ......................................................................................................... 40
Figure 3. 10 3D shell Drawing .............................................................................................................. 41
Figure 3.11 3D drawing of head ........................................................................................................... 41
Figure 3. 12 3D drawing of flange ........................................................................................................ 42
Figure 3. 13 3D drawing of saddle support ........................................................................................... 42
Figure 3. 14 3D drawing of bolt............................................................................................................ 42
Figure 3. 15 3D drawing of nut ............................................................................................................. 43
Figure 3. 16 3D assembly drawing ....................................................................................................... 43

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List of Table

Table 3. 1.Given specification data ...................................................................................................... 18

Table 3. 2 The value of (L/D) by corresponding value of pressure [2]................................................. 21

Table 4. 1Result of Shell……………………………………………………... 46

Table 4. 2Result of Head .................................................................................... 46

Table 4. 3Result of Nozzles and openings .......................................................... 46

Table 4. 4 Results in manhole ............................................................................. 47

Table 4. 5Results of bolted and nut flange joints ............................................... 48

Table 4. 6Results of dead weight of vessel and contents ................................... 48

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Abbreviations and Nomenclature

P i = internal pressure

PD = design pressure

σd = design stress

σH = hoop stress

σL = longitudinal stress

C = corrosion allowance

E = joint efficiency

Ri = internal radius of shell

ts = thickness of the shell

th = thickness of head

tn = minimum thickness of nozzle

trn = required minimum thickness of nozzle

trs = required minimum thickness of shell

L = length of vessel

Ls = length of shell

Ln = length of nozzle

Di = internal diameter of shell

Do = outer diameter of shell

Dm = mean diameter of shell

vs = volume of shell

Hi = inner head

Ho = outer head

K = stress intensity factor

vh = volume of head

RL = latitudinal radius of curvature

Rm = meridional radius of curvature

h= depth of head

di = inner diameter of inlet nozzle

do = outer diameter of inlet nozzle

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Ar = reinforcement area

dc = core diameter of the bolt

σtb = permissible tensile stress the bolt

ρm = density of material

ρf = density of fluid

ws = weight of shell

wn = weight of nozzle

wh = weight of head

wv=weight of shell

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 CHAPTER ONE

1.1Introduction
The pressure vessels (i.e. cylinders or tanks) are used to store fluids under pressure. The fluid
being stored may undergo a change of state inside the pressure vessel as in case of steam
boilers or it may combine with other reagents as in a chemical plant. [1]

Pressure vessels are enclosed containers used to hold liquids, vapors, and gases at a pressure
significantly higher or lower than the ambient pressure. They are widely used in various
industries such as petrochemical, oil and gas, chemical, and food processing industries. It’s
any structure such as pipes, barrels, bottles or any walled container that is capable of holding
pressure. [2] [1]
Vessels can theoretically be almost any shape, but shapes made of sections of spheres,
cylinders, and cones are usually employed. A common design is a cylinder with end caps
called heads. Head shapes are frequently either hemispherical or dished (tori spherical). More
complicated shapes have historically been much harder to analyze for safe operation and are
usually far more difficult to the pressure vessels to store fluids under pressure. The fluid
being stored may undergo a change of state inside a pressure vessel as in case of steam boiler
or it may combine with other reagents as in a chemical plant. [3]
A pressure vessel is not an easy structure. Actually, it is characterized by a regular and simple
shape but requires special care, especially when modern approach to structural design is
concerned.

Figure 1. 1Horizontal pressure vessel [4]

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Vessels, tanks and pipelines that carry, store or receive fluids are called pressure vessel. 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
situations.
Pressure vessel is often a combination of high pressure and high temperature and in some
cases flammable fluids or high radioactive materials. In addition, these vessels have to be
designed carefully to cope with the operating temperature and pressure. The pressure vessel is
designed with great care because rapture of a pressure vessel means an explosion which may
cause loss of life. [3]

1.2 Background of pressure vessel

The design of pressure vessels dates back to the 15th century it is believed that the first proper
design for pressure vessel was made by Leonardo Davin chi in 1495. In his codex Madrid I
paper Leonardo tried to show that tanks felled with air submerged under water can be used to
lift very heavy weights he called his invention Leonardo’s pressurized bags of air [5]
In an early effort to design a tank capable of withstanding pressures up to 10,000 psi (69 Mpa),
a 6-inch (150 mm) diameter tank was developed in 1919 that was spirally-wound with two
layers of high tensile strength steel wire to prevent sidewall rupture, and the end caps
longitudinally reinforced with lengthwise high-tensile rods. [2]

Also, in 1870 building of pressure vessels began by making boilers for the British admiralty,
were manufactured from riveted steel plates (boilerplate). The idea and requirement for the
pressure vessel code came in the ninetieth century after a major failure on a pressure vessel
then called boilers. [4]

Numerous boiler explosions took place through the late 1800s and early 1900s. This led to
the enactment of the first code for construction of steam boilers by the Commonwealth of
Massachusetts in 1907. This subsequently resulted in the development and publication of the
ASME Boiler and Pressure Vessel Code in 1914, which sought to standardize the design,
manufacturing, and inspection of boilers and pressure vessels. [6]
In 1921 the National Board of Boiler and Pressure Vessel Inspectors was organized to
promote consistent inspection and testing. The publication of the section on locomotive
boilers also appeared in 1921. The ASME and the ASTM (American Society for Testing and
Materials) material specification merged in 1924. [6]

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The year 1928 saw the advent of welded pressure vessels. For higher pressures the welded
shells were made thicker than 70 mm. These required nondestructive examination (NDE)
before service. In 1934, a joint API–ASME Committee published the first edition of an
unfired pressure vessel code specifically for the petroleum industry. In 1952 these two
separate codes merged into a single code – the ASME Unfired Pressure Vessel Code, Section
VIII. The ASME Pressure Vessel Code, Section VIII Division 2: ‘‘Alternative Rules for
Pressure Vessels,’’ was published in 1968 and the original code became Section VIII
Division 1: ‘‘Pressure Vessels.’’ [7]
A considerable boost was provided to the understanding of the basic behavior of pressure
vessel components following the development of the nuclear power program in the U.S. and
Europe in the late 1950s and early 1960s. Similar developments can be found in the British,
French, German and Japanese codes, to name but a few. By 1960 the need for a code for
pressure vessels for commercial nuclear plants became imperative. This resulted in publication
of the 1963 Edition, Section III: ‘‘Nuclear Pressure Vessels.’’ [6] This was a design by analysis
code with a theoretical safety factor of 3. [8]

The rapid development of finite-element software has remarkably impacted the detailed design
of pressure vessel components. These developments along with continuing increase in
computing speed and storage capacity of the computer have really made the design process
extremely quick and at the same time have led to very accurate design assessment. Initially in
the early to mid-1970s, detailed finite-element analyses were generally performed for
confirmatory analyses. Today these tasks are routinely accomplished in an interactive mode.

In spite of some of the most rigorous, well-conceived safety rules and procedures ever put
together, boiler and pressure vessel accidents continue to occur. In 1980, for example, the
National Board of Boiler and Pressure Vessel Inspectors reported 1972 boiler and pressure
vessel accidents, 108 injuries and 22 deaths.

The pressure vessel explosions are of course rare nowadays and are often caused by incorrect
operation or poorly monitored corrosion. Safety in boiler and pressure vessels can be achieved
by proper utilization of the standard design codes and considerations. [8] [2] [5]

1.3 Statement of the problem

Our design is Pressure vessels with working fluid of steam, They are typically subjected to
corrosion due to the contact of the steam to the wall and pressure loading and internal or
external operating pressure different from ambient pressure. Due to the corrosion the wall

3
will lose its thickness and due to the pressure loading the wall of pressure vessel expand and
may also burst. In our design project we will try to consider such cases and design good, long
life and strong with light weight horizontal pressure vessel.

Failure in Pressure vessel occurs due to improper selection of material, defects in material,
incorrect design data, design method, shop testing, improper or insufficient fabrication
process including welding. To obtain safety of pressure vessel and to design Pressure vessel
the selection of code is important. Corrosion allowance is the main consideration in vessel
design.

During service, pressure vessel may be subjected to cyclic or repeated stresses. Fatigue in
pressure vessel occurs due Fluctuation of pressure, Temperature transients, Restriction of
expansion or contraction, Forced vibrations, Variation in external load, Safety features of
pressure vessel

1.4 Objective of the project

1.4.1 Main objectives
The main objective of our project is to design a horizontally oriented steam pressure vessel
which has hemispherical & ellipsoidal head and supported by saddle support to withstand a
design pressure of 5 MPA and a temperature of 350℃.

Assume there will be significant wind loading, internal pressure, dead weight of vessel and
contents and there is no loading from piping and external equipment and from earthquake.

1.4.2Specific objectives
The specific objectives are listed below include the following component designs:-

• Designing of shell,
• Designing of ellipsoidal head,
• Designing of the nozzles
• Designing of the man hole
• Designing of saddle support,
• Designing of welded flange joint,
• Selecting of standard flanges,
• Designing of 2D&3D modeling CATIA software
• Cost analysis for the components, Preparing each component of
the pressure vessels and the assembly drawing.

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1.5Scope and limitation of the study
1.5.1Scope of the project
This project is about the designing of pressure vessel. The scope of this design project was on
the detail design and analysis of each component of a horizontal steam pressure vessel that
have been designed to operate at pressure 5M pa and a temperature 350℃ and to draw out the
detail drawing of each component using CATIA software with the help of optimization concept
and design procedure. The scope of design and manufacturing of the pressure vessel is based
on the material availability and the application of the knowledge we have acquired.

1.5.2 Limitations of the project

Since our project is to design a horizontal steam pressure vessel, the design is not concerned
with any type of pressure vessel. And it only withstands a pressure of below 5 Mpa, temperature
of 350℃,total inside volume(3m3), corrosion allowance (2.5), and working fluid is steam.

1.6 Significance of the project

The significance of this project is to bring better pressure vessel with steam as working fluid.
Which efficiently work in industries and make change in the production process and service
sector.as well as give the industry better recognition in the field. Within cost, quality and
accessibility.

1.7 Methodology
In order to design a pressure vessel with hemispherical & ellipsoidal head with design
pressure of 5 Mpa and temperature 350℃, we follow the following procedures.

Material selection: - the selection of material for the design is the first requirement based on
the design specification.

There are many considerations to select the material for designing purposes based on
considering the working fluid, the pressure (internal pressure) and the temperature at the
design pressure vessel.
In order to select the material, we will take consideration of:

✓ Cost of the material

✓ Availability of the material
✓ Suitability of the material for working consideration such as pressure, temperature

5
 ✓ Mechanical properties such as strength, stiffness, toughness.
✓ Also, the material fatigue and creep resistances
Design of pressure vessel: we consider the followings components including their stress
analysis
✓ Design of shell
✓ Design of head
✓ Design of opening
✓ Design of support

Analyzing the size horizontal pressure vessel: depending on the given parameters

Designing the load, temperature and pressure: calculating the loads that have significant
impact such as wind loading, internal pressure and Dead weight of vessel and contents.so, here
we ignore loading from piping and external equipment and earthquake (earth dam).

Design procedure: - the tasks to do in this step are: - Identify the specifications, Geometry
analysis, Stress analysis, prepare part and assembly drawing and giving conclusion based on
the result we get.

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 CHAPTER TWO

2.1 Definition of pressure vessel

Pressure vessels are used to store fluids under pressure. The fluid being stored may undergo a
change of state inside a pressure vessel as in case of steam boiler or it may a combine with
other reagents as in a chemical plant.
In general pressure vessels are closed container designed to hold gases or liquids at a pressure
different from the ambient pressure.
2.2 Literature review
DiCarlucci et al [9] , in year 2008 has done the work on ASME norms should be considered
for designing. Seismic loads should be considered while designing a pressure vessel. Wind load
and seismic load creates moment at lug. The greater moment should be considered for design
to avoid accidents.

David Heckman [10], tested three dimensional, symmetric and axisymmetric models; the
preliminary conclusion is that finite element analysis is an extremely powerful tool when
employed correctly. Depending on the desired solutions, there are different methods that
offers faster run times and less error. The two recommended methods included symmetric
models using shell elements and axisymmetric models using solid elements. Contact elements
were tested to determine their usefulness in modeling the interaction between pressure vessel
cylinder walls and end caps.

Yogesh Borse and Avadesh K. [11] Sharma present the finite element modeling and Analysis
of Pressure vessels with different end connections i.e., Hemispherical, Ellipsoidal & Toro
spherical. They describe its basic structure, stress characteristics and the engineering finite
element modeling for analyzing, testing and validation of pressure vessels under high stress
zones. Their results with the used loads and boundary conditions which remain same for all
the analysis with different end connections shows that the end connection with hemispherical
shape results in the least stresses when compared to other models not only at weld zone but
also at the far end of the end-connection.
PallaviPudke Prof. S. B. Rane [12], done their research on “Design and Analysis of Saddle
Support: a case study in vessel Design and Consulting Industry” and concluded that A rigid
support will give rise to greater stress concentration compared to a flexible one. The main
cause of stress concentration is the abrupt transition of structural rigidity between the support

7
and the vessel concentration compared to a flexible one. The main cause of stress
concentration is the abrupt transition of structural rigidity between the support and the vessel.

M.A. Guerrer, C. Betego´n, J. Belzunce [12] A finite element analysis (FEM) was used to
calculate the behavior of a pressure vessel (PV) made of high strength steel (P500) subject to
the design loads and assuming the existence of the „„worst case‟‟ crack allowed by the
European standards in order to demonstrate the safe use of these steels and the too
conservative design rules currently applied by the PV manufacture codes. analysis was
checked by the simulation of a Wide Plate Test. A good agreement was obtained with the
experimental values determined using strain gauges and with the analytical KI expression
available for this specific geometry. It was demonstrated that the presence of cracks on
fracture toughness of the material (coarse grain heat affected zone.).
PavoBaličević [13]proposed method for stress analysis in cylindrical pressure vessels with
ellipsoidal heads, based on the ax symmetric shell theory. The starting point were the
approximate solutions of the differential equation system that were used to get mathematical
expressions for determining internal forces, moments and displacements in the vessel walls.
Application of the method was shown on a selected numerical example, while a special
computer programmed was created for calculation purposes.
L. P. Zick [9] indicates the approximate stresses that exist in cylindrical vessels supported on
two saddles at various locations. Knowing these stresses, it is possible to determine which
vessels may be designed for internal pressure alone, and to design structurally adequate and
economical stiffening for the vessels which require it. Formulas are developed to cover
various conditions, and a chart is given which covers support designs for pressure vessels
made of mild steel for storage of liquid weighing 42 lb. per cu. ft.

2.3 Classification of pressure vessels

Pressure vessels can be broadly classified in different categories based on different
accordance as follows

2.3.1 According to the material

The pressure vessels are according the material classified as: -

✓ Brittle material pressures vessels

✓ Ductile material pressure vessels

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2.3.2According to the dimension
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.

✓ Thin shell: if the ratio of D/t is less than 1/10 is called thin shells.
✓ Thick shell: if the ratio of D/t is equal or greater than 1/10 is called thick shell used
in High pressure cylinders, gun, barrels and other equipment where as thin shells
are Used in boiler, tanks and pipes.

N.B:- Another criterion to classify the pressure vessels as thin shell or thick shell is the internal
fluid pressure (P) and the allowable stress (σt If the internal fluid pressure (P) is less than 1/6
of the allowable stress, then it is called a thin shell .On the other hand, if the internal fluid
pressure is greater than 1/6 of the allowable stress, then it is said to be a thick shell.

According to the end construction

This can be classified in to two groups: -
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
circumferential or hoop stresses are induced by the fluid pressure. And the other one is 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 temperature
This can be classified in to two groups: -

✓ Normal temperature vessel: -20< T ≤200℃.

✓ Medium temperature vessel between normal & high Temperature vessels.
✓ Low temperature vessel Temperature less than -20 ℃
✓ High temperature vessel where the wall temperature is above the creep
temperature.

According to pressure and its type

This can be classified in to two groups: -
➢ Internal Pressure Vessel: vessels where the media pressure inside the vessel
are larger than that outside (gauge pressure).
• Low pressure vessel (L): 0.1≤P < 1.6 MPa
• Medium pressure vessel (M):1.6 ≤P < 10 MPa
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 • High pressure vessel (H): 10 ≤ P < 100 MPa
• Ultra-high-pressure vessel (U): P ≥100 MPa
➢ External Pressure Vessel: vessels where the media pressure inside the vessel
are lower than that outside (gauge pressure). When the internal pressure less
than 0.1 MPa (absolute pressure), such vessels are called Vacuum Vessel.
According to geometrical shapes
This can be classified in to two groups: -
✓ Cylindrical geometrical shapes
✓ Conical
✓ Spherical vessel with one or two cones.

According to the position arrangement

This can be classified in to three groups: - Horizontal pressure vessel, Vertical pressure vessel
and Spherical pressure vessel.

2.4 Component of pressure vessels

Components of pressure vessels this are: -
• head, shell, nozzle, support, Flange, Pressure gage and Temperature gage
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.

10
 Figure 2. 1vessel head at different cross section [2]

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.
Nozzles
A nozzle is a cylindrical component that penetrates the shell or heads of a pressure Vessel.
The nozzle ends are usually flanged to allow for the necessary connections and to permit easy
disassembly for maintenance or access. Nozzles are used for the following applications: -
• Attach piping for flow into or out of the vessel.
• Attach instrument connections, (e.g., level gauges, thermo wells, or pressure gauges).
• Provide access to the vessel interior at man-ways.
• Provide for direct attachment of other equipment items, (e.g., a heat exchanger or
mixer)

Figure 2. 2Types of Nozzles [2]

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 Supports
The type of support that is used depends primarily on the size and orientation of the pressure
vessel. In all cases, the pressure vessel support must be adequate for the applied weight, wind,
and earthquake loads. Calculated base loads are used to design of anchorage and foundation
for the pressure vessels. Typical kinds of supports are as follow:-
i. Skirt Support
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. [2] [5]

Figure 2. 3Skirt Support [2]

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. [2]

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 Figure 2. 4Leg Support [2]
iii. Saddle Support
Horizontal drums are typically supported at two locations by saddle supports. A saddle Support
spreads the weight load over a large area of the shell to prevent an excessive local stress in the
shell at the support points. The width of the saddle, among other design details, is determined
by the specific size and design conditions of the pressure vessel. One saddle support is normally
fixed or anchored to its foundation. [2]

Figure 2. 5Saddle Support [2]

Lug support
Lugs that are welded to the pressure vessel shell, which are shown on, may also be used to
support vertical pressure vessels. The use of lugs is typically limited to vessels of small to
medium diameter (1 to 10 ft.) and moderate height-to-diameter ratios in the range of 2:1 to 5:1.
Lug supports are often used for vessels of this size that are located above grade within structural
steel. The lugs are typically bolted to horizontal structural members to provide stability against
overturning loads; however, the bolt holes are often slotted to permit free radial thermal
expansion of the drum. [2]

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 Figure 2. 6Lug Support [2]

Flange
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. Screwed joints are often used for small-diameter pipe connections, below 40 mm.
Flanged joints are also used for connecting pipe sections where ease of assembly and
dismantling is required for maintenance, but pipework will normally be welded to reduce
costs. Flanges range in size from a few millimeters’ diameter for small pipes, to several
meters diameter for those used as body or head flanges on vessels. [2]
Types of flanges, and selection
Several different types of flanges are used for various applications. The principal types used in
the process industries are:Welding-neck flanges ,Slip-on flanges, hub and plate types ,Lap-joint
flanges ,Screwed flanges Blank or blind, flanges.
Welding-neck flanges: have a long-tapered hub between the flange ring and the welded joint.
This gradual transition of the section reduces the discontinuity stresses between the flange and
branch, and increases the strength of the flange assembly. Welding-neck flanges are suitable
for extreme service conditions; where the flange is likely to be subjected to temperature, shear
and vibration loads. They will normally be specified for the connections and nozzles on process
vessels and process equipment.

14
 Figure 2. 7Welding-neck flange [2]

Slip-on flanges: slip over the pipe or nozzle and are welded externally, and usually also
internally. The end of the pipe is set back from 0 to 2.0 mm. The strength of a slip-on flange is
from one-third to two-thirds that of the corresponding standard welding-neck flange. Slip-on
flanges are cheaper than welding-neck flanges and are easier to align, but have poor resistance
to shock and vibration loads. Slip-on flanges are generally used for pipe work.

Figure 2. 8Slip-on flange [2]

Lap-joint flanges: are used for piped work. They are economical when used with expensive
alloy pipe, such as stainless steel, as the flange can be made from inexpensive carbon steel.
Usually, a short-lapped nozzle is welded to the pipe, but with some schedules of pipe the lap
can be formed on the pipe itself, and this will give a cheap method of pipe assembly. Lap-joint
flanges are sometimes known as “Van-stone flanges”.

15
 Figure 2. 9Lap-joint flange [2]

Screwed-flanges: are used to connect screwed fittings to flanges. They are also sometimes
used for alloy pipe which is difficult to weld satisfactorily.

Figure 2. 10Screwed flange [2]

Blind flanges (blank flanges): are flat plates, used to blank off flange connections, and as
covers for manholes and inspection ports.

Figure 2. 11Blind flange [2]

Pressure gages

Are instruments for measuring the condition of a fluid (liquid or gas) that is specified by the
force that the fluid would exert when at rest on a unit area, such as N/c.m2.

Temperature gages

Are instruments for measuring the condition of a fluid (liquid or gas) that is specified by the
temperature that the fluid would exert when at rest on a unit area, such as N/c.m2.

16
2.5Application of pressure vessel
Pressure vessels are leak proof containers, as the name implies their main purpose is to
contain a given medium under pressure and temperature. Pressure vessels are commonly used
in industry to carry both liquid and gases under require pressure and temperature limit. This
pressure and temperature come from an external source or by the application of heat from a
direct or indirect source or any combination of them. They may be of any shape and size
ranging beer canes, automobile tires or gas tank, to more sophisticated ones encountered in
engineering applications.

Some applications of pressure vessel are;

• Sub marine and space ship habitats

• Medical sterilization system
• Nuclear reactors and space ship habitats
• Rail vehicles air brake reservoirs
• Food production facilities
• Chemical processing plants
• Compressed air tank
• Petro chemical and pharmaceutical
• Storage vessels for liquids, gas like ammonia, propane, butane … etc

The size and geometric form of pressure vessels vary greatly from the large cylindrical
vessels used for high-pressure gas storage to the small size used as hydraulic units for
aircraft. Some are buried in the ground or deep in the ocean, but most are positioned on
ground or supported in platforms.

17
 CHAPTER THREE

3.1Detailed Design and Analysis

3.2General design specification

Table 3. 1.Given specification data

Design of horizontal layout pressure vessel

Parameter Value Unit

Design pressure 5 MPa

o
Design temperature 350 C

Corrosion 2.5 Mm
allowance

Volume 3 m3

Work fluid Steam

Vessel orientation Horizontal

Head type Ellipsoidal

Support Saddle

•To design this horizontal pressure vessel we have consider several design considerations.

Procedure

ASSUMPTION

➢ Neglecting gust wind and earth quake

3.3 Material selection

We choose a material of low alloy carbon steel for our design purpose. There are a lot of
reason that makes us to choose low alloy carbon steel for our design purpose. Such as,

• The working temperature of our design

• The working (allowable stress) of the design
• Low alloy carbon steels are very though, hard, corrosion resistant, and wear
resistant.

18
 • Low alloy carbon steels have highly machinability, formability and weld
ability
All components of vessel are composed of this material because it makes easy to weld
together and all will have similar strength. The pressure vessel design codes and standards
include lists of acceptable materials; in accordance with the appropriate material standards.

3.4 Design pressure

A vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation.
• For vessels under internal pressure, the design pressure is normally taken as the
pressure
at which the relief device is set. This will normally be 5 to 10 per cent above the
normal working pressure, to avoid spurious operation during minor process upsets.
• 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 design pressure is already given but to be safe we are going to find the internal
pressure Pi with allowance as follow
PD = Pi +Pi×0.1…. eqn.1 where, pd is design pressure

pi is internal pressure

PD =5Mpa from the given data

5=Pi(1.1),Pi=5/1.1=4.54Mpa,

Therefore, the internal pressure=4.54Mpa

PD > 0.385*SE then the wall of the cylinder is thick, otherwise

PD< 0.385*SE or less than 300psi, the wall of the cylinder is thin.

1𝑝𝑠𝑖 = 6894.8𝑃𝑎

𝑥 = 5𝑀𝑃𝑎

5𝑀𝑃𝑎∗1𝑝𝑠𝑖
𝑥= = 725.2𝑝𝑠𝑖 > 300psi, therefore thick walled pressure vessel is employed
6894.8𝑃𝑎

19
3.5 Design temperature
The strength of metals decreases with increasing temperature so the maximum allowable design
stress will depend on the material temperature. The design temperature at which the design stress is
evaluated should be taken as the maximum working temperature of the material, with due allowance
for any uncertainty involved in predicting vessel wall temperatures [2]. In our case the design
temperature is given as:-
𝐷𝑒𝑠𝑖𝑔𝑛 𝑡𝑒𝑚𝑝𝑟𝑎𝑡𝑢𝑟𝑒 = 350℃ From the given data.
We take tensile strength and design stress from table 13.2
Thus, design stress… … . . 𝜎𝑑 = 230𝑀𝑝𝑎.
Tensile strength….𝜎𝑡 = 550𝑀𝑝𝑎.

3.6 Design of Shell

Among the three geometrical shapes of a pressure vessel:
• Cylindrical shell
• Conical wall
• Spherical vessel with one or two cones
We are select cylindrical shape of shell because of the following reasons: -
• Easy to manufacture
• Installation economical to be maintain
• Shell stress will be greater than that of the two principal stress

Figure 3. 1Cylindrical shell [4]

For cylindrical shell design the minimum thickness required to resist internal pressure, the
length of shell, internal & external diameter of shell, volume of shell, and general stresses
applied on the shell can be determined using mathematical formula as follow.

𝜋𝐷3 𝜋𝐷2
V= + L Where V = Volume of vessel in 𝑚3
12 4

D = Internal diameter of shell in m

L = Length in m

20
Table 3. 2 The value of (L/D) by corresponding value of pressure [2]

Pressure(psi) L/D ratio

0-250 3
250-500 4
>500 5

Unit conversion
Our design pressure: - P = 5Mpa =725.188psi since (1psi=6894.76 pa)
Hence, 250<725.188>500 (psi) we take the ratio L/D = 5 therefore, L = 5Di

Where L=length shell

Di =internal diameter

V vessel=V Shell + 2Vhead

𝜋𝐷 2 L
But, Volume of shell = 4
πd3
Volume of ellipsoidal = 12

VT = Vs + Vel, Where, VT=total volume

Vs=Volume of the shell

Vel= Volume of ellipsoidal

πD3 πD2L
VT = + here from the given data V= 3m3
12 4

𝜋𝐷3 𝜋𝐷2(5𝐷)
3𝑚3 = +
12 4
3 36
𝐷𝑖 = √ = 0.895 ≅ 0.9𝑚
50.27

So, L=5Di, 𝐿 = 5 × 0.9, 𝐿 = 4.5𝑚

0.9
2𝐻𝑖 2
𝐷 2× 4
𝐿𝑠 = L - = 4.5 - 4
= 4.5– = 4.35 m
3 3 3
Where 𝐿𝑠 = length of the shell
𝐻𝑖 = inner height of the ellipsoidal
𝜋𝐷 2 𝜋0.92
𝑉𝑠 = 𝐿𝑠 = × 4.35 = 2.767𝑚3
4 4

21
To calculate the thickness of shell, use the following formula
𝑆𝐸+𝑃
If 𝑃𝐷 > 0.385SE……………..use 𝑡𝑠 = R× [√𝑆𝐸−𝑃𝐷 − 1]………………………eq(3)
𝐷

𝐷 ×𝑅 𝑃
𝐼𝑓 𝑃𝐷 <0.385SE……………….use 𝑡𝑠 = 𝑆𝐸−0.6𝑃
𝐷

Design stress: - 𝑆 = 230𝑁/𝑚𝑚2

Tensile strength: - 𝜎𝑡 = 550 𝑁/𝑚𝑚2
0.385SE = 0.385× 230𝑀𝑝𝑎 × 1 = 88.55MPa
𝐷 ×𝑅 𝑃
Since 𝑃𝐷 (5Mpa) < 88.55 Mpa…………………….use 𝑡𝑠 = 𝑆𝐸−0.6𝑃
𝐷

5×450
𝑡𝑠 = (230×1)−0.6×5 = 9.91mm which is without corrosion allowance

*For analysis purpose we use the sum of the shell and corrosion allowance thus:
∴ t = ts + corrosion allowance(C )
∴ 𝑇𝑡 = (9.91 + 2.5)𝑚𝑚 = 12.41mm
Where:
Pd– design pressure
S– Allowable stress
E– Joint factor or efficiency, E=1
𝑅𝑖 – Internal Radius of the shell. R = D/2 =0.9/2 =0.45 m=450mm
ts-thickness of the shell
𝑡
To check the cylinder is thin or thick use [𝐷] ratio
𝑡 1
For [𝐷] <10 ………...………………… ……. thin shell
𝑡 1
For [𝐷] ≥ 10 …………………………….. Thick shell
𝑡 12.41𝑚𝑚 1
[𝐷] = = 0.01378<10
900𝑚𝑚

Therefore, the cylinder is thin shell

The condition is satisfied therefore the shell thickness is safe
The outside diameter of the shell will be:
𝐷𝑜 =𝐷𝑖 +2𝑇𝑡

Where:
𝐷𝑜 – Outer diameter
𝐷𝑖 – Inner diameter,𝐷𝑖 =0.9m=900mm.
∴ 𝐷𝑜 = 𝐷𝑖 +2𝑇𝑡 =900mm + 2(12.41) mm ∴

22
 𝐷𝑜 =924mm=0.924m

3.6.1Stress Analysis For The Shell

Now let us find the circumferential or hoop stress and longitudinal stress
𝐷𝑚 = D + t=900+12.41=912.41mm
𝑃𝐷×𝐷𝑚 5×912.41
𝜎ℎ = 𝜎𝑦 = = = 183.81 𝑀𝑝𝑎 𝑤ℎ𝑒𝑟𝑒 𝜎ℎ = hoop stress
2𝑡 2×12.41

Dm= mean diameter

. Know check hoop stress is less than design stress for safe design
𝜎ℎ < S ………….. 183.81 𝑀𝑝𝑎 < 230Mpa therefore our design is safe

Longitudinal stress is given by

𝑃𝐷 ×𝐷𝑚 𝜎ℎ 183.81𝑀𝑝𝑎
𝜎𝐿 = 𝜎𝑥 = = = =
4𝑡 2 2

91.9Mpa…………………………………………….eq(6)
Know check longitudinal stress is less than the design stress
for safe design
𝜎𝐿 < S ………….. 91.9Mpa < 230Mpa therefore our design is
safe the design of cylindrical shell is safe for longitudinal and
hoop stress.
N.B:-Since all stress on the above are less than design stress 230Mpa; therefore the design is
safe.
To check the safety of the design
𝜎𝑦
𝜏𝑚𝑎𝑥 < 2

91.9N/mm2< 230N/mm2

Therefore, our design of shell is safe.

23
 Figure 3. 2 2D drawing of shell

3.7 Design of head

Our project is design pressure vessel with ellipsoidal head so we take the following formula
to calculate the value of the thickness of head.
𝑃𝑑𝐷𝑖
𝑡ℎ = 2𝑆𝐸−0.2𝑃𝑖, Where 𝑡ℎ is the thickness of the head, S = allowable design stress

E = joint efficiency………..take E = 1
5𝑀𝑝𝑎×900𝑚𝑚
𝑡ℎ = 𝑁 =9.84mm ………. Which is without corrosion allowance
2×1×230 2 −0.2×5𝑀𝑝𝑎
𝑚𝑚

Then t = 𝑡ℎ + C Where C, Corrosion allowance

t = 9.84mm + 2.5mm = 12.34mm so this is approximately equal with the thickness of shell which is
equal to 12.41 mm

𝐷
𝑆𝑓 = 12 =900/12 = 75𝑚𝑚 Where 𝑆𝑓 = straight factor
𝐷
𝐻𝑖 = 4
= 900/4 = 225mm 𝐻𝑖 = inner head of the ellipsoidal
𝐷𝑜
𝐻𝑜 = 4
=924mm /4 =231mm 𝐻𝑜 = outer head of the ellipsoidal

2×𝜋×𝐷2 𝜋×𝐷2 2𝐻𝑖

𝑉ℎ = × 𝑠𝑓 + ×
4 4 3

2×𝜋×𝐷2 𝐷 𝜋×𝐷2 2𝐷
𝑉ℎ = × + ×
4 12 4 34

24
 𝜋×𝐷3
𝑉ℎ =
12

𝜋×0.93
𝑉ℎ = = 0.191𝑚3
12

Know we sum up the two volume and check with the total volume
𝑉 = 𝑉ℎ +𝑉𝑠 = 0.191𝑚3 +2.767 𝑚3 = 2.958𝑚3
Therefore 2.958𝑚3 ≈ 3𝑚3

3.7.1 Stress analysis of ellipsoidal head

𝑃𝐷×𝐷𝑚 5𝑀𝑝𝑎×912.41𝑚𝑚
Hoop stress, 𝜎ℎ = == = 184.85Mpa
2𝑡 2×12.34𝑚𝑚

Now check hoop stress is less than design stress for safe design

𝜎ℎ < S ………….. 184.85Mpa < 230Mpa therefore our design is saf

Longitudinal stress (𝝈𝒍)

𝑃𝐷 ×𝐷𝑚 𝜎ℎ 184.85𝑀𝑝𝑎
𝜎𝐿 = = = = 92.42Mpa……………………………………………..eq(4)
4𝑡 2 2

Now check longitudinal stress is less than the design stress for safe design

𝜎𝐿 < S ………….. 92.42Mpa < 230Mpa therefore our design is safe

Therefore the design of ellipsoidal head is safe for longitudinal and hoop stress

Figure 3. 3 2D drawing of head

25
3.8 Design of Nozzle and Reinforcement
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. [2]

Nozzles are used for the following applications:

• Attach piping for flow into or out of the vessel.

• Attach instrument connections, (e.g., level gauges or pressure gauges).

• Provide access to the vessel interior at manways.

• Provide for direct attachment of other equipment items, (e.g., a heat exchanger
or mixer).

𝑫𝒊 = 900 mm

1 mm = 0.03937 in
∴ 900 mm =35.433in
1 inch=25.4mm
2 in =Dn
From appendix A ∴ 𝐷𝑛 (Nozzle diameter) =50.8 mm

𝑑𝑖 50.8𝑚𝑚
𝑟𝑖 = = =25.4mm
2 2

Assume our inlet opening pipe is placed on the cylindrical shell.

𝑡𝑟𝑛 =The required minimum thickness of the nozzle for inlet pipe is given by:-

𝑃𝑑∗𝑟𝑖
𝑡𝑟𝑛 =
𝐸∗δd−0.6Pd

5𝑀𝑃𝑎∗25.4𝑚𝑚
𝑡𝑟𝑛 = 1∗230𝑀𝑝𝑎−0.6∗5𝑀𝑃𝑎

𝑡𝑟𝑛 =0.56mm

But for safe design 𝑡𝑛 = 0.56mm + c where c= corrosion allowance

𝑡𝑛 = 0.56mm + 2.5mm

𝑡𝑛 = 3.06mm

26
Length of the nozzle

Ln=Di/2 +t +tn-3C

=50.8/2 +12.41+3.06-3*2.5

=33.37mm

The outer diameter of nozzle is given by:-

𝐷𝑜 = 𝐷𝑖 + 2𝑡𝑛 ………..but

= (50.8+2*3.06) mm

=56.92mm

Area of reinforcement Available

A = dt r ,

pi∗ri 4.54∗25.4
tr= tr = f ∗J− 0.6 ∗P = =0.51mm
i 1∗230−0.6∗4.54

A = 50.8mm ∗ 0.51mm

A = 25.78mm2

Area of reinforcement required

Figure 3. 4nozzles [2]

Area available in vessel wall,

27
 𝐴1 = (𝑡 − 𝑡𝑟 )𝑑

𝐴1 = (12.41𝑚𝑚 − 0.51𝑚𝑚)50.8mm

𝐴1 =604.52mm

Area available in nozzle wall (outward)

𝐴2 = 5𝑡(𝑡𝑛 − 𝑡𝑟𝑛 )

𝐴2 = 5 ∗ 12.41𝑚𝑚(3.06𝑚𝑚 − 0.56𝑚𝑚)

𝐴2 = 155.13mm2

𝐴2 = 5𝑡𝑛 (𝑡𝑛 − 𝑡𝑟𝑛 )

𝐴2 = 5 ∗ 3.06(3.06 − 0.56)

𝐴2 = 38.25mm2

∴ We take the smaller value that is 𝐴2 = 38.25mm2

Area available in nozzle wall (Inward):

𝐴3 = 5𝑡(𝑡𝑛 )

𝐴3 = 5 ∗ 12.41𝑚𝑚(3.06𝑚𝑚)

𝐴3 = 189.87mm2

Area of weld

𝐴4 = 2𝑡 2

𝐴4 = 2(12.412 )

𝐴4 = 308.02mm2

Total area

∴ At= 𝐴1 + 𝐴2 + 𝐴3 + 𝐴4

At = 604.52mm2 + 38.25mm2 + 189.87mm2 + 308.02mm2

At = 1140.66mm2

28
 Since our total reinforcement area available is less than area reinforcement required
( 25.78mm2 < 1140.66mm2 ) so the our disegn is safe.

3.9 Design Manhole

In our design we take the inlet and outlet pipe diameter Dm=diameter of manhole;
dim=16*38.25mm2=612mm

Ri=dm/2=612/2=306mm

𝑃𝑑∗𝑅𝑖
𝑡𝑟𝑛 =𝐸∗δd−0.4Pd

5𝑀𝑃𝑎∗306𝑚𝑚
𝑡𝑟𝑛 = 1∗230𝑀𝑝𝑎−0.6∗5𝑀𝑃𝑎

𝑡𝑟𝑛 =6.74mm

But for safe design 𝑡𝑛 = 6.74mm + C(1) where c= corrosion allowance

𝑡𝑛 = 6.74mm + 2.5mm

𝑡𝑛 = 9.24mm

The outer diameter of manhole is given by:-

𝑑𝑜 = 𝑑𝑖 + 2𝑡𝑛 = 612𝑚𝑚 + 2 ∗ 9.24𝑚𝑚 = 630.48𝑚𝑚

Area of reinforcement Available

A = dt r Where t r = 0.51mm

A = 612mm ∗ 0.51mm

A = 312.12mm2

Area of reinforcement required

𝐴1 = (𝑡 − 𝑡𝑟 )𝑑

𝐴1 = (12.41𝑚𝑚 − 0.51𝑚𝑚)612mm

𝐴1 =7282.8mm2

Area available in nozzle wall Outward

𝐴2 = 5𝑡(𝑡𝑛 − 𝑡𝑟𝑛 ),𝐴2 = 5 ∗ 12.41𝑚𝑚(9.24𝑚𝑚 − 6.74𝑚𝑚)

29
 = 155.13𝑚𝑚2

Inward

𝐴2 = 5𝑡𝑛 (𝑡𝑛 − 𝑡𝑟𝑛 )

𝐴2 = 5 ∗ 9.24(9.24 − 6.74)

𝐴2 = 115.5mm2

∴ We take the smaller value that is 𝐴2 = 115.5mm2

Inward

𝐴3 = 5𝑡(𝑡𝑛 )

𝐴3 = 5 ∗ 12.41𝑚𝑚(9.24𝑚𝑚)

𝐴3 = 573.34mm2

Area of weld

𝐴4 = 2𝑡 2

𝐴4 = 2(12.41)2

𝐴4 = 308.02mm2

∴ At= 𝐴1 + 𝐴2 + 𝐴3 + 𝐴4

At=7282.8mm2 + 115.5mm2 + 573.34mm2 + 308.02mm2

At=8279.66mm2

Since our total reinforcement area available is less than area reinforcement required
(312.12mm2 < 8279.66mm2 ) so our design is safe.

Next find the stress analysis of the nozzle by finding of the hoop (𝜎ℎ )and longitudinal (𝜎𝑙 )
stresses by the following formulas:

𝑃𝑑 𝐷𝑖 𝑃𝑑 𝐷𝑖
𝜎ℎ = 𝑎𝑛𝑑 𝜎𝑙 =
2𝑡 4𝑡

5 ∗ 900 𝑁
𝜎ℎ = 𝜎1 = = 243.51
2 ∗ 9.24 𝑚𝑚2

30
 5 ∗ 900
𝜎𝑙 = 𝜎2 = = 121.75𝑁/𝑚𝑚2
4 ∗ 9.24

Find the maximum shear stress (𝜏𝑚𝑎𝑥 )

σ1 − σ2
τmax =
2

𝑁
243.51 − 121.75𝑁/𝑚𝑚2
τmax = 𝑚𝑚2 = 60.88𝑁/𝑚𝑚2
2

Then, check it is safe by comparing it with design stress.

𝜎𝑦
𝜏𝑚𝑎𝑥 <
2

60.88𝑁/𝑚𝑚2 < 115 𝑁/𝑚𝑚2

∴ As a result, the design is safe, and we can determine if the design is safe or not by
considering factor safety; however, we consider working stress to be radial stress (hoop
stress) in the nozzle, because hoop stress has a greater impact on the nozzle.

𝑑𝑒𝑠𝑖𝑔𝑛 𝑠𝑡𝑟𝑒𝑠𝑠 230𝑁/𝑚𝑚2

F s=𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 = 60.88𝑁/𝑚𝑚2 = 3.78

Then our factor of safety is greater than 1.5 and less than 5 therefor our design is safe.

3.10 Design of Support

The saddles must be designed to withstand the load imposed by the weight of the
vessel and contents. They are constructed of bricks or concrete, or are fabricated from steel
plate. The contact angle should not be less than 120o, and will not normally be greater than
150o. Wear plates are often welded to the shell wall to reinforce the wall over the area of
contact with the saddle. Our saddle support is constructed from low carbon steel. We use

31
120o contact angle. Mostly saddle support horizontal pressure vessels are subject to several
stresses these are :-

• Longitudinal bending stress

• Tangential bending stress
• Circumferential stress

We consider the following factors when designing these three legs.

The major sources of dead weight loads are:
✓ The shell of the vessel
✓ The vessel heads
✓ The vessel fitting, manhole and nozzle
✓ Wind load
✓ Weight of fluid
Weight of shell: is the sum of the weight of shell material and the fluid stored on it.

Figure 3. 5 2D drawing of saddle support

3.11Dead weight of vessel and contents

In dead weights we consider these in our design:

32
 ✓ The weight of the head(𝑊ℎ),Weight of the shell(𝑊𝑠), weight of
insulation(𝑊𝑖),weight of the medium (weight of water) (𝑊𝑓),Weight of longitudinal
and lateral material of the nozzle

3.11.1Weight of the shell

Weight due to vessel shell material (Ws)

The material is low alloy steel we take 𝜌 = 7850kg/m3

Ws=mg but m =v.  m

=  m VS g

There fore 𝑤𝑠 = 7850 Kg/m3×2.767m3× 9.81 =213.083KN

Weight of shell fluid

Ws f=mf*g but mf= 𝜌*Vf where Vf=volume of the fluid on the shell, 𝜌 of steam at
pressure 5Mpa=2.669kg/m3
𝜋∗Di2
ms f = 𝜌*vf Vf = 𝐿𝑠 ( )
4
𝜋∗0.92
ms f =2.669 ∗2.77=7.39kg Vf =4.35 ( ), Vf = 2.77m3
4

Ws f = ms f *g
Ws f = 7.39*9.81
Ws f = 72.46 N

3.11.2 Weight of head

is the sum of the weight of head material and the fluid stored in it.

Weight of head material

The material is low alloy steel we take 𝜌 = 7850kg/m3

Wh= mg =  m Vhg

∴ 𝑊ℎ = 7850× 0.191 × 9.81 =14.708KN

Where: Wh =weight of head material

Vh =volume of the head

Weight of head fluid

33
 𝜋Di3
Vh = where Vh=volume of the fluid on the head but Di= 0.525m, 𝜌 of steam at
8

5Mpa=2.669Kg/m3
𝜋∗0.93
Vh = 12

Vh = 0.191m3
mhf= 𝜌×V= 2.669×0.191
mhf=0.51Kg
Whf =mhf ×g
Whf =0.51×9.81
Whf = 5N

3.11.3Weight of Nozzle
Weight of the nozzle material

The material is low alloy steel we take 𝜌 = 7850kg/m3

Wn = mn *g where mn = mass of nozzle

But mn = 𝜌*Vn where Vn = volume of nozzle material

𝜋(𝑑𝑜 2 − 𝑑𝑖 2 )𝐿
Vn =
4

where do = outlet nozzle diameter

di= inlet nozzle diameter
L= length of nozzle
𝐷𝑖 900𝑚𝑚
𝑟𝑖 = 25.4mm and Ri= = =450mm
2 2

C=𝑅𝑖 -√𝑅𝑖 2 − 𝑟𝑖 2 where C=length of part of the nozzle entering to shell

C=450-√4502 − 25.42
C=0.717mm
where, C = the length of the nozzle entering to the shell
t = thickness of the shell
n = length of the nozzle out of the shell assume n = 55mm
𝐿𝑛 = length of the nozzle

Ln= C+ t s + n
L= 0.717mm+ 12.41mm + 55mm

34
 L=68.127mm
𝜋(𝑑𝑜 2 − 𝑑𝑖 2 )𝐿 𝜋(56.922 − 50.82 )∗68.13
Vn = Vn = = Vn = 35275.7 mm3
4 4

mn = 𝜌*Vn mn = 7850* 35275.7* 10 -9 kg mn = 0.277kg

Wn = mn *g Wn = 0.277*9.81 Wn = 2.72N

Weight of nozzle fluid

Wnf =mf *g but mf = 𝜌*Vf where Vf = volume of the fluid on the nozzle

𝜋𝑑𝑖 2 𝐿
Vf = 4
𝜋50.82 ∗68.13
Vf = 4

Vf = 0.000138m3
We take 𝜌 of steam at 5Mpa =2.669kg/m3
mf = 𝜌*Vf
mf = 2.669*0.000138m3
mf = 0.000368 kg
Wfn =mf *g
Wfn = 0.000368*9.81
Wfn = 0.0032 N

Wtotal = Ws + Wsf +Wh + Whf + Wn + Wfn

=213083+72.46+14708+5+2.72+0.00362
=227.87KN
Mass=wtotal/g
=227.87KN/9.81
=23,228kg

3.12Wind loading
Take dynamic wind pressure as: Pw=1280 N/m2.
Mean diameter
𝐷𝑚 = 𝐷𝑖 + 2 ∗ (𝑡𝑠 ) ∗ 10−3 = 0.9 + 2 ∗ (12.41) ∗ 10−3 = 0.924𝑚

Next, loading (per linear meter)

35
 N
𝐹𝑤 = 𝑃𝑤 ∗ 𝐷𝑚 = 1280 ∗ 0.924 = 1183.21
m
Find the effect of the bending momentMx
𝑀𝑋 = (𝐹𝑤 ∗ 𝑥 2 )/2 = (1183.21 ∗ 4.52 )/2 = 11.98 KNm

✓ Pressure Stresses:
𝑃 ∗𝐷 4.54 𝑀𝑝𝑎 ∗0.9 𝑚
Longitudinal Stresses (𝜎𝑙 )= 𝜎𝑙 = 4𝑖 ∗𝑡 𝑖 = = 82.31 𝑀𝑃𝑎
4 ∗12.41 𝑚𝑚
𝑃𝑖 ∗ 𝐷𝑖 4.54 𝑀𝑝𝑎 ∗0.9 𝑚
Hoop Stresses (𝜎ℎ )= 𝜎ℎ = = = 164.6𝑀𝑃𝑎
2∗𝑡 2∗12.19 𝑚𝑚

✓ Dead weight Stress:

𝑤𝑣 213.16𝐾𝑁
𝜎𝑤 = = = 5.99𝑀𝑃𝑎 (𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒)
𝜋 ∗ (𝐷𝑖 + 𝑡) ∗ 𝑡 𝜋 ∗ (0.9 + 0.01241) ∗ 0.01241

✓ Bending Stresses

𝐷𝑜 = 0.9 + (2 ∗ 12.41 ∗ 10−3 ) = 0.924 𝑚

𝜋 𝜋
𝐼𝑣 = (𝐷𝑜 4 − 𝐷𝑖 4 ) = (0.9244 − 0.94 ) = 0.00358 𝑚4
64 64

𝑀 𝐷𝑖 11980 0.9
𝜎𝑏 = ± ∗ ( + 𝑡) = ± ∗( + (12.19 ∗ 10−3 )) = ±1.55𝑀𝑃𝑎
𝐼𝑣 2 0.00358 2

Therefore, the resultant longitudinal Stress is:

𝜎𝑧 = 𝜎𝑙 − 𝜎𝑤 ± 𝜎𝑏

Substitute numerical value:

𝜎𝑧 (𝑈𝑝) = 82.31 − 5.99 + 1.55 = 77.87 𝑀𝑃𝑎

𝜎𝑧 (𝐷𝑜𝑤𝑛) = 82.31 − 5.99 − 1.55 = 74.77𝑀𝑃𝑎

The greatest difference between the principal stresses will be on the down – wind side:

(𝜎ℎ) − 𝜎𝑧 (𝐷𝑜𝑤𝑛) = 164.6 − 74.77 = 89.83𝑀𝑃𝑎

36
3.13 Design Flange (Standard flanges)
Design Flange 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.
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 [2].

Figure 3. 6 Flange [2]

The proportions of standard flanges are set out in the various codes and standards. A typical
example of a standard flange design is shown in appendix C given for standard flange design.
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 [2].
From table 3.6
1inche=25.4mm
= 900mm
35.4inche=internal diameter, therefore 35.4 is between 32 and 40 so now as we design the
bolt before our bolt size is M12 standard size. For this reason, our
flange design parameters are in the first row of the table above that means:
d1= 48.3mm, d2= 14mm, d3= 70mm, d4=80mm, h=26mm, b= 14mm, D= 130mm,
f= 3mm, K= 100mm, Bolt M12

37
 Figure 3. 7 2D drawing of flange

3.14Design of bolted and nut flange joints

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 [3].
There are two main types of bolted joint design: Tension joint& Shear joint
➢ Tension 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 [3].
➢ Shear joint
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 [3].
Here we know that the upward force acting on the cylinder cover is:
F=πDi2∗PD/ 4 ……………………………… (1)
where Di = internal diameter of cylinder
PD = design pressure in the cylinder
dcb = core diameter of the bolt
𝑑𝑐𝑛 = core diameter of the nut
σtb= permissible tensile stress of the bolt

38
 𝑛1 = number of bolts
𝑛2 = number of nuts

This force is resisted by n number of bolt and the resisting force offered by n number
of bolts is Fp= πdc2∗σ𝑡𝑏∗n 4 ……………………………. (2)
From equation (1) the upward force acting on cylinder cover is
𝜋𝐷𝑖2∗𝑃𝐷
F= 4
𝜋∗900∗900∗5
= 4

F = 3180.86KN ≈3181KN
From equation (2) the resisting force by the bolt FR= πdc2∗σ𝑡𝑏∗n 4
In our design we select the material for the bolt is low alloy steel. So, σtb= 550N/mm2
the core diameter is from the table by taking standard M12 size.
We take dcb=9.858mm

𝜋dc2∗𝜎𝑡𝑏∗𝑛1 𝜋∗9.858∗9.858∗550∗𝑛1
FR= =
4 4
3180862.6
F𝑅=41978.8n1 since F=FR ,∴ 𝑛1= = 71.77 ≈ 72bolts
41978.8

And also from the table we take dcn=10.106mm

πdcn2∗σtb∗n2 π10.106∗10.106∗550∗n2
FR= =
4 4
3180862.6
FR = 44117.52𝑛2 where, F = FR 𝑛2 = = 72.1≈ 72 nuts
44117.52

39
 Figure 3. 8 2D drawing of bolt

2D assembly drawing

Figure 3. 92 D assembly drawing

40
3.16 3D Design of the Model
Shell

Figure 3. 10 3D shell Drawing

Head

Figure 3.11 3D drawing of head

41
Flange

Figure 3. 12 3D drawing of flange

Saddle support

Figure 3. 13 3D drawing of saddle support

Bolt

Figure 3. 14 3D drawing of bolt

42
Nut

Figure 3. 15 3D drawing of nut

Assembly drawing

Figure 3. 16 3D assembly drawing

3.17 Cost analysis for the components

In this topic we discussed about manufacturing cost of the vessel including labor cost and
power. We use Standard cost data for calculating the price.

Low alloy high strength HSLA ST 52.3 steel plate ST52 carbon steel sheet price per ton.
$599.00-$700.00/ Ton. 1Ton=1000Kg

3.17.1Cost of Shell
first let’s calculate the mass of the vessel.
wv=213.15KN 1$=51.22ETB

43
Wv =mv*g 0.599$=?

mv =wv/g =30.68ETB

mv =213.15KN/9.81m/s2 1$=51.22ETB

mv =21727.8 kg 0.7$= ?

=35.85ETB

1kg =30.68ETB 1 kg=35.68ETB

0.479kg=? 21727.8kg=?

=30.68ETB*21727kg/1kg = 35.85ETB*21727 kg/1kg

=666,584.4ETB =775,248.9ETB

✓ The cost the shell in the current market is666,584.8ETB-775,248.9ETB

3.17.2cost of head
we use the weight of head to calculate the mass of the head

Wh=14713N

mv = wh/g

14713N/9.81m/s2

=1499.8kg

1kg = 30.68ETB 1kg= 35.85ETB

1499.8kg = ? 1499.8kg = ?

=1499.8kg*30.68ETB = 1499.8*35.85ETB

=46013.7ETB =53767.83ETB

✓ The cost the head in the current market is 46013.7ETB-53767.83ETB

3.17.4 Cost of the longitudinal and lateral material of the nozzle

Weight of longitudinal and lateral material of nozzle =

mass of longitudinal and lateral material of the nozzle*gravity

44
 mass=Wnm/g

=2.7232N/9.81m/s2

=0.277kg

The cost of the longitudinal and lateral material of the nozzle per kg is 30.38-35.85ETB

Thus ,0.277kg*30.68ETB/1kg=8.52ETB

0.277kg*35.85ETB/kg=9.68ETB

Thus, the total purchasing cost is

TC=666584.4ETB+46013.7ETB+8.52ETB

=712,606.62ETB

=ETB is our total purchasing cost

TC=77524.9ETB+53767.83ETB+9.68ETB

=131,302.41ETB

Therefore, the total cost will be 712,606.62ETB-131,302.41ETB

45
 CHAPTER FOUR

4.1Result and discussion

4.1.2Result
Table 4. 1Result of Shell

Geometrical analysis Stress analysis result

result
Internal pressure 4.54Mpa Hoop stress 183.81N/mm2
Length 4.35m Longitudinal stress 91.9 N/mm2
Thickness of shell 9.91mm Shear maximum 45.95N/mm2
Total thickness 12.41mm
Internal diameter 0.9m
Outer diameter 0.924m
Volume 2.767m3

Table 4. 2Result of Head

Geometrical analysis Stress analysis of

of result result
Height(outer) 231mm Shear maximum 46.23Mpa
Height (inner) 225mm
Internal radius of 450mm Longitudinal stress 92.45Mpa
shell
Design stress 230Mpa Hoop stress 184.85Mpa

Thickness of head 9.84mm

Total thickness 12.34mm

Volume of the head 0.191m3

Table 4. 3Result of Nozzles and openings

46
 Reinforcement limit result

Required minimum thickness of nozzle 0.56mm

Total thickness 3.06mm
Length of nozzle 33.37mm
Outer diameter 66.92mm
Inner diameter 50.8mm
Area of reinforcement 25.78mm2
Area available in vessel result 604.52mm2
Area available in nozzle wall(outward) 38.25mm2
Area available in nozzle wall(inward) 189.87mm2
Area of weld 308.02mm2
Total area 1140.66mm2

Table 4. 4 Results in manhole

Reinforcement limit Stress analysis

result

Required minimum 6.74mm Hoop stress 243.51Mpa

thickness
Outer diameter 630.48mm Longitudinal 121.75Mpa
stress

Area reinforcement 312.12mm2 Shear max 60.66Mpa

available
Area available in vessel 7282.8mm2
result
Area available in nozzle 115.15mm2
wall(outward)

47
 Area available in nozzle 573.34mm2
wall(inward)
Area of weld 308.02mm2
Total area 8279.66mm2

Table 4. 5Results of bolted and nut flange joints

Parameter
d1 d2 d3 d4 H b D f k
Resisting force
force
48.3mm 14mm 70mm 80mm 26mm 14mm 130mm 3mm 100mm 3881KN 41.978Knuts

number of bolt Number of nuts

72 72

Table 4. 6Results of dead weight of vessel and contents

Dead weight

Weight of head material 14.708KN

weight of head fluid 5N
Total weight of head 14.71KN
Weight of Shell material 213.083KN
Weight of shell fluid 72.46N
Total weight of shell 213.16KN
Weight of nozzle material 2.72N
Weight of nozzle fluid 0.0032N
Total weight of nozzel 2.723N
Total weight 227.87KN
Mass total 23.228kg

4.2 Discussion
In this pressure vessel design we have designed a total inside volume, V= 3m3 Pressure vessel
which’s working fluid is steam. In this process we have designed shell, head, inlet and outlet
nozzle, flange, man 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.

48
When we compare this pressure vessel design with the previous pressure vessels as much as
possible, we have tried to design of pressure vessel which considers all the failures which
occurs on pressure vessels. And try to solve this problem.

49
 CHAPTER FIVE

5.1Conclusion and Recommendation

For the designing of a horizontal pressure vessel subjected to 3500c temperature and 5Mpa
designed pressure the following conclusions were made. The vessel is analyzed under various
conditions of operation, the designs above is designed to satisfy all the required requirements
to be able to work under the above parameters The shell is a thick shell since the design
pressure vessel is a steam pressure vessel (thank) it is safe.
The pressure vessel is made of a material that is cheaper and at the same time reliable
therefore, the above pressure vessel can be manufactured with low cost and it can be used
with in its capacity and working conditions.
The horizontal vessel is successfully designed so that it withstands all the mechanical stresses
acting on it. The vessel is analyzed under various conditions of operation. All forces are
carried according to ASME codebook. The vessel also with stands the internal pressure of
fluid at working conditions. The various forces analyzed are pressure exerted by weight of
the fluid, wind force. The stresses in above-mentioned conditions are found out and thickness
of various parts is selected such that the stresses produced in each member are within the
maximum allowable range. All the selected have been successfully verified and hence the
design of vessel is safe.

5.2 Recommendation
When we design this project, we have to collect information from different source. Like
references books, journals and web sites. So, the materials needed for design case must be
fulfilled in order to perform applicable design for all users.

We recommended that the pressure vessel design should consider earthquake wind loading,
vibration, material strength and mass in which the pressure vessel parts are made. More try to
study the load analysis by recent software and it is our suggestion to test the pressure vessel in
laboratory before use.

50
REFERENCE

Bibliography

[1] R.S.Khurmi&J.K.Gupta, "a text book of machine design,," 2005.

[2] “. Coulson and Richardson’s, "chemical engineering design” volume 6.".

[3] u. source, horizontal pressure vessel.

[4] Wikipedia. [Online].

[5] u. s. wikepidia. [Online].

[6] "‘‘Nuclear Pressure Vessels.’’," 1963 Edition, Section III: .

[7] "Alternative Rules for Pressure Vessels,," – the ASME Unfired Pressure Vessel Code, Section VIII.
The ASME Pressure Vessel Code, Section VIII Division 2: ’’ , no. 1952.

[8] P. Don W. Green & Robert H. Perry, "Chemical Engineers’ Handbook, Eighth Edition".

[9] ,. L. P. Zick, "“Stress in Large Horizontal Cylindrical Pressure Vessel onto Saddle Support”,," The
Welding Journal Research Supplement(WJRS) Vol.3, Issue 4,April 2015.

[10] D. Heckman, "Finite Element Analysis of Pressure Vessels," pp. pp(1-7), 2014,.

[11] Y. a. A. Sharma, “Modeling of Pressure Vessels with Different End.

[12] P. S. B. R. PallaviPudke, "“Design and Analysis of Saddle Support: a case study in vessel Design
and Consulting Industry”," International Journal of Mechanical Engineering andTechnology
(IJMET) Vol. 4, Issue 5, Sept-Oct 2013.

[13] D. PavoBalicvic, "Strength Of Pressure Vessel WithEllipsoidal Heads”," Journal Of Mechanical

Engineering 5410, pp. 685-692, 2008.

51
[14] P. v. h. 1. edition.

[15] "Nuclear Pressure Vessels," 1963 Edition, Section III:.

APPENDIX A
Inspections of opining

52
APPENDIX B

53
APPENDIX C

Standard flange joint

54
APPENDIX D
Standard bolt size

55
56