BONGA UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTEMENT OF MECHANICAL ENGINEERING

COUERSE TITEL: DESIGN PROJECT

GROUP ASSIGNMENT

NO NAME ID NO
1 NIGUSE NURAMO RU 2796/13
2 ANIMUT YENEW RU 0059 /13
3 GUDINA KASAHUN RU 2101/13
4 SITOTAW ENDLEMEW RU 0654/13

SUBMITTED TO INS: Ermiyas T.

(Ms.c)

SUBMISSION DATE: JAN 2024

BONGA, ETHIOPIA
 ABSTRACT

Vertical pressure vessels play a critical role in various industrial sectors, confining substances
under pressure for key processes. This concise abstract encapsulates the multifaceted
significance, design complexity, and operational importance of vertical pressure vessels. It
emphasizes their pivotal role in industries such as oil and gas, chemical processing, and power
generation. Safety, structural integrity, and compliance with industry codes are central themes,
highlighting the crucial balance between innovation and regulatory adherence. By encapsulating
these facets, this abstract offers a succinct yet comprehensive overview of the immense
significance and intricate considerations associated with vertical pressure vessels, setting the
stage for broader exploration and understanding.

2
 ACKNOWLEDGEMENT

Thanks to GOD, for everything we have achieved so far in our life, because none of them would
have been possible without His plan for our life. We would also like to express our greatest
gratitude to the Supervisor of this project. Ermiyas Tefera (MSc), for his guidance and advices
throughout the process of conducting and completing this Project. Without him, it would
impossible to finish the project within the time frame. Lastly, special thanks to my friends and
individuals who have directly or indirectly offered me friendly help and invaluable information
to we during the whole period of Project.

3
Table of Contents
ABSTRACT....................................................................................................................................................2
ACKNOWLEDGEMENT.................................................................................................................................3
CHAPTER ONE..............................................................................................................................................8
INTRODUCTION...........................................................................................................................................8
1.1 BACKGROUND OF THE PROJECT...............................................................................................8
1.2 Classification Of Pressure Vessel......................................................................................................9
1.2.1 According to the end construction..............................................................................................9
1.2.2 According To Dimension............................................................................................................9
1.2.3 According To Geometrical Shape.............................................................................................10
1.2.4 According To Position Arrangement........................................................................................10
1.3 pressure Vessel components............................................................................................................11
1.3.1 Head.........................................................................................................................................11
1.3.2 Shell..........................................................................................................................................12
1.3.3 Nozzle.......................................................................................................................................12
1.3.4 Support.....................................................................................................................................12
1.3.5 Man Hole..................................................................................................................................14
1.4 Applications of Pressure Vessel......................................................................................................14
1.2 Problem Of Statement.....................................................................................................................14
1.3 OBJECTIVE....................................................................................................................................15
1.3.1 General Objective.....................................................................................................................15
1.3.2 Specific Objective.....................................................................................................................15
1.4 Scope...............................................................................................................................................15
1.5 Benefit of Project.............................................................................................................................15
1.6 Design Methodology.......................................................................................................................16
CHAPTER TWO...........................................................................................................................................18
LITERATURE REVIEW......................................................................................................................18
CHAPTER THREE........................................................................................................................................20
GENERAL DESIGN CONSIDERATIONS.........................................................................................................20
3.1. Design pressure..............................................................................................................................20
3.1.1 Design temperature...................................................................................................................20
3.1.2 Material selection.....................................................................................................................20
3.1.3 Corrosion allowance.................................................................................................................22
3.1.4 Design load...............................................................................................................................22
4
 3.2 PART AND ASSEMBLY...............................................................................................................25
3.2.1 Design Of Cylindrical Shell......................................................................................................25
3.2.2 Design of hemispherical heads.................................................................................................28
3.2.3 Design of nozzle inlet..............................................................................................................29
3.2.4 Design Of Manhole..................................................................................................................31
3.2.5 Design Of Ladder.....................................................................................................................34
3.2.6 Leg design....................................................................................................................................35
CHAPTER FOUR..........................................................................................................................................39
CONCLUSION AND RECOMMENDATION...................................................................................................39
5.1 CONCLUSION...............................................................................................................................39
5.2 RECOMMENDATION...................................................................................................................40
REFERENCES..............................................................................................................................................41

Figure 1 stresses developed on the shell......................................................................................................18

Figure 2 Head of pressure vessel.................................................................................................................20
Figure 3 inlet nozzle with flange.................................................................................................................22
Figure 4 Plate closure..................................................................................................................................22

5
Table 1 maximum allowable stress of some alloy steel at a given temperature.......................................21
Table 2 general formulas of vessel components........................................................................................26
Table 3 crushing stress and Rankine constant of materials.......................................................................36

6
 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

In the realm of engineering and industrial processes, vertical pressure vessels stand as pivotal
components, providing the essential capability to contain and manage fluids, gases, or other
substances under high pressure conditions. Vertical pressure vessels are distinguishable by their
upright orientation, offering space-efficient solutions in various industrial settings. Their design
and operation directly impact the safety, efficiency, and reliability of critical processes across an
array of industries, from oil and gas to chemical manufacturing and power generation.

Pressure vessels are used in a wide number of industries, which are first the power generation
industry for fossil and nuclear power. Secondly, they are used in the petrochemical industry for
storing and processing crude petroleum oil in tank farms as well as storing gasoline in service
stations. Besides that, they are used in the chemical industry, specifically in the chemical
reactors. In other word, pressurized equipment is essential for industrial plant for storage and
manufacturing purposes. Pressure vessels came out in various shapes and sizes. The designation
and geometry of pressure vessels vary according to standards in the industries. Therefore, this
project uses the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel
Code, Section VIII Division 1 as the standard. It is crucial for the engineers to have engineering
software application to ease their work in designing the pressure vessels these days. Therefore,
this project is very important as the project is to design a support system for the pressure vessel
design. This project will use MatLab as a programming language tool to develop the support
system to design the pressure vessel model according to the desired specifications.

A pressure vessel is considered as any closed vessel that is capable of storing a pressurized fluid,
either internal or external pressure, regardless of their shape and dimensions. The cylindrical
vessels, to which we refer in this volume, are calculated on the principles of thin-walled
cylinders. The first step in designing a container is choosing the best type for the service for
which it is intended. The factors influencing the choice of type are the function of the container,
the location, the nature of the fluid that has to be stored, the temperature and operating pressure
and their ability to store the volume needed by the process.

Pressure vessels are one of the main equipment those widely used in industrial facilities. The
pressure vessels defined as cylindrical or spherical vessels those designed to store or hold
pressurized liquids, gases or fluids with a differential pressure between inside and outside.
7
Usually, the inner pressure is higher than the external pressure, except in some cases. The fluid
inside these vessels may undergo a change in state as in the case of steam boiler or may combine
with other reagent as in the case of chemical reactor. The reservoirs designed such that no
leakage can occur, also deal with operational levels of high pressure and high temperatures. The
pressure vessels are differ in terms of capacity, heat and pressure, some of these vessels may
contain more the half million barrels of crude oil, the temperatures sometimes more than 200 oC
specially in asphalt tanks and high viscosity products, the temperatures may slope down to 14oC
especially in tanks store hydrocarbons materials such as propane, butane and others, so it is
necessary to understand the types of reservoirs and their components as well as the appropriate
storage methods. Pressure vessels usually are cylindrical or spherical with semi-spherical covers
(domes) and cylindrical tanks. Cylindrical vessels very wide in use and very simple to
manufacture and ease in use such as boilers, heat exchangers, refineries. According to the
importance of pressure vessels, many of published researches achieved especially in Designing
and Analysis of Stresses on the reservoirs as well as the exact use of designing standards,
methods of numerical analysis and the mathematical simulation models to identify different
collapse occur on reservoirs.

1.2 Classification Of Pressure Vessel

Pressure vessels can be classified in different categories as follows: -

1.2.1 According to the end construction

This can be classified in to two groups;

l. Open end construction pressure vessel- ln this case, the hoop stress is induced by the fluid
pressure. Example-a simple cylinder with piston, Such as cylinder of press.

2. Closed end construction pressure vessel-In this case, longitudinal stress in addition to hoop
stress are induced.

1.2.2 According To Dimension

The pressure vessel, according to their dimension, may be classified as:

A) Thin walled pressure vessel-if the ratio of is less than, then the pressure vessel is called thin
walled vessel. In this case, the radial stress is small and it can be neglected and the longitudinal
and the circumferential stress are constant.

8
B) Thick-walled pressure vessel- if the ratio of is greater than or equal to, it is called thick
walled vessel.in this case, the radial stress can't be neglected and the other two stress are not
constant. Thick-walled pressure vessels are mostly used in case of high pressure such as guns,
barrels, high pressure cylinder etc.

1.2.3 According To Geometrical Shape

The pressure vessel, according to their geometrical shape, can be classified as follow

i. Cylindrical shape
ii. Conical shape
iii. Spherical shape with one or two cone

1.2.4 According To Position Arrangement

The pressure vessel, according to their position arrangement, may be classified as follow;

A. Vertical pressure vessel

B. Horizontal pressure vessel
C. Spherical pressure vessel

A). Vertical pressure vessel:

Vertical pressure vessels are used fora 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.

B) 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.

9
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 fora 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,

1.3 pressure Vessel components

A pressure vessel constitutes of the following parts

 Shell,
 Head
 Nozzes
 Man hole
 support

1.3.1 Head

All pressure vessel shells must be closed at the ends by heads (or another shell section) Heads is
typically curved rather than flat.

There are four types of head:

A, Flat Plates and Formed Flat Heads.

B, Hemispherical Head

C Ellipsoidal Heads.

D, Tori-spherical Heads.

Flat plates are used as covers for access ports or manholes, and as the channel covers of heat
exchangers. Standard Tori-spherical heads are the most commonly used end closures for vessels
up to operating pressures of 15 bars. They can be used for-higher pressures, but above 10 bars,
their cost should be compared with that of an Ellipsoidal head. Above 15 bars, an Ellipsoidal
head will usually prove to be the most economical closure to u Hemispherical head is the

10
strongest shape, capable of resisting about twice the pressure of a Tori-spherical head of the
same thickness. The cost of forming hemispherical head will, however, be higher than fora
shallow Tori-spherical head. Hemispherical heads are used for high pressure.

1.3.2 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.

1.3.3 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, level gauges, thermos wells, or pressure) gauges). . Provide
access to the vessel interior at man-holes.

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

1.3.4 Support
The method used to support a vessel will depend on the size, shape, and weight of the vessel; the
design temperature and pressure; the vessel location and arrangement: and the internal and
external fittings and attachments. Horizontal vessels are usually mounted on two saddle supports.
Skirt supports are used for tall, vertical columns. Brackets, or lugs, are used for all types of
vessel. The supports must be designed to carry the weight of the vessel and contents, and any
superimposed loads, such as wind loads. Supports will impose localized loads on the vessel wall,
and the design must be checked to ensure that the resulting stress concentrations are below the
maximum allowable design stress. Supports should be designed to allow easy access to the
vessel and fittings for inspection and maintenance. Typical kinds of supports are as follow :-

A. Skirt support

B. Leg

C. Saddle
11
 D. Lug

A. 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.

B. 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.

C. 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.

D. 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 (I to 10 ft.) and moderate height-to diameter ratios in the range of to 5: I. 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.

12
1.3.5 Man Hole
It is identical to a nozzle except it does not belt to piping and it has a cover plate which is belted
to the flange.

1.4 Applications of Pressure Vessel

Pressure Vessels are most widely used in the following sectors

 Refinery and Petro-chemical

 Fertilizer

 Oil and Gas

 Chemical

 Power Plants

1.2 Problem Of Statement

The problem statement for a vertical pressure vessel typically involves calculating the stress and
deformation in the vessel's walls under various operating conditions, such as internal pressure,
temperature, and external loads. This may also include determining the optimal material and
thickness for the vessel to ensure it meets safety and performance requirements.Vessel failures
can be grouped into four major categories, which describe why a vessel failure occurs. Failures
can also be grouped into types of failures, which describe how the failure occurs. Each failure
has a why and how to its history. It may have failed through corrosion fatigue because wrong
material was selected. The designer must be as familiar with categories and types of failure as
with categories and types of stress and loadings.

13
1.3 OBJECTIVE

1.3.1 General Objective

The general objective of this project is to design thin, unfired vertical pressure vessel.

1.3.2 Specific Objective

 To design pressure vessel with ASME code.
 To design each Component of pressure vessel.
 To compare the design with the ASME code and Check failures.
 To sketch the designed components.
 To determine safe design method with enhanced factor of safety.
 To know the proper process.
 To know the proper material selection process for our design.

1.4 Scope
The scope of a vertical pressure vessel project typically encompasses various critical aspects that
need to be meticulously addressed to ensure a successful and reliable implementation. Here's an
outline of the typical scope. In sophisticated pressure vessels encountered in engineering
construction; high pressure, extremes of temperature and severity of functional performance
requirements pose exciting design problems. The word "DESIGN" does not mean only the
calculation of the detailed dimensions of a member, but rather is an all-inclusive term,
incorporating: The reasoning that established the most likely mode of damage or failure. The
method of stress analysis employed and significance of results.

1.5 Benefit of Project

The implementation of a vertical pressure vessel project offers a wide range of benefits across
various industrial applications. Here are the key advantages associated with such projects.
Vertical pressure vessels offer efficient use of space, allowing for a smaller footprint compared
to horizontal vessels. This space-saving design can be particularly advantageous in facilities
where floor space is limited. Enabling compact integration and efficient use of available area.
The vertical orientation of the vessel provides operational flexibility, enabling seamless
integration into a variety of industrial processes. This design not only accommodates diverse
installation scenarios but also allows for efficient maintenance and serviceability. Vertical

14
pressure vessels facilitate effective fluid management and pressure containment, contributing to
process optimization.

Their design allows for efficient fluid dynamics, ensuring smooth material flow and pressure
management within industrial processes. Properly designed and manufactured vertical pressure
vessels ensure safe containment of pressurized substances, thereby reducing the risk of leaks and
enhancing overall industrial safety. Compliance with industry standards and rigorous quality
control measures adds to the safety and reliability of these vessels.

Projects involving vertical pressure vessels demand adherence to industry regulations and
standards, ensuring that the vessels meet established safety criteria. Compliance with codes such
as ASME Boiler and Pressure Vessel Code ensures regulatory alignment and operational safety.
Efficient design and operation of vertical pressure vessels can contribute to resource and energy
efficiency, leading to sustainable industrial practices and reduced environmental impact. By
optimizing space, improving safety, and enhancing operational workflows, vertical pressure
vessel projects contribute to economic viability and operational cost-effectiveness, ultimately
supporting enhanced productivity and long-term financial benefits. The design flexibility of
vertical pressure vessels enables their usage across a broad spectrum of industrial applications,
ranging from chemical processing and oil refining to power generation and beyond. By
maximizing space effectiveness, optimizing processes, and ensuring safety and compliance,
vertical pressure vessel projects significantly contribute to the overall operational efficiency,
safety, and sustainability of industrial processes.

1.6 Design Methodology

The methodology for a vertical pressure vessel project typically involves a systematic approach
encompassing key phases from design and material selection to manufacturing, and compliance
verification. Here are the essential aspects of the methodology.

1. Material Selection and Analysis:

Material Evaluation: Analyze and select suitable materials, particularly low steel, based on
considerations such as mechanical properties, corrosion resistance, and cost-effectiveness
for the vessel construction.
2. Design Calculations and Parameters:

15
Shell Thickness Calculation: Precisely determine the required shell thickness, considering
the specified design pressure, temperature, and material properties to ensure safety and
reliability.

16
3. Stress Analysis and Internal Volume:

Stress Evaluation: Conduct stress analysis to ensure the vessel's structural integrity under operational
conditions and determine the optimal internal volume to meet the specified requirements.

4. Compliance and Regulatory Considerations:

Regulatory Adherence Ensure that the vessel design complies with relevant industry standards and
codes, adhering to the ASME Boiler and Pressure Vessel Code or other applicable regulations.

5. Documentation and Reporting:

Comprehensive Documentation: Generate detailed design calculations, drawings, and

specifications to support the vessel's design validation and compliance with engineering
standards.

6. Testing and Validation:

Prototype Testing: Conduct prototype testing to validate the vessel's performance under
simulated conditions, ensuring its safety, reliability, and compliance with specified parameters.

7. Project Management and Oversight:

Project Coordination: Coordinate and oversee the various stages of the project, ensuring
effective collaboration and communication between the design, construction, and quality
assurance teams.

By engaging in these essential aspects, a comprehensive and effective methodology is

established for the design, construction, and validation of a vertical pressure vessel, emphasizing
safety, quality, and compliance with industry standards and regulations.

17
 CHAPTER TWO

LITERATURE REVIEW

E. 0. Bergman states that the external loads applied to vertical 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.

Jaroslav Mackerle gives finite element methods (FEMs) applied for the analysis of pressure
vessel structures/components and piping from the theoretical as well as practical. He classified
his reference papers in these categories: linear and nonlinear, static and dynamic, stress and
deflection analyses; stability problems; thermal problems; fracture mechanics problems; contact
problems; fluid–structure interaction problems; manufacturing of pipes and tubes; welded pipes
and pressure vessel components; development of special finite elements for pressure vessels and
pipes; finite element software; and other topics. Among the numerical procedures, finite element
methods are the most frequently used.

Yogesh Borse and Avadesh K. Sharma present the finiteelement modelling and Analysis of
Pressure vessels with different end connections i.e. Hemispherical, Ellipsoidal & Toro\ spherical.
They describes its basic structure, stress characteristics and the engineering finite element
modelling for analysing, 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.

M. Shaik Abdul Lathuef and K.Chandra Sekhar discusses some of the potential unintended
consequences related to Governing Thickness of shell as per ASME. Here have a scope to
change the code values by take the minimum governing thickness of pressure vessel shell to the
desired requirements and also relocate of nozzle location to minimize the stresses in the shell. In
this paper nozzle located at five places and analysis with ANSYS here nozzle locates at shell

18
left end, at the shell middle, at the shell right end, at dished end of both side and calculate stress.
And they found from result that the stress would be Minimum at the dished end with hillside
orientation. A low value of the factor of safety results in economy of material this will lead to
thinner and more flexible and economical vessels. Here we evaluated the stress in the vessel by
Zick analysis approach.

Levend Parnas and Nuran Katırcı, analytical procedure is developed to design and predict the
behavior of fiber-reinforced composite pressure vessels under combined mechanical and
hydrothermal loading. The cylindrical pressure vessel is analyzed using two approaches, which
are thin wall and thick wall solutions. It is shown that for composite pressure vessels with a ratio
of outer to inner radius, up to 1.1, two approaches give similar results in terms of the optimum
winding angle, the burst pressure, etc. As the ratio increases, the thick wall analysis is required.

19
 CHAPTER THREE

GENERAL DESIGN CONSIDERATIONS

`

3.1. Design pressure

A 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.

3.1.1 Design temperature

The strength of metals decreases with increasing temperature. so the maximum allowable stress will
depend on the material temperature. The maximum design temperature at which the maximum allowable
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. The minimum design
metal temperature (MDMT) should be taken as the lowest temperature expected in service.

3.1.2 Material selection

Pressure vessels are constructed from plain carbon steels, low and high alloy steels, other alloys,
clad plate, and reinforced plastics. Selection of a suitable material must take into account the suitability of
the material for fabrication (particularly welding) as well as the compatibility of the material with the
process environment The pressure vessel design codes and standards include lists of acceptable materials,
in accordance with the appropriate material standards. this gives maximum allowable stresses as a
function of temperature and maximum temperatures permitted for ferrous and nonferrous metals.

20
Table 1 maximum allowable stress of some alloy steel at a given temperature

We can select the low allow steel material form property table.The material selection for low
alloy steel in pressure vessel construction involves a detailed consideration of several key factors
to ensure the vessel's structural integrity, performance under pressure, and resistance to
environmental conditions. Here's a guide to the material selection process:

Material Requirements:

1. Strength and Toughness: Evaluate the required strength and toughness properties
needed to withstand the operating pressure and potential impact loads in the intended
service conditions.

2. Corrosion Resistance: Assess the susceptibility to corrosion from the vessel's operating
environment and decide on an alloy composition that provides the necessary corrosion
resistance.

3. Weldability: Consider the vessel's fabrication and assembly requirements, ensuring

that the chosen low alloy steel grade is weldable and does not lead to welding-related
issues.

Operating Conditions:
21
1. Pressure and Temperature: Determine the design pressure, operating temperature, and
allowable stress levels to verify that the chosen low alloy steel material possesses suitable
pressure-temperature ratings for the application.

2. Chemical Exposure: Understand the nature of the substances handled within the vessel
and verify that the material is compatible with the contained media to avoid degradation
or reactivity issues.

Material Properties and Alloying Elements:

1. Alloy Composition: Select a low alloy steel grade with a specific combination of
alloying elements such as chromium, molybdenum, nickel, or vanadium. These elements
contribute to improved mechanical properties, corrosion resistance, and high-temperature
performance.

2. Impact Toughness: Assess the material's ability to resist fracture, impact, and stress
concentrations, especially in dynamic or high-load environments.

3. Creep Resistance: If the vessel will be subjected to elevated temperatures, consider the
material's resistance to creep deformation over time.

3.1.3 Corrosion allowance

The “corrosion allowance” is the additional thickness of metal added to allow for material lost by
corrosion. 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, no corrosion allowance is
needed when past experience indicates that corrosion is only superficial or does not occur.

3.1.4 Design load

Pressure vessels are subjected to other loads in addition to pressure and must be designed to withstand the
worst combination of loading without failure. It is not practical to give an explicit relationship for the
vessel thickness to resist combined loads. A trial thickness must be assumed (based on that calculated for
pressure alone) and the resultant stress from all loads determined to ensure that the maximum allowable
stress intensity is not exceeded at any point.

The main sources of load to consider are:

22
 1. Pressure
2. Dead weight of vessel and contents
3. Wind
4. Earthquake (seismic)
5. External loads imposed by piping and attached equipment

The primary stresses arising from these loads are considered for cylindrical vessels.

Primary Stresses are:

1. The longitudinal and circumferential stresses due to pressure (internal or external), given
by

PDi
σ L=
4t

PDi
σ ℎ=
2t

2. The direct stress σw due to the weight of the vessel, its contents, and any attachments.
The stress will be tensile (positive) for points below the plane of the vessel supports, and
compressive (negative) for points above the supports. The dead-weight stress will
normally only be significant, compared to the magnitude of the other stresses, in tall
vessels.
Wz
σ w=
( Di+t ) t
Where Wz = is the total weight supported by the vessel.
3. Bending stresses resulting from the bending moments to which the vessel is subjected.
Bending moments will be caused by the following loading conditions:
a. The wind loads on tall self-supported vessels
b. Seismic (earthquake) loads on tall vessels
c. The dead weight and wind load on piping and equipment that is attached to the vessel,
but offset from the vessel center line.

d. For horizontal vessels with saddle supports, from the disposition of dead-weight load
23
 M Di
σ b= ( + t)
Iv 2

4 Tensional shear stresses τ resulting from torque caused by loads offset from the vessel axis. These loads
will normally be small, and need not be considered in preliminary vessel designs. The torsional shear
stress is given by

T Di
τ= ( +t)
Ip 2

24
3.2 PART AND ASSEMBLY

Given design parameters

Design pressure………………………………………………………….10mpa

Nominal volume…………………………………………………………1.6m3

Working temperature………………………………………………… 2000c

Working fluid…………………………………………………………….…Alcohol

Corrosion allowance……………………………………………………… 2mm

Welding efficiency…………………………………………………………. 1

3.2.1 Design Of Cylindrical 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. Tall vertical towers are constructed in a wide range of shell diameters and
heights Shell structures support applied external forces efficiently by virtue of their geometrical form,
i.e., spatial curvatures; as a result, shells are much stronger and stiffer than other structural forms

Total volume =volume of shell + volume of heads

V T =V S+ 2V H

where v = volume of vessel , Vs=volume of shell , VH = volume of head, h=height of cylinder head
h = height of cylinder

2 4 3
1.6= π r ℎ+ πr
3

1.6 = π r 2 ¿

3 4 3
1.6 = 6( π r ¿+ πr
3

4
1.6=r 3(6 π + π )
3

3
1.6=r (23.026)

25
 3 1,6
r=
23.026

r =∛ 0.06948=0.411m=411 mm

Table 2 general formulas of vessel components

Figure 1 stresses developed on the shell

26
thickness of the shell for circumferential stress

PR
t= +c where P=design pressure, R=internal radius of
SE − 0.6 P

10 ∗ 411
t= +2 the S=maximum allow, E=welding efficiency, t=thickness of the shell
240∗ 1 −0.6 ∗ 10

¿ 19.56 mm ≈ 20 mm and C=corrosion allowance

PDi 10 ∗822
σ= = =205.5 Mpa
2t 2 ∗20

σmax 240
f . s= = =1.16
σallow 205.5

For longitudinal stress

PR 10 ∗ 411
t= +C= +2
2 SE+0.4 P 2∗ 240 ∗1+0.4 ∗10

¿ 10.49 mm

PDi 10 ∗ 822
σ= = =195.9 Mpa
4 t 4 ∗10.49

σmax 240
f . s= = =1.22
σallow 195.9

The thickness of the shell have to be taken for circumferential that is 20mm

Total height of cylindrical shell (h)

ℎ=6 R=6 ∗ 411=2466 mm

Outer radius of the shell (R0) is determined as

Ro =R+t=411+20=431 mm

Mass of cylindrical shell

27
 M s=V s ∗ ρ but

2 2
V s=πℎ( Ro − R )

¿ 3.14 ∗ 2466(4312 – 4112) where Ms = mass of the shell

3 3
¿ 130396161.6 mm =0.1303961616 m Vs =volume of cylindrical shell

ρ= density of material

M s=0.1303961616 ∗ 7748.6=1010.387 kg

3.2.2 Design of hemispherical heads

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. Most of used closing heads are curved to resist pressure,
reduce thickness and cost reduction. There are many types of closing heads and mostly used is semi-
elliptical head.

PR
t ℎ= +C
2 SE −0.2 P

10∗ 431
¿ +2=11.0167 mm
2∗ 240 ∗1 −0.2 ∗10

Mass of heads

The two heads form a sphere having external radius R0 and internal radius

4
Vh = π(R03 – R3)
3
but R 0=R +t ℎ

¿ 411+11.0167=422.0167 mm

4
V ℎ= π ( 422.0167 3 −4113)
3

¿ 24017850.153 mm 3=0.024017850153 m3

M ℎ=V ℎ ∗ ρ

28
 0.024017850153 ∗7748.6=186.1 kg

By considering that manhole and nozzles will be affected by shrinkage design pressure have to be
increased by 10% of original design pressure that is used for design of shell and the heads.

Means P= p+ 0.1 p 10+(10)0.1=11mpa

Figure 2 Head of pressure vessel

3.2.3 Design of nozzle inlet

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.. The nozzle ends are usually flanged to allow for the necessary connections and to
permit easy disassembly for maintenance or access.

take assume inlet pipe diameter di = 80mm

di 80
ri = = =40 mm
2 2

PR
tnz = +C where tn= thickness of nozzle
SE − 0.8 P

11∗ 40
= +2 E=welding S=maximum efficiency ,allowable stress
240∗ 1 −0.8 ∗11

=3.903mm P = design pressuref.s = factor of safety

29
 PD 11∗80
σ= = = 112.73Mpa Mn = mass of the nozzle
2∗ tn 2∗ 3.903

σmax 240
f.s = = =2.128 Vn =volume of cylindrical nozzle
σalow 112.73

ρ= density of material

di=internal diameter of nozzle

Mass of nozzle inlet with flange

Length of nozzle inlet and outlet is assumed to be 60mm

M n=ρ ∗ v n do= outer diameter of nozzle

π π
vn = (do2- di2)L = (87.82-802)60 = 61677.63mm3
4 4

= 0.00006167763m3

Mn = 7748.6* 0.00006167763

= 0.478kg

Mass of Flange

π π
M =v ∗ ρ= (d o 2− d i 2)L ∗ ρ= (117.82 −87.8 2)∗ 15 ∗7748.6
4 4

= 0.56kg

Mass of plate

Plate is a circular disc which used for closing the openings joined by bolt and nut fastener.

Thickness of plate is assumed to be 15mm and external diameter of plate is 117.8mm

M =V ∗ ρbut V = A ∗ t

π
¿ (117.82) ∗15=192416.738 mm 3=0.00016348266975 m 3
4

30
 M =0.00016348266975 ∗ 7748.6=1.27 kg

Total mass of nozzle inlet=0.48+0.56 +1.27=2.31kg

Figure 3inlet nozzle with flange

Figure 4 Plate closure

3.2.4 Design Of Manhole

internal diameter of manhole is assumed to be 400mm and 50mm long with relative to volume the vessel.

where; t= thickness of manhole

31
 PDmℎ
t= p=design pressure
2 SE −1.6 t

dmh =diameter of man hole

11×400
= +2 S=maximum allowable stress
2× 240 ×1− 1.6 ×11

¿ 11.515 mm ≈ 12 mm E=Design efficiency

PDmh 11×400
σmh= = =183.3 Mpa C=corrosionallowance
2t 2× 12

σmax 240
Fs¿ = =1.3 so it is safe L =length of manhloe
σℎ 183.3

Mass of manℎole =V mℎ ∗ ρ

π
V mℎ= (d o 2 – 400 2)∗ L
4

π
¿ (423.022 – 400 2)∗50=0.00074334009175 m 3
4

M mℎ=0.0074334009175 ∗7748.6=5.76 kg

Design of manhole flange

di=do+2 tmℎ=400+2(11.51)=423.02 mm di=internal diameter flange

d oflange=d i+ 60=423.02+ 60=484.02 mm do= outer diameterof manhole

assume thickness of flange to be 15 mm.

M flange=density × volume

π ( do −di ) t 3.14 ( 484.02 − 423.02 )

V flange= = ∗ 15
4 4

¿ 0.00064 m3

M flange=7748.6 ×0.00064=4.96 kg .
32
Mass of plate

Mass of manhole plate =Density × volume

π π
V plate= ( D o 2∗ t)= (484.02 2)∗15
4 4

¿=0.00275064783723 m3

M plate=7748.6 × 0.00275064783723=21.3 kg

Total mass of manℎole =5.76+ 4.96+21.3

¿ 32.02 kg

Design of bottom discharge

PR
t b= +C wℎere t b=tℎickness of bottom discℎarge
2 SE −0.8 P

11∗ 40
¿ +2 E=welding efficiency
(2 ∗240 ∗ 1)−(0.8 ∗11)

¿ 2.93 mm S=maximum allowable stress

PD
σ ℎ= P=design pressure
2∗ tn

11∗80
¿ =193.85 mpa f . s=factor of safety
2∗ 2.93

σmax 240
Fs= = =2.55
σℎ 193.85

Mass of nozzle outlet with flange

M =ρ ∗ v b wℎere M =mass of outlet nozzle

π
V b= (d o 2 −d i2) L V b=volume of bottom discℎarge
4

33
 π
¿ (85.86 2 − 802)∗60 L=lengtℎ of outlet nozzle
4

¿ 0.0000458 m 3 d 0=outer diameter of outlet nozzle

M =7748.6 ∗ 0.0000458 di=internal diameter of outlet nozzle=0.35 kg

Mass of Flange

π 2 2
Mflange = v*ρ = (Do - Di ) *t*ρ where Di=internal diameter flange
4

Di= di +2*t = 80+2*2.93 =85.86mm Do= outer diameterof outlet nozzle

Do = 85.86 + 2*30 = 145.86mm Vf=volume of outlet flange

π
Vf= (145.862-85.862)*15
4

=0.000163793m3

Mflange =7748.6*0.000163793

= 1.27kg

Mass of plate

M plate=v p ∗ ρ

π
V plate= A ∗ t= (145.86 2)∗ 15
4

¿ 0.0000250641 m3

M plate=7748.6 ∗ 0.0000250641

¿ 1.94 kg

Total outlet nozzle=1.94+1.27 +0.35=3.56 kg

34
3.2.5 Design Of Ladder
When selecting a material for ladder design, several factors should be considered, including
strength, weight, corrosion resistance, and cost. Aluminum: is lightweight, corrosion-resistant,
and offers good strength-to-weight ratio. It's also low maintenance and highly durable.
Considerations it may be more expensive than some other materials, and its impact resistance
may be lower compared to steel.

As the total length of the vessel is much higher, ladder should be essential to work on it.our
ladder is hollow rectangular bock which has a thickness of 2mm.

Mass of ladder =volume of ladder *density of material

Volume of ladder =area of ladder * total length of ladder

[ ( 25 ∗25 ) – ( 20 ∗20 ) ] ∗10

¿ 0.00225 mm 3

M =v ∗ ρ=0.00225∗ 7748.6

¿ 17.43 kg

Total mass of the system

Mass of two heads =186.6 kg

Mass of shell = 1010.38kg

Mass of fluid =1342.3kg

Mass of manhole with plate closure =32.02kg

Mass of discharge with pate and flange = 4.49kg

Mass of nozzle with plate and flange =2.31kg

Mass of ladder =17.43kg

Total mass of vessel = 2595.53kg

Weight due to load =total mass of vessel *gravity

2595.53 kg ∗ 10 m/s 2=25955.3 N

Total height of vessel =Hs+2Hh+allowances

35
 2
Vh= π R H ℎ

17649835= π ( 411 )2 ( Hℎ )

Hℎ=33.258 mm

Ht=24466+2(33.258)+2

¿ 2534.518 mm

3.2.6 Leg design

When considering materials for leg design, especially for industrial equipment such as support
structures, several key factors including strength, corrosion resistance, environmental conditions,
and structural design requirements come into play. Here are a few materials commonly used for
leg design, each with its own advantages and considerations: Mild steel offers good strength and
is generally cost-effective. It's widely used in industrial applications and can be suitable for
standard leg designs. Consideration it may be prone to corrosion in certain environments, and
additional protective coatings or treatments may be needed for long-term durability. Leg have to
be designed by considering dead load ,and wind effect that acted up on the vessel.

Load due to earthquake

F e=a e( W v / g) where ae = the acceleration of the vessel due to the earthquake

g = the acceleration due to gravity

Wv = total weight of the vessel and contents

According to real phenomena related to earthquake occurred in Ethiopian history is that

happened on 06/01/1961 in the kara kore region with a magnitude of 6.5 on richiter scale is our
design reference. It has a moderate damage and its acceleration is in the range between 0.18-
0.34(g).

F e=0.34(25955.3 /10)=882.48 N

total compressive load =load due to earthquake +dead load

36
 ¿ 882.48+25955.3=26837.78 N

The vessel is assumed to have four legs ,so the load applied on each leg is computed as

Load on single leg ¿ 26837.78/ 4=6709.445 N

Table 3 crushing stress and Rankine constant of materials

Selected material for the leg is mild steel with a given properties in table above.

Let the length of the leg is 1m =1000mm which has hollow circular geometry with hole diameter
is 0.6times external diameter but end condition leg is both ends are fixed.so effective length is
half of actual length = 500mm

P=(σ c ∗ A)∗(1/1+ ά (Le /k )2)

π 4
I= D –¿
4

π 4
¿ (0.8704 D )
4
4 2
¿ 0.0289665 D =A k

π
A= ¿
4

k =0.320156 D

load on a single leg

P=(σ c ∗ A)∗¿
2
26387.78=320∗ 0.2826 D ∗(1/ 1+ 1/7500 (500/0.320156 D)2)

37
 4 2
90.432 D – 19341.72 D −62899.52=0
2
D =¿
2
D =289.73 mm

D=17.02 mm

Internal diameter ¿ 0.8 ∗17.02 mm=13.616 mm

CHAPTER FOUR
CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION
In conclusion, the design and construction of a vertical pressure vessel capable of withstanding a
design pressure of 10 MPa and operating at a temperature of 200°C, with an internal volume of
1.6 m³, presented a series of critical considerations. The allowance of 2mm for material thickness
and the requirement for an efficiency factor of 1, utilizing low steel material, demanded
meticulous attention to safety, regulatory compliance, and structural integrity throughout the
design process.

The culmination of this design endeavor required integrated considerations spanning material
selection, precise thickness calculations, compliance with regulatory standards, and careful
allowances for material efficiency and structural stability. Integrating these elements, the vessel's
design prioritized safety, efficiency, and reliability, ensuring that it complied with the industry's
stringent safety and quality standards, particularly the ASME Boiler and Pressure Vessel Code.

38
The use of low steel material necessitated a comprehensive assessment of mechanical and
thermal properties, ensuring that the vessel design could effectively withstand the specified
pressure and temperature parameters. Considering a robust safety margin, meticulous stress
analysis, and an allowance for thermal expansion, the design aimed to ensure that the vessel
would operate safely under a range of operational conditions.

Overall, the project's conclusion emphasized the critical balance between structural integrity and
operational practicality, supporting efficiency and safety across industrial applications. The
project's successful completion underscores the commitment to delivering a compliant, reliable,
and robust solution for industrial fluid containment, ensuring safe and efficient operation while
aligning with stringent quality and regulatory standards.

By integrating these considerations, the project aimed to deliver a vertically-oriented pressure

vessel that embodies precision, reliability, and safety. The conclusion of this design endeavor
stood as a testament to the meticulous approach and commitment to engineering excellence in
ensuring the vessel's safe and efficient operation within the specified operational parameters.

39
5.2 RECOMMENDATION

It is recommended that the support system for pressure vessel design to be further developed and
modified in the future. For example, the list of materials should be provided to the user to be
chose from the system so that the user will have more choices in creating the design of pressure
vessel. As the material is listed, the allowable stress, yield strength and tensile strength should
given to the user to be selected. It is easier and time-saving in that way. Besides that, the
mechanical design of pressure vessel should include the design of head, design of shell, design
nozzle, design of flanges and covers and as well as the design of support. Then, the design of
pressure vessel will be completed. Furthermore, the support system for the pressure vessel design
is more preferable to be created in Mat lab GUI as it gives more user-friendly conditions to the
user. The programmer can be saved as the executable programmed and it can be used in any
computer without any Mat lab software.

40
 REFERENCES

ALEHEGN, S. (FEB 27, 2023). DESIGN PREJECT. In S. A. SHETU, DESIGN PREJECT (pp. 1-30).
bonga: BONGA UNIVERSITY.

Aziz, H. J. (2014). Design Support System for Pressure Vessel Design. In B. S. Iskandar, DESIGN
SUPPORT SYSTEM FOR PRESSURE VESSEL DESIGN (pp. 4-10). thoroh: Mechanical
Engineering Programme.

Kristaq Hazizi1, *. M. (2007). Design and Analysis of a Typical Vertical Pressure Vessel using ASME
Code and FEA Technique. In K. Hazizi1, Engineering Department, Bedford College, Bedford
(pp. 33-44). UK: Faculty of Arts, Science and Technology, University of Northampton,
Northampton - NN1 5PH.

Mohammad Ghaleeh. (2007). Typical Vertical Pressure Vessel. In K. Haziz, Design and Analysis of a
Typical Vertical Pressure Vessel (pp. 33-44). uk: , Faculty of Arts, Science and Technology,
University of Northampton, Northampton.

R., D. (2004). Pressure vessels-Design and construction-Handbooks, manuals, etc. I. Title. . tokyo: Gulf
Gulf .

Richardson’s, C. &. (2005). Chemical Engineering Design. tokyo: Elsevier’s Science & Technology
Rights.

Saraei., M. A. (July, 2011). “Pressure Vessel Design, Guides & Procedures”. Washington D.C. :
petrochemical industry named Hampa Energy Engineering .

41