R/1658/05 DESIGN OF PRESSURE VESSEL; BY ALELIGN FANTAYE

DIRE DAWA
INTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

MACHINE DESIGN PROJECT
TITLE: PRESSURE VESSEL
DISIGNED BY:
ALELIGN FANTAYE……………..R/1658/05

SUBMITTED TO: TEWODROS

SUBMITION DATE:

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CHAPTER CONTENTS AND PAGES

CHAPTER ONE

1.1. INTRODUCTION………………………………………………………………………………. 4
1.2. CLASSIFICATION OF PRESSURE VESSEL…………………………………………… 4
1.3. GIVEN PARAMETERS…………………..…………………………………………….………. 5
1.4. COMPONENT OF PRESSURE VESSEL…………………………………………………. 5
1.5. DETERMING THE DIAMETER AND LENGTH OF A PRESSURE VESSEL … 6
CHAPTER TWO
2.1. SELECTION OF MATERIAL………………………….…………………………………………… 8
2.2. STRENGTH……………………………………………………………………………………………. 8
2.3. Corrosion resistance………………………………………………………………………………. 9
2.4. Resistance to hydraulic attack……………………………………………………………… 10
2.5. Fracture toughness………………………………………………………………. 10
2.6. FABRICABILIY………………………………………………………………………………………… 11
2.7. CONCLUSION ABOUT THE MATERIAL SELECTION…………………………………… 11
CHAPTER THREE
3.1. WELDING TYPE…………………………………………………………………. 13
3.2. CONCLUSION ON THE TYPE OF WELDING TYPE …………………………………….. 15
CHAPTER FOUR
4.1. SHELL THICKNESS FOR INTERNAL PRESSURE…………………………………………. 16
4.2. Review different type of head……………………………………………...... 17
4.3. CALCULATE REQUIRED HEAD THICKNESS……………………………………………….. 18
4.4. HEAD TO SHELL TRANSITION……………………………………………….. 19
CHAPTER 5
5.1. SELECTION OF FLANGE BASED ON THE TEMPERATURE AND
PRESSURE RATING…………………………………………………………………………… 20
5.2. FLANGE AND GASKAT DESGIN …………………………………………………………………… 20
5.3. Flange stress …………………………………………………………………………………………….. 23
CHAPTER SIX (6)
6.1. CALCULATING WALL THICKNESS OF THE NOZZLE .………………… 27
6.2. Calculation of reinforcement required……………………… 27
6.3. DESIGN OF MANHOLE OR INSPECTION …………………………………. 28
CHAPTER SEVEN (7)
7.1. SUPORT DESIGN AND CHECK OF PRESSURE VESSLE……………… 29
7.1.1. STRESSES IN RESPONSE TO DIFFERENT LOADS……………………………………. 29
7.2. WEIGHT………………………………………………………………………………………………….. 30

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7.3. STRESS DUE TO WEIGHT………………………………………………………………………… 31

7.4. STRESS DUE TO EARTHQUAKE………………………………………………………………. 34
7.5. COMBINATION OF STRESSES…………………………………………………………………… 36
7.6. FABRICATION AND WELDING METHOD…………………………………………………. 37

REFERENCES ……………………………………………. 39

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CHAPTER ONE

1.1. INTRODUCTION
Pressure vessel is a closed container designed to hold gases or liquid at a pressure
substantially different from the ambient pressure. Pressure vessel design, manufacturing
and operation are regulated by engineering authority backed by legislation. For these
reasons the definition of a pressure vessel varies from country to country but involves
parameters such as maximum safe operating pressure and temperature.
The fluid being stored may undergo a change of state inside the pressure vessel in case of
steam boiler or it may combine with other reagents as in chemical reaction. Provide a
temperature and pressure control environment.
 APPLICATION OF PRESSURE VESSEL
Pressure vessels are used in a variety of application in both industry and private
sector. They appear in these sector as industrial compressed air receives and domestic hot
water storage tanks. Other example of pressure vessel are diving cylinders, recompression
chambers, distillation towers, pressure reactors, auto claves, and many other vessels in
mining operation, oil refineries and petrochemical plants nuclear reactor vessel, submarine
and space ship habitats, pneumatic reservoirs, hydraulic reservoirs under pressure vessel,
rail vehicle air brake reservoir and storage vessel for liquefied gases such as ammonia,
chlorine, propane, butane and LPG.
A unique application of a pressure vessel is the passenger cabin of an airline; the outer
skin carries both the air craft maneuvering loads and the cabin pressurization loads.
1.2. CLASSIFICATION OF PRESSURE VESSEL
1/ Based on the end of constriction pressure vessel are classified into open and closed
ends.
 OPEN END eg. Piston
 CLOSED END its end closed. eg. Tanks
2/ Based on the thickness and its diameter ratio
 THIN CYLINDER:
If the ratio of the thickness to the internal diameter i.e. t/d is less than about 1/20, the
cylinder is assumed to be thin cylinder. And also the thickness (t) of the shall less than 1/10
of thediameter (D) of the shell.
 THICK CYLINDER:
If the ratio of thickness to the internal diameter i.e. t/d is greater than 1/20, the
cylinder is assumed to be thick cylinder. And also the thickness(t) of the shell greater
than 1/10 the diameter(D) of the shells.

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1.3. GIVEN PARAMETERS

SPECIFICATION
 MAIN PARAMETER
Medium = paraffin oil
Inner Service Pressure, [Mpa] = [ 0.25 ]
Nominal Volume, [m3] = 1
Service Temperature, [ C ] = 250
Position = horizontal
 Supporting Element
Saddle frame
 CONNECTING PIPES
2 longitudinal & 1 lateral pipes nominal diameter, [mm] = 125
Bottom discharge nominal diameter, [mm] =40
1.4. COMPONENT OF PRESSURE VESSEL
The pressure vessel have different components
1. Vessel 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 either cylindrical, spherical, or conical in shape. Horizontal drums have
cylindrical shells and are fabricated in a wide range of diameters and lengths.

Fig.1.1. vessel shell

2. 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. Heads can
also be used inside a vessel. These “intermediate heads” separate sections of the pressure
vessel to permit different design conditions in each section.

Fig.1.2. hemispherical head

3. Saddle Frame
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

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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. The
other support is normally free to permit unrestrained longitudinal thermal expansion of
the drum.

Saddle frame

Section A.A.
Fig.1.2. Horizontal Drum on Saddle Supports
4. 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. A narrow or tapering part at the end of
a tube or pipe, used to direct or control the flow of a liquid or gas.
5. Flange
Used to coupling the pipe which the fluid enter or live the pipe to the pressure
vessel. 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.
6. MANHOL
Identical to a nozzle except it does not bolt to piping and it has a cover plate (or blind
flange), which is bolted to the flange. When unbolted it allows access to the inside of the
vessel.
1.5. DETERMING THE DIAMETER AND LENGTH OF A PRESSURE VESSEL
We know that the volume of a pressure vessel is 1m 3 and the volume is equal to the
sum of the volume of the head/bottom (hemispherical) and the volume vessel shell (which
is in cylindrical in shape).
According to process equipment design, brown ell and young suggest that the ratio of
L/D can be determined according to their presser value. And the ratio of L/D is given
blower. The pressure that was given for my operating pressure is 0.25MPa (381Psi).
 OPERATING PRESSURE is a pressure which required for the process, served by
the vessel, at which the is vessel normal operated.
 DESIGN PRESSURE is the pressure used in the design of a vessel. It recommended
designing a vessel and its parts for higher pressure than the operating pressure.
Design pressure = operating pressure+ 5 to 10 percent operating pressure
Lets select 10 percent for more safety purpose.
= 0.25 + 0.1*0.25
Design pressure = 0.275
Since the total volume is 1m3 .
Total volume = volume of two head + volume of shell

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V = Vs + 2 Vh Where V = total volume

Vs =volume of shell
Vh = volume of head
D = diameter of
R = radius of
L = length
Then Vh = 4/3*( * R3 )
Vs = π*R2*L
V =2*4/3*( * R3 ) + π*R2*L = 1m3
From table of pressure we gate the ratio of L/D = 3
L = 3D = 6R
Then V = R3 [(8/3)* π + 6π] = 1m3
R3 = 3/(26π)m3
R = 0.3325m
D = 2*R = 2*0.3325 = 0.665m
When we standardize the diameter is D = 1m
R = 0.5m
L = 3*D = 3*0.7 = 3m
These properties are very important for the selection of the material by using different
kind of standard such as ASMS.

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CHAPTER TWO
2.1. SELECTION OF MATERIAL
Many factors have to be considered when selecting engineering materials, but for Chemical
process plant the overriding consideration is usually the ability to resist corrosion. The
process designer will be responsible for recommending materials that will be suitable for
the process conditions. He must also consider the requirements of the mechanical design
engineer; the material selected must have sufficient strength and be easily worked. The
most economical material that satisfies both process and mechanical requirements should
be selected; this will be the material that gives the lowest cost over the working life of the
plant, allowing for maintenance and replacement. Other factors, such as product
contamination and process safety, must also be considered.
While selecting suitable materials, the requirements of the relevant part relating to the
function, strength, stress conditions, and service life have first of all to be considered. The
choice of material cannot be made independently of the choice of process by which the
material is to be formed, joined, finished, and otherwise treated. Cost enters, both in the
choice of material and in the way the material is processes.
 The material selection is based on the following factors:
A. Strength
B. Corrosion resistance
C. Resistance to hydraulic attack
D. Fracture toughness
E. Fabricability.
2.2. STRENGTH
Strength is the ability of a material to resist deformation. the strength of a component is
usually considered based on the maximum load that can be borne before failure is
apparent.
The strength of the material are based on the mechanical propriety of the material that used
for the most easy ,fast ,strong and low cost of production .some of the mechanical properties are
(yield strength ,ultimate tensile strength ,creep strength and rupture strength).
Yield strength: Yield strength is the region which a material changes from plastics to
elastic deformation.
Tensile strength: The tensile strength (tensile stress) is a measure of the basic strength
of a material. It is the maximum stress that the material will withstand, measured by a standard
tensile test. The older name for this property, which is more descriptive of the property, was
Ultimate Tensile Strength (UTS). The design stress for a material, the value used in any design
calculations, is based on the tensile strength, or on the yield or proof stress. Proof stress is the
stress to cause a specified permanent extension, usually 0.1 per cent.
Creep strength: Material are often pleased in a service at elevated temperature
and exposed to static mechanical stress the deformation under such circumstance is
termed creep .The time dependent and permanent deformation of material when
subjected to a constant lode and stress.

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Creep is the gradual extension of a material under a steady tensile stress, over a prolonged
period of time. It is usually only important at high temperatures; for instance, with steam
and gas turbine blades. For a few materials, notably lead, the rate of creep is significant at
moderate temperatures. Lead will creep under its own weight at room temperature and
lead linings must be supported at frequent intervals. The creep strength of a material is
usually reported as the stress to cause rupture in 100,000 hours, at the test temperature.
Rupture strength: Is the martial resistance to the fracture caused by the internal
pressure of the fluid that was present inside the tank. And it is proportional to tensile
strength(UTS) which means the martial have high UTS and it have good Rupture
strength.
Stiffness: Stiffness is the ability to resist bending and buckling. It is a function of the
elastic modulus of the material and the shape of the cross-section of the member (the
second moment of area).
Toughness: Toughness is associated with tensile strength, and is a measure of the
material’s resistance to crack propagation. The crystal structure of ductile materials, such
as steel, aluminium and copper, is such that they stop the propagation of a crack by local
yielding at the crack tip. In other materials, such as the cast irons and glass, the structure is
such that local yielding does not occur and the materials are brittle. Brittle materials are
weak in tension but strong in compression. Under compression any incipient cracks
present are closed up. Various techniques have been developed to allow the use of brittle
materials in situations where tensile stress would normally occur.
2.3. Corrosion resistance
Corrosion: Corrosion is the deterioration of a material due to interaction with its
environment. It is the Process in which metallic atoms leave the metal or form compounds
in the presence of water and Gases. Metal atoms are removed from a structural element
until it fails, or oxides build up metals, Such as gold, are subject to corrosive attack in some
environments. The corrosion of metals is a natural process. Most metals are not
thermodynamically stable in the metallic form inside a pipe until it is plugged. All metals
and alloys are subject to corrosion. Even the noble; they want to corrode and revert to the
more stable forms that are normally found in ores, such as oxides. Corrosion is of primary
concern in nuclear reactor plants. Corrosion occurs continuously throughout the reactor
plant, and every metal is subject to it. Even though this corrosion cannot be eliminated, it
can be controlled. Corrosion is also partial or complete wearing away, dissolving, or
softening of any substance by chemical or electrochemical reaction with its environment.
The term corrosion specifically applies to the gradual action of natural agents, such as air
or salt water, on metals.
The most familiar example of corrosion is the rusting of iron, a complex chemical
reaction in which the iron combines with both oxygen and water to form hydrated iron
oxide. The oxide is a solid that retains the same general form as the metal from which it is
formed but, porous and somewhat bulkier, is relatively weak and brittle.
Chemical Cast iron Aluminum Nickel Copper Steen less
steel18Cr/8Ni(304)

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Oil G G C C G
Table2.1. Corrosion property
Where: G-good and C-caution-depending on the martial
2.4. Resistance to hydraulic attack
The tensile strength (UTS) and elastic modulus of metals decrease with increasing
temperature. The temperature that give for my presser vessel is 250 0C (482F) above 600F,
hydrogen attack cause irreparable damage through the component thickness & can
damaged carbon and low alloy steel.
Hydrogen attack differs from corrosion in that damage occurs throughout the thickness of
the component, rather than just at its surface, and occurs without any metal loss. In
addition, once hydrogen attack has occurred, the metal cannot be repaired and must be
replaced. Thus, it is not practical to provide a corrosion allowance to allow for hydrogen
attack. Instead, materials are selected such that they are resistant to hydrogen attack at the
specified design conditions.
Hydrogen attack is a potential design factor at hydrogen partial pressures above
approximately 100 psia. Material selection for these hydrogen service applications is based
on API 941, Steels for Hydrogen Service at Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical Plants. API 941 contains a family of design curves
(the Nelson Curves) that are used to select appropriate material based on hydrogen partial
pressure and design temperature.

Material Cast Aluminum copper Steen less steel

iron 18Cr/8Ni(304)
Tensile 414 90 200 510
strength(ULT)Ma
p
Design stress at -- -- -- 110
temperature
(2500C)Map
Table2.2. temperature
2.5. Fracture toughness
Fracture toughness: Ability of material to withstand conditions that could cause brittle
fracture.
 Brittle fracture
– Typically at “low” temperature
– Can occur below design pressure
– No yielding before complete failure
 Conditions required for brittle fracture
– High enough stress for crack initiation and growth
– Low enough material fracture toughness at temperature
– Critical size defect to act as stress concentration

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 Fracture toughness varies with:

- Temperature
- Type and chemistry of steel
- Manufacturing and fabrication processes
 Other factors that influence fracture toughness:
- Arc strikes, especially if over repaired area
- Stress raisers or scratches in cold formed thick plate
Metal alloys Aluminum Copper Cast iron Stain less steel18Cr/8Ni(304)
Yield strength 35 69 197 205
(Map)
UTS (Map) 90 200 414 510
Fracture 44 LOW LOW 76
toughness(K),
(Map)

Table2.3. Property of selected material

2.6. FABRICABILIY
Fabricability is a measure of the ease with which a material can be worked and made into
desirable shapes and forms.
Based on how it made and cost of production. A guide to the fabrication properties of
common metals and alloys are shown blow.
S -satisfactory
D -Difficult, special techniques needed.
U - Unsatisfactory.
Martial Mashing Cold Hot Castin Welding Annealing
work work g temperate(co)
Cast iron S U U S U/D _
Stainless S S S D S 1050
steel(18Cr,8Ni)30
4
Nickel S S S S S 1150
Aluminum S S D S S 550
Copper(dioxides) D S S S D 700
Table. fabricability.
S - satisfactory

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D - Difficult, special techniques needed.

U – Unsatisfactory.
2.7. CONCLUSION ABOUT THE MATERIAL SELECTION
 I select stainless steel because it has good yield strength(205MPa), tensile(UTS)
strength(510MPa), good fracture toughness, good resistance of temperature, good
corrosion resistance and it can fabricate in different mated except casting.

Material Tensile strength Modulus of Hardness Specific

(UTS), Map elasticity, Gap Brunel gravity
Stainless steel 510 210 160 8.0
18Cr/8NI (304)
Table. Revision of property of stainless steel.

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CHAPTER THREE
3.1. WELDING TYPE
Welding, in engineering, any process in which two or more pieces of metal are joined
together by the application of heat, pressure, or a combination of both. There are several
methods to make welded joints. In a particular case the choice of a type from the numerous
alternatives depend on:
1. The circumstances of welding.
2. The requirements of the code.
3. The aspect of economy.

THE CIRCUMSTANCES OF WELDING:

In many cases the accessibility of the joint determines the type of welding. In a small
diameter vessel (under 18-24 inches) from the inside, no manual welding can be applied.
Using backing strip it must remain in plate. In larger diameter vessels if a man way is not
used, the last (closing) joint can be welded from outside only. The type of welding may be
determined also by the equipment of the manufacturer.
CODE REQUIREMENTS:
Regarding the type of joint the Code establishes requirements based on service, material
and location of the welding. The welding processes that may be used in the construction of
vessels are also restricted by the Code. The Code-regulations are tabulated on the following
pages under the titles:
(a). TYPES OF WELDED JOINTS: Joints permitted by the code, their efficiency and
limitations of their application. Table UW-12
Type-1 Type-4
Type-2 Type-5
Type-3 Type-6

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(b). DESIGN OF WELDED JOINTS: Types of joints to be used for vessels in various services
and under certain design conditions.) UW-2, UW-3
(c).JOINT EFICIENCIES AND STRESS REDUCTIONS: Efficiencies of joints at certain
locations and reduced allowable stress to be used in calculations of vessel components.
The data of the table are based on the following Code regulations: Full, spot, partial
radiographic examination or no radiography of A, B, and C joints. UW-11
For longitudinal stress calculation the efficiency of partially radio graphed joints is the
same as for spot radio graphed joints. Seamless vessel sections and heads with Category
B,C or D butt joints that are spot radio graphed shall be designed for circumferential stress
using a stress value equal to 85% of the allowable stress value of the material; UW-12(b)
When the joints are not radio graphed and for joint efficiency, E the value in column of
table “Types of welded joints” are used, in all other design calculation, a stress value equal
to 80% of the allowable stress value of material shall be used except for unstained flat
heads, etc. UW-12(c)
 THE ECONOMY OF WELDING:
If the two preceding factors allow free choice, then the aspect of economy must be the
deciding factor.
Some consideration concerning the economy of welding-edge preparation, which can be
made by torch cutting, is always more economical than the use of J or U preparation.
Double V preparation requires only half the deposited weld metal required for single V
preparation.
Increasing the size of a fillet weld, its strength increases in direct proportion, while the
deposited weld metal increases with the square of its size. Lower quality welding makes
necessary the use of thicker plate for the vessel. Whether using stronger welding and
thinner plate or the opposite is more economical, depends on the size of vessel, welding
equipment, etc. this must be decided in each particular case.
There are different kind of welding based on IS-28-25 it categorized in to 4 select
(A) category A: longitudinal welded joints within the main sheet, communicating,
Chambers, nozzles and any welded joints within a formed or flat Head.
(B) Category B: circumferential welded joints within the main shell communicating
chambers, nozzles and transitions in diameter including joints between the translations
and a cylinder at either the large of small end, circumferential welded joints connecting
from heads to main shells to nozzles and to communicating hampers.

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(C) Category c: welded joints connecting flanges, tubes sheets and flat heads to
main shells, to formed heads, to nozzles or to communicating chambers and any welded
joints connecting one side plate to another side plate of a flat sided vessel.
(D) Category d: welded joints connecting communicating chambers or nozzles to
main shell, to heads and to flat sided vessels and those joints connecting nozzles to
communicating chambers

Fig. weld joints –typical location and category of welds

3.2. CONCLUSION ON THE TYPE OF WELDING TYPE
I select Category A (type 1) and butt joint for the shell and head. And its radiographic
examination (full), joint efficiency is (E=1).
Property of the selected welding

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CHAPTER FOUR
4.1. SHELL THICKNESS FOR INTERNAL PRESSURE
The body of static equipment under pressure is in many cases a cylindrical shape. The
shell thickness calculation is to calculate the wall thickness of a cylinder, cone,, and sphere
under pressure. And it is therefore a basic strength calculation. Calculation codes are ASME
rules.
To find the thickness of the pressure vessel which subjected to internal design
pressure of P=0.25MPa there are different equations and its corrosion allowance for
stainless steel 18Cr/8Ni(304) is (2mm) from the table. There will be a minimum wall
thickness required to ensure that any vessel is sufficiently rigid to withstand its own
weight, and any incidental loads.
Terms used in this calculation
t = min. required thickness of shell, mm
P = internal design pressure, Pa
R = inside radius of shell, mm
S = max. Allowable stress, Pa
E = joint efficiency (min)
C.A=corrosion allowance, mm
D=inside diameter, mm
Pm=minimum allowable working pressure (design pressure) in Mpa
Where
Pm= S*E*t /(R+0.6P) and t= (PR /SE-0.6P) + C.A
Given parameters
P=0.25Mpa,
R=0.5mm,
C.A=2mm,
S=110Mpa, ……………………………… Ref[1]
E=1
Req.
Thickness, t ?
Solution:
 Case 1 using
(A)Circumferential stress (longitudinal joint)

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In this the given internal pressure should be less than 0.385SE in order to be acceptable for
the pressure.
P ≤ 0.385SE
P ≤ 0.385*110MPa*1
0.25MPa ≤ 42.35MPa ---------------- (satisfied)
Therefore t=PR/ (SE-0.6P) + C.A
t = (0.25*0.5) / (110*1-0.6*0.25) + 0.002
t = 0.00314m
t = 3.14mm ---------------------------------- (ans)
 case 2 using
(b) Longitudinal stress (circumferential stress)
P ≤ 1.25SE
P ≤ 1.25*110MPa*1
0.25MPa ≤ 137.5MPa ------------------ (satisfied)
There for t =PR/(2SE+0.4P) + C.A
= (0.25MPa*0.5m)/ (2*110MPa*1 + 0.4*0.25MPa) + 0.002m
t = 0.00258m = 2.58mm
t=2.58mm --------------------------------------- (ans)
From the above two cases we take the smallest thickness to minimize the weight. Since, as
we increase the thickness we are also increasing the weight of the vessel that can harm the
support legs. So the minimum thickness is 2.58mm and it should be approximated to the
standard thickness of a pressure vessel i.e. 5mm (from table). Ref [1]

Therefore t= 5mm
To find the external radius and diameter we can use these formulas.
R0= R+ t = 0.5 + 0.005 => R0 = 0.505m
D0=2*Ro=2*0.505 => D0 = 1.01m
4.2. Review different type of head
There are different kinds of pressure vessel closed heads. Some of them are listed blow

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A) Flanged head
B) Hemispherical head
C) Elliptical head
D) Torispherical head
E) Conical head
F) toriconical head

Where P=internal design pressure

E=joint efficiency
R0= external radius
Ri=internal radius
S= allowable shear
t=thickness of the head
A) Flanged head
Formed domed heads are made with a short straight cylindrical section, called a
flange or skirt. This ensures that the weld line is away from the point of discontinuity
between the head and the cylindrical section of the vessel.
B) ASMS hemispherical
The design thickness of hemispherical head is given by
t=PR/ (2SE-0.2P)
C) ASMS elliptical head
The design thickness of elliptical head is given by
t=PDK/ (2SE-0.2P) where D-shell diameter,
K-stress intensity factor
2
K= [1/6 + (a/b) ] a and b semi-major, semi-miner axes of ellipse
D) ASMS Torispherical head
The design thickness of Torisphericalhead is given by
t=PLM/ (2SE-0.2P) where L-spherical cross radiuses
1/2
M=1/4[1/3 + (L/R) ] M-shear intensity factor
R-knuckle radiuses
E) ASMS conical head
The design thickness conical head is given by
t=PD/2cosα (SE-0.6P) where α-seem-apex angel
F) ASMS toriconical head
The design thickness toriconical head is given by
For conical region tic= PD/2cosα (SE-0.6P)
For Torispherical region to=PLM/ (2SE-0.2P)
M=1/4[1/3 + (L/R) 1/2] M- shear intensity factor
L=D1/cost

4.3. CALCULATE REQUIRED HEAD THICKNESS

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My pressure vessel is hemispherical head in shape and 0.25MPa internal design pressure
is applied on it and it’s thickness is given below
According on the two theory
1) thin-shell theory
S= (PR)/ (2t)
2) ‘’exact’’ theory
S= [PRi3/R30-R3i] [1+R30/2R3i]
Given values
Ri =0.5m
Ro=0.505m
P=0.25MPa
t=0.005m=5mm
E=1
C.A=2mm=0.002m
1) thin-shell theory
S= (PR)/ (2t)
S= (0.25MPa*0.505m)/ (2*0.005m)
S=12.625MPa ---------------------------------------------- (ans)
2) ‘’exact’’ theory
S= [PRi3/ (R30-R3i)] [1+R30/2R3i]
S= [(0.25MPa)*(0.505m) 3/ (0.5053-0.53) m3] *[1 + (0.5053/2*0.53)]
S=12.9MPa ------------------------------------------------------- (ans)
Therefore, lets find the head thickness and take the largest value for S=12.9MPa.
the =PRi/ (2SE-0.2P) + C.A
= (0.25MPa*0.5m)/ (2*12.9MPa*1 – 0.2*0.25MPa) + 0.002m
the = 0.00685m=6.85mm ---------------------------(ans)
4.4. HEAD TO SHELL TRANSITION
To joined the head and shell I use butt walled joint according on the (category a see page
11) and the head shell have deferent thickness in according to CODE UW-9(c),UW-13.
Joining of a plate unequal thickness with butt weld, the thickness of the plate shall be
tapered is more than 3.125mm (1/8in). Ref [2]

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Fig 6.waldig type of head to shell

Thickness of head (th=24mm) and shell (ts=30mm), their deference (6mm) is greater than
3.125mm (1/8in) or 3.175mm.
l ≥ 3*y and y=6mm
l ≥ 18mm.
CHAPTER 5
5.1. SELECTION OF FLANGE BASED ON THE TEMPERATURE AND
PRESSURE RATING
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 pipe work will
normally be welded to reduce costs. Ref [1]
.
The material I select is Alloy steel ANSI B16.5 Ref. [2]
Several different types of flange are used for various applications. I select Welding-neck
flanges with Narrow-faced (where the face contact area is located within the circle of
bolts); because, Welding-neck flanges are 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. Ref [1]
The given temperature is 250oC (482oF) and pressure is 0.25MPa (381PSi) is standard.
Carbon steel class 150 flange would be specified for temperatures below 300°C; Ref [1]
Class 150lb.
Hydrostatic test/design pressure MPa(PSi) 0.25Mpa(381psi)
o
Temperature , C Maximum allowable non-shock pressure,
MPa(PSi)
0
250 C 0.18Mpa(274.32psi)

 There are 3 flange that I used for my pressure vessel their value is shown
blow.
 Two longitudinal pipe with D=125mm(4.92in).
 One lateral pipe with D=125mm (4.92in).
 Bottom discharge D=40mm (1.575in)

5.2. FLANGE AND GASKAT DESGIN

 The laod on the flange can be given as fallow
Hg = gasket reaction (pressure force), = π+-G(2b)mPi
Ht; = pressure force on the flange face = H – Hd,
H = total pressure force = (π/4) G2Pi,

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Hd = pressure force on the area inside the flange =(π/4) B2Pi,

G = mean diameter of the gasket,
2b = effective gasket pressure width,
b = effective gasket sealing width,
m=gasket factor
Pi=internal pressure of flange = 1.8Mpa (from table)
A= Diameter of the bore, mm(in)
B=in side diameter of a flange for each pipe = A/2
tf=thickness of flange tf =J
hd= (G + H – 2E)/4
hg= (H - G)/4
ht= (G + H)/4
G’=mean diameter of gasket = B + (ht-hg)
E =Diameter of the hub at the point of welding
The minimum required bolt load under the operating conditions is given by:
Wm1= H + Hg
The forces and moments on the flange must also be checked under the bolting-up
conditions.
 The moment Matm is given by:
Matm = Wm2 hg
where Wm2 is the bolt load required to seat the gasket, given by:
Wm2 = yπGb
where y is the gasket seating pressure (stress).
o The moment on the flange is
Mop = Hd * hd + Ht * ht + Hg * hg
 Let’s calculate the laod and moment
There gasket factor width and internal pressure for the flange are the same:
b= 10mm,
m= 2 (asbestos gasket)
y= 11N/mm2
Pi= 1.8bar=0.18Mpa

Nominal Diameter Length Diameter Diameter Outside Thickne Outside boltin

pipe size, of the through of the hub of the hub diameter ss of the diameter g
mm(in) bore, the hub at the at the flange flange the
mm(in) [C] point of base [G] [H] [J] raised

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[A] welding face [K]

[E]
40(1.575) 46.7(1.84 63.5(2.5 60.5(2.38) 77.8(3.06 152.4(6) 19.05(0. 92.075( M16
) ) 25) 75) 3.625)
125(4.92 128.27(5. 88.9(3.5 141.224(5. 163.5(6.4 254(10) 23.8(0.9 185.74( M24
) 05) ) 56) 375) 375) 7.3125)

Table. Flanges standard ANSI B16. Ref [2]

Therefore,

The, hd = (G + H - 2E)/4
For 40mm, hd = (77.8+152.4-2*60.5)/4=27.3mm
For 125mm, hd = (163.5+254-2*141.224)/4=33.8mm
The, hg= (H - G)/4
For 40mm, hg = (152.4-77.8)/4=18.65mm
For 125mm, hg = (254-163.5)/4=22.625mm
The, ht= (G + H)/4
For 40mm, ht = (77.8+152.4)/4=57.55mm
For 125mm, ht = (163.5+254)/4=104.375mm
The, tf =J
For, 40mm tf =19.05mm
For, 125mm tf =23.8mm
The, B = A/2
For, 40mm B = 46.7/2=23.35mm
For, 125mm B =128.27/2=64.135mm
The, G’= B + (ht-hg)
For, 40mm G’= 23.35+(57.55-18.65)=62.25mm
For, 125mm G’=64.135 + (104.375-22.625)=145.885mm
The, H= (π/4) G’2Pi
For, 40mm H = (π/4)*62.252 mm2*0.18Mpa=547.8N
For, 125mm H= (π/4)*145.8852mm2*0.18Mpa=3008.73N
The, Hd= (π/4) B2Pi
For, 40mm Hd = (π/4)*23.352mm2*0.18Mpa=77.08N
For, 125mm Hd = (π/4)*64.1352mm2*0.18Mpa=581.5N
The, Ht=H-Hd
For, 40mm Ht=547.8-77.08=470.72N
For,125mm Ht= 3008.73-581.5=2427.23N
The, Hg=πG’ (2b)mPi
For, 40mm Hg=π*62.25mm*(2*10mm)*2*0.18Mpa=1408.06N
For, 125mm Hg=π*145.885mm*(2*10mm)*2*0.18Mpa=3299.84N
 The moment is

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Mop=Hd*hd + Ht*ht + Hg*hg

For 40mm pipe,
Mop=77.08*27.3+470.72*57.55+1408.06*18.65
=55454.5Nmm=55.4545Nm
For 125mm pipe,
Mop=581.5*33.8+2427.23*104.375+3299.84*22.625
=347656Nmm=347.656Nm
 The minimum load required bolt load under the operating condition given by
Wm1=H + Hg
Wm1, 40mm=547.8+1408.06=1955.86N
Wm1,125mm=3008.73+3299.84=6308.57N
 The force and the momentum must be checked under the bolting up conditions.
The moment is given by
Matm=Wm2*hg
 Where Wm2 is the bolt load required to sat the gasket, given by
Wm2=yπG’b
y=gasket sating pressure (stress)=11MPa (from table) Ref [1]
Then, Wm2, 40mm=11MPa*π*62.25mm*10mm=6847.5N=6.8475KN
Matm,40mm=6.8475KN*18.65mm=127.7KNmm=127.7Nm
Wm2, 125mm=11MPa*π*145.885mm*10mm=50414N=50.414KN
Matm,125mm=50.414KN*22.625mm=1140.6KNmm=1140.6Nm

5.3. Flange stress

where M is taken as Mop or Matm, whichever is the greater; and the factors F1, F2, F3 &
F4 are funtctions of the flange type and dimensions, and are obtained from equations and
graphs given in the codes and standards (BS 5500, clause 3.8). Ref [1]
 They are obtained as followed, Ref [2] & Ref [3]
F1= 1/λ gt2 gt= (G-A)/2
λ=δ + γδ=t3/d and δ=t3/d, γ=α/T, α=tf e+1
d= (u/v)hogo2 , go=J and ho= (B’go)1/2=(B’J)1/2=(u/v)(B’J)1/2J2, B’=(G-A)/2
F2=β/λtf2 tf=thickness of the flange=J
β=1.333tfe+1
F3=y/t2 y=(1-v2)u
F4=z z=k-factoer
K=A’/B’ A’= (H-G)/2 and B’=(G-A)/2

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K= (H-G)/(G-A)
K40mm= (6-3.0625) in./ (3.0625-1.84)in.
= 2.403
K125mm= (10-6.4375) in./ (6.4375-5.05)mm
=2.56

Nominal pipe K T Z Y, MPa(Psi) U

Dia. (mm)
40 2.403 1.37 1.42 2.36 2.59
125 2.56 1.32 1.36 2.19 2.41
Table 10.value of (K, T, Z, Y and U) R [3]
Y-gasket seating design stress
 Let’s find the value of (e)
e=F/ho =F/(B’J)1/2
Let’s find the value of F (in y-axis) by using ASME code, section viii, Dev 1.in x-axis
g1/go(or B’/J) and (**)
h/ho(or (C-J)/(B’-J)1/2)
After calculating of this value I fined F for each flange
and the values are shown blow.
F40mm=0.805
F125mm=0.86
e=F/ho =F/(B’J)1/2=F/(((G-A)/2)*J)1/2
e40mm=0.805/17.21mm=0.0468/mm
e125mm=0.86/20.475mm=0.042/mm
Then lets find (α and β)
α=tf e+1=Je+1
α40mm=19.05mm(0.0468/mm)+1=1.89
α125mm=23.8mm(0.042/mm)+1=1.9996
β=1.333tfe+1
β40mm=1.333*19.05mm(0.0468/mm)+1=2.1884
β125mm=1.333*23.8mm(0.042/mm)+1=2.3325
and γ=α/T
γ40mm=1.89/1.37=1.38
γ125mm=1.9996/1.32=1.515
lets find the value of v from ASME code Viii Div. 1 using by the value of (**) and it will be
v40mm=0.402
v125mm=0.31
d= (u/v)hogo2=(u/v)(B’J)1/2J2will be
d40mm=(2.59/0.402)(17.21mm)(19.05mm) 2
=40240mm3
d125mm=(2.41/0.31)(20.475)(23.8mm)2
=90464mm3
The value of δ=t3/d will be
δ40mm=(19.05mm)3/40240mm3
=0.0004734

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δ125mm=(23.8mm)3/90464mm3
=0.000263
Let’s find the value of λ=δ + γ
λ40mm=0.0004734+1.38*=1.3604734
λ125mm=0.000263+1.515=1.515263
y=(1-v2)u will be
y40mm= (1-0.4022)2.59=0.926
y125mm= (1-0.312)2.41=1.1474
gt=(G-A)/2 will be
gt =(77.8-46.7)/2=15.55mm
gt =(163.5-128.27)/2=17.615mm
 Then, F1= 1/λ gt2, F2=β/λt2, F3=y/t2, F4=z
Nominal Dia. F1(1/mm2) F2 (1/mm2) F3(1/mm2) F4
(mm)
40 0.0473 0.00443 0.00255 1.42
125 0.0375 0.002718 0.002026 1.36
Table 11.value of the constant
To find the stress on the flange we must the value of the moment M and it is the largest
of them(Mop/B’ or Matm/B’). And it is given blow
Nominal diameter(mm) Mop, (Nm) Matm(Nm)
40 55.4545 127.7
125 347.656 1140.6
Table
Therefore, M=Mop/B’ the stress is
 Longitudinal hub stress σhb=F1M
For 40mm=0.0473(1/mm2)(127.7Nm/15.55mm)
=0.38844MPa
For 125mm=0.0375(1/mm2)(1140.6KNmm/17.615mm)
=2.43MPa
 Radial flange stress σrd=F2M
For 40mm=0.00443(1/mm2)(127.7KNmm/15.55mm)
=0.03638MPa
For 125mm=0.002718(1/mm2)(1140.6KNmm/17.615mm)
=0.2MPa
 Tangential flange stress σtg =F3M-F4σrd
For 40mm =0.00255(1/mm2)(127.7KNmm/15.55mm)-(1.42*0.03638)MPa
=0.031MPa
For 125mm =0.002026(1/mm2)(1140.6KNmm/17.615mm)-1.36*0.2MPa
=0.14MPa
The flange must be sized so that the stresses given by equations satisfy the following
criteria: when ffo=8.202MPa(12.5KPSi) is the maximum allowable design stress for the
flange material at the operating conditions. R[1] and [2]
σhb > 1.5ffo

For 40mm 0.3884MPa > 1.5*(8.202)MPa=12.303 ---- (satisfied)

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F0r 125mm 2.43MPa >1.5* (8.202)MPa =12.303---- (satisfied)

σrd > ffo

For 40mm 0.03638MPa >8.202MPa ------- (satisfied)

For 125mm 0.2MPa > 8.202MPa ------ (satisfied)

0.5(σhb+σrd) > ffo

For 40mm 0.2124MPa > 8.202MPa --- (satisfied)

For 125mm 1.315MPa > 8.202MPa --- (satisfied)

0.5(σhb+σtg) > ffo

For 45mm 0.20972MPa > 8.202MPa --- (satisfied)

For 80mm 1.285MPa > 8.202MPa --- (satisfied)

The bolt spacing must be selected to give a uniform compression of the gasket. It
will not normally be less than 2.5 times the bolt diameter, to give sufficient clearance for
tightening with a wrench or spanner. The following formula can be used to determine the
maximum bolt spacing:
From the table R [1] and R [2] the material [SA-193-B7] and maximum allowable stress (f b)
for the bolt is 172.37MPa(25KPSi).
The minimum bolt area is given by
Abf=Wm/fb
Where Wm greatest of Wm1or Wm2
Nominal Dia.(mm) Wm1(KN) Wm2(KN)
40 1955.86 6.8475
125 6308.57 1140.6
Table13.
Abf=Wm1/fb
For 40mm =1955.86/8.202MPa=238.46mm2
For 125mm =6308.57KN/8.202MPa=769.15mm2
The bolt spacing must be selected to give a uniform compression of the gasket. It will
not normally be less than 2.5 times the bolt diameter, to give sufficient clearance for
tightening with a wrench or spanner. The following formula can be used to determine the
maximum bolt spacing:

Pb=2db+6tf/ (m+0.5)
Where Pb-bolt pitch (spacing), mm
db- bolt diameter, mm
tf- flange thickness, mm
m- Gasket factor, 1.25
Pb will be
For 40mm
=2*16mm+6*19.05mm/(2+0.5)=77.72mm

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For 125mm
=2*24mm+6*23.8mm/(2+0.5)=105.12mm

CHAPTER SIX (6)

6.1. CALCULATING WALL THICKNESS OF THE NOZZLE Ref [2]
To find the thickness of the nozzle
tn= PR/ (SE-0.6P) +
C.A
Where tn-thickness of the flange
P-maximum allowable
E-joint efficiency (E=1)
S-maximum allowable stress
R-internal radius of the pipe
C.A-corrosion allowance
For my nozzle I selects SA-106-B from the table and S= MPa(KPSi). Ref [2]
Given
Nominal Dia. (mm) P, MPa(PSi) C.A, mm(in) Radius(mm)
40 21.6 (3139) 1.6 (1/16) 20
125 20.6 (2992) (3/16) 40
Table,
E=1 S=83.63MPa
Therefore, tn will be:
tn,40mm=[(21.6MPa*20mm)/(83.63MPa*1- 0.6*21.6MPa)]+1.6mm
=7.7mm
tn,125mm=[(20.6MPa*40mm)/(83.63MPa*1-0.6*20.6MPa)]+4.8mm
=16.4mm
6.2. Calculation of reinforcement required
The "equal area method" is the simplest method used for calculating the amount of
reinforcement required, and is allowed in most design codes and standards. The principle
used is to provide reinforcement local to the opening, equal in cross-sectional area to the
area removed in forming the opening. If the actual thickness of the vessel wall is greater
than the minimum required to resist the loading, the excess thickness can be taken into
account when estimating the area of reinforcement required. Similarly with a branch
connection, if the wall thickness of the branch or nozzle is greater than the minimum
required, the excess material in the branch can be taken into account. Any corrosion
allowance must be deducted when determining the excess thickness available as compensation.
The standards and codes differ in the areas of the branch and shell considered to be effective for
reinforcement, and should be consulted to determine the actual area allowed and the disposition
of the various types of reinforcement. For branch connections of small diameter the
reinforcement area can usually be provided by increasing the wall thickness of the branch pipe.
Ref [1]
 First calculate the reinforcement area, Ref [3]

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A=D*t*F, where, tr-shell thickness=0.64((D+ tn)tn)1/2

F-correction factor=1
D-diameter of the pipe
tn - nozzle material thickness
E-joint efficiency=1
t- Shell material thickness= (for shell 30mm or for head 24mm)
A=D*t*F
A40mm=40mm*12.3mm*1=490.62mm2
A125mm=125mm*30.82mm*1=1852.5mm2
 By taking A1 as the largest of the A11 or A12 calculating the reinforcement area of the
vessel
A11= (Et-F*tr) D and A12=2(E*t-F*tr)*(t + tn)
A11, 40mm = (1*30mm-1*12.3mm) 40mm=708mm2
A12, 40mm =2(1*30mm-1*12.3mm) (30mm+12.3mm) =1497.42mm 2
A11, 125mm = (1*30mm-1*30.82mm) 125mm=102.5mm2
A12, 125mm =2(1*30mm-1*30.82mm) (30mm+16mm) =75.44mm 2
 Therefore, A1 (reinforcement in shell) will be the largest value of (A 11 or A12)
A1, 40mm=708mm2
A1, 125mm=1497.42mm2
 By taking A2 as the smaller of A11 or A22 and calculate the available nozzle wall.
A21= ( tn - trn)5t and A22=2( tn - trn)(2.5tn-te), te=0(no pad)
A21, 40mm=(30mm-12.3mm)5*7.7mm=177.7mm2
A22, 40mm=2(30mm-12.3m)(2.5*7.7mm-0)=390mm2
A21, 125mm=(30mm-16.4mm)5*125mm=8500mm 2
A22, 125mm=2(30mm-16.4mm)(2.5*16.4mm-0)=1115.2mm 2
A2 will be
A2, 40mm=8500mm2
A2, 125mm=1115.2mm2
total Atotal=A1+A2
A40mm, total = (708+8500) mm2=9208mm2
A125mm, total = (1115.2+1497.42) mm2=2612.62mm2
Nominal Dia.(mm) Atotal(mm2) A(mm2)
40 9208 490.62
125 2612.62 1852.5

6.3. DESIGN OF MANHOLE OR INSPECTION Ref [9]

All pressure vessels for use with compressed air and those subject to internal corrosion,
erosion or mechanical abrasion, shall be provided with suitable manhole, hand hole, or
other inspection openings for examination and cleaning. The required inspection openings

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shown in the table below are selected from the alternatives allowed by the Code, UG46, as
they are considered to be the most economical. Ref [9]
The inside diameter of my pressure vessel is 1m(39.37in).
According to the diameter its manhole recommended is 381mm(15in). Ref [9]
Di mm(in) Inspection opening required, mm(in)
1000(37.37) 381(15)
Table

CHAPTER SEVEN (7)

7.1. SUPORT DESIGN AND CHECK OF PRESSURE VESSLE
7.1.1. STRESSES IN RESPONSE TO DIFFERENT LOADS
The method used to support a vessel will depend on the size, shape, and weight of vessel;
the design temperature and pressure; the vessel location and arrangement; & 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
localised loads on the vessel wall and the design must be checked to ensure that the
resulting stress concentration are below the maximum allowable design stress. Supports
should be designed to allow easy access to the vessel and fittings for inispection and
maintenance
Design of saddles
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 120Ž , and will not normally be greater than 150Ž .
Wear plates are often welded to the shell wall to reinforce the wall over the area of contact
with the saddle. The dimensions of typical “standard” saddle designs are given in Figure
below. To take up any thermal expansion of the vessel, such as that in heat exchangers, the
anchor bolt holes in one saddle can be slotted.
A) DUE TO INTERNAL PRESSURE Ref. [2]
As we are treating methanator as a thin cylinder so the values of hoop stress & longitudinal
stress are calculated as under. Therefore radial stresses are ignored (very small) so we
consider the following primary membrane stresses.
(a)Hoop Stresses and (b) Longitudinal Stresses
 HOOP STRESSES (S 1)
S1 = PiDi /2t
= (0.18MPa) (1000mm) / 2(30mm)
= 3MPa
 LONGITUDINAL STRESS (S 2)

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S2 = PiDi/ 4t
= (0.18MPa) (1000mm) / 4(30mm)
= 1.5MPa
As hoop stress is greater so design is based on hoop stress. Ref. [2]

b) STRESS DUE TO WEIGHT OF VESSEL & ATTACHMENT

It is assumed that weight of the vessel and its attachments results in compressive stress
only & eccentricity doesn’t exist and the resulting force coincides with the axis of the
vessel.
The weight shall be calculated for the various conditions of the tower as follows.
A. Erection weight
B. Operating weight
C. Test weight
The compressive stress due to the weight is given by
S = W / ct --------------------------------------------- (a)
Where S = unit stress, MPa
W = weight of vessel above the section under consideration, N
c = circumference of shell or skirt on the mean diameter, mm
t = thickness of shell or skirt, mm
The weights of different vessel elements are given in the tables attached. Ref. [2]
7.2. WEIGHT
A)ERECTION WEIGHT
1) SHELL=ρshell*Vshell *g
=8,000Kg/m3*2.356m3*9.81m/s2=185.1KN
2) HEADS = ρhead*Vhead*g
=8,000Kg/m3*0.524m3*9.81m/s2 =41.2KN
3)FLANGES (6) = n* (SIZE) = 7*mflange*g=7*2485.7kg*9.81m/s2
=170.7KN
ERECTION WEIGHT=(185.1+41.2+170.7)KN=387KN --------------- (ANS)
B) OPERATING WEIGHT

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Which include the weight of the erection + operating liquid

ERECTION WEIGHT = 387KN
WEIGHT FOR OPERATING LIQUID = ρliquid*vpressure vessel*g
= 800Kg/m3*1m3*9.81m/s2
=7.85KN
Total weight=7.85KN + 387KN=394.85KN ------ (ans)

7.3. STRESS DUE TO WEIGHT

Putting values in the formula (a)
Where, c = π * D mean = π*1000mm =3142mm
t = 30mm
Sw = 394.85KN/(3142mm*30mm) =4.2MPa (compressive)----------(1)
c) STRESS DUE TO WIND LOAD:
Towers under wind pressure are considered as uniformly loaded cantilever beams. The
computation of wind is based on standard ANSI A58.1-1982. Where terrain features and
local records indicate that 50 years at standard height are higher than those shown in the
map, those higher values shall be the minimum basic wind speed.
The minimum basic wind speed for determining design wind pressure shall be taken
from the map of wind speed. Design wind pressure shall be determined by the following
formula:-
F=wind load=q*G*Cf* A
P = qs*G*Cf A/A=q*G*Cf
Where, P= Design wind pressure, MPa
q = Wind stagnation pressure at the standard height of 9.144m (30 feet) as
tabulated:
Basic wind speed, 70 80 90 100 110 120 130
mph, V
Pressure PSf, q 13 17 21 26 31 37 44
Table wind pressure Ref. [2]
Cf = Pressure coefficient (shape factor):
Round or elliptical towers----------------------------0.8

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G = Combined height, exposure and gust factor coefficient as tabulated:

Height above ground, ft. Coefficient G

Exposure C Exposure B
0-20 1.2 0.7
20-40 1.3 0.8
40-60 1.5 1.0
60-100 1.6 1.1
100-150 1.8 1.3
150-200 1.9 1.4
Table 17 .Coefficient of C and B Ref [2]
Exposure C---------------------The most severe exposure
Exposure B ---------------------Intermediate exposure
For the methanator we will take a wind speed of 112.7Km/hr(70mph), so the
value of
qs =0.089MPa (13psf)
Cf = 0.8-------------------------For circular vessel
G = 1.3 ---------------Intermediate exposure & vessel height of 6.524m(21.4ft)
There for the value of wind pressure using the above formula will be;
P = 0.089MPa
We will take the wind pressure 0.089MPa.
QUANTITIES FORMULAS
Shear V= Pw*D1*H
Moment at base M=Pw*D1*H*h1
Moment at height h(t) Mt = M- ht{V-0.5PwD1ht}

Stress S= 12M / R2*π*t

Table Formula Ref. [2]

Where, D1= width of the vessel with insulation, 1.05m=1050mm
E = Efficiency of the welded joints = 1.0
h1= lever arm, ft = H / 2 = 3.26m=3260mm
ht = distance from base to section under consideration, 1.52m=1520mm
H = length of vessel section, 6.524m=6524mm
M = Maximum moment (at the base), Nm

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Mt= Moment at height h t, Nm

Pw= Wind pressure, 0.089MPa
R = Mean radius of vessel, 0.5m=500mm
S = Stress due to wind, MPa =?
V = Total shear, N
t = Thickness of shell excluding corrosion, 30mm
The values of shear, moment at base & moment at skirt joint are calculated as under and
then the stress developed in response to the moment M(t) using the formulae listed in the
table above. By putting the values of the parameters listed above for methanator.
Shear V = 0.089MPa*1.06m*6.524m
V = 0.62MN=62KN
Moment (at base) M = 0.089MPa*1.06m*6.524m*3.26m
=1.92MNm
Moment at head to skirt joint
Mt = M – 1.52m{V – 0.5*0.089MPa*1.52m*1.06m}
Mt = 1.372MNm
Stress due to wind = 12*M / (R)2*π*t
=12*1.92MNm/ (0.5m)2*π*0.03m
= 978.34MPa ------------ (tensile)
D) STRESS DUE TO SEISMIC LOAD
a) PERIOD OF VIBRATION
As a result of wind tall towers develop vibration. The period of vibration should be
limited, since large natural periods of vibration can lead to fatigue failure. The allowable
period has been computed from the maximum permissible deflection.
QUANTITIES FORMULAS
Period of vibration, T sec T=0.0000265(H / D)2*(w*D /t)½
Maximum allowable period of vibration, Ta=0.80(WH /Vg) ½s
Ta (sec)
Table 19 .Formula for time of vibration Ref [2]
Where, D = Outside diameter of vessel, 1.01m=1010mm
H = Length of vessel including skirt, 6.524m=6524mm

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g = 9.8m / sec2 gravitational acceleration

t = Thickness of skirt at the base, 10mm
V = Total shear = ZICW/Rw (calculated ahead) =1038.6N
W= Weight of tower, =394.85KN
w= weight of tower per mater of height, = 60.52KN
Putting values to get period of vibration for methanator
T = 0.0000265(6.524/1.01) 2*(60.52*1.01*1/0.01) ½
T = 0.08644sec
Now allowable period of vibration
Ta = 0.80{W*H / V*g} ½=0.8{(60.52*6.524)/(9.81*1038.6)} 1/2
Ta = 0.1575sec
As ‘T’ is less than ‘Ta’ hence the condition is satisfied
7.4 STRESS DUE TO EARTHQUAKE
The loading condition of the tower under seismic forces is similar to that of the
cantilever beam when the load increases uniformly towards the free end
FORMULAS
Shear Moment
V=ZICW/Rw M=[FtH+(V-Ft)(2H /3)]
Mx= M(x/H)
2/3
Where C = Numerical coefficient=1.25S/T
= 1.25*1/(0.08644) 2/3 =2.71
=2.71(should not be more than 2.75)
Rw=Numerical coefficient (use 2.9 for vessels)
E = Efficiency of welded joints = 1.0
Ft = Total horizontal seismic force at the top of the vessel, 0N(because T < 0.7)
= 0.07TV (Ft shall not exceed 0.25V)
= 0, for T < 0.7
H =Length of vessel including skirt, 6.524m=6524mm
I = Occupancy importance coefficient (use 1.0 for vessels)
K = Horizontal force factor (use 2.0 for vessels)
M = Maximum moment at the base, Nm
Mx= Moment at distance x, Nm

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S = Numerical coefficient for site structure resonance

= 1.0
The product CS shall not exceed 0.14
W = Weight of the vessel, 394.85KN
Z = Seismic factor
= 0.15
Shear = (0.15*1*0.0299*394.85KN)/2.9
V = 1038.6N
Ft = 0.07*T*V =0.07*0.08644*1038.6N=6.284N
0.25V= 259.65N
As condition is that Ft should not exceed 0.25V so it is satisfied for methanator
Therefore Moment
M = [6.284*6.524 + (1038.6-6.284)*(2*6.524/3)]
M =4530.88Nm
Moment at skirt to head joint
Mt = M(x/H) where x=H/3=6.524m/3=2.17m
=4530.88Nm*(2.17m/6.524m)
=1510.3Nm

Therefore stress due to earthquake

Seq = 12* Mt / R2 *π* t
= 12*1510.3/ (0.5)2*π*0.03
=769.2MPa

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7.5. COMBINATION OF STRESSES

The stresses induced by the previously described loadings shall be investigated in
combination to establish the governing stresses.
It is assumed that wind and earthquake loads do not occur simultaneously
Thus the tower should be designed for either wind or earthquake load
Whichever is greater?
In case of methanator the stress due to internal pressure is the hoop stress (membrane
stresses), the stress due to earthquake (greater) & stress due to weight (compressive) is
considered
Combination of stresses will be as follows
+stress due to earthquake
+stress due to internal pressure
-stress due to weight
From the previous calculations putting the values of stresses
+769.2MPa
+3MPa
-1.5MPa
Combined stress at the head to skirt joint on the vessel in operating conditions
=770.7MPa
COMPARISON
The governing stress will be tensile as shown by the positive sign, which is lesser
than allowable stress of the given material at that particular temperature
Therefore the design is safe.
7.6. FABRICATION AND WELDING METHOD
Fabrication and welding method of the pressure vessel is based on the economic
aspects of the shell and the head. I used for the fabrication of the head and the shell by
using but joint welding for the contacting of the shell and head. We know that the martial
for the pressure vessel is stainless steel 18Cr/8Ni type 304 and its length is 3m by 1m and
this stainless steel are join by but welding joint.
Shell fabrication
Shell is fabricated by rolling the sheet of stainless steel and welds it together to get the
cylindrical shape of the vessel by using but weld joint.

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Head fabrication
Head shall is fabricated by making it in to different parts and by using but weld joint.
And finally support joining with the shell by using but joint welding. And different parts of
welding is shown blow in the figure.

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REFERENCES
Ref [1]-Coulson and Richardson’s, CHEMICAL ENGINEERING, Volume 6

Ref [2]-PREESURE VESSL HANDBOOK, 11th Edition

Ref [3]-PRESSURE VESLL DESIGN MANUAL,3rd Edition, BY Dennis Moss

Ref [4]-CHEMICAL ENGNEER’S HANDBOOK, Robert H.Berry and Don

W.Geern

Ref [5]-Material science and Engineering, 7th Edition, By William D.callister

Jr.

Ref [6]-STANDARED HANDBOOK OF MACHINE DESIGN, by (Joseph

E.shigey, Charles R.mischke and Thomass H.brown)

Ref [7]-PRESSURE VSSLE DESIGNE AND PRACTICE

Ref [8]-TEXTBOOK OF MASHINE DESIGN

Ref [9]-PREESURE VESSEL HANDBOOK, 10th Edition

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