WOLLEGA UNIVERSITY

INISTITUTE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

COURCE NAME: MACHINNE DESIGN PROJECT

TITLE: DESIGN OF VERTICAL PRESSURE VESSEL

NAME ID NO.

GIRMA MEGERSA…………………………………………0548/15

CHECKED BY: MR. BEYENE

SUBMITION DATE :

Contents pages

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Acknowledgement

Abstract

CHAPTER ONE (1)

1.1. Introduction

1.2. back ground

1. 3. Classification of pressure vessel

1.4 .Components of pressure vessel

1.5. Advantages and Disadvantages of pressure vessel

1.6. Application Areas of Pressure vessel

1.7.Problem statement

1.8.Objective

1.8.1.General objective

1.8.2.Design specification

1.9.Scope

1.10.Siginificance

1.11.Future Study

ACRONOMY L= length of shell

DM = mean diameter

CA=Corrosion allowances

S= Allowable stress

Pi=internal design pressure

R = internal radius of the shell

ts= thickness of the shell

Do=Outside diameter of the cylindrical shell

Vs=volume of shell

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E=joint efficiency

D= inner diameter of the shell

Tensile strength

=Design stress

Do=outside diameter of manhole

S=stress of material

Pb=bolt pitch (spacing)

db= bolt diameter

ASME: American Society of Mechanical Engineers

ACKNOWLEDGMENTS

First of all I would like that our almighty God for helping us to finish this project successfully

I am also indebted to express our heartfelt and deeper to our advisor and teacher mr-Beyene
who first introduced me as project of machine design, leader for his critical comments,
constructive correction and very useful fruit full advice. I would also like to extend our sincere
and thanks for the direction and supervision to finish this project successfully. I would like to
again our family for financial support.

ABSTRACT

The pressure vessel contains high pressurized fluid so that the selection of material and

the design of the pressure vessel are most important. The pressure vessel contains high
internal pressure. It must passes the sequence of hydrostatic test this test gives the
capability of the construction to survive internal pressure. The analytical design of the
pressure vessel is by using as per ASME code sec VIII division I. The dimension and
stresses which works on pressure vessel can be found out by ASME code. These stresses
are studying by using FEM and equate with theoretical value. The input parameters are
type of material, pressure, temperature, and diameter and corrosion allowance. Analysis
performed the calculations of internal and external pressure, weight of the element,
allowable stresses, vessel longitudinal stress check, nozzle check and saddle check. Design

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of pressure vessel depends on its pressure and temperature. When pressure and
temperature get changed every pressure vessel is new. In pressure vessel design safety is
the main consideration. The structural integrity of mechanical components of pressure
vessel requires a fatigue analysis including thermal and stress analysis.

CHAPTER ONE

PRESSURE VESSEL

1.1. INTRODUCTION

The term pressure vessel referred to those reservoirs or containers, which are
subjecteressd to internal or external pressure. The pressure vessels are used to store fluids
under pure. The fluid being stored may undergo a change of state inside vessels as in case
of steam boilers or it may combine with other reagents as in chemical plants. High pressure
is developed in pressure vessel so pressure vessel has to withstand several forces
developed due to internal pressure, so selection of pressure vessel is most critical. The
material of pressure vessel may be brittle such as cast iron or ductile such as mild steel.
Failure in Pressure vessel occurs due to improper selection of material, defects in material,
incorrect design data, design method, shop testing, improper or insufficient fabrication
process including welding. Vertical pressure vessels are containers for the containment of
pressure, either internal or external. The first requirement in vessel design is to determine
the actual values of the loads and the conditions in which the vessel will be subjected in
operations. A design engineer should determine conditions and all pertaining data as
thoroughly and as accurately as possible and rather be conservative. The principle loads to
be considered in the design of PVs are Design Pressure, dead loads, wind loads, earthquake
loads, temperature loads, piping loads, impact and cyclic loads. Many different
combinations of the above loadings are possible, the designer must select the most
probable combination of simultaneous loads for Pressure vessels have been in wide use for
many years in chemical, petroleum, military industries as well as in nuclear power plants.
They are usually subjected to high pressures and temperatures which may be constant or
cycling. Factors such as vessel material, the shape, chemical composition and physical
substances used in it, the environment of vessels and etc. all are factors which each can

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have different effects on performance of pressure vessels. A pressure vessel is a container
having a pressure differential with respect to the atmosphere.

1.2. BACK GROUND

Vertical pressure vessels find their application usually in oil and gas industries. They
contain a number of trays which are designed for mixing between a rising gas and a falling
liquid. The vessel is similar to a horizontal and vertical drum that comprises of two dished
heads, one at the top and one at the bottom. It is supported by a saddle which is welded to
the bottom head. Saddle is a cylindrical steel shell which rests on the reinforced concrete
foundation. It is due to the massive structure and large capacities of the vessels for which
octagonal foundations are preferred. The monopoles are also designed with octagonal
foundations underneath. The design includes analyzing of loads from superstructure,
design of base plate and foundation bolt, design of pedestal and footing. The design of pile
is kept outside the scope of the study [1].

1.3. Classification of pressure vessel

The pressure vessels may be classified as follows:

1. According to the dimensions. The pressure vessels, according to their dimensions,
may be classified as thin shell or thick shell. If the wall thickness of the shell (t) is less than
1/10 of the diameter of the shell (d), then it is called a thin shell. On the other hand, if the
wall thickness of the shell is greater than 1/10 of the diameter of the shell, then it is said to
be a thick shell. Thin shells are used in boilers, tanks and pipes, whereas thick shells are
used in high pressure cylinders, tanks, gun barrels etc
2. According to the end construction. The pressure vessels, according to the end
construction, may be classified as open end or closed end. A simple cylinder with a piston,
such as cylinder of a press is an example of an open end vessel, whereas a tank is an
example of a closed end vessel. In case of vessels having open ends, the circumferential or
hoop stresses are induced by the fluid pressure, whereas in case of closed ends,
longitudinal stresses in addition to circumferential stresses are induced.
3. According to the geometrical shape. It can be classified
 cylindrical geometrical shape

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  Conical geometrical shape
 Spherical with one or two cones
4. According to the position arrangement. Can be classified
 Horizontal pressure vessel
 Vertical pressure vessel
 Spherical pressure vessel
5. According to the material. Can be classified
 Brittle material pressure vessel
 Ductile material pressure vessel
6. According to the direction of acting on the wall of vessel. Can be classified
 Subjected to internal (pi)
 Subjected to external (p)
1.4. PRESSURE VESSEL COMPONENTS
Pressure vessels have many components there are;
 Vessel shell
 Heads
 support
 Nozzle
 Flanges
 Manhole
 Bolt and Nut
 VESSEL SHELL
It is the primary component that contains the pressure. Pressure vessel shells in the form
of different plates are welded together to form a structure that has a common rotational
axis.
Shells are either cylindrical, spherical or conical in a shape. Horizontal drums have
cylindrical shells and are constructed in a wide range of diameter and length. The shell
sections of a tall tower may be constructed of different materials, thickness and diameters
due to process and phase change of process fluid. Shell of a spherical pressure vessel is
spherical as well.

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 Figure 1.1 vessel shell

 HEAD
All the pressure vessels must be closed at the ends by heads (or another shell
section).Heads are typically curved rather than flat. The reason is that 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 and are known as intermediate
heads. These intermediate heads are separate sections of the pressure vessels to permit
different design conditions .

Figure 1.2 vessel head

There are different types of heads:

Elliptical Heads - The 2:1 semi-elliptical head is the most commonly used head type. Half
of its minor axis (i.e., the inside depth of the head minus the length of the straight flange
section) equals one-fourth of the inside diameter of the head. The thickness of this type of
head is normally equal to the thickness of the cylinder to which it is attached Hemispherical
Heads - The required thickness of a hemispherical head is normally one-half the thickness
of an elliptical or tori spherical head for the same design conditions, material, and
diameter. Hemispherical heads are normally fabricated from segmented sections that are
welded together, spun, or pressed. Hemispherical heads are an economical option to
consider when expensive alloy material is used. As elliptical or tori spherical heads because
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of higher fabrication in carbon steel construction, hemispherical heads are generally not as
economical cost. Carbon steel hemispherical heads may be economical for thin, very large-
diameter vessels, or in thick, small-diameter vessels.
Tori spherical Heads - A tori spherical (or flanged and dished) head is typically somewhat
flatter than an elliptical head and can be the same thickness as an elliptical head for
identical design conditions and diameter.

The minimum permitted knuckle radius of a tori spherical head is 6% of the maximum
inside crown radius. The maximum inside crown radius equals the outside diameter of the
head

 NOZZLE
A nozzle is a cylindrical component that penetrates into the shell or head of pressure
vessel. They are used for the following applications.
 Attach piping for flow into or out of the vessel.
 Attach instrument connection (level gauges, Thermowells, pressure
gauges).
 Provide access to the vessel interior at MANWAY.
 Provide for direct attachment of other equipment items (e.g. heat
exchangers).

Figure 1.3.Nozle

 SUPPORTS

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Support is used to bear all the load of pressure vessel, earthquake and wind loads. There
are different types of supports which are used depending upon the size and orientation of
the pressure vessel.
It is considered to be the non-pressurized part of the vessel.
Type of support
 LEG SUPPORT:
 Small vertical drums are typically supported on legs that are welded to the lower
portion of the shell.
 The max. ratio of support leg length to drum diameter is typically 2 : 1
 Reinforcing pads are welded to the shell first to provide additional local
reinforcement and load distribution.
 The number of legs depends on the drum size and loads to be carried.
 Support legs are also used for Spherical pressurized storage vessels.
 Cross bracing between the legs is used to absorb wind or earth quake loads.
 LUG OR BRACKET SUPPORT:
 Vertical pressure vessels may also be supported by lugs.
 The use of lugs is typically limited to pressure vessels of small and medium diameter
(1 to 10 ft)
 Also moderate height to diameter ratios in the range of 2:1 to 5:1
 The lugs are typically bolted to horizontal structural members in order to provide
stability against overturning loads.
 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).
 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.
 SADDLE SUPPORTS

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 In horizontal drums (See the above Figure) 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. The other support is normally free to permit unrestrained longitudinal
thermal expansion of the drum.

Figure 1.4.Saddle frame

 FLANGES

A flange is an external or internal rib, or tip which is used for strength, or for a glade or for
attachment to another object. Flanges are standard materials which can be selected from
tables and designed for the vessel body and some other devices’ for example, sample
values, lateral and longitudinal pipes, safety valves, openings having higher diameters are
connected using flanges. I.e. flanged joints are used for connecting pipes and instruments to

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vessel, and for removable vessel heads when case of access is required. Threaded
(Screwed) Flanges made of steel, are confined to special applications. Their chief merit is
that they can be assembled without welding: this explains their use in extremely high
pressure services, particularly at or near atmospheric temperature where alloy steel is
essential for strength and where the necessary post–weld heat treatment is impractical.
Screwed flanges are unsuitable for conditions involving temperature or bending stresses of
any magnitude, particularly under cyclic conditions where leakage through the threads
may occur in relatively few cycles of heating or stress: seal welding is sometimes employed
to overcome this, but cannot be considered as entirely satisfactory
 MANHOLE
A manhole is an opening using for the inspection of the vessel during operation. They are
using for regular maintenance such as painting if corrosion occurs cleaning and
examination if same un-wanted dust exist inside the vessel. Manholes are not to be less
than 300 x 400 mm or 400 mm in inside diameter. Where the neck height of a manhole is
excessive, the size of the manhole is to be suitably increased.
1.5. Advantages and Disadvantage of Pressure Vessel
Advantages:-
To apply simple shop fabrication process that eliminates redundant fabrication and non- need
experience improved quality control via the reduction of traceability and inspection. Receive cost
reduction advantages when production costs are reduced. Make use of marketing advantages for
using reinforced nozzle manufacturing. Increase your sales revenue with an increase in
production. Enjoy a set cost and quality level.
Disadvantages:-
The failure of pressure vessels may result in: loss of Life, Health Hazards and Damages to
the property.
Venting
Oil build up
Ice up problems
Limited flow rate
Space requirement
Pre fill venting
Cost
refurbishing

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 1.6. Application Areas of Pressure Vessel
Pressure vessels have wide range of applications in thermal and nuclear power plants, process
and chemical industries, in pharmaceutical industries and food and beverage industries.
Pressure vessels often have a combination of high pressure together with high temperature and
in some cases flammable fluids (or) high radio-active materials. Because such hazards it is
imperative that the design be such of no leakage can occur. With increasing demands from
industrial process for high operating pressure and high temperature new technologies have
been developed to handle the present day specialized requirement. The materials of pressure
vessel may be brittle such as cast iron, or ductile such mild steel. Various parameters of
pressure vessel are designed and checked according to the principles standards of American
Society Of Mechanical Engineering (ASOME).

1.7.Problem Statement Pressure vessel

Since many industry and company are needed from me and from all of us the design of
pressure vessel used for storing the liquid as well as air by proper ways and also by quality
and by amount of store.

But the pressure vessel that can be manufacture in many industries has having such
problem so I will improve this problem for my people or in other ways for our industry that
are found in our country.

1. 8.OBJETIVE
1.8.1 General Objective
To design pressure vessel used for store the oil that can be supported by saddle frame

1.8.2. Design Specification

 Use medium: oil product

 Inner service pressure :0.6MPa
 Nominal volume: 0.5m3
 Service temperature: 2000C
 Position: vertical
 2 longitudinal &1lateral pipe nominal diameter: 150mm
 Bottom discharge nominal diameter: 25m
1.9. SCOPE

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 The scope of this project is to design saddle frame for vertical pressure vessel. Investigating on
material selection and analysis of design calculation is also under study of this project. There
are many kind of pressure vessel based on position and supporting element but in kinds of
pressure vessel my project is depends up on vertical pressure vessel under oil product
supported by saddle frame.

1.10. SIGNIFICANCE OF PRESSURE VESSEL

Pressure vessels is used in variety of applications in both industry and privet sector.
Pressure vessels can theoretically be almost any shape, but shapes made of section of
spheres, cylinders and cones usually employed. A common design is a cylinder with end
caps called heads. Heads spheres are frequently either hemispherical or dished (tori
spherical). More complicated shapes have historically been match harder to analyze for
safe operation and are usually far more difficult to construction. It used also in,For
chemical process ,Pneumatic reservoir ,Hydraulic reservoir ,Diving cylinder ,Distillation
tower ,Dining compressor e t c.
1.11. FUTURE STUDY
Most of the methods available to design pressure vessel are in handbook where they are
troublesome and not interactive. I want to design computer aided pressure vessel, but due
to business benefit, the system may not be saleable or pricey. In addition the formulas and
concepts applied in the system are always unknown.

CHAPTER TWO

2.1. LITERATURE REVIEW

Dmodeavid Heckman:[3] tested three dimensional, symmetric and axisymmetric ls;
the preliminary conclusion is that finite element analysis is an extremely powerful tool
when employed correctly. Depending on the desired solutions, there are different
methods that offers faster run times and less error. The two recommended methods
included symmetric models using shell elements and axis symmetric models using solid
elements. Contact elements were tested to determine their usefulness in modeling the
interaction between pressure vessel cylinder walls and end caps.

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 Yoges Borse and Avadesh K. Sharma [4] present the finite element modeling 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 modeling for analyzing, testing and validation of
pressure vessels under high stress zones. Their results with the used loads and
boundary conditions which remain same for all the analysis with different end
connections shows that the end connection with hemispherical shape results in the
least stresses when compared to other models not only at weld zone but also at the far
end of the end-connection.

A .J. Dureli (1973) presented work on the stresses concentration in a ribbed cylindrical
shell with a reinforced circular hole subjected to internal pressure, by several experimental
methods and the results obtained were compared with those corresponding to a non-
reinforced hole in a ribbed and un-ribbed shell and also to a reinforced hole in an un-
ribbed shell. From the result it was found that the maximum value of hoop stress, and
longitudinal stress, in shells always occurred at the points θ = 0° and θ = 90°, respectively,
along the edge of the hole, θ being the angle measured clockwise from the longitudinal axis
of the hole R. C.B

Gwal tney (1973) compared theoretical and experimental stresses for spherical
shells having single non-radial nozzles. The stress distributions for radial and
non-radial nozzle geometry are analyzed. Stress distributions for the non-radial
and the radial nozzle attachments are quite similar but the non-radial nozzle
configuration gave the maximum normalized stress, both theoretical and
experimental, for internal pressure and for axial loads on the nozzle as well as for
pure bending moment loading in the plane of obliquity.
M.A. Guerrer, C. Betego´n, J. Belzunce [5] A finite element analysis (FEM) was
used to calculate the behavior of a pressure vessel (PV) made of high strength
steel (P500) subject to the design loads and assuming the existence of the „„worst
case‟‟ crack allowed by the European standards in order to demonstrate the safe
use of these steels and the too conservative design rules currently applied by the
PV manufacture codes. Analysis was checked by the simulation of a Wide Plate

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 Test. A good agreement was obtained with the experimental values determined
using strain gauges and with the analytical KI expression available for this specific
geometry. It was demonstrated that the presence of cracks on pressure vessels
made of P500 high strength steel non detected during non-destructive tests, do
not endanger the safety of the vessel, from the fracture mechanics point of view,
since the maximum values of the stress intensity factor along the crack tip is
always much lower than the room temperature fracture toughness of the material
(coarse grain heat affected zone). That is why, although high strength P500 steel
is excluded by EN 13445 Part 2, Annex B for the manufacture of pressure vessels,
because it has a yield strength higher than 460MPa, its application can be fully
successful and safe even under the worst allowed conditions, given way to
significant reductions of wall thicknesses, weights and costs. f the vessel.
Imran M. Jamadar et al researched on structural analysis of inclined pressure
vessel using FEM. They find out stresses in IPV for its structural stability. Inclined
pressure vessel is used for the production of the nitrous oxide by ammonium
nitrate pyrolysis reaction. They carried out study of induced von- misses stress at
different for different angle of inclined pressure vessel and finally they conclude
that equivalent von messes stresses increases with inclination of pressure vessel.
Rayapuri Ashok et al made research on design and analysis of CFRP multilayer
high pressure vessel and burst pressure analysis for various fiber orientation
angles. Here the main objective is to design and analysis of multilayer pressure
vessel and advantages of it over solid walled pressure vessel.
M. Giglio et al presented his research on Fatigue analysis of different types of
pressure vessel nozzle. He carried out comparison of two different methods for
the construction of pressure vessel nozzle. He conclude that failure of nozzles was
carried out by crack passing through their thickness. Both designs (external and
integral reinforcement) give good fatigue life results but nozzle with external
reinforcement is easy to produce than with integral one. Choice of simply
produced nozzle obtained with a cylindrical tube and a reinforcement plate gives
good results in terms of stress and fatigue life.

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 M.A Khan et al carried out his research on “Stress distribution in horizontal
pressure vessel and saddle supports”. Here quarter of the pressure vessel is
modelled. After that stress distribution is carried out for pressure vessel. He
concluded that highly stressed area is the flange plate of saddle.
6. M.A Guerrero et al presented their work on “Fracture analysis of pressure
vessel of high strength steel (HSS)”. Here finite element analysis is used for
calculating behaviour off pressure vessel and they assuming the existence of
‘worst case’. Here pressure vessel is made of material P500. Finally results shows
that presence of cracks on PV made of HSS P500 non- detected during NDT, do not
endanger the safety of danger. So it is a better option.
7. Eui so kim et al researched on “Risk analysis of CNG composite pressure
vessel via computer aided method and fractography”. Here, Cause or pressure
vessel is investigated through formal inspection and engineering test procedure.
After experiments results shows that Visual inspection does not advert the
possibility of catastrophic failure. So it is necessary to develop monitoring system
to check structural health of vessel.
8. Avinash R.Kharat et al carried out his research on “Analysis of stress
concentration at opening in pressure vessel using ANOVA”. The motivation for
this research isto analyse the stress concentration occurring at the openings of
the pressure vessels and the means to reduce the effect of the same. Finally
conclusion shows that sudden change in strain flow lines causes the strain and
stress to rise abruptly. Strain increases with increasing the opening size in the
geometric.
M. Jeyakumar et al researched on “Influence of residual stresses on failure
pressure of cylindrical pressure vessel”. Here main criteria is to study the effect of
residual stresses on the pressure vessel. Conclusion shows that there is a
reduction in failure pressure due to un favorable residual stresses.
10. Prof. Shag Husain S.Maghrabi et al presented their work on “Elastic
behavior of Cylindrical Vessels with Lateral Nozzle under internal pressure”. The
objective of this work is to study the elastic stress distribution, deformation,
characteristic and ry. They use Carbon fiber epoxy material. Finally overall

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 research shows that uniform stress distribution is good in CFRP multilayer
pressure vessel and this will not only reduced overall weight of the material but
also results in good material saving. So multi-layered pressure vessels are
superior than single walled pressure vessel for high pressure and high
temperature operating conditions.
Manish M. Utagikar et al carried out research on finite element analysis of
obround pressure vessel. They carried out determination of stresses in open
ended pressure vessel of shape. Due to limited space elliptical or obround shape
is used. Only quarter portion is selected for analysis due to its symmetry and
material they considered is steel. The results shows that hoop stress and
deformation induced in obround are higher than in circular shape. As thickness
increases, stresses reduce and hoop stress is directly proportional to pressure
applied in pressure vessel. Siva Krishna Raparla et al carried out their study on
design and analysis of multi-layered high pressure vessel. The stresses developed
in solid wall pressure vessel and multilayer pressure layer are analysed using
ANSYS. Finally they reached on a conclusion that there is percentage of saving
material of 26.02% by using multilayer pressure vessel in place of solid walled
vessel. This decreases overall weight of the vessel and saves the material. Stress
variation from inner to outer side is also less in multi-layered pressure vessel as
compared to solid wall vessels.
M. Javed Hyder et al made research on optimization of location and size of
opening in a pressure vessel cylinder using ANSYS. Analysis is performed for
three thick walled cylinder with different internal diameters. From the research it
is concluded that location and size of the hole depends upon the size of the
cylinder. The optimum location is where von- Misses stress is minimum and also
the hole size should be such that von-Misses stress should be minimum around
the vicinity of the hole.
Javad Marzbanrad et al researched on finite element analysis of composite high
pressure hydrogen storage vessels. CPV are largely used in industry applications
such as softening, filtration and storage. In design they used Unit load method
under various internal pressure and analysis is carried out in ABAQUS. The

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 results shows that fatigue lifetime of vessel depends on crack density, cyclic
loading amplitude and stress induced in it.
Bandarupalli Praneeth et al carried out research on finite element analysis of
pressure vessel and piping design. The stresses developed in solid layer pressure
vessel and multilayer pressure vessel are analysed. Here, theoretical and ANSYS
results are compared. Finally they conclude that theoretical calculated values are
very closestress concentration factor (SCF) of a cylindrical vessel with lateral
nozzle. Finally they conclude that when the geometric parameters of the vessels
are fixed, SCF of the structure will increase with decreases in the lateral angle.
Shyam R. Gupta et al researched on “Optimize nozzle location for minimization
of stress in pressure vessel”. Different nozzle location without reinforcement of
nozzle for offset of 0 ,8 16, 24 and 32 inch from vertical centre line at central cross
section with different inclination angles like 0˚, 15˚, 30˚ and 45˚ are modeled with
Creo Parametric 2.0. ANSYS workbench is used to analyse the model. And
conclusion shows that Stress level is within the allowable stress in pressure
vessel with reinforcement which is within the range of allowable stress in
pressure vessel without reinforcement.

2.2. DEFECT OF THE PRESSURE VESSEL

1. Elastic deformation-Elastic instability or elastic buckling, vessel geometry, and stiffness

as well as properties of materials are protection against buckling.

2. Brittle fracture-Can occur at low or intermediate temperatures. Brittle fractures have

occurred in vessels made of low carbon steel in the 40’50°F range during hydrotest where
minor flaws exist.

3. Excessive plastic deformation-The primary and secondary stress limits as outlined in

ASME Section VIII, Division 2, are intended to prevent excessive plastic deformation and
incremental collapse.
4. Stress rupture-Creep deformation as a result of fatigue or cyclic loading, i.e., progressive
fracture. Creep is a time dependent phenomenon, whereas fatigue is a cycle-dependent
phenomenon.

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5. Plastic instability-Incremental collapse; incremental collapse is cyclic strain
accumulation or cumulative
cyclic deformation. Cumulative damage leads to instability of vessel by plastic deformation.
6. High strain-Low cycle fatigue is strain-governed and occurs mainly in lower-strength
high-ductile materials.
7. Stress corrosion-It is well known that chlorides cause stress corrosion cracking in
stainless steels; likewise caustic service can cause stress corrosion cracking in carbon
steels. Material selection is critical in these
services.
8. Corrosion fatigue-Occurs when corrosive and fatigue effects occur simultaneously.
Corrosion can reduce fatigue
life by pitting the surface and propagating cracks. Material selection and fatigue properties
are the major considerations.
2.2.1.How the defect can happened
 Material-Improper selection of material; defects in material.
 Design-Incorrect design data; inaccurate or incorrect design methods; inadequate
shop testing.
 Service-Change of service condition by the user; inexperienced operations or
maintenance personnel; upset conditions.
 Some types of service which require special attention both for selection of material,
design details, and fabrication methods
 In dealing with these various modes of failure, the designer must have at his
disposal a picture of the state of stress in the various parts. It is against these failure
modes that the designer must compare and interpret stress values. But setting
allowable stresses is not enough! For elastic instability one must consider geometry,
stiffness, and the properties of the material.
 Material selection is a major consideration when related to the type of service.
Design details and fabrication methods are as important as “allowable stress” in
design of vessels for cyclic service.
 The designer and all those persons who ultimately affect the design must have a
clear picture of the conditions under which the vessel will operate

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 CHAPTER THREE
3.1. Design Methodology

The methods of design of vertical pressure vessel are primarily based on elastic analysis. There
are also other criteria such as stresses in plastic region, fatigue, creep, etc. Elastic analysis is
therefore in most important method of designing pressure vessel shells and components
beyond the elastic limit, the material yields and the plastic region (spreads with increased value
of load. The load for which this occurs is called collapse load rusting pressure which needs
consideration in certain cases. To design vertical pressure vessel the selection of code are
important as a reference guide to achieve the secure pressure vessel, for my design my
selection code is ASME. The carbon steel is the material selection that I select based on design
temperature for my design.

The design of vertical pressure vessel can according to the following chart.

Fig 3.1 Steps calculation of designing pressure vessel.

The important materials used for construction of vertical pressure vessels are listed below.
Metals used are generally divided into three groups as.

 Stainless steel low cost Cast iron, Cast carbon and low alloy steel, carbon steel and

Low alloy steel.

 Medium cost - High alloy steel (12%chromium and above), Aluminum, Nickel,

W.U .DEPARTMENT OF MECHANICAL ENGINEERINGPage 20

 Copper and their alloys, Lead

 High cost - platinum, Tantalum, Zirconium, Titanium silver.

» Since vertical pressure vessel needs the material that has high strength, long life,
Corrosion resistance, Resistance to hydrogen attack, Fracture, cost ductile etc. I
select carbon steel because it has all the property that is listed.

 For the selection of materials the physical, mechanical, chemical, and their
manufacturing process are the most important decision the designer has to make.

 Mechanical properties

 strength stiffness

 fatigue hardness

 elasticity

 plasticity

 ductility

 brittleness

 machine ability

 toughen

 Chemical properties

 oxidation stability

 corrosion resistance

 degradation

 toxicity

 flammability

 Physical properties

 density

 specific heat

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  thermal expansion

 conductivity

 melting point

 electric properties

 magnetic properties

 Material Types

 ductile

 brittle

 Plastics

 Composites

 Ferrous

 non-ferrous

 alloys

 Manufacturing process

 cast sanding

 shell molding

 hot working

 cold working

 machining

 joining

 powder metal gory

 Heat treatment

 annealing

 tempering

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  quenching

According to different kind of standard such as ASME the following given below are used for the
selection of materials

A) Strength

B) Corrosion resistance

Table 1 :1. Corrosion property

Medium Cast iron Aluminum Nickel Copper Carbon steel

Oil G G C C G

C) Resistance to hydraulic attack

D) Fracture toughness

E) Fabricablity/predictability

3.1.2 Welding type

Welding, in engineering, any process in which two or more pieces of metals are joined together
by the application of heat, pressure, or a combination of both. There are several methods to
make welded joints. The welding processes may be broadly classified into the following two
groups:

1. Welding processes that use heat alone e.g. fusion welding.

2. Welding processes that use a combination of heat and pressure e.g. forge welding.

Types of Welded Joints

Following two types of welded joints are important from the subject point of view:

1. Lap joint or fillet joint, and

2. Butt joint.

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Figure 3.2 Types of lap or fillet joint

Table 3:2. material selection

Yield UTS CHEMICAL Tensile Poisson’s Designed

strengt strength ratio stress
Material
h (MPa) (UST)
(v)

Carbon 490MPa 635 Oil product 360MPa 76 105

steel

When I conclude my material selection ,from my material of construction carbon steel it has
good yield strength ,tensile strength, good fracture toughness ,good resistance of
temperature ,&has good resistance to corrosion & it can be fabricated in different method
except casting-because difficult & special technique needed.

Consider all property I select carbon-steel (killed or semi killed) which satisfies all conditions in
the given working conditions.

 It has highest tensile strength

W.U .DEPARTMENT OF MECHANICAL ENGINEERINGPage 24

  are highest corrosion resistant materials

 It is commonly used and inexpensive material

 Weld ability and higher hardening ability

 have good mechanical properties

 strength in high temperature condition

 generally, It is suitable specially for our design

Table 3.3. Tensile strength & design stress of material selection

[5]

Properties of carbon steel

 Tensile strength = 360 N/

 Modules of elasticity =207 KN/
 Specific density = 7870 Kg/
 Design stress@c= 105N/
 Specific gravity = 7.9

3.1.2 Mechanical Properties of Metals

 The mechanical properties of the metals are those which are associated with the ability
of the material to resist mechanical forces and load. These mechanical properties of the
metal include strength, stiffness, elasticity, plasticity, ductility, brittleness, malleability,
toughness, resilience, creep and hardness. I discus these properties as follows:

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  Strength. It is the ability of a material to resist the externally applied forces without
breaking or yielding. The internal resistance offered by a part to an externally applied
force is called *stress.

 Stiffness. It is the ability of a material to resist deformation under stress. The modulus
of elasticity is the measure of stiffness.

 Elasticity: It is the property of a material to regain its original shape after deformation
when the external forces are removed.

 Plasticity: It is property of a material which retains the deformation produced under

load permanently. This property of the material is necessary for forgings, in stamping
images on coins and in ornamental work.

 Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percentage
reduction in area.

 Brittleness: It is the property of a material opposite to ductility. It is the property of

breaking of a material with little permanent distortion

 Malleability: It is a special case of ductility which permits materials to be rolled or

hammered into thin sheets and etc. [3]

3.2 Design Procedure

 The given specifications of my project are the followings:

 Medium: oil product

 Inner service pressure = 0.6Mpa

 Nominal volume = 0.5 m3

 Service Temperature = 200 0 C

 2 longitudinal & 1 lateral pipes nominal diameter =152mm

 Bottom discharge nominal diameter =27mm

 Position: vertical

 Support saddle frame

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So now I need to calculate by procedure

1. Design Pressure and Material Selection

2. Calculation of length

3. Design of the thickness of the cylinder shell and all parts of vertical pressure vessel.

3.2.1 To Determine the Diameter and Length of Pressure Vessel

The volume of a pressure vessel is 0.5m3 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 by according to their presser value. But mostly it is recommended to take L/D
ratio 3:1. The pressure that was given for my operating pressure is 0.6 mpa.

Pressure table used to find the ratio of D/L =K

 Operating Pressure: is a pressure which required for the process, served by the vessel.

 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+1.257 to 2 percent operating pressure.

I select 2 percent for more safety purpose.

=0.6MPa+ (0.02x0.6) MPa

=0.612MPa

» So the diameter and length can determine depend on design pressure:

Table 3.4. Indication of length to diameter ratio

L/D PSI MPA

3 0-250 0.000-1.724

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 4 250-500 1.724-3.48

5 >500 >3.448

Since the design pressure =0.612Mpa, then from the table the ratio of L/D is 3 then L=3D
because the design pressure is between 0.000-1.724 Mpa

As mention before the total volume is equal to the sam of head volume and shall volume
Let Vh- volume of head
Vs- volume of shell
D – diameter of shell
R – internal diameter of shell
 When the head of pressure vessel volume is
V=V cylinder +V Hemispherical
V=πD2L /4+ πD3/6 given V=0.5m3
0.5=πD2L/4 + πD3/6

0.5=3(πD2L) + 2(πD3)
12 L=3D
0.5=3(πD2 × 3D) + 2(πD3)
12
6=9(πD3) + 2(πD3)
6=11(πD3)
6=34.55D3
6 = D3
34.55
Di = 0.557 m.
The Standard Diameter Is: D=0.6m

Radius of Pressure Vessel , D=2r

0.6=2r
0.6 =r

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 2
Ri =0.3m.
Now I find the length of the pressure vessel
L=3D
L=3×0.6
L=1.8m.
3.2.2 DESIGN OF TEMPERATURE

The strength of metals decreases with increasing temperature, so the maximum allowable
design stress ill depend on the material temperature. The design temperature at which the
design stress is evaluated should be taken as the maximum working temperature of the
material, with due allowance for any uncertainty involved in predicting vessel wall
temperatures.

 Then the given operation temperature for this project is:

To=200OC

 From typical design stress table find the stress for stainless steel:-

Design stress: ( =105Mpa

Tensile strength: 360Mpa

3.2.3 Design of shell

In this sub topic I design the thickness of the shell and the materials which are more suitable for
this shell to resist the given parameters and also calculate thickness and volume of the shell.

For cylindrical shell thickness required to resist internal pressure can be determined from the
formula.

t = +CA

Where:

S = allowable stress

E = joint factor

Pin=internal pressure

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 R=internal radius of shell

t=thickness of shell

Table 3.5. Allowable stress & joint efficiency

Notation MKS

P=internal design pressure 0.612 MPa

D=inside diameter 0.6 M

S= Allowable stress(design stress) 105 MPa

E= joint efficiency 1

CA=Corrosion allowance 0.002 M

Tensile stress 360 MPa

 From the above table the value of:

Pin= 0.612Mpa

S= = design stress

S=105Mpa

R= 0.3m

CA= 0.002m

So for calculate the thickness of the shell.

(a) Circumferential stress (longitudinal joint)

P ≤ 0.385SE

0.612 ≤ 0.385*105MPa*1

0.612MPa ≤ 40.425MPa ---------------- (satisfied)

(b) Longitudinal stress (circumferential stress)

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 P ≤ 1.25SE

P ≤ 1.25*105MPa*1

0.612MPa ≤ 131.25MPa ------------------ (satisfied)

 Therefore:

t = +CA

+0.002m= 0.004

Total thickness(design thickness)

For carbon steel corrosion allowance is 2mm and insulation thickness is 50mm

tT = minimum thickness + corrosion allowance + insulation thickness

Therefore,

tT = 0.004m + 0.002m + 0.05m= 0.056m.

Outside diameter of the cylindrical shell.

Do = 2tT + Di

Do = 2(0.056m) + 0.6m

Do = 0.712m

Ro = 0.356m

0.004m˂ 0.6m˟

0.004m˂ 0.06m

Since ts is less than (1/10)*Di therefore the shell classified as thin wall.

3.2.4 Design of hemispherical head

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Hemispherical head is the strongest shape, capable of resisting about twice the pressure of Tori
spherical head of the same thickness.

The design thickness of hemispherical head is given by

th = +CA

th = =0.003m.

The stress on the hemispherical head calculated using a thin shell theory.

The hoop stress and longitudinal stress are equal in hemispherical head.

Therefore: σh=

MPa.

Wight of hemispherical head is given by:

Wh=1.57dm2×t×ρ×g……….where ρ = density of carbon steel.

dm = mean vessel diameter.

dm = d+t

= 0.6m+0.003m

dm = 0.603m. The standard=0.7m

Wh= 1.57× (0.603m)2×0.003m×7870kg/m3×9.8m/s2

= 132.4N

To calculate hemispherical head volume

---------Head volume (hemispherical head)

= = 0.11

V=0.11 is for one head but for both bottom and top head the volume is twice of the individual
head that means Vh=2V=0.22 Vs=V-Vh=0.5-0.22=0.28m3

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 Figure 3.3 Hemispherical head

3.2.5 Stress on the shell using a thin shell theory.

Calculate the stress.

Hoop stress: - is the tensile stress in the direction tangential to the circumference.

σh = = =50Mpa. Where t: shell thickness

Longitudinal stress: - tensile stress acting in the direction of the axis is called longitudinal stress.
It’s acting in the transverse or circumferential section or on the ends of the vessel.

σL= = =23Mpa.

As hoop stress is greater so the design is based on hoop stress.

3.2.6 .Head to shell transition

Heads to shells attachment by butt welded joints of plates of unequal thickness. Joining plates
of unequal thicknesses with butt weld. 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).

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 Figure 3.4: welding type of head to shall

Thickness of head (th=0.003m) and shell (ts=0.004m), their deference (0.001m), tapered is more
than 3.125mm (1/8in) or 3.175mm.

L >3*y and y=0.001m.

3.2.7 Weight of the cylindrical shell

Weight of cylindrical vessel given by (WS).

WS = × DM ×ρ × ts× g × LS ……………..where

DM is mean diameter And ρ is the density of carbon steel

WS = × 0.7m × 0.004m × 9.81m/s2 × 1.8m × 7870 Kg/

WS = 1.2KN

Erection Weight

 Shell=densityshell*Vshell *g

=7870kg/m3*0.28m3*9.81m/s2=21.6KN

 Heads = density head*Vhead*g

=7870kg/m3*0.22m3*9.81m/s2=16.9KN

Erection weight= 21.6KN+16.9KN=38.5KN

 *Vpressure Vessel*g

= 900kg/m3*0.5m3*9.8m/s2

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 =4.4KN

 Total weight=4.4KN+38.5KN=43KN

Stress Due To Weight

 Putting Values in the Formula

Where, C = Π * D Mean = 3.14 *0.7m =2.19m = 2190mm

tT= 0.056m = 55mm where tT is total thickness

Sw = 43KN/ (2190mm*55mm) =0.4mpa (Compressive)

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.

3.2.7. DESIGN OF MANHOLE

3.2.7.1 Design of manhole or inspection

A pressure vessels for use with oil product 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. To resist the load subjected (applied) on the man hole it
must be design from a material having enough strength to resist the applied load, having
stainless steel is a material which satisfy all this, so it selected.

3.2.7.2 Dimension for man hole

The dimension of man hole must allow getting in to the vessel who wants to clean its internal
part. Assume the diameter of internal manhole is: D=0.35m

To calculate the thickness of manhole wall will be;

o Where p=internal pressure

o Di=selected inside diameter of manhole
o Do=outside diameter of manhole

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 o S=stress of material

t = =0.001m

When corrosion allowance is added (2mm)

t=0.001m+0.002m=0.003m

Therefore thickness of wall of manhole, t=0.003m.

And the outer diameter of the manhole

=+2t

= 0.35m + 2*0.003m

= 0.356m

Design of inlet and outlet

This party pressure vessel is used to input the material you want to store and used to remove
the material input offer used to the way to omitted or throughout from the material by this
things.

The general thickness equation inlet and outlet is used the thickness formula for the shell from
the above

1e t= (Pi×di)/ (2s-Pi) +C.A

Where,

o Pi = internal press are

o di = internal diameter
o s = allowable stress

t= [(0.35*0.612)/ ((2*105)-0.612))] +0.002=0.003m; so thickness of inlet and out let is 0.003m.

Design of manhole load

Load is the stress that being or applied on the vessel part of man hole design that is the stress
subjected to the vessel part of tangential and horizontal or parallel to the vessel

The circumferential stress (σ1) =x/2t

σ1 =0.612*0.35m/2*0.003m=35.7MPa

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 The longitudinal (σ2)

σ2 = 0.612*0.35/4*0.003= 17.85MPa

 Maximum shear stress

According to maximum shear stress theory, the maximum shear stress is one-half the algebraic
difference of the maximum and minimum principal stress. Since the maximum principal stress is
the hoop stress (σ1) and minimum principal stress is the longitudinal stress (σ 2),

Therefore

From this when the longitudinal stress is equal to half of circumferential stress. Also hence the
calculated stress is less than allowable stress then my design is safe.

3.3 Calculation on Thickness of the Nozzle

Figure: 3.5 Nozle

To find the thickness of the nozzle

tn=PR/ (SE-0.6P) + C.A

Where:

o tn-thickness of the flange

o P-maximum allowable
o E-joint efficiency (E=0.85)

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 o S-maximum allowable stress
o R-internal radius of the pipe
o C.A-corrosion allowance

I Select Material for Nozzle S-106-B from the Table and S=83.63mpa (13.0kpsi). R [2]

Given

Table 3.5.Properties of material of nozzle

Nominal Dia. (mm) P( MPa) C.A, mm Radius(mm)

25 0.612 1.08 13.5

150 0.612 2.3 76

E=0.85

S=85MPa

3.3.1. Wall thickness of nozzle

tn will be:

tn = +CA

tn25mm = +1

= 1.113mm

=0.0001m

tn150mm= +2.3

=2.9mm

=0.003m

I select the nozzle with nominal diameter is 150mm.

3.3. Calculation overall mass of oil in vessel

To calculate the overall mass, first the mass of pressure vessel and its components have to be
calculated
W.U .DEPARTMENT OF MECHANICAL ENGINEERINGPage 38
Mass of the vertical pressure vessel; M = [()-()]

Where; r2=r

= r + the actual thickness=0.3+0.056=0.356m, the actual thickness= 0.056m

L1 = L + the actual thickness=1.8+0.056=1.856m

Density carbon steel= 7870kg/m3

M = [0.739-0.509]*7870

M=1810kg (M: mass of the vertical pressure vessel)

Then now I calculate the mass of the oil Moil which is possessed in the pressure vessel

Moil = V×

Where

V=volume of tanker,

=density of oil =900kg/m3

Moil=0.5*900=450kg

Total mass of the tanker = mass of oil +mass of the pressure vessel

M (total) = (450+1810) kg=2260kg

But the overall mass include all components of the vertical pressure vessel so add 15% of
additional mass to the total mass

M (overall) = M (total) + 15%M (total)

=2260kg + (0.15*2260) kg

M (overall) =2599kg

3.4. Design Calculation of support (saddle frame)

First to calculate the load on the saddle the mass of the over load of the pressure vessel and its
components like frame have to Calculated. Mass of the pressure vessel; Density of the carbon
steel is ρ = 7870 Kg/m3

M = ΔV*ρ

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M= [(π×L1) - (π×L)] ×ρ=1810kg

Now I calculate the mass of the oil, which is possessed in the pressure vessel

=450kg

Finally calculate the weight

W=g

= 259.81

= 25.5KN

3.5. DESIGN OF BOLT

Bolt is used to join the part of instrument with a vessels part by using connecting methods Load
on bolt. The load that applied on bolt is subjected to the stress due to the stress due to the
torque transmitted and depends on the number of bolts and to tall load on the all bolts. Load
on each bolt is given by:-

The total load on all bolts:

F=

But the normal load on the bolt is given by:-

F = A × P = *P

Where D= diameter of bolt given suppose (assumed)

=allowable stress for bolt

3.5.1. Material selection for bolts

For my design I select low alloy steel of code SA-193-B7. Because to serve the given
temperature (2000c) the bolt material should be properly selected. From allowable stress table
for bolt of pressure vessel design manual book 3rd edition the maximum allowable stress for SA-
193-B7 type at 2000c is 25ksi. But 1ksi=1000psi then, to obtain in MPa multiplying by 0.006894,

W.U .DEPARTMENT OF MECHANICAL ENGINEERINGPage 40

yields allowable stress 172.35MPa. So is 172.35MPa. And I assumed external diameter of the
bolt 80mm. But internal diameter becomes 40mm.

Load in each bolt; F= (πd2/4)* =*802 /4*172.35= 121765.3N=866.3KN

Total load on all the bolt F= = *n; where n is number of bolt

But the normal load on the bolt is given by:-

F=A*P= (πd2/4)*P=*802 /4*0.612= 3076.24N=3.07KN

Now since the load on all bolt is not equal to the normal load on the bolt;

*P

Number of bolts (n) = multiple of 4 from standard design.

So those number of bolts on in 8 the average one. In the bolt design the diameter is equal to
the thickness material bolt d = t. So the thickness of the bolt is t = 80 mm=0.08m

3.6. Types of flange, and selection

Several different types of flange are used for various applications. The principal types used
in the process industries are:
1. Welding-neck flanges.
2. Slip-on flanges hub and plate types.
3. Lap-joint flanges.
4. Screwed flanges.
5. Blank, or blind, flanges.
Welding-neck flanges: have a long tapered hub between the flange ring and the welded
joint. This gradual transition of the section reduces the discontinuity stresses between the
flange and branch, and increases the strength of the flange assembly.
Slip-on flanges: slip over the pipe or nozzle and are welded externally, and usually also
internally. The end of the pipe is set back from 0 to 2.0 mm. The strength of a slip-on flange
is from one-third to two-thirds that of the corresponding standard welding-neck flange.
Lap-joint flanges, as shown in Figure, are used for pipe work. They are economical when
used with expensive alloy pipe, such as stainless steel, as the flange can be made from

W.U .DEPARTMENT OF MECHANICAL ENGINEERINGPage 41

inexpensive carbon steel. Usually, a short-lapped nozzle is welded to the pipe, but with
some schedules of pipe, the lap can be formed on
the pipe itself, and this will give a cheap method of pipe assembly. Lap-joint flanges are
sometimes known as Van-stone flanges.
Screwed flanges, as shown in Figure d, are used to connect screwed fittings to flanges.
They are also sometimes used for alloy pipe, which is difficult to weld satisfactorily.
Blind flanges (blank flanges) are flat plates, used to blank off flange connections, and as
covers for manholes and inspection ports.

Figure3.6:Flange types. (a) Welding-neck. (b) Slip-on. (c) Lap-joint. (d) Screwed
3.6.1. Gasket
Gaskets are used to make a leak-tight joint between two surfaces. It is impractical to
machine flanges to the degree of surface finish that would be required to make a
satisfactory seal under pressure without a gasket. Gaskets are made from ‘‘semi plastic’’
materials, which will deform and flow under load to fill the surface irregularities
between the flange faces yet retain sufficient elasticity to take up the changes in the flange
alignment that occur under load.The following factors must be considered when selecting a
gasket material:
1. The process conditions: pressure, temperature, corrosive nature of the process
fluid;
2. Whether repeated assembly and disassembly of the joint are required;
3. The type of flange and flange face
Gasket Materials in ASME BPV Code Sec. VIII Taken from chemical engineering design book
3.6.2 Flange Faces

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Flanges are also classified according to the type of flange face used. There are two
basic types:1. Full-faced flanges, 2. Narrow-faced flanges

Figure:3.7.Flange types and faces. (a) Full-face. (b) Gasket within bolt circle. (c) Spigot and
socket. (d) Ring-type joint
3.6.3. Flange and gasket desig
Flange applied load and flange moment
 There gasket factor width and internal pressure for the flange are the same
m=1.25, b=10mm and Pi=1.8MPa
We know that the flange is class 300lb and the material is Forged steel SA 105.I
select Welding-neck flanges, because have a long tapered hub between the flange
ring and the welded joint. This gradual transition of the section reduces the
discontinuity stresses between the flange and branch, and increases the strength of
the flange assembly.

Welding-neck flanges are suitable for extreme service conditions; where the flange is likely
to be subjected to temperature, shear and vibration loads. They will normally be specified
for the connections and nozzles on process vessels and process equipment.
There are 5 flange that I used for my pressure vessel their value is shown
blow.
 Two longitudinal pipe with D=150mm
 ,One lateral pipe with D=150mm
 One bottom discharge D=25mm

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 Figure3. 7.welding neck flange

3.6.Table values of flange parts

Since the value of give nominal size is not there directly from the table, I take the ratio between two
points

And the value of: A =E-10 Where B=A/2

C=h1, D=H, E=d1, G=d3, J=b, K=d4

3.7.Table Flanges standard ANSI 105

Nom Diameter Length Diameter Diameter Outside Thickness Outside Bolting

inal of through of the of the diameter of the diameter
pipe the the hub hub flange flange the
size, bore, Hub at the at the [H=D] [b=J] raised
Mm mm [h1=C] point of base Face
[A] welding [d3=G] [d4=K]
[d1=E]

25 26.18 40.57 36.18 48.85 122.14 18 89.28 M12

150 160.332 75.56 170.332 194.08 304 28 221.36 M24

All dimensions in mm

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  Flange and Gasket Design R [1]
 Flange Applied Lode and Flange Moment

The lode on the flange can be given as fallow

m=gasket factor

Pi=internal pressure of flange

Pi=4.8MPa

B=in side diameter of a flange for each pipe

B=A/2

A=d1-10mm, we take assumption the thickness is 10mm

b=effective gasket selling width

2b=effective gasket pressure width

tf=thickness of flange

tf=J

hd= (G + H – 2E)/4

hg= (H - G)/4

ht= (G + H)/4

G’=mane diameter of gasket

=B + (ht-hg)

Hg=gasket reaction forces (pressure forces)

=πG’ (2b) mPi

H=total pressure

(π/4)G’2Pi

Hd=pressure force of area inside the flange

= = (π/4) B2Pi

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Ht=pressure for a flange face

=H - Hd

The moment on the flange is

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

3.8.Figure forces act on internal flange

3.8.Figure gasket material and gasket factor

3.8.Table typical pressure –temperature rating for carbon steel

Let’s calculate the lode and moment

There gasket factor width and internal pressure for the flange are:

m=2.5 b=10mm and Pi=4.8MPa

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 hd= (G + H – 2E)/4

For 25mm= (46+115-2*33.7) For 25mm= (46+115-2*33.7)mm/4=23.4mm

For 150mm = (192+300-2*168.3)mm/4=38.85mm

hg= (D – d3)/4

For 25mm= (115-46)mm/4=17.25mm

For 150mm= (300-192)mm/4 =27mm

ht=(d3+D)/4

For 25mm= (46+115)mm/4=40.25mm

For 150mm= (192+300)mm/4=123mm

tf=b

For 25mm=18mm

For 150mm=28mm

B=A/2 (assumption) A=d1-10mm

For 25mm= (33.7-10)mm/2=11.85mm

For 150mm= (168.3-10)mm/2=153.3mm

G’=B + (ht - hg)

For 25mm=11.85mm + (40.25-17.25) mm=34.85mm

For 150mm=153.3mm + (123-27) mm=249.3mm

H= (π/4) d3’2Pi

For 25mm= (π/4)(46mm)2*4.8MPa=7,977.13N

For 150mm= (π/4)(192mm)2*4.8MPa=138,974N

Hd= (π/4) B2Pi

For 25mm= (π/4)(11.85mm)24.8MPa=529.4N

For 150mm= (π/4)(153.3mm)2*4.8MPa=88,596.3N

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 Ht =H-Hd

For 25mm= (7977.13-529.4)N=7447.73N

For 150mm= (138974-88596.3)N=50,377.7N

Hg=πd3’(2b)m Pi

For 25mm=π (46mm)(2*10mm)2.5*4.8MPa=34,683.2N

For 150mm=π(192mm)(2*10mm)2.5*4.8MPa=144,764.6N

The moment is

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

For 25mm pipe

Mop=(529.4)(23.4mm)+(7447.73)(40.25mm)+(34683.5)(17.25mm)

=910454.15Nmm=910.45415Nm

For 150mm pipe

Mop=(88556.3)(38.65mm)+(50377.3)(123)+(144764..6)(27mm)

=13545464.36Nmm

The minimum load required bolt load under the operating condition given by

Wm1=H + Hg

Wm1, 25mm=7977.13N +34683.2 N=42,660.33N

Wm1, 150mm=138974N + 144764.6N=283738.6N

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=yπd3’b

y=gasket sating pressure (stress) =20MPa

Wm2, 25mm=20MPa*π*46mm*10mm=28902.65N=28.902KN

Matm, 25mm=28902.65N*17.25mm=498570.75Nmm=498.57N
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Wm2, 150mm=20MPa*π*192mm*10mm =120,637.2N=120.6372KN

Matm, 150mm =126,637.2N*27mm =3257,204.4Nmm=3,257.2044Nm

Flange stress

Flange stress are given by

Longitudinal hub stress

σhb=F1M

Radial flange stress

σrd=F2M

Tangential flange stress

σtg=F3M - F4σrd

where M is taken as Mop/B’ or Matm/B’, whichever is the greater; and the factors F1, F2, F3 and F4
are functions of the flange type and dimensions, and are obtained as followed

F1= 1/λ gt2 gt= (G-A)/2

λ=δ + γ α=te+1

d= (u/v)hogo2 ho= (B’go)1/2=(B’J)1/2

=(u/v) (B’J)1/2J2 B’=(G-A)/2

F2=β/λt2 t=thickness of the flange=J δ=t3/d

β=1.333te+1 γ=α/T

F3=y/t2 y=(1-v2)u go=J

F4=z z=k-factoer A’= (D-d3)/2 =

B’=(d3-A)/2

B’25mm =(40-23.7)/2=8.15

B’150mm = (194.08-160.332)/2=16.874

K=A’/B’
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 =(D- d3)/(d3-A)

K25mm=(115-46)mm/(46-22.7)mm=2.97

K150mm= (304-194.08) mm/ (194.08-160.332) mm=3.25

And from R[3] we find this table

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

Dia.(mm)

25 2.97 1.21 1.25 1.88 2.07

150 3.25 1.19 1.23 1.55 1.9

Table 3.9.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’b)1/2

Let’s find the value of F (in y-axis) by using ASME code, section viii, Dev 1.in x-axis g1/g o(or
B’/J) and h/ho(or (h1-b)/(B’-b)1/2)

After calculating of this value I fined F for each flange

and the values are shown below.

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 Assumption g1/g0=2 (g0)25=10

Figure3.9. values of v (integral flange factor) from ASME code section VIII Div,1,

Figure 3.10. values of F integral flange factor) from ASME section VIII Div.1,

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I take these two figures from pressure vessel design manual 3 rd edition.

Figure values of v (integral flange factor) from ASME code section VIII Div,1,

 Assumption g1/g0=2 (g0)25=10.4 say 10

(g0)150 =25.41 Say 25

h=h1-b , h/h0=h/(Bg0)1/2

h25mm=22mm , h/h0=22/(8.15*10) ½=2.43

h150mm= (75.56-28) mm=47.56 , h/h0=47.57/(16.874*25) 1/2=2.3

F25mm=0.6

F150mm=0.5

e25mm=0.6/(11.65*18)1/2mm=0.6/14.48mm=0.04143mm

e150mm=0.5/(16.874*28)1/2mm=mm=0.023mm

let’s find (α and β)

α25mm=10 mm(0.0414/mm)+1=1.41

α150mm=10mm (0.023mm) +1=1.23

β25mm=1.333*10mm(0.0414/mm)+1=1.55

β150mm=1.333*10mm (0.023mm) +1=1.30659

and γ will be

γ25mm=1.414/1.21=1.1686

γ150mm=1.23/1.19=1.033

lets find the value of v from ASME code Viii Div. 1 using by the value of (**) and it will be

v25mm=0.12

v150mm=0.09

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 d = (u/v)hogo2 where ho= (B’go)1/2

then,

d will be

d5mm=(2.07/0.12)(10.7935)(10mm)2

=18618.78mm3

d150mm= (1.9/0.09) (20.53) (25mm)2

=270881mm3

The value of δ will be

δ=t3/d

δ25mm=(10mm)3/18618.78mm3

=0.0537

δ150mm= (10mm)3/270881mm3

=0.00369

Let’s find the value of λ

λ=δ + γ

λ25mm = 0.0537+1.1686=1.222

λ152mm = 0.003+1.033=1.036

y will be

y = (1-v2)u

y25mm = (1-0.122)2.07=2.04

y152mm = (1-0.092)1.9=1.884

gt will be

gt= (d3-A)/2

gt25=11.65mm

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 gt150mm=(194.08-160.332)/2=16.874

F will be

F1= 1/λ gt2, F2=β/λt2 F3=y/t2 F4=z

Nominal Dia. (mm) F1(1/mm2) F2 (1/mm2) F3(1/mm2) F4

25 0.00602 0.01268 0.0204 1.25

150 0.003 0.0126 0.01884 1.23

Table 3.11. 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(KNmm) Matm(Nm)

25 1795.96(1795.96) 498.57

150 16348.3(16348.5) 3059.5

Table3.12. value constant

There for M=Mop/B’ the stress is

σhb=F1M

For 25mm=0.00602(1/mm2)(1795.96KNmm/8.15mm)

=1326.58MPa

For 150mm=0.0033 (1/mm2) (16348.3KNmm /16.874mm)

=3197.19MPa

For 150mm=0.0033 (1/mm2) (16348.3KNmm /16.874mm)

=3197.19MPa

σtg =F3M-F4σrd

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For 25mm=0.0204(1/mm2)(1795.96KNmm/11.65mm)-1.25(1/mm2)(1950)

=707.3MPa

For 150mm=0.0117(1/mm2) (16348.3KNmm/16.874mm)

=11335MPa

The flange must be sized so that the stresses given by equations satisfy the following criteria:
when

f fo=102.04MPa(14.8KPSi) is the maximum allowable design stress for the flange material at the
operating conditions. R[1] and [2]

σhb > 1.5ffo

For 25mm 1326.58MPa > 153.06MPa -(satisfied)

For 150mm , 3197.19MPa > 153.06MPa --(satisfied)

σrd > ffo

For 25mm 1950MPa >102.02MPa ---- (satisfied)

For 150mm 11335MPa > 102.04MPa -----(satisfied)

0.5(σhb+σrd) > ffo

For 25mm 1638.29MPa > 102.04MPa -(satisfied)

0.5(σhb+σrd) > ffo

For 25mm 1638.29MPa > 102.04MPa -(satisfied)

For 150mm 7266MPa > 102.04MPa ---------------- (satisfied)

0.5(σhb+σtg) > ffo

For 25mm 1016.9MPa > 102.04MPa ---(satisfied)

σrd > ffo

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 CHAPTER FOUR

ASSEMPLY DRAWING

4.1 .Assembly

 The assembling procedure of pressure vessel is as follow:- First weld the hemispherical head to

the cylinder.

 Second weld the saddle support to the bottom side.

 Then insert the outlet and inlet nozzle on the upper part of the vessel.

4.2 Disassembling

The assembling procedure of pressure vessel is as follow

 First disassemble the support from the vessel

 Second disassemble the heads and nozzles.

4.3 Working Principle

0
The pressure vessel which is mounted on vertical saddle support is used to store oil at 200 c. The internal

pressure of the pressure vessel is 0.612MPa and all parts is constructed from stain less steel.

4.4 Component Construction

Components of hemispherical head pressure vessel are discussed as follow:-.

 There is a one shell which is at the middle of two heads.

 There are two heads at both side with inner diameter 0.6m and thickness 0.004m of the cylinder.

The pressure is supported by saddle frame at the bottom sides of the heads.

4.5 Improvement and Futurity

4.5.1. Improvement

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 » When I relate to my project with the former one is from Aluminum/steel and it has the following

properties:

 Its strength is not that match.

 It is Expensive.

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  It is affected by corrosion.

But now in my project I improve these properties

 Strength and hardness increase.

 It can elongate beyond the yield point since it is from different alloy steel.

 Its Costs are fair.

CHAPTER FIVE

RESULT AND CONCLUSION

5.1 RESULT

 Summary of Results Will Be As Shown

Table 5.1 Summery Of Result

Determined Parameters Symbol Value

Length Of Pressure Vessel L 1.8m

Diameter Of Pressure Vessel D 0.6m

Thickness Of The Cylinder ts 0.004m

Shell

Thickness Of Hemisphere th 0.003m

Thickness Of Manhole tm 0.004m

Recommendation

Based on personal experience on this work, the following recommendations were made;

the system can be equipped with a rubber in the linkages; so that as soon to reduce the vibrations

experienced during carrying, the system can be equipped with a harmonic filter to enhance the efficient

functioning of the remote control without experiencing retriggering actions. the design is equipped with

pressure vessel components. Process equipment is fabricated by a number of well-established methods such

as fusion welding, casting, forging, machining, brazing and soldering and sheet metal forming.

Conclusion

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 Generally vertical pressure vessel is a closed container to store oil, gas, liquids at a pressure substantially different

from the ambient pressure. Pressure vessels are used in a variety of application in both industry & the private sector.

They appear in these sectors as industrial compressed air receivers and domestic hot water storage tanks. Pressure

vessels may theoretically be almost any shape, but shapes made of sections of spheres, cylinders, heads, & cones are

usually employed. A common design is a cylinder with end caps called heads, heads shapes are frequently either

hemispherical or dished (tori spherical). We can calculate length & diameter of vessels by using nominal vessel volume

for typical ratio of length to diameter by using standard table used to find L/D ratio depending on the inner service

pressure given. While selecting suitable materials, the requirements of the relevant part relating to the function, stress

conditions, and service life have first of all to be considered. The ends of a cylindrical vessel are closed by heads of

various shapes. The corrosion allowance is the additional thickness of metal added to allow for material lost by

corrosion & erosion, or scale. The strength of metals decreases with increasing temperature. Pressure vessels are built

up from preformed parts; cylinders heads & fitting joined by fusion welding. Heads to shells attachment by butt

welded joints of plates of unequal thickness. The method used to support a vessel will depend on the size shape &

weight of the vessels, the design temperature & pressure the vessel location & arrangement & the internal & external

fittings attachments. Generally when we design pressure vessel we have to used gasket, flanges, consider

reinforcement of openings, manhole ,earthquake loading, wind load, external load ,dead weight of vessel , pressure,…

etc.

REFERENCES

1. Horn, D (2004) “Monopole Base Design”, Technical Manual 1, C-Concepts, Inc.

2. Standard Handbook Of Machine Design, by (JosephE.shigey, Charles R.mischke and ThomassH.brown)

3. Textbook Of Machine Design

4. Pressure Vessel Design And Practice

rd
5. Pressure Vessel Design Manual 3 Edition

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