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vertical pressure vessel design

Mechanics II (University of Gondar)

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Design I, Design of Vertical Pressure Vessel

UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL AND
INDUSTRIAL ENGINEERING

DESIGN PROJECT ONE

Section 03

PROJECT-1:-DESIGN OF COLUMN (VERTICAL LAYOUT) PRESSURE VESSEL

No. Name Id no.

1 Abiyenezer Ayalinehe 4093/08
2 Adugnaw mulu 4124/08
Submitted to; Mr. Teferi.S (Msc.)

Submission date 02/09/2010

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Design I, Design of Vertical Pressure Vessel

Abstract

In this project there are five chapters are included here; In chapter one discuses about
the general over view of the project; chapter two tells about literature review and chapter three
is focus on complete analysis of the design of a pressure vessel basis on several design
consideration. Geometrical analysis, wind load analysis, and stress analysis are conducted on
this design and select the proper material for components of the pressure vessel through taking
some standard tables and standard machine element components. After all, dimensions and
materials are decided for the design component, on the last two chapters result discussion
conclusion and recommendation as well as the part and assembly drawing also provided for
complete description. The main thing here is that the designed pressure vessel can hold the
required fluid of 1.6m3 as we have checked after we designed the vessel.

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Design I, Design of Vertical Pressure Vessel

Acknowledgement

First of all we would like to thank our GOD for the successful completion of our project. We
would like to express our deepest gratitude and sincere appreciation to Mr. Teferi Sitotaw (Msc.)
for his guidance, follow-up, and advice throughout the project period. . We would like to extend
our thanks to those who helped us with different ideas and motivation which inspire us for the
successful completion of this project. . Last but not the least; we would like to thank our beloved
family, for giving birth to us at the first place and supporting us spiritually throughout our life.

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Design I, Design of Vertical Pressure Vessel

Table of Contents

Abstract.......................................................................................................................................................ii
Acknowledgement......................................................................................................................................iii
Table of Contents………………………………………………………………………..…………………iv

List of Table……………………………………………………………………………….…………….…vi

List of Figure……………………………………………………………………………………………...vii

Chapter -1....................................................................................................................................................1
1. Introduction.............................................................................................................................................1
1.1. Over view of the project...................................................................................................................1
1.1.1definition of pressure vessel.........................................................................................................2
1.1.2 Back ground of pressure vessel...................................................................................................3
1.1.3. Application................................................................................................................................5
1.1.4. Use.............................................................................................................................................5
1.1.5. TYPES OF PRESSURE VESSEL.............................................................................................6
1.1.6. Working principle......................................................................................................................9
1.1.7 Main Components of Pressure Vessel.......................................................................................10
1.2 Statement of the problem................................................................................................................21
1.3 Objective........................................................................................................................................21
1.3.1 General objective......................................................................................................................21
1.3.2 Specific objective......................................................................................................................22
1.4. Scope of the project.......................................................................................................................22
1.5. Methodology..................................................................................................................................22
Chapter- 2..................................................................................................................................................23
Literature review...............................................................................................................................23
Chapter- 3..................................................................................................................................................25
3.1. Introduction...................................................................................................................................25
3.2. General Design Considerations:.....................................................................................................26
3.3. Detail design and analysis of a column (vertical layout) pressure vessel.......................................28
3.3.1. Design of shell:........................................................................................................................28
3.3.2. Design of Head:.......................................................................................................................35

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Design I, Design of Vertical Pressure Vessel

3.3.3. Design of inlet and outlet nozzle..............................................................................................42

3.3.4. Design of Skirt Support...........................................................................................................45
3.3.5. Design of bolted flange joint....................................................................................................57
3.3.6. Design of Nut...........................................................................................................................60
3.3.7. Flange design:..........................................................................................................................62
3.3.8. Design of circular handhold:....................................................................................................65
3.3.9. Design of welded joint:............................................................................................................67
3.3.10. Design of Gaskets..................................................................................................................68
Chapter-4………………………………………………………………………………………..…………70
4.1. Result and discussion:....................................................................................................................70
4.1.1. Result.......................................................................................................................................70
4.1.2 Discussions...............................................................................................................................72
Chapter - 5.................................................................................................................................................73
5. Conclusion and recommendation........................................................................................................73
5.1. Conclusion....................................................................................................................................73
5.2. Recommendation:.........................................................................................................................73
Chapter- 6..................................................................................................................................................74
6. 3D Part and Assemble Drawing.......………………………………………………….……….……74

6.1.3D Part Drawing....…………………………………………………...……………………...……74

6.2. 3D Assembly Drawing..………………………………….……………………………………….75

Reference...................................................................................................................................................78
Appendix................................................................................................Error! Bookmark not defined.78

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List of table
Table 1. Given specification data...............................................................................................................25
Table 2.Joint factor table ...........................................................................................................................27
Table 3. Appropriate standard material .....................................................................................................30
Table 4. Appropriate material for shell .....................................................................................................30
Table 5. Optimum vessel proportion .........................................................................................................31
Table 6.stress analysis for head .................................................................................................................38
Table 7. Material selection for bolt design ................................................................................................57
Table 8 . Material selection for the nut design ..........................................................................................61
Table 9. Nut standard dimension .............................................................................................................62
Table 10 .material selection for the nut design ..........................................................................................63
Table 11.result table ..................................................................................................................................70
Table 12. Standard bolt and nut dimension ...............................................................................................78

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Design I, Design of Vertical Pressure Vessel

List of Figure

Figure 1.Pictorial view of vertical pressure vessel.......................................................................................2

Figure 2 . Pressure vessel ...........................................................................................................................3
Figure 3 . Working principle .....................................................................................................................10
Figure 4 . Fabrication of shell by rolling ...................................................................................................11
Figure 5. Machining of shell .....................................................................................................................12
Figure 6. Fabrications of head of pressure vessel .....................................................................................13
Figure 7. Ellipsoidal (or) elliptical head ...................................................................................................14
Figure 8. Hemispherical head ...................................................................................................................14
Figure 9 . Flanged and dished (or) tori spherical head ..............................................................................15
Figure 10.Tori conical head ......................................................................................................................16
Figure 11.Tall vertical tower with skirt support ........................................................................................18
Figure 12. Pictorial view of vertical pressure vessel with leg support.......................................................19
Figure 13 . Pictorial view of horizontal pressure vessel with saddle support ............................................20
Figure 14. Pictorial view of vertical pressure vessel with lug support ......................................................21
Figure 15 . Stress analysis ........................................................................................................................34
Figure 16.2D shell structure .....................................................................................................................35
Figure 17. 2D of head structure ................................................................................................................38
Figure 18. Head stress analysis..................................................................................................................40
Figure 19 . 2D of inlet and outlet nozzle ...................................................................................................45
Figure 20. Wind load pressure vessel.........................................................................................................53
Figure 21 . 2D. diagram of bolt ................................................................................................................60
Figure 22. 2D diagram of nut ...................................................................................................................62
Figure 23. 2D. diagram of flange...............................................................................................................65
Figure 24. Shell ........................................................................................................................................74
Figure 25. Head ........................................................................................................................................74
Figure 26.Hand hole .................................................................................................................................75
Figure 27. Inlet and outlet nozzle .............................................................................................................75
Figure 28. Bolt ..........................................................................................................................................75
Figure 29. nut ...........................................................................................................................................76
Figure 30. flange .......................................................................................................................................76
Figure 31. skirt support.............................................................................................................................77
Figure 32.Assembly drawing of vertical pressure vessel...........................................................................77

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Design I, Design of Vertical Pressure Vessel

Chapter -1

1. Introduction

1.1. Over view of the project

Pressure vessel are probably one of the most wide spread equipment with the different industrial
sector.in fact ,there is no industrial plant without pressure vessels ,steam boilers, tanks autoclaves
,collectors ,pipe ,heat exchangers etc…

The pressure vessel which are either cylindrical or tanks are used to store fluid under pressure.
Pressure vessel and tanks are in fact essential to the chemical, petroleum, petro chemical and
nuclear industry.it is in the class of equipment that the reaction. Separation and storage of raw
material occur. Similarly pressurized equipment is required for a wide range of industrial plant
for storage and manufacturing purpose, Also It has a container with pressure differential between
inside and outside. The inside pressure is usually higher than the outside. Pressure vessel has a
combination of high pressure together with high temperature and in some case highly radioactive
material or flammable fluid. Due to such hazards it is imperative that the design be such that no
linkage can occur.

A pressure vessel is not an easy structure. Actually it is characterized by a regular and simple
shape but requires special care, especially when modern approach to structural design is
concerned.

In the case of shell, opening requiring reinforcement in vessel under internal pressure the metal
removal must be replaced by the metal of reinforcement.in addition to providing the area of
reinforcement, adequate welds must be provided to attach the metal of reinforcement and the
induced stress must be evaluated. material used for reinforcement shall have an allowable stress
value equal to or greater than of the material in this vessel wall except that, when such material
is not available, lower strength material may be used ;provided, the reinforcement is increased in
inversed proportion to the ratio of the allowable stress values of the two material to the ratio of
the two materials to compensate for the allowable stress value of any reinforcement having a
higher allowable stress value than that of the vessel wall [1].

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Design I, Design of Vertical Pressure Vessel

Figure 1.Pictorial view of vertical pressure vessel [2].

1.1.1.definition of pressure vessel

A pressure vessel is a container designed to hold gasses or liquids at a pressure substantially
different from the ambient pressure vessel design, manufacture, and operation are regulated by
engineering authorities backed by legislation. For these reasons, the definition of a pressure
vessel varies from country to country.

Design involves parameters such as maximum safe operating pressure and temperature, safety
factor, corrosion allowance and minimum design temperature (for brittle fracture). Construction
is tested using nondestructive testing, such as ultrasonic testing, radiography, and pressure
tests. Hydrostatic tests use water, but pneumatic tests use air or another gas. Hydrostatic testing

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Design I, Design of Vertical Pressure Vessel

is preferred, because it is a safer method, as much less energy is released if a fracture occurs
during the test (water does not rapidly increase its volume when rapid depressurization occurs,
unlike gases like air, which fail explosively).

Figure 2 . Pressure vessel [2].

1.1.2 Back ground of pressure vessel

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

material specification merged in 1924. The first publication of Section VIII ‘‘Unfired Pressure
Vessels,’’ appeared in 1925. This document was referred to as one of a theoretical factor of safety
of 5. The petroleum industry did not consider it to be adequate for their purposes and also desired
better utilization of available materials. The year 1928 saw the advent of welded pressure
vessels. For higher pressures the welded shells were made thicker than 70 mm. These required
nondestructive examination (NDE) before service. In 1934, a joint API–ASME Committee
published the first edition of an unfired pressure vessel code specifically for the petroleum
industry. In 1952 these two separate codes merged into a single code – the ASME Unfired
Pressure Vessel Code, Section VIII. The ASME Pressure Vessel Code, Section VIII Division 2:
‘‘Alternative Rules for Pressure Vessels,’’ was published in 1968 and the original code became
Section VIII Division 1: ‘‘Pressure Vessels.’’ A considerable boost was provided to the
understanding of the basic behavior of pressure vessel components following the development of
the nuclear power program in the U.S. and Europe in the late 1950s and early 1960s.similar
developments can be found in the British, French, German and Japanese codes, to name but a
few. By 1960 the need for a code for pressure vessels for commercial nuclear plants became
imperative. This resulted in publication of the 1963 Edition, Section III: ‘‘Nuclear Pressure
Vessels.’’ This was a design by analysis code with a theoretical safety factor of 3. After the
publication of Section III: ‘‘Nuclear Pressure Vessels’’ in 1963, it was necessary to modify
Section VIII for general pressure vessels. ASME Code Section VIII Division 2: ‘‘Alternate Rules
for Pressure Vessels’’ appeared as a result and provided a theoretical factor of safety of 3. In
1971, Section III: ‘‘Nuclear Power Components’’ were classified as (a) pumps, (b) valves, and
(c) piping. The stress limits for emergency and faulted conditions were introduced. In addition,
the addenda of 1971 added storage tanks. The addenda of summer 1972 introduced Appendix G
on non-ductile failure. The Appendix F on evaluation of faulted conditions was included in the
addenda of winter 1972. The design of component supports and core support structures appeared
in the addenda of winter 1973. ASME Section III Division 1 is devoted entirely to nuclear power
components and also contains the rules for the design of nuclear pumps and valves. The
recognition of concrete reactor and containment vessels led to the publication of the Section II
Division 2 code in 1975. Three subsections (NB, NC and ND) of ASME Section III Division 1
cover the design and construction of equipment of Classes 1, 2, and 3, respectively. The most
stringent is Class 1, which requires design by analysis. Class 2 permits design by analysis as well

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Design I, Design of Vertical Pressure Vessel

as the use of formulas. Class 3 prescribes design by formula, and is equivalent to Section VIII
Division 1. The designer evaluates the safety function of each pressure vessel and applies the
appropriate code class. Design of supports for Section III Division 1 vessels are not prescribed in
the ASME Code. Section III has a subsection NF, which prescribes the design of. Supports for
Class 1, 2, and 3 pressure vessels. The addenda of winter 1976 changed the nomenclature of
design, normal, upset, testing and faulted conditions to level A, B, C and D service conditions. In
the 1982 addenda, the fatigue curves were extended to 1011 cycles. In the 1996 addenda, the
design rules for high-temperature service were incorporated. In 1976, Division 3 was published
which contained rules on transport of irradiated materials. The need for uniform rules for in-
service inspection of nuclear power plants led to the issuance of the 1970 edition of Section XI:
‘‘Rules for In-service Inspection of Nuclear Plant Components’’[5].

1.1.3. Application
Pressure vessel is the container for fluid under high pressure. They are used in variety of
industries like:

 Petroleum refining

 Chemical plant

 Power plant

 Food and beverage

 medical application

 LPG tanks and many more

In addition it also can store fluid such as liquid vapor and gas under pressure .pressure vessel had
been used in various water treatment application like mixed bed exchanger , activated carbon
filters ,sand filters, dual medical filters etc. with internal rubber lining carbon steel internal
including strainers and screen laterals ,ladders and plate form etc…

1.1.4. Use
Pressure vessels are used in a variety of applications in both industry and the private sector. They
appear in these sectors as

 industrial compressed air receivers and domestic hot water storage tanks.

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Design I, Design of Vertical Pressure Vessel

 Other examples of pressure vessels are diving cylinders,

 recompression chambers,

 distillation towers,

 pressure reactors,

 autoclaves,

 and many other vessels in mining operations, oil refineries and petrochemical plants,

 nuclear reactor vessels,

 submarine and space ship habitats,

 pneumatic reservoirs,

 hydraulic reservoirs under pressure,

 rail vehicle airbrake reservoirs,

 road vehicle airbrake reservoirs,

 And storage vessels for liquefied gases such as ammonia, chlorine,

and LPG (propane, butane).

A unique application of a pressure vessel is the passenger cabin of an airline

or the outer skin carries both the aircraft maneuvering loads and the cabin
pressurization loads.

1.1.5. Types of pressure vessel

The most common types of pressure vessels can be classified:-

According to structural materials

 Steel
 Cast iron
 Copper, and
 Plastic pressure vessels.

According to methods of fabrication

a) Welded

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Design I, Design of Vertical Pressure Vessel

b) Cast

c) Brazed, and

d) Flanged pressure vessels.

According to their functions

a) Storage vessels

b) Reactors

c) Boilers

d) Mixers, and

e) Heat exchangers.

According to size and geometric form

The size and geometric form of pressure vessels diverge greatly from the large cylindrical
vessels used for high-pressure gas storage to the small size used as hydraulic units for aircraft.
Some of the vessels are buried in the ground or deep in the ocean, but most are positioned on
ground or supported in platforms. There are four types of pressure vessels. But mainly two types
of pressure vessels usually available in industry:

a. Cylindrical.

b. Spherical
c, Conical, and.
d. Combined

The two main types of pressure vessels usually available in industry:

a) Cylindrical Pressure Vessel

This type of a vessel designed with a fixed radius and thickness subjected to an internal gage
pressure. This vessel has an axial symmetry. The cylindrical vessels are generally preferred, since
they present simpler manufacturing problems and make better use of the available space. Boiler
drums, heat exchangers, chemical reactors, and so on, are generally cylindrical.

Advantages of cylindrical pressure vessels:

 It is easier to fabricate.
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Design I, Design of Vertical Pressure Vessel

 They are probably cheaper to construct.

 They pack more efficiently into rectangular structures such as boxes and buildings.

b) Spherical Pressure Vessel

This type of pressure vessels are known as thin walled vessels. This forms the most typical
application of plane stress. Plane of stress is a class of common engineering problems involving
stress in a thin plate. Spherical vessels have the advantage of requiring thinner walls for a given
pressure and diameter than the equivalent cylinder. Therefore they are used for large gas or liquid
containers, gas-cooled nuclear reactors, containment buildings for nuclear plant, and so on.

Advantages of spherical pressure vessels:

 For the same internal design pressure, a spherical vessel will require only half the wall
thickness as a cylindrical vessel.

 Spherical vessels have the advantage of holding the largest volume per unit surface area
of the container [7].

According to scheme of loading:

 Vessel working under internal pressure and,

 Vessel working under external pressure.

According to operating temperatures

 Low temperature vessels (less than or equal to -20C)
 Normal temperature vessels (between -20oC to 150C)
 Medium temperature vessels (between 150oC to 450C)
 High temperature vessels (more than or equal to 450C)

According to operating pressure

 Low pressure vessel (0.1 MPa to 1.6 MPa)
 Medium pressure vessel (1.6 MPa to 10 MPa)
 High pressure vessel (10 MPa to 100 MPa)
 Ultra high pressure vessel (More than 100 MPa)

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According to its usage mode

 Fixed pressure vessel
 Mobile pressure vessel

According to corrosion action

 High corrosion effect and

 Moderate corrosion effect pressure vessels

According to the orientation in space:

 Vertical

 Horizontal and

 Sloped pressure vessels

 According to the methods of assembly:

Detachable and

 No detachable pressure vessels

According to the wall thickness:

Thin walled (t/D<1/10) and, Thick walled (t/D≥1/10) pressure vessels. Where; t and D are the
thickness and diameter of the shell respectively [4].

According to the end construction

 Open end, and

 Closed end pressure vessels [2].

1.1.6. Working principle

Pressure tanks store alcoholic fluid, which release from the industry and convert those alcoholic
fluids to neutral inside the vessel before releasing to the river.

Diagrammatically:-

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Design I, Design of Vertical Pressure Vessel

Industry

alcohol and
poisenes fliuid
realesed from
industry

pressure vessel
store alcohols
and convert to
neuteral fluid

finally realese to
the river

Figure 3 . Working principle [2].

1.1.7 Main Components of Pressure Vessel
The following are the main components of pressure Vessels in general

a) Shell

b) Head

c) Nozzle

d) Support

e) Flanges

a) 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.
 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

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diameters due to process and phase change of process fluid.

 Shell of a spherical pressure vessel is spherical as well.

The shell is the main component of any vessels that contains the pressure. Material of shell
normally come in plate or rolled steel. Commonly, some pressure vessel shells has a rotational
axis and be welded together to form a structure. Most pressure vessel shells are cylindrical,
spherical, or conical in shape [6].

Figure 4 . Fabrication of shell by rolling [2].

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Design I, Design of Vertical Pressure Vessel

Figure 5. Machining of shell [2].

b) Head

All pressure vessel shells must be closed at the ends by heads. Heads that usually used are
typically in curved rather than flat.

Configurations of curved shape stronger and let the pressure vessel's heads to be thinner, lighter
and less expensive rather than flat heads. Inside a vessel, heads can also be used.
Elliptical, hemispherical, and tori spherical are the most commonly used head types.

Note that; all head types have a straight flange (sf) section, which simplifies welding the head to
the adjacent cylindrical shell section.

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The elliptical and tori spherical heads have an indicated head

depth (h), which is measured from the straight flange to the maximum point of curvature on the
inside surface.

Heads are usually can be categorized by their shapes.

Figure 6. Fabrications of head of pressure vessel [2].

1) Ellipsoidal (or) elliptical

This is also called a 2:1 elliptical head. The shape of this head is more economical and
not exposed to wind loading, because the height of the head is just a quarter of the
diameter. Its radius varies between the major and minor axis. As our vessel is vertically
oriented it’s merely exposed to wind loading, if so the elliptical head can withstand the
wind load in a slight extent when compared with others. Even if an elliptical head is
exposed to snow loading and the edge between the straight flange (sf) and the curved
head became crack easily, whenever this condition are present we select it as a best head
by fabricating from carbon and low alloy steel as it is hard and strong with a moderate
ductility properties as well as low cost and availability.

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Design I, Design of Vertical Pressure Vessel

Figure 7. Ellipsoidal (or) elliptical head [2].

Ellipsoidal would be the most common type of heads, which is used during the designing of a
new pressure vessel.

2) Hemispherical

A sphere is the ideal shape for a head, because the pressure in the vessel is divided
equally across the surface of the head. The radius (r) of the head equals the radius of the
cylindrical part of the vessel. 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.

Figure 8. Hemispherical head [2].

3) Flanged and dished (or) Tori spherical,

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Design I, Design of Vertical Pressure Vessel

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.

Figure 9 . Flanged and dished (or) tori spherical head [2].

4) Conical (or) Tori conical,

Tall towers may have sections with different diameters along their length. The transition
between the different diameters is made in a conical section. The most common design
for a conical transition does not have formed knuckles at the ends of the cone. The
cylindrical sections of different diameter are welded to each end of the cone. Formed
knuckles are sometimes used at the cone-to-cylinder transition in order to reduce
localized stresses. When knuckles are used, the transition is called Tori conical. The use
of knuckles is 106 mandatory when the cone half-apex angle exceeds 30°. Knuckles are
also sometimes used for smaller angles when there is concern about potentially high local
stresses at the cone-to-cylinder junction. The ASME Code has design procedures for tori
conical sections.

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Design I, Design of Vertical Pressure Vessel

Figure 10.Tori conical head [2].

Reinforcement of openings

The philosophy is based on providing additional material in the region of the opening by
thickening the shell or adding a pad material. The additional material is deemed effective
in carrying the higher loads. On most vessels, is provided on the outside of the vessel. In
some vessels, the reinforcement appears inside, while in others both inside and outside
regions are reinforced. On many vessels, however, the arrangement is such that no
reinforcement can be placed on the inside because of interfering components [7].

c) Nozzles

A nozzle is a cylindrical component that penetrates and mounts whether at the shell or
heads of a pressure vessel surface. The nozzle ends are generally flanged.

Flanges function is to allow the necessary connections. Flanges also use to permit easy
disassembly for routines maintenance or easy access. Nozzles commonly are used for the
following applications [2].

 Attach piping for flow inlet or outlet of the vessel.

 Attach instrument connections such as level gauges, thermo wells, or pressure

gauges.

 Provide access to the vessel interior at manholes.

 Provide for direct attachment of heat exchanger or mixer.

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Design I, Design of Vertical Pressure Vessel

 Nozzles sometimes extended into the vessel interior for some applications, such
as for inlet flow distribution or to permit the entry of thermo wells.

 They are used for the following applications [6].

 2:1 Ellipsoidal head

 Sphere and hemispherical end

 Tori spherical head

 Conical head

d) Support

The type of support that is designed and used depends on the orientation of the pressure
vessel whether horizontally or vertically.

In any situation, the pressure vessel support must be enough to support the applied weight
and other loads.

Design pressure of the vessel is not being considered in the design of its support because
the support is not be pressurized. But, design temperature should be considered for
support design.

It should be considered from the perspective of material selection and provision for
differential thermal expansion.

There are different types of supports which are used depending upon the size and
orientation of the pressure vessel.

These are;-

 Skirt support

 Leg support

 Saddle support

 Lug support

 Skirt support

This type of support generally been used for tall, vertical, cylindrical pressure vessels.

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This type of support is a cylindrical shell section which is be weld either to

the bottom of the vessel shell or to the bottom head for the cylindrical vessels.
Skirt support for spherical vessel is welded to the vessel near the mid plane of the
shell.

The skirt is normally design long enough to provide flexibility so that radial
thermal expansion of the shell does not cause high thermal stresses at its junction
with the skirt.

Base ring/flange

Base ring is a part of skirt support which is used to distribute the vertical load over a sufficient
area of the concrete foundation. In addition it serves also to accommodate the anchor bolts [7].

Figure 11.Tall vertical tower with skirt support [2].

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Design I, Design of Vertical Pressure Vessel

 Leg support

Small vertical drums are normally supported by legs that are welded to the bottom of the
pressure shell.

The maximum ratio of support provides for leg length to drum diameter is typically 2:1.

The number of legs is designed depends on the drum size and the loads to be carried.

Support legs are also usually designed for spherical pressure vessels.

The support legs for small vertical vessels and spherical storage vessels normally made from
high carbon material such as structural steel columns or pipe sections, which provides a more
efficient and perfect design.

Figure 12. Pictorial view of vertical pressure vessel with leg support [2].

 Saddle support

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Horizontal drums are normally supported by saddle.

This type of support divides the weight load over a large area of the shell to avoid an
unnecessary stress in the shell at two different locations.

The width of the saddle is considered by the specific size and design conditions of the pressure
vessel.

One saddle support is normally fixed or anchored to its foundation.

Figure 13 . Pictorial view of horizontal pressure vessel with saddle support [2].
 LUG SUPPORT:
Vertical pressure vessels may also be supported by lugs.
Diameter (1 to 10 ft) Also moderate height to diameter ratios in the range of 2:l1 to 5:1
The lugs are typically bolted to the use of lugs is typically limited to pressure vessels of
small and medium horizontal structural members in order to provide stability against
overturning loads [7].

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Design I, Design of Vertical Pressure Vessel

Figure 14. Pictorial view of vertical pressure vessel with lug support [3].
1.2 Statement of the problem
In Ethiopia the contamination of most river caused by realizing poisons liquid west product
(alcohol and acid) from industry’s and, the contaminate river supplied for the drinking purpose of
different animal and those animals suffering for different dieses and caused to death. In order to
solve this problem first store those acid and alcohols by a column (vertical layout ) pressure
vessel and then renewed to neutrals by performing proper chemical reaction, then after we can
realize the renewed fluid to the river.so for this application we are initiate to design a vertical
layout pressure vessel.

1.3 Objective
1.3.1 General objective
The main objective of our project is to design a column (vertical layout) pressure vessel that has
an ability to store alcohol with in the given specification of

 Total volume 1.6 m3

 Design pressure 10mpa
 Design temperature 200c and
 Corrosion allowance 2.5

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Design I, Design of Vertical Pressure Vessel

1.3.2 Specific objective

Specifically we will to design all components of a column (vertical layout) pressure vessel by its
own procedure:

Those components which are design at the end of the project are, shell, nozzle, and standard
flange, Columns supporting skirt and base ring/flange .An ellipsoidal head and others.

1.4. Scope of the project

This project is about the designing of pressure vessel. The type of pressure vessel that we are
asked in this project was column (vertical layout) pressure vessel. The scope of this design
project was on the detail design and analysis of each component of column (vertical layout)
pressure vessel and to draw out the detail drawing of each component using AutoCAD software
with the help of optimization concept and design procedure.

Limitation of the project

Since our project is to design a column (vertical layout) pressure vessel based on the given
specification that is design pressure(10mpa), design temperature(200 0C), total inside
volume(1.6m3), corrosion allowance(2.5), and working fluid is alcohol but we are limited to
apply the schedule time for the design purpose since we have taken other courses parallel. And
also there is no sufficient material in our workshop to manufacture the design.

1.5. Methodology
For this particular design project we follow the following project design methodology to solve
the design problem

IDENTIFICATION OF NEED
Design of a column (vertical layout) Pressure vessel

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Design I, Design of Vertical Pressure Vessel

DEFINITION OF PROBLEM

We are asked to design a column (vertical layout) pressure vessel

which has capacity to store alcohol.

ANALYSIS AND OPTIMIZATION

Selecting suitable material, Geometric, force, cost and stress analysis for each component, Such as: shell, head, nozzle,
flange, bolt and skirt support, Checking the maximum principal and shear stress with the permissible stress of material
of component.

RESULT AND CONCLUSION

PRESENTATION
Part drawing and assembling drawing of the column (vertical layout) pressure
vessel using Auto CAD software.

Chapter- 2

Literature review
Prof. Sha Husain S.Maghrabi et al [6] 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 stress concentration factor (SCF) of a

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Design I, Design of Vertical Pressure Vessel

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.

M. Jeyakumar et al [6] researched on Influence of residual stresses on failure pressure of

cylindrical pressure vessel. Here a main criterion is to study the effect of residual stresses on the
pressure vessel. Conclusion shows that there is a reduction in failure pressure due to unfavorable
residual stresses.

M. Giglio et al [6] 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 concludes that failure of nozzles was carried out by crack passing through their
thickness. Both designs (external and internal 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.

Di Carlucci et al [7] in year 2008 has done the work on ASME norms should be considered for
designing. Seismic loads should be considered while designing a pressure vessel. Wind load and
seismic load creates moment at lug. The greater moment should be consider for design to avoid
accidents.

E. 0. Bergman [8] states that the external loads applied to vertical pressure vessels produce axial
loading and bending moments on the vessel. These result in axial tensions and compressions in
the shell, which must be combined with the effects of the pressure loading to give the total
longitudinal stress acting in the shell. The design method to be used depends on whether the
longitudinal stress in the shell is tension or compression, and on whether the vessel is subjected
to internal or external pressure.

From the above journals we conclude that a column (vertical layout) pressure vessel
are fail due to certain factors such as: External loading, Wind loading, Crack passing
through the thickness of nozzle, Effect of residual stress.

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Design I, Design of Vertical Pressure Vessel

In order to improve the life and efficiency of vertical or column pressure vessel. When we
design vertical or column pressure vessel, we must consider external loads such as wind
load and seismic load, and also we should select material.

Chapter- 3
3.1. Introduction
In this chapter includes detail design of all component of vertical pressure vessel such as design
of shell, head, inlet and outlet nozzle, support, flange, etc. not only this, but also all calculation
and stress analysis of each part which is important to the vessel are done in accurate and precise
way. For better alignment and long lives of those components we take appropriate material from
the standard table based on the given parameter. Hence different standard table and figures are
presented in this topic. In addition to that, by using the dimension value the corresponding 2D
drawing of those components are drawn and presented. In general four our design of vertical
pressure vessel we take bolt flange and weld joint for correct assembly, also use gasket for a leak
– tight. Generally the pressure vessel is designed by considering internal pressure, wind loading
and dead weight.

Table 1. Given specification data [1].

Design of column (vertical layout)pressure vessel specification

Parameters Value Unit
Design pressure 10 Mpa
Design temperature 200 c
Total inside volume 1.6 m3
Corrosion allowance 2.5
Working fluid Alcohol
Vessel Vertical

3.2. General Design Considerations:

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Design pressure
A vessel must be designed to withstand the maximum pressure to which it is likely to be
subjected in operation. For vessels under internal pressure, the design pressure is normally taken
as the pressure at which the relief device is set. This will normally be 5 to 10 per cent above the
normal Working pressure, to avoid spurious operation during minor process upsets [9]. When
deciding the design pressure, the hydrostatic pressure in the base of the column should
be added to the operating pressure, if significant. Vessels subject to external pressure should
be designed to resist the maximum differential pressure that is likely to occur in service.From the
equation of design pressure we can get the normal working pressure (or) internal pressure” Pi” as
shown below:-
PD =P+ P*10%

Since, PD = P+ P*10%

PD = Pi (1+10%)

Pi= PD/1.1

Pi= 10Mpa/1.1

Pi= 9.0909Mpa.

Design temperature
The strength of metals decreases with increasing temperature so the maximum allowable design
stress will depend on the material temperature. The design temperature at which the design stress
is evaluated should be taken as the maximum working temperature of the material, with due
allowance for any uncertainty involved in predicting vessel wall temperatures [9].

TD = 200c

Corrosion allowance

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Design I, Design of Vertical Pressure Vessel

The corrosion allowance is the additional thickness of metal added to allow for material lost by
corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer. Corrosion is a complex phenomenon, and it is not possible to give
specific rules for the estimation of the corrosion allowance required for all circumstances. The
allowance should be based on experience with the material of construction under similar service
conditions to those for the proposed design [9].

Corrosion allowance (C) = 2.5

Welded joint efficiency, and construction categories

The strength of a welded joint will depend on the type of joint and the quality of the
welding. The soundness of welds is checked by visual inspection and by non-destructive testing
(radiography). The possible lower strength of a welded joint compared with the virgin plate is
usually allowed for in design by multiplying the allowable design stress for the material by a
“welded joint factor” E. The value of the joint factor used in design will depend on the type of
joint and amount of radiography required by the design code [9]. Taking the factor as 1.0 implies
that the joint is equally as strong as the virgin plate; this is achieved by radio graphing the
complete weld length, and cutting out and remaking any defects. The use of lower joint factors in
design, though saving costs on radiography, will result in a thicker, heavier, vessel, and the
designer must balance any cost savings on inspection and fabrication against the increased cost
of materials [9].

Table 2.Joint factor table [1].

Degree of radiography
Type of joint 100 % Spot None
Double-welded butt or 1.0 0.85 0.7
equivalent
Single-weld butt joint 0.9 0.80 0.65
with bonding strips

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Design I, Design of Vertical Pressure Vessel

In our design we use joint efficiency value E=1

3.3. Detail design and analysis of a column (vertical layout) pressure vessel

3.3.1. Design of shell:

The shell is the primary component that contains the pressure. Pressure vessel shells are welded
together to form a structure that has a common rotational axis. Most pressure vessel shells are
cylindrical, spherical, or conical in shape. Horizontal drums have cylindrical shells and are
fabricated in a wide range of diameters and lengths [2].
In our design we select low alloy steel to design the shell because it has high working stress
compared to others, has high atmospheric corrosion resistance capacity, suitable to welding.

The design procedures in pressure vessel codes for cylindrical shells are mostly based on linear
elastic assumption, occupationally allowing for limited in elastic behavior over a localized
region. The shell the thickness is the major design parameter and usually controlled by internal
pressure and sometimes by external pressure which can be produce bucking. Now to determine
the thickness and diameter of shell first categorized our pressure vessel according to its design
pressure compared to standard. Therefore check for which non opposition that our pressure is
safe.

Table 3. Appropriate standard material [1].

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Design I, Design of Vertical Pressure Vessel

From the above table we select the material, design stress and tensile strength for shell based on
the design temperature, and design pressure.

Table1 4. Appropriate material for shell [1].

Material Tensile strength Design stress at 2000c

in N/mm2 in N/mm2
Low alloy steel 550 240

If PD > 0.385ᵟd* E ………………………use = -1) …equation 1

PD < 0.385ᵟd* E …………………………. use = ……equation 2

Where ᵟd = design stress

E = joint factor
= thickness of shell

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Design I, Design of Vertical Pressure Vessel

= internal reading of shell

PD = design pressure
Equation 1 for thick shell and equation 2 for thin shell

Then check our vessel categorization

= 0.385ᵟd* E

0.385*240N/mm2*1=92.4mpa

But Pd =10mpa

10mpa<92.4mpa so our vessel categorized in thin cylinder then we use equation 2

To calculate the thickness of the shell, first find the diameter .from the given volume 1.6m 3 and
also find vessel ratio

F1= C – 0.6) where c= corrosion allowance

ᵟd = Design stress

E= joint factor
F1
F1=58.5mm
Now convert the unit in to inch by using conversion factor
1inch=25.4mm
X? =58.5mm
X = F1=2.303inch
To know ratio we use the vessel ratio and total inside volume.
First let us change the unit of volume in to ft3 by using conversion factor
1ft3=0.028317m3
1ft3=0.028317m3
V? = 1.6m3
V=56.5ft3
By using V=56.5ft3 and
F1=2.303inch, then to find the diameter change the design pressure unit to PSI.

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Design I, Design of Vertical Pressure Vessel

1mpa =145.04PSI
10mpa=pd
pd=1450.4PSI

Table 5. Optimum vessel proportion [1].

Pressure in psi L/D ratio

0-250 3
250 4
>500 5

From the above table we take L/D ratio = 5

So, V= + but L=5

1.6= +
=
1.6* =Di3
Di= m
=0.72556m
Di = 725.56mm

R= =
0.3627m =362.7mm

By using equation 2 above

=

ts= =15..5mm.
but for safe design we consider corrosion allowance .
ttotal= +c
=15.5+2.5 = 18mm
= + 2*

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Design I, Design of Vertical Pressure Vessel

=725.566+2(18) =761.566mm

=+t
= 725.566 + 18mm
= 743,566mm
And length of the cylinder can be found by:

=5
L= 5
L=5*725.566mm
L=3627.83mm
From this the length of the shell is given by:
= L- but
Hi=
Where Hi is inner head for ellipsoidal head

Hi= = 181.39mm
= L-
= 3627.63mm -
= 3506.9mm

=
= 3.5069 ()

= 1.449m3

Where: - = mean diameter of shell

DO = outer diameter of the shell
Di =inner diameter of shell
ts = thickness of shell
vs=volume of shell

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Design I, Design of Vertical Pressure Vessel

Ls= length of shell

Stress analyses of cylindrical shell

Thus the wall of a cylindrical shell subjected to an internal pressure has to withstand tensile
stresses of the following two types:
(a) Hoop stress ( )
Consider a thin cylindrical shell subjected to an internal pressure tensile stress acting in
a direction tangential to the circumference is called circumferential or hoop stress. In other
words, it is a tensile stress on longitudinal section (or on the cylindrical walls).We know that
the total force acting on a longitudinal section (i.e. along the diameter) of the shell

Where Pd = design pressure

Dm = mean diameter of shell
t = thickens of shell

(b)Longitudinal stress
Consider a closed thin cylindrical shell subjected to internal pressure tensile stress acting in the
direction of the axis is called longitudinal stress. In other words, it is tensile stress acting on the
transverse or circumferential section Y-Y (or on the ends of the vessel).

Calculate the design stress analysis of the shell thickness to know whether it is safe or not.

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Design I, Design of Vertical Pressure Vessel

Figure 15 . Stress analysis [2].

As we know

===206.546 N/mm2 <240 N/mm2

And

== =103.27 N/mm2 <240 N/mm2

H =2l
Since both hoop and longitudinal stress are less than the allowable (Design) stress our design is
safe.

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Design I, Design of Vertical Pressure Vessel

Figure 16.2D shell structure [2].

3.3.2. Design of Head:
Heads are one of the important parts in pressure vessels and refer to the parts of the vessel that
confine the shell from below, above, and the sides. The ends of the vessels are closed by means
of heads before putting them into operation. The heads are normally made from the same
material as the shell and may be welded to the shell itself. They also may be integral with the
shell in forged or cast construction. The head geometrical design is dependent on the geometry of
the shell as well as other design parameters such as operating temperature and pressure.
The heads may be of various types such as:
 Ellipsoidal
 Tori spherical
 Hemispherical
 Conical
ASME equation for Ellipsoidal heads
The design thickness of an Ellipsoidal head is given by:
Where: D– shell diameter
s-allowable Stress
k – stress intensity

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Design I, Design of Vertical Pressure Vessel

a-semi minor axis

b-semi major axis of the Ellipsoidal head
which is 2:1

For safe design we should consider corrosion allowance.

t total = th+2.5 = 15.1792+2.5 = 17.6792  17.68mm

, but

Do=di+2ttotal

=725.566+2(17.68)

=760.926mm

Ho =

=190.2mm

Total volume of ellipsoidal head can be calculated as follows.

= 2* ( + *) but

Hi= and

Sf= =

= 2* ( + *)

= 2* ( + )

= 2*

= 2*

= but Di= 0.725566m

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Design I, Design of Vertical Pressure Vessel

= 0.14999m3

Then the total volume of the vessel of a cylinder becomes:

=+

= 1.4499mm3 + 0.15mm3

= 1.5999mm31.6mm3

 Then our design is safe.

Figure 17. 2D of head structure [2].

Stress analysis on head

The stresses are considered in to three parts as -shown below:

Table 6.stress analysis for head [1].

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Design I, Design of Vertical Pressure Vessel

At any point x At center At tangent

-ᵟx= ᵟx= ᵟx=

-ᵟ= ᵟ= ᵟx ᵟ=

Where RL = latitudinal radius of curvature, in mm.

= meridional radius of curvature, in mm.

P = internal pressure,

h = depth of head, mm.

R = inside radius of head.

x =

 Longitudinal stress.

There are two types of stress in head due to internal pressure. This are

Longitudinal stress ()

Meridional stress (x)

Then analysis the stress

 At any point x
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Design I, Design of Vertical Pressure Vessel

 At the center and,

 At the tangent

First let’s find RL, Rm, h and x

h=

h= = 181.39mm

R= = = 362.78mm

Figure 18. Head stress analysis [2].

Note:from the diagram above h≤X≤R

Let x=250mm

RL=

RL=

= RL=

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Design I, Design of Vertical Pressure Vessel

= RL=

RL=582.18mm

Rm=

Rm=

Rm =374.8mm

 The stress analysis at any point x:

x = and  = (1-RL /2Rm)

x = =161.716mpa < 240 MPa

=

= 323.4(1-0.7766)

=72.23MPa <240MPa

= =2.0which is>1.42

ratio exceeds 1.42,hoop stress in the knucle become compressive.

 stress analysis at center:

x =

x =

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Design I, Design of Vertical Pressure Vessel

x =201.5N/mm2<240MPa

 stress analysis at tangent:

x =

x =

x =100.77 N/mm2

=

= -201.54N/mm2 MPa<240MPa

As we see from the above result the negative sign shows the presence of compressive stress.
When we see from the above three cases stress is maximum at the center of head and this stress
is less than the allowable or design stress, so our design of head is safe.
3.3.3. Design of inlet and outlet 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 [9].

All process vessels will have openings for connections, man ways, and instrument fittings. The
presence of an opening weakens the shell, and gives rise to stress concentrations. The stress at
the edge of a hole will be considerably higher than the average stress in the surrounding plate. To
compensate for the effect of an opening, the wall thickness is increased in the region adjacent to
the opening. Sufficient reinforcement must be provided to compensate for the weakening effect
of the opening without significantly altering the general dilation pattern of the vessel at the
opening. Over-reinforcement will reduce the flexibility of the wall, causing a hard spot, and
giving rise to secondary stresses [9].

We select low alloy steel material to design inlet and outlet nozzles because it is suitable for
welding, has high atmospheric corrosion resistance capacity. The standard table is found at the
above table 3.3.

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Design I, Design of Vertical Pressure Vessel

Nozzle attached to pipes to convey the working fluid inside and outside of the vessel.

Like shell design we select low alloy steel for design of inlet and out let nozzles because it is
suitable for welding has high atmospheric corrosive resistance capacity.
 For opening in cylindrical shell are limited to that sizes
 In shell 60inch and less in diameter ,the opening shell not exceed 0.5 diameter or 2inch
 In shell over 60inch in diameter, the opening shell not exceed 0.33diameter or 4inch
where di=inner diameter of the shell, so diameter of shell=28.56inch which is less than
60 inch so the opening diameter =0.5 diameter or 2 inch
 Dn=1inch=25.4mm
Therefore 2inch is 50.8mm because of internal diameter the nozzle is over 18inch and
less than 36inch so
Rn= Dn/2 =25.4mm
Assume our inlet opening pipe is placed on the cylindrical shell.

tr - minimum required thickness of shell

tn - nominal thickness of nozzle
t - Nominal thickness of shell
trn - required thickness of nozzle
A - Area of required reinforcement

= =1.082mm
But ri=

t=tr+c = 15.5+2.5=18mmm

tn=8.5699mm from standard table

assume our inlet opping pipes placed on the cylinderical shell.

The stress develops in the nozzle is as follows:

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Design I, Design of Vertical Pressure Vessel

This is an acceptable value b/c 127MPa<240MP

Reinforcement of opening design

tr – 15.5mm
tn -8.5699mm from standard table
t – 18mm
trn – 2mm
A-

Area of reinforcement required

Area of Reinforcement Available.

A) Area available in vessel wall, A1, is the larger of:

For safe design take the larger value

B) Area available in nozzle wall

For out ward

Take the smaller A2= 281

Inward mm2

C) Area of weld (in ward and out ward weld)

=2*0.5*182=324mm2

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Design I, Design of Vertical Pressure Vessel

The total area is At=A1+A2+A3+A4

(127+281.5+771.29+324)mm2=1503.8mm2

Area of reinforcement available

At=1503.8mm2

The available area > the required area, it means the design is safe.

Figure 19 . 2D of inlet and outlet nozzle [2].

3.3.4. Design of Skirt Support
A skirt support consists of a cylindrical or conical shell welded to the base of the vessel.
A flange at the bottom of the skirt transmits the load to the foundations. Openings must be
provided in the skirt for access and for any connecting pipes; the openings are normally
reinforced. The skirt may be welded to the bottom head of the vessel. Skirt supports are
recommended for vertical vessels as they do not impose concentrated loads on the vessel shell;
they are particularly suitable for use with tall columns subject to wind loading.

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Design I, Design of Vertical Pressure Vessel

In the specification, it is given that the support type is a skirt support, and we choose the
arrangement of the skirt to be conical because it has a large surface contact to the ground as a
result it transmit a load perfectly. The use of conical skirts is more expensive from a fabrication
standpoint, and unnecessary for most design situations

Weight of shell material: is the sum of weight of shell material and fluid

Where; Wsm=weight of shell

Wsf = weight of shell fluid

Weight of shell fluid ( Wsf )

f=mf*g but mf= *Vf where Vf=volume of the fluid on the shell

=density of alcohol =789kg/m3

Mf=mass of fluid

But =
= 3.50699 ()
Vf =1,44999m3
msf = 1.45m3

=114.4kg

f = f *g

f = 114.4*9.81=1122.26N

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Design I, Design of Vertical Pressure Vessel

Weight of shell material (Wsm) : the material is low alloy steel

We take low alloy=7850kg/m3

Wsm=πDmtsgLg

Where: Dm=mean diameter

g=acceleration due to gravity taken as 9.81m/s2

But L=Ls+2Hd

L=3506+2(Do/4), Do=outside diameter of shell

L=3506.9mm+2(761.566/4)

=3887.68mm=3.88768m

Dm =Di+ts

=725.566+18=743.5666mm=0.7435m

Wsm=πDmtsLg

Wsm =π*0.743566*0.018*7850*3.88768*9.81

Wsm =4007N

Weight of head (Whm)

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

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Design I, Design of Vertical Pressure Vessel

= 1.084*th**g where = mean diameter of ellipsoidal head

g= acceleration due to gravity taken as 9.81m/s2

th=thickness of head

m= 1.084*th**g

= 1.084***9.81

=830.76N

Weight of Nozzle: is the sum of the weight of nozzle material and the fluid stored on it.

= *g but = *

= 0.0004696m3

We take of alcohol =789kg/m3 from the table

= *Vf

= *0.0004696m3

= 0.37kg

= *g

= 0.37 *9.81

=3.6346N

Weight of nozzle material

The material is low alloy steel we take 3

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Design I, Design of Vertical Pressure Vessel

= *g But = *Vn

= where = outlet nozzle diameter

di= inlet nozzle diameter

L= length of nozzle

= volume of nozzle material

= mass of nozzle

== = 25.4mm and Ri= ==362.78mm

l=- where l=length of part of the nozzle entering to shell

l=3-

l=0.887mm

L= l+ + length of part of the nozzle leaving the shell

L= 0.887mm+ 18mm + 212.8mm

L=231.687mm

D=d+dtn, But d=di+2l

=50.8+2(2.5) = 55.8mm

=do=55.8*2(18)=91.8

= 1063885.6 mm3 =0.0010638856

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Design I, Design of Vertical Pressure Vessel

=*

= *0.0010638856

= 8.35kg

=*g

= 8.35*9.81

= 81.9N

Weight of nozzle fluid

= *g but = * where volume of the fluid on the nozzle

= 0.0004696m3

We take of alcohol =789kg/m3 from the table

= *Vf

= *0.0004696m3

= 0.37kg

= *g

= 0.37 *9.81

= 3.6346N

Weight of Wind

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Design I, Design of Vertical Pressure Vessel

The atmospheric pressure is varies from place to place then we take the mean atmospheric
pressure in BAHIR DAR.

The wind effect has its own role in pressure vessel design. When we design pressure vessel with
pressure height we have to consider the effect of wind on the vessel.

= * where = mean atmospheric pressure

= projected area

But = *

But = + 2 + we take length of the skirt ( ) = 114mm

= 3506.9mm + 2 *181.35mm + 320mm

=4189.68mm

=*

= 0.76156m*4.18968m

= 3.19m2

= 1009N/m2*3.19m2

= 3218.71N

The moment of the vessel due to wind is calculated as;

=w Where = moment due to wind

X is the distance measured from the free end (approximately equal to

Total height of the vessel = 1.8139mm) and

’w’ the load per unit length (Newton Per meter) and calculated as follows:

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Design I, Design of Vertical Pressure Vessel

=+t where = mean diameter of vessel

= 7.5625mm +18mm

= 743.56mm = 0.74356m
And

w = * = 0.74356m* 1009N/m2

w = 750.2N/m

And

=w

= 750.2*

= 1234Nm

.
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Design I, Design of Vertical Pressure Vessel

Figure 20. Wind load pressure vessel [2].

Now we can find the total weight as follows:

For material;

=Wsm+Whm+Wnm

=4007N+830.76N+8.35N

=4846.11N

For fluid

=++

=1122.26N +116N +3.6N

=1241.89N

=+ +

= 4084.11N+ 1241.89N+3218.71N

= 8544.71N

Then we find the design weight as follows:

= + *10

= 8544.71N + 8544.71N *10/100

= 9399.18N

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Design I, Design of Vertical Pressure Vessel

Now let us find the loading on each leg:

P= where n= number of legs=3

P= load

= design weight

P=

P=3133N

The area of legs calculated as follows:

In our design the support of pressure vessel is straight skirt and we choose 5.8 (carbon steel)
material to design because of it has excellent fatigue resistance, good temperature resistance it is
tougher and has high strength.

ᵟd= where ᵟd= design or allowable stress=510N/mm2 for 5.8(carbon steel) material

A=

A=

A=672mm2

Skirt thickness
The skirt thickness must be sufficient to withstand the dead-weight loads and bending
Moments imposed on it by the vessel; it will not be under the vessel pressure.

We can give the thickness and diameter of skirt by its standard:

Internal diameter of skirt () = 60mm=0.06m

Thickness of skirt () = 30mm = 0.03m

Stress analysis of skirt support

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Design I, Design of Vertical Pressure Vessel

(Tensile) = – And

(Compressive) = +

The Bending stress on the skirt (is calculated as:

= (= 1250N.m)

=9824379N/m2

The Dead weight stress in the skirt () is calculated as:

= Maximum bending moment evaluated at the base of the skirt (Due to wind loading)

Ds =Inside diameter of the skirt at the base

= Skirt thickness

= Total weight of the vessel and contents (WT =1526.8N)

= 1007357.6N/m2

To calculate the resultant tensile stress on the skirt:

(Tensile) = –

(Tensile)=9824379N/m2– 1007357.6N/m2

(Tensile) = 8817021N/m2

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Design I, Design of Vertical Pressure Vessel

To calculate the resultant compressive stress on the skirt:

(Compressive) = +

(Compressive) = 9824379N/m2 + 1007357.6N/m2

(Compressive) = 10831736.6N/m2

Since both (Tensile) and (Compressive) are less than the allowable or design stress that is ᵟd= 510
* N/m2 therefore our design is safe.

3.3.5. Design of bolted flange joint

We select mild steel material to design bolted flange joints because of easily workable, very hard,
yet malleable, good for construction, easy to shape and machine and very flexible and can be
harden. for miled steel

Table 7. Material selection for bolt design [1].

Steel grade Measured Yield strength Tensile strength

direction () ()

HT50 A 542 591

HT80 A 693 830

Mild steel A 452 497

HT50 B 501 562

HT80 B 657 799

Mild steel B 439 471

HT50 C 531 587

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Design I, Design of Vertical Pressure Vessel

HT80 C 665 811

Mild steel C 447 478

Use the following formula important to find the size and number of bolt.

Let = internal diameter of cylinder

= design pressure in the cylinder

= core diameter of the bolt

= permissible tensile stress of the bolt

n = number of bolt

Here we know that the upward face acting on the cylinder cover is:

F= ……………………………….. (1)

This force is resisted by n number of bolt and the resisting force offered by n number of bolts i
= …………………………………………. (2)

From equation (1) the upward force acting on cylinder cover is

F=

F=

F=4134628.95N

From equation (2) the resisting force by the bolt

From equation 2 the resisting force by the bolt

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Design I, Design of Vertical Pressure Vessel

=497N/mm2 for mild steel and we take the core diameter from the table by taking standard M30
then dc=25

=257937.96n

NOTE: the upper force is equal with the resistant force

FR=F

257937.96n=4134628.9

n= = 16

Nominal or major diameter of nut and bolt (d=D) = 30.000mm

Stress analysis of bolt

F=4134628.9N is the total force acted in the whole 16 bolts. Then in single bolts can be
calculated as follow

258414.3N

Stress on a bolt =

The tensile strength of bolts is = 497N/mm2

Since 365.58Mpa<497MPa hence our design is safe.

Then we will calculate the total length and thread length of bolt

D<90, let us take L=86

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Design I, Design of Vertical Pressure Vessel

Length of the bolt on the thread part

Figure 21 . 2D. diagram of bolt [2].

3.3.6. Design of Nut
We select mild steel material to design nut the same as bolt flange joint because of easily
workable, very hard, yet malleable, good for construction, easy to shape and machine and very
flexible and can be harden.

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Design I, Design of Vertical Pressure Vessel

Table 8 . Material selection for the nut design [1].

Steel grade Measured Yield strength Tensile strength

direction () ()

HT50 A 542 591

HT80 A 693 830

Mild steel A 452 497

HT50 B 501 562

HT80 B 657 799

Mild steel B 439 471

HT50 C 531 587

HT80 C 665 811

Mild steel C 447 478

By reading from the above standard table we get:

 minor or core diameter of nut () = 26.211mm

 effective or pitch diameter of nut () = 27.727mm
 nominal or major diameter of nut and bolt (d=b) = 30.000mm

Table 9. Nut standard dimension [1].

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Design I, Design of Vertical Pressure Vessel

Size Pitch Major Effective Minor or Depth Stress Base Heig Helix
or or pitch core of area of ht of thickne
nomina diameter diameter thread nut nut ss
l of nut of nut
diamet
er of
nut
M30 3.5m 30mm 27.727m 26.211m 2.147m 561mp 44m 24m 1.5
0 m m m m a m m

Figure 22. Schematic diagram of nut [2].

3.3.7. Flange design:

Flanged joints are used for connecting pipes and instruments to vessels, for handhole covers, and
for removable vessel heads when ease of access is required. Flanges may also be used on the
vessel body, when it is necessary to divide the vessel into sections for transport or maintenance.
Flanged joints are also used to connect pipes to other equipment, such as pumps and valves.
Standard flanges will be specified for most applications. Special designs would be used only if
no suitable standard flange were available; or for large flanges, such as the body flanges of
vessels, where it may be cheaper to size a flange specifically for the duty required rather than to
accept the nearest standard flange, which of necessity would be over-sized [9].
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Design I, Design of Vertical Pressure Vessel

Standard flanges

Standard flanges are available in a range of types, sizes and materials; and are used extensively
for pipes, nozzles and other attachments to pressure vessels. The proportions of standard flanges
are set out in the various codes and standards. A typical example of a standard flange design is
shown below. The relevant British Standards are BS 1560, Part 3 and BS 4504, Part 3, which
cover flanges for pipes, valves and fittings, in carbon and alloy steel [9].

Table 10 .material selection for the nut design [1].

Now as we design the bolt before our bolt is Bolt M30 standard size

For this reason our flange design parameters are in the first row of the table above that means

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Design I, Design of Vertical Pressure Vessel

d1= 914.4mm

d2= 33mm

d3= 950mm

d4=1005mm

h1=95mm

h2 = 20mm

b= 34mm

D= 1115mm

f= 5

K= 1050mm

Bolt M30

Figure 23. 2D. diagram of flange [2].

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Design I, Design of Vertical Pressure Vessel

3.3.8. Design of circular handhold:

Since in our design we get smaller shell diameter the hand hole should be used in order to do
some operations on the pressure vessel. We take the diameter of hand hole as 0.20m.
Then the wall thickness of the handhold can be calculated as follows:
= (PD *)/ (E-0.6PD)

Where PD =deign pressure (10Mpa)

=radius of hand hole(R=D/2=0.10m)
= Design stress for the materials of hand hole (low alloy
steel)=240N/mm2

E =Joint efficiency factor (E =1)

= (PD *)/ (E-0.6PD)

= (10 *150)/ (240*1 - 0.6*2.07)

= 6.4mm

Hand hole by considering corrosion allowance =

= +C

= 6.4mm + 2.5mm
= 8.9mm
Area for the hand hole will be:

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Design I, Design of Vertical Pressure Vessel

=31415.9 mm2
Stress analysis for hand hole

L=Longitudinal stress
H=hoop stress
L = (PD *)/ (4* )
L= (10Mpa*200mm)/ (4*8.9mm)
L = 56.18N/mm2
H=2*L
H = (PD *)/ (2*)
H= (10Mpa*200mm)/(2*8.9mm)
H=112.36N/mm2
Since both longitudinal and circumferential stress less than the allowable or design stress
therefore our design is safe.

3.3.9. Design of welded joint:

A welded joint is a permanent joint which is obtained by the fusion of edge of two parts to be
joined together with or without the application of pressure and filler material. Electric arc
welding is extensively used because of greater speed of welding [2].

The main considerations involved in the selection of weld type are:

 The shape of welded component required

 The thickness of the plates to be welded
 The direction of force to be applied

We Select butt joint especially square butt joint for the connection of both head and shell but For
the connection of nozzle to the shell part select corner joint.

Stresses analysis for Welded Joints

The stresses in welded joints are difficult to determine because of the variable and unpredictable
Parameters like homogeneity of the weld metal, thermal stresses in the welds, changes of

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Design I, Design of Vertical Pressure Vessel

physical Properties due to high rate of cooling etc. The stresses are obtained, on the following
assumptions.

Since the stress in the weld material is to be 81Mpa our electrode is mild steel electrode. The
recommended minimum size of weld is 20mm size of weld over 58mm.

F= where = outside diameter of the nozzle

= inside diameter of the nozzle

Since do=50.8+2(18) =86.8mm consideration of corrosion allowance

F=

F=

F= 3890.5 …………………… (1)

And

=20268.299nN …………………… (2)

From equation 1 and 2 we calculate as follows:

Since = F

3890m=20268.299

= = 5.2 N/mm2

5.8MPa<81MPa therefor our design is SAFE.

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Design I, Design of Vertical Pressure Vessel

3.3.10. Design of Gaskets

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,
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 is required.
3. The types of flange and flange face.

A great variety of proprietary gasket materials is used, and reference should be made to the
manufacturers' catalogues and technical manuals when selecting gaskets for a particular
application. The minimum seating stress y is the force per unit area (pressure) on the gasket that
is required to cause the material to low and fill the surface irregularities in the gasket face.
The gasket factor m is the ratio of the gasket stress (pressure) under the operating conditions to
the internal pressure in the vessel or pipe. The internal pressure will force the flanges' faces apart,
so the pressure on the gasket under operating conditions will be lower than the initial tightening-
up pressure. The gasket factor gives the minimum pressure that must be maintained on the gasket
to ensure a satisfactory seal. In addition to that the operating temperature, pressure and
corrosiveness of the process will be the controlling factor in gasket selection. i.e.
 Vegetable fiber and synthetic rubber gaskets can be used at temperatures of up to 100°C.
 Solid polyfluorocarbon (Teflon) and compressed asbestos gaskets can be used to a maximum
temperature of about 260°C.
 Metal-reinforced gaskets can be used up to around 450°C.
 Plain soft metal gaskets are normally used for higher temperatures.
 For our case Solid polyfluorocarbon (Teflon) and compressed asbestos gaskets is desirable
because it can resist the operating temperature. Then the total moment (M op) acting on the flange
is given by:

Mop  Hdhd  Htht  H ghg

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Design I, Design of Vertical Pressure Vessel

Where Hg=gasket reaction (pressure force) = G(2b)mpi

Ht=pressure force on the flange force = H-H d,
H=total pressure force = (/4)G2 pi
Hd =pressure force on the area inside the flange = (/4)B2 pi
G=mean diameter of the gasket,
B=inside diameter of the flange,
2b=effective gasket pressure width,
B=effective gasket sealing width,
The minimum required bolt load under the operating conditions is given by:
Wml = H + Hg
The forces and moments on the flange must also be checked under the bolting-up conditions.
The moment Mat is given by:
Mat = M m2hg ,and
Wm2 = y Gb
The flange stresses are given by:
Longitudinal hub stress, hb =F1M
Radial flange stress, rd = F2M
Tangential flange stress, rg = F3M- F4rd
The minimum bolt area required Abf will be given by:
Abf= Wm/fb

Where Wm is the greater value of Wm1 or Wm2

fb the maximum allowable bolt stress.
y is the gasket seating pressure (stress)
Wm2 is the bolt load required to seat the gasket

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Design I, Design of Vertical Pressure Vessel

Chapter- 4
4. Result and discussion:
4.1. Result
The following table shows the overall geometry of vertical pressure vessel.

Table 11.result table [1].

Components Material type Design of the components

1) shell Iow alloy steel

= 760.926mm
725.56mm
= 18mm
743.56mm
= 3506.9mm
= 1.449m3
2) ellipsoidal head
=760.926mm
= 181.39mm
Iow alloy steel = 190.2mm
= 15.179mm
= 0.15m3
3) Inlet and outlet nozzle = = 50.8mm
= = 8.57mm
Iow alloy steel = 55.8mm
= 2mm
= 15.5mm
4) bolt flanged joint =9.858mm
M30
n= 16
=30mm
Miled steel =20mm
D=d= 30mm

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Design I, Design of Vertical Pressure Vessel

5) Flange d1= 914.4mm

d2= 33mm
d3= 950mm
d4=1005mm
h1=95mm
Miled steel h2 = 20mm
b= 34mm
D= 1115mm
f= 5
K= 1050mm
Bolt M30

6) Nut
=26.211mm
Miled steel = 27.727mm
D=d= 30mm

7) hand hole Low alloy = 8.9mm

= 70685.8mm2
= 8.9mm
8) vessel support 5.8(carbon steel) = 70685.8mm2

4.2. Discussions
the pressure vessel is designed as the shell will have shell thickness of 18mm and a
diameter of 760.926mm with a total or overall length of 3.5069m so as to with stand to hold
1.6m3of alcohol under 10MPa and a temperature of 2000C.
The ellipsoidal head designed variety of shell thickness because of it has high resistance
for the same value of stress with the cylindrical shell so to compensate with its costive we have
considered.

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Design I, Design of Vertical Pressure Vessel

Chapter - 5

5. Conclusion and recommendation

5.1. Conclusion

Conclude from this pressure vessel design the pressure with nominal volume 1.6m3
which is used to store alcohol (we take sample of ethanol) at 10MPa and 200oc designed above
is designed to satisfy all the required requirements to be able to work under the above
parameters. The pressure vessel is made of a material that is low alloy steel by considering
their high stress value at its high temperature (200C0) and at the same time reliable therefore,
the above pressure vessel can be manufactured with appropriate cost and it can be used with in
its capacity and working conditions. It is observed that all the pressure vessel components are
selected on basis of available ASME standards and the manufactures also follow the ASME
standards while manufacturing the components. Selection of pressure vessels components should
be according to standards rather than customizing the design:-
 As abiding by the standards lead to;
 A universal approach
 Less time consumption
 Easy replacement.

5.2. Recommendation:
We recommend that when we design some part we have to collect information from different
source. This means the design is performed by using many references and web sites. So the
materials needed for design case must be fulfilled in order to perform applicable design for all
users. And also in our pressure vessel design we don’t consider the earthquake loading, vibration,
loading from piping and external equipment but in actual case must be considered.

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Design I, Design of Vertical Pressure Vessel

Chapter- 6

6. 3D Part and Assembly drawings of a column (vertical layout) pressure vessel.

6.1. 3D part drawings

6.1.1. Shell or Cylindrical section

Figure 24. Shell [2].

6.1.2. Heads or End closures

Figure 25. Head [2].

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Design I, Design of Vertical Pressure Vessel

Figure 26.Hand hole [2].

6.1.3. Inlet and outlet nozzle

Figure 27. Inlet and outlet nozzle [2].

6.1.4. Bolt

Figure 28. Bolt [2].

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Design I, Design of Vertical Pressure Vessel

6.1.5. Nut

Figure 29. Nut [2].

6.1.6. Flange

Figure 30. Flange [2].

6.1.7. Skirt support

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Design I, Design of Vertical Pressure Vessel

Figure 31. Skirt support

6.2.3D Assembly Drawing of the vertical pressure vessel.

Figure
.Assembly drawing of
vertical pressure vessel.

Reference
[1] Coulson and Richardson’s, Chemical Engineering Design, Volume 6, third Edition,
Butterworth Heinemann, 1996

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Design I, Design of Vertical Pressure Vessel

[2] Chirag H. Panchigar PG student of mechanical department A Review Paper on Design and
Analysis of Pressure vessel.
[3] Dennis Moss, “Pressure vessel design manual”.

[4] David Heckman, “Finite element analysis of pressure vessels”, MBARI 1998.
[5] International Journal of innovative Research in Technology & science (IJIRTS).

[6] pressure vessel design and practice 2 , somnath chattopadhyay.

[7] a text book of machine design, R.S. KHURMI & J.K. GUPTA , [A Textbook for the Students
of B.E. / B.Tech., U.P.S.C. (Engg. Services); Section ‘B’ of A.M.I.E. (I)] EURASIA
PUBLISHING HOUSE (PVT.) LTD. RAM NAGAR, NEW DELHI-110 055.
[8] M. Giglio, “Fatigue analysis of different types of pressure vessel nozzle”, revised 19
November 2002; accepted 20 November 2002.
[9]Bergman, Alhambra, Calif. The Design of Vertical Pressure Vessels Subjected to Applied
Forces. University of new south wates, Sydney, Australia, Welding technology institute of
Australia, Austral.
[10] WWW.Google.com: Web sites.

Appendix
Appendix B:
Table 12. Standard bolt and nut dimension [1].

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