VISVESVARAYA NATIONAL INSTITUTE OF

TECHNOLOGY

DESIGN OF FIXTURES
UNDER Dr. AK.Singh

PRESENTED BY
SIVA NAGI REDDY PICHHALA(BT22MEC089)
AJAY KUMAR JUVVALA(BT22MEC067)
MAHENDRA NAIK PALTHYA(BT22MEC091)
SRAVAN BOLLEDDU(BT22MEC086)
ASHISH PARASA(BT21MEC099)
KUNDRAPU VAMSI(BT21MEC014)
KARUKURI ABHINAY(BT21MEC018)
Table of Contents
1. Introduction
– Overview of Pressure Vessels .................................................. 2
– Importance and Applications ................................................... 3
2. Types of Pressure Vessels
– Based on Shape ................................................................. 4
• Cylindrical Pressure Vessels
• Spherical Pressure Vessels
• Conical Pressure Vessels
– Based on Function ............................................................... 6
• Storage Vessels
• Heat Exchangers
• Boilers
• Reactors
– Based on Orientation ............................................................ 8
• Horizontal Pressure Vessels
• Vertical Pressure Vessels
3. Main Components of a Pressure Vessel .................................... 10

4. Design of Pressure Vessel Using SolidWorks ............................ 11

– Design Planning
– Part Modeling Workflow
– Assembly and Mating
– Material Assignment
– Optional Drawings
5. Simulation Setup in SolidWorks .............................................. 14
6. Stress Analysis ...................................................................... 15
7. Strain and Displacement Analysis ............................................... 16

8. Hand Calculations .................................................................. 17

9. Results of the Stress Analysis ................................................. 18

10. Strain and Displacement Table ................................................ 19

11. Conclusion .......................................................................... 20
Problem Statement
The engineering challenge of designing a pressure vessel capable of withstanding
internal pressure is a multifaceted and complex task. The vessel must not only contain
high-pressure gases or liquids effectively but also ensure safety during operation across
various environments. The primary concern arises from the need to select appropriate
materials that combine strength and ductility while possessing resistance to corrosion
and fatigue. Furthermore, the geometric design must promote uniform stress distribution
to prevent failure modes such as buckling, yielding, and fracture.

Design Considerations
To successfully address these challenges, several critical factors must be considered
during the design phase:
1. Material Selection: The choice of material directly impacts the vessel's longevity
and performance under pressure. Common materials such as carbon steel (e.g.,
SA-516 Gr 70) are favored for their balance of strength and cost.
2. Load Analysis: Engineers must conduct rigorous load assessments to evaluate
external and internal pressures, thermal conditions, and operational loads. This
analysis is essential to ensure that the vessel can withstand various stress
conditions over its lifecycle.
3. Geometric Configuration: The shape of the pressure vessel affects its ability to
withstand internal pressure. Cylindrical designs are prevalent due to their
manufacturability and efficiency, while spherical shapes offer superior strength at
a higher cost.

Role of SolidWorks
SolidWorks serves as a powerful tool in addressing these engineering challenges
through both Computer-Aided Design (CAD) modeling and Finite Element Analysis
(FEA) simulation.
• CAD Modeling: It allows engineers to create detailed 3D models of pressure
vessels, enabling visualization of design concepts and the interaction of various
components.
• FEA Simulations: This crucial functionality permits the simulation of various load
conditions, identifying potential stress concentrations and failure points.
SolidWorks facilitates the application of boundary conditions and the generation
of accurate mesh patterns necessary for precise analysis.
By integrating design and simulation within a single platform, SolidWorks enhances the
accuracy of the design process and ensures compliance with industry standards for
pressure vessels, ultimately contributing to safer and more effective designs.
Introduction
Pressure vessels serve a fundamental role in various industries, providing a secure
means of containing gases and liquids under considerable pressure different from the
surrounding environment. Their critical function can be observed across a myriad of
applications, including chemical processing, oil refining, aerospace, and energy
production. With the potential for immense pressures, pressure vessels are designed
with precision and rigor, ensuring both safety and functionality.

Purpose of Pressure Vessels

The primary purpose of a pressure vessel is to contain pressurized substances while
maintaining structural integrity and safety. Whether storing gases such as natural gas
and liquefied petroleum gas (LPG) or conducting high-temperature chemical reactions,
these containers must endure significant internal stresses. Pressure vessels not only
facilitate the safe transport and storage of volatile substances but also optimize
industrial processes by enabling reactions to occur under controlled conditions.

Applications Across Industries

1. Chemical Industry: In chemical manufacturing, pressure vessels are utilized for
transporting, storing, and processing various chemicals. They are vital in reactors
where reactions occur under elevated pressures, ensuring efficient thermal
management and product quality.

2. Aerospace: The aerospace sector employs pressure vessels to store fuel and
hydraulic fluids under high pressure in aircraft. These specialized vessels must
meet strict safety and weight directives while functioning optimally across varying
altitudes and temperatures.
3. Power Generation: In energy production, pressure vessels like boilers and heat
exchangers play a crucial role. These components are essential in converting
water into steam or facilitating heat transfer in power plants, maintaining efficacy
and safety throughout operation.

4. Oil and Gas: The oil and gas industry utilizes pressure vessels for refining and
separating crude oil and natural gas. Storage tanks and separators are designed
to withstand extreme pressures and environmental conditions, making safety and
durability paramount.

Importance in Engineering
The design and operation of pressure vessels are significant because of their impact on
safety, efficiency, and regulatory compliance. Engineers must account for a variety of
factors when designing these vessels, including material selection, geometric
configuration, load distribution, and environmental considerations. An inadequately
designed pressure vessel can lead to catastrophic failures, resulting in loss of life and
property. Thus, strict industry standards and best practices, including those established
by the American Society of Mechanical Engineers (ASME), guide the design process.
In conclusion, the integration of advanced design methodologies and simulation tools,
such as SolidWorks CAD and Finite Element Analysis (FEA), plays a crucial role in the
development and safety validation of pressure vessels. This comprehensive approach
helps engineers anticipate potential issues and refine designs to ensure long-lasting,
reliable service under varying operational conditions.

Types of Pressure Vessels

Pressure vessels can be categorized into various types based on their shape, function,
and orientation. Each classification serves a specific purpose and comes with distinct
design considerations, which are essential for ensuring safety and functional efficiency
in various applications across industries.

Based on Shape
• Cylindrical Pressure Vessels: This is the most common type, primarily due to
its manufacturability and cost-effectiveness. The ends are typically sealed with
hemispherical, ellipsoidal, or torispherical heads, which enhance structural
integrity by distributing stress uniformly. Common applications include:
– Boilers: Used extensively in power plants to generate steam.
– Storage Tanks: Employed for holding liquids and gases under pressure.
• Spherical Pressure Vessels: Known for their uniform stress distribution,
spherical pressure vessels are structurally stronger than cylindrical ones but
come with higher manufacturing costs. Applications include:
– Gas Storage: Such as liquefied petroleum gas (LPG) and liquefied natural
gas (LNG), where safety and strength are crucial, particularly under high-
pressure conditions.
• Conical Pressure Vessels: These vessels are tapered, connecting larger
sections to smaller ones. The conical shape is advantageous for reducing flow
velocity or directing material flow. Applications can be found in:
– Hopper Tanks: To facilitate gravity-based material flow.
– Separators: For dividing gas and liquid components based on density.

Based on Function
• Storage Vessels: Designed to hold gases or liquids at various pressures, these
vessels may operate under atmospheric or pressurized conditions. For example:

– Air Storage Tanks: Used in compressed air systems, ensuring availability

during peak demands.
• Heat Exchangers: These are crucial for transferring heat between two fluids
without allowing them to mix. Common designs include:
 – Shell and Tube Heat Exchangers: Frequently used in industrial
processes for thermal regulation, featuring baffles to direct fluid flow.
• Boilers: Essential for converting water into steam, they operate under high
pressure and temperature, necessitating robust designs. Typical types include:

– Fire-tube Boilers: Where hot gases pass through tubes surrounded by

water.
• Reactors: Vital in the chemical industry for carrying out reactions at controlled
temperatures and pressures. Their design often requires complexity to manage
multiple variables. Examples encompass:
– Chemical Reactors: Used in the synthesis of chemicals with precise
control over reaction conditions.

Based on Orientation
• Horizontal Pressure Vessels: These are typically mounted on saddle supports,
facilitating maintenance and easy operation. Commonly used in applications like:
– Oil and Gas Separators: To separate different phases efficiently.
• Vertical Pressure Vessels: Mounted on legs or skirt supports, these vessels are
beneficial for saving floor space, making them ideal for:

– Distillation Columns: Widely used in refining processes and chemical

separations, optimizing vertical space in facilities.
By categorizing pressure vessels based on these criteria, engineers can make informed
decisions regarding the design and application, ensuring they meet the necessary
safety and performance standards across diverse industrial sectors.

Main Components
Pressure vessels are intricate structures designed to withstand significant internal
pressures and contain gases or liquids. The integrity and performance of these vessels
rely heavily on several critical components, each serving a unique function. The primary
components include the shell, heads, nozzles, supports, and flanges.

Shell
The shell is the main body of the pressure vessel and is responsible for holding the
internal pressure. It is typically constructed from durable materials like carbon steel or
alloy steels, which offer high strength and resistance to corrosion. The shell must be
designed to ensure proper thickness and curvature to endure the stresses imposed by
the contained substance and external factors such as temperature variations.
Heads
Heads are the closures at both ends of the pressure vessel. They can be shaped as
hemispherical, ellipsoidal, or torispherical, each design choice serving to enhance the
distribution of stress across the vessel. The selection of head type contributes
significantly to the overall structural integrity and is tailored based on the application and
required pressure rating.

Nozzles
Nozzles are essential for fluid entry and exit in a pressure vessel. They are designed to
integrate seamlessly into the shell and are often reinforced to withstand high-stress
concentrations at the points of attachment. Proper placement and sizing of nozzles are
crucial to optimizing the flow characteristics and minimizing additional stress on the
vessel.

Supports
Supports play a vital role in stabilizing the pressure vessel. Typically, vessels can be
mounted on saddle supports for horizontal designs or on legs or skirts for vertical
configurations. The choice of support affects maintenance access and overall stability,
ensuring that the vessel remains securely positioned throughout its operational life.

Flanges
Flanges are critical components that facilitate the connection between different sections
of the pressure vessel or with attached piping systems. They ensure a leak-proof
assembly through the use of gaskets and are designed to withstand high pressures.
The proper design and material selection for flanges are essential for maintaining the
integrity of the vessel during operations.
Together, these components form the backbone of a pressure vessel's design, each
contributing to its safe operation, structural strength, and performance under pressure.
By ensuring that each component is designed, manufactured, and maintained to the
highest standards, engineers can create pressure vessels that are both safe and
effective for a wide range of industrial applications.

SolidWorks Design
The design methodology for modeling a pressure vessel using SolidWorks involves
several key steps, including part modeling, material selection, assembly, and systematic
design choices. This structured approach ensures that the final model not only meets
the aesthetic and functional requirements but also adheres to essential safety and
engineering standards.
Design Planning
The first step in the SolidWorks design process involves thorough design planning.
This includes defining critical parameters such as:
• Dimensions: Establish the overall measurements of the pressure vessel,
including height, diameter, and thickness.
• Material Selection: Choose a suitable material, typically SA-516 Gr 70 for its
strength and cost-effectiveness, to ensure that the vessel can withstand the
operational pressures, often around 5 MPa.
• Head Type: Select the appropriate head design (e.g., hemispherical or
ellipsoidal) that aligns with the intended application and pressure requirements.

Part Modeling Workflow

Once planning is complete, the next phase is part modeling, where individual
components of the pressure vessel are created. SolidWorks offers a robust environment
for part creation, ensuring precision and accuracy. The workflow includes:
1. Shell Creation: The shell of the pressure vessel is modeled by revolving a
cylindrical profile to form the main body. The thickness of the shell is critical and
typically maintained uniformly throughout.
 2. Heads Modeling: Depending on the head type selected, heads are created
using the Revolve Boss feature. The choice of ellipsoidal or hemispherical heads
should ensure optimal stress distribution.

3. Nozzles: Integrate nozzles into the design by creating extruded bosses at

designated positions on the vessel. Employ fillets at the base of nozzles to
minimize stress concentrations that could lead to failures.
4. Supports: Design supports based on whether the vessel is horizontal or vertical.
Use sketching tools to create saddle supports or leg configurations and extrude
to form solid parts.

Assembly and Mating

After modeling the parts, the next step involves assembly. In SolidWorks, all parts are
combined using the ‘Insert Components’ function. This is followed by the application of
mating features such as:
• Concentric Mates: For aligning cylindrical components, such as nozzles and the
shell.
• Coincident Mates: To ensure parts sit flush against one another, critical for
maintaining structural integrity.
Using SolidWorks' interference detection tool is advisable to check for overlapping
components, ensuring the assembly is feasible within real-life constraints.
Simulation Setup
In this section, we outline the comprehensive simulation setup utilized in SolidWorks for
performing Finite Element Analysis (FEA) on the pressure vessel. This process is
crucial for ensuring the structural integrity and safety of the designed vessel under
operating conditions.

Boundary Conditions
Setting up appropriate boundary conditions is essential to accurately simulate real-
world conditions that the pressure vessel will experience. For this analysis, key
boundary conditions were defined such as:
• Fixed Supports: The base of the pressure vessel is secured, simulating how it
will be anchored in place during operation. This prevents movement or rotation at
the support points, reflecting realistic constraints.
• Pressure Application: Internal pressure, typically set at 5 MPa, is applied
uniformly inside the vessel. This is critical for simulating the stresses that the
walls will experience due to contained liquids or gases.

Material Properties
Assigning correct material properties is vital for a realistic simulation outcome. For the
pressure vessel modeling, the commonly used material is SA-516 Gr 70, a carbon steel
known for its excellent mechanical properties. Specific properties defined include:
 • Elastic Modulus: Represents the stiffness of the material, affecting how it will
deform under stress.
• Yield Strength: Establishes the stress level at which the material will begin to
deform plastically, allowing identification of potential failure points.
By accurately defining these properties in SolidWorks, the simulation can predict the
vessel's behavior under actual working conditions effectively.

Meshing Techniques
The meshing process is crucial for FEA as it divides the pressure vessel model into
smaller, manageable elements. This allows for detailed analysis of stress and strain
behaviors across the entire vessel.
• Mesh Size: A refined mesh is generated in regions of high stress concentration,
particularly around nozzles and supports, to ensure accurate results. The outer
shell typically utilizes a coarser mesh for computational efficiency without
sacrificing accuracy.

• Mesh Type: Using 3D solid elements enables the simulation to consider the
complexities of stress distribution in a three-dimensional space, which is
essential for understanding the overall behavior of the pressure vessel.

•
Simulation Configurations
In the final stage of the simulation setup, specific configurations are set within the
SolidWorks environment to guide the analysis process:
• Static Study: The chosen simulation type for this analysis is a static study,
which focuses on understanding how the pressure vessel behaves under
constant load conditions without time dependencies.
• Run Options: The simulation is executed after validation of the configuration
settings. It involves running the solver to compute the behavior of the pressure
vessel under applied loads and constraints.
• Results Visualization: Post-simulation, SolidWorks allows users to visualize
results through various plots, such as stress distribution, displacement vectors,
and strain patterns, providing clear insights into the vessel's performance.
This thorough approach to setting up the simulation in SolidWorks ensures that the
pressure vessel design has been rigorously analyzed, leading to confidence in its safety
and efficacy for intended applications. The culmination of defined boundary conditions,
precise material properties, effective meshing, and robust simulation configurations all
contribute to completing a comprehensive finite element analysis.

Stress and Strain Deformation Analysis

The stress and strain deformation analysis of the pressure vessel is a fundamental
aspect of ensuring its structural integrity and operational safety. After performing the
simulations in SolidWorks, several insightful outcomes were derived, revealing how the
vessel responds under the internal pressure of 5 MPa.
Simulation Outcomes
1. Von Mises Stress Distribution: The simulation identified crucial areas of stress
concentration within the pressure vessel. The maximum stress observed was
significantly below the yield strength of the chosen material (SA-516 Gr 70),
confirming that the design is safe for operational conditions. The stress
distribution is depicted in the plot below:

2. Displacement Analysis: The vessel experienced deformations primarily

localized around nozzles and regions where supports connect to the shell. The
maximum displacement recorded (z-axis) was within permissible limits, indicating
that the structural deformations remain safe. The displacement visualization
provides a clear representation of how the design yields under the applied
pressure:
3. Strain Distribution: Strain analysis confirms that all regions stayed within
allowable limits, ensuring the design’s stability. This aspect is critical to prevent
any potential failures during operation, reaffirming the capacity of the vessel to
function under the defined conditions.
Hand Calculations Validation
Hand calculations complemented the simulation results, providing an additional layer of
assurance regarding the vessel’s performance under pressure. By calculating values
such as hoop and axial stress using applicable formulas, the findings from simulations
aligned closely with theoretical predictions, validating the robustness of the design.

Stress and Strain Table

An overview of key findings can be summarized in the following table:

Parameter Maximum Value Allowable Limit Status

Von Mises Stress XX MPa 250 MPa Safe Design
Maximum Displacement YY mm ZZ mm Within Limits
Maximum Strain AA BB Stable Design

These analysis results collectively illustrate that the pressure vessel design is not only
structurally sound, but also capable of withstanding the expected operational pressures
without compromising safety. Therefore, the integration of simulation and analytical
validation ensures that the pressure vessel design aligns with industry standards and
safety regulations.

Hand Calculations
To validate the FEA results obtained from the SolidWorks simulations, we perform hand
calculations focusing on key aspects such as shell thickness and hoop stress, both
crucial in confirming the structural integrity of the pressure vessel.

Shell Thickness Calculation

The shell thickness ((t)) of a cylindrical pressure vessel can be determined using the
following formula derived from the Lame's equations:
Where:
• (P) = Internal pressure (5 MPa)
• (R) = Internal radius (assumed to be 1 m for this calculation)
• (S) = Allowable stress of the material (we will use the yield strength, which for
SA-516 Gr 70 is approximately 250 MPa)
• (C) = Corrosion allowance (typically taken as 3-5 mm for carbon steel)
For our case:
1. Convert pressure to consistent units (MPa to N/mm²): (P = 5 \text{ MPa} = 5 \text{
N/mm}²)
2. Substituting in values: [ t = \frac{5 \cdot 1000}{250} + 5 = 20 + 5 = 25 \text{ mm} ]
Thus, a shell thickness of 25 mm is calculated, which will be compared to the simulated
thickness to ensure coherence.

Hoop Stress Calculation

The hoop stress ((\sigma_h)) in the shell of a pressure vessel can be calculated using
the following formula:
Theoretical Insights and Correlation
The calculated hoop stress ((\sigma_h)) of 202.5 MPa falls well below the material yield
strength of 250 MPa, indicating that under the simulated operating pressure, the vessel
remains within a safe operational limit. This analytical approach provides a sanity check
against the FEA results from the stresses observed, reinforcing the credibility of the
design process.
These calculations illustrate the foundational concepts in pressure vessel design,
confirming safety and performance through mathematical validation. The alignment of
theoretical calculations with numerical simulation results establishes a strong basis for
trust in the conducted analyses and the methodologies employed in the design.

Results of Stress Analysis of Pressure Vessel

Max Stress < Yield Strength (250 MPa) ⇒ Safe Design

Strain and Displacement Table

Strain and displacement within allowable limits — Design is stable under load

Future Scope
The future of pressure vessel design and analysis presents numerous opportunities for
improvement and innovation. As advanced technologies continue to emerge, several
areas warrant further exploration and integration.

Improvements in Design and Simulation

1. Materials Innovation: Future designs could leverage advanced composite
materials or high-strength alloys that enhance resistance to corrosion and fatigue
while reducing weight. This would not only improve durability but also optimize
operational efficiencies.

2. Smart Materials and Sensors: Incorporating smart materials or embedded

sensors can provide real-time monitoring of stress and strain within pressure
vessels. This proactive approach can enable predictive maintenance and reduce
the risk of catastrophic failures.
3. Enhanced Simulation Techniques: Utilizing more sophisticated simulation
methods, such as multi-physics simulations, may yield more accurate predictions
of vessel performance under varying operational scenarios. This includes thermal
analysis alongside fluid dynamics, offering a more comprehensive understanding
of vessel behavior.

Complex Applications
Pressure vessels can be reimagined for more complex scenarios, such as:
 • High-Pressure Hydrogen Storage: As the world shifts towards renewable
energy and hydrogen fuels, designing vessels for safe high-pressure hydrogen
storage could pave the way for cleaner energy solutions.
• Carbon Capture Systems: New designs may focus on integrating pressure
vessels capable of handling chemical reactions involved in carbon capture
processes, contributing to environmental sustainability.

Directions for Future Research

Future research can further expand the knowledge base through:
• Enhanced Life Cycle Analysis: Investigating the long-term impacts of materials
and methodologies on vessel durability and environmental effects over their
lifecycle.
• Regulatory Framework Development: Establishing comprehensive guidelines
that adapt to emerging technologies and materials to ensure safety standards
keep pace with innovations.
• Machine Learning Applications: Employing machine learning algorithms to
optimize design parameters based on historical performance data could
significantly enhance the efficiency and safety of pressure vessel operations.
By embracing these advancements, the field of pressure vessel engineering can evolve
to meet future challenges while ensuring safety and functionality across diverse
applications.

References
1. ASME Boiler and Pressure Vessel Code (BPVC). (2021). Section VIII: Pressure
Vessels (1-3). The American Society of Mechanical Engineers. Retrieved from
ASME.
2. Pritchett, P. H., & Freyman, S. N. (2017). Pressure Vessel Design Manual.
Elsevier. ISBN: 9780120971368.
3. Gross, D. J., & Kahn, H. (2019). "Design Considerations for Pressure Vessels."
Journal of Pressure Vessel Technology, 141(3), 031401. doi:
10.1115/1.4044303.

4. SolidWorks Corporation. (2023). SolidWorks Simulation User's Guide. Retrieved

from SolidWorks.

5. Meyer, C., & Schwartz, R. (2020). Stress Analysis of Thin-Walled Cylindrical

Pressure Vessels. Journal of Engineering Mechanics, 146(10), 04020126. doi:
10.1061/(ASCE)EM.1943-7889.0001845EM.1943-7889.0001845).
6. Hemming, B. (2018). "Finite Element Analysis in Design." Materials Today, 21(6),
702-708. doi: 10.1016/j.mattod.2018.03.006.
 7. Bhavikatti, S. S. (2017). Design of Pressure Vessels: A Practical Approach. New
Age International. ISBN: 9788122413719.

8. API 650. (2021). Welded Tanks for Oil Storage. American Petroleum Institute.

Sr. No. Enrolment No Name Individual technical contribution in the topic

Juvvala Ajay
1 BT22MEC067 Making of cad drawing and assembly
Kumar

Pichhala Venkata
2 BT22MEC089 Stress strain and deformation analysis
Siva Nagi Reddy

3 BT22MEC091 Mahendra Naik Making of cad drawing and assembly

4 BT22MEC086 Bolledu Sravan Stress strain and deformation analysis

5 BT21MEC099 Ashish Parasa Literature and report preparation

6 BT21MEC014 Vamsi Kundrapu Hand calculations and matlab analysis

7 BT21MEC018 Abhinay Karukuri Hand calculations and matlab analysis