MEng3161

Course: Machine Design Project (Meng3161)

Introduction to
Machine Design

Lecture BY: Besufekad G. (MSc.)

Mechanical Engineering Department, CEME
Addis Ababa Science and Technology University

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Introduction to Mechanical Engineering Design

Design: To design means
oto formulate a plan for the satisfaction of a specified
need
oto solve a problem
It is an innovative and iterative process.
Mechanical Engineering Design: Mechanical
engineering design involves all the disciplines of
mechanical engineering.
Machine design, machine elements design, machine
component design, system design and fluid power
design, internal combustion engine design etc are all
focused to mechanical engineering design.
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161Phases and Interactions of the Design
Process
The process begins with an identification of a
need and a decision to do something about it.
After many iterations, the process ends with
the presentation of the plans for satisfying the
need.
Depending on the nature of the design task,
several design phases may be repeated
throughout the life of the product, from
inception to termination.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Recognition of the need
Identification
of Need and phrasing
Background
Research
Definition
of Problem
Goal Statement

Design Specification
Synthesis
(Requirement List)

Concept design
Analysis and
Optimization Construct Mathematical
model that simulates
real system
Evaluation
Selection

Detailed Design
Production
Presentation Prototyping and Testing
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
Figure: The phases in design
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Design Considerations
Sometimes the strength required of an element in a
system is an important factor in the determination of
the geometry and the dimensions of the element.
In such a situation we say that strength is an
important design consideration. When we use the
expression design consideration, we are referring to
some characteristic that influences the design of the
element or, perhaps, the entire system.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Design Considerations
 Usually quite a number of such characteristics must be
considered and prioritized in a given design situation.
 Many of the important ones are as follows (not necessarily in
order of importance):
1) Functionality 14)Noise
2) Strength/stress 15)Styling
3) Distortion/deflection/stiffness 16)Shape
4) Wear 17)Size
5) Corrosion 18)Control
6) Safety 19)Thermal properties
7) Reliability 20)Surface
8) Manufacturability 21)Lubrication
9) Utility 22)Marketability
10) Cost 23) Maintenance
11) Friction 24) Volume
12) Weight 25) Liability
13) Life 26) Remanufacturing/resource
recovery
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
 The design engineers professional
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responsibilities
Satisfy the needs of a customer
Use a systematic approach (Understand,
Identify, assumptions, analysis, evaluation,
presentation)

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Standard and Codes

A standard is a set of specification for the parts,
processes and materials intent to achieve uniformity
A code is a set of specifications for the analysis,
design, manufacture and construction of something.
All of the organizations and societies listed below
have established specifications for standards and
safety or design codes.
Aluminum Association (AA) American Bearing Manufacturers Association
American Gear Manufacturers Association (AGMA) (ABMA)7
American Institute of Steel Construction (AISC) British Standards Institution (BSI)
American Iron and Steel Institute (AISI) Industrial Fasteners Institute (IFI)
American National Standards Institute (ANSI) Institution of Mechanical Engineers (I. Mech. E.)
ASM International International Bureau of Weights and Measures (BIPM)
American Society of Mechanical Engineers (ASME) International Standards Organization (ISO)
American Society of Testing and Materials (ASTM) National Institute for Standards and Technology
American Welding Society (AWS) (NIST)8
Society of Automotive Engineers (SAE)

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Safety and Product Liability

Manufacturer of an article is liable for any damage or harm
that results because of a defect.
Analysis and design, quality control and testing procedures
are important.
Warnings and instructions for use.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Economics
Cost plays an important role in design decision
process
No matter how great the idea may be, if it’s
not profitable it may never be seen
The use of standard sizes and large
manufacturing tolerances reduce costs
Evaluating design alternatives with regard to
cost
Breakeven Points
Cost Estimates

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Stress and Strength

 Strength is a property of a material or of a mechanical
element.
 The strength of an element depends on the choice, the
treatment, and the processing of the material.
Strength is an inherent property of a part, a property
built into the part because of the use of a particular
material and process.
 Stress is a state of property at a specific point within a body
which is a function of load, geometry, temperature and
manufacturing process.
The designer must allow the maximum stress to be less
than the strength by a sufficient margin so that despite
the uncertainties, failure is rare.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Uncertainty
Examples of uncertainties concerning stress and strength
include:
Composition of material and the effect of variation on
properties.
Variations in properties from place to place within a bar of
stock.
Effect of processing locally, or nearby, on properties.
Effect of nearby assemblies such as weldments and shrink
fits on stress conditions.
Effect of thermomechanical treatment on properties.
Intensity and distribution of loading.
Validity of mathematical models used to represent reality.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Intensity of stress concentrations.

Influence of time on strength and geometry.
Effect of corrosion.
Effect of wear.
Uncertainty as to the length of any list of uncertainties.
Engineers must accommodate uncertainty. Uncertainty
always accompanies change.
Material properties, load variability, fabrication fidelity, and
validity of mathematical models are among concerns to
designers.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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 There are mathematical methods to address uncertainties.

The primary techniques are the deterministic and
stochastic methods.
The deterministic method establishes a design factor based
on the absolute uncertainties of a loss-of-function parameter
and a maximum allowable parameter. Here the parameter
can be load, stress, deflection, etc.
Thus, the design factor is defined as

If the parameter is load, then the maximum allowable load

can be found from

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Design Factor and Factor of Safety

 A general approach to the allowable load versus loss-of-
function load problem is the deterministic design factor
method, and sometimes called the classical method of
design.
The fundamental equation is equation

where is called the design factor.

All loss-of-function modes must be analyzed, and the mode
leading to the smallest design factor governs.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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After the design is completed, the actual design

factor may change as a result of changes such as
rounding up to a standard size for a cross section or
using off-the-shelf components with higher ratings
instead of employing what is calculated by using the
design factor.
The factor is then referred to as the factor of
safety, n.

The factor of safety has the same definition as the

design factor, but it generally differs numerically.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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 Since stress may not vary linearly with load, using load
as the loss-of-function parameter may not be
acceptable.
It is more common then to express the design factor in
terms of a stress and a relevant strength. Thus equation
of design factor can be rewritten as

The stress and strength terms in the equation must be

of the same type and units. Also, the stress and strength
must apply to the same critical location in the part.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Reliability.
 Reliability is the statistical (Stochastic) measure of probability
that a mechanical element will not fail in use .
Example
The failure of 11 parts out of every 2780 manufactured parts
might be considered as an acceptable failure rate for a certain
class of products.
This represents a reliability of R

OR 99.6 % means that there is a 99.6 percent chance that the

part will perform its proper function without failure.
Good statistical data and estimates are essential to perform an
acceptable reliability analysis. This requires a good testing and
validation of the data. In many cases, this is not practical and a
deterministic approach to the design must be undertaken.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

 Safety Factors—Selection of a Numerical
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Value
After going as far as is practical in determining the
significant strength of the actual fabricated part and the
details of the loading to which it will be subjected, there
always remains some margin of uncertainty that must be
covered by a safety factor.
The part must be designed to withstand a “design overload”
somewhat larger than the normally expected load.
In the last analysis, selection of the safety factor comes
down to engineering judgment based on experience.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Recommended Values for a Safety Factor

For this purpose, the following recommendations of Joseph
Vidosic are suggested. These safety factors are based on yield
strength.
1. SF = 1.25 to 1.5 for exceptionally reliable materials used
under controllable conditions and subjected to loads and
stresses that can be determined with certainty—used almost
invariably where low weight is a particularly important
consideration.
2. SF = 1.5 to 2 for well-known materials, under reasonably
constant environmental conditions, subjected to loads and
stresses that can be determined readily.
3. SF = 2 to 2.5 for average materials operated in ordinary
environments and subjected to loads and stresses that can be
determined.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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4. SF = 2.5 to 3 for less tried materials or for brittle materials

under average conditions of environment, load, and stress.
5. SF = 3 to 4 for untried materials used under average
conditions of environment, load, and stress.
6. SF = 3 to 4 should also be used with better known materials
that are to be used in uncertain environments or subjected to
uncertain stresses.
7. Repeated loads: The factors established in items 1 to 6 are
acceptable but must be applied to the endurance limit rather
than to the yield strength of the material.
8. Impact forces: The factors given in items 3 to 6 are
acceptable, but an impact factor should be included.
9. Brittle materials: Where the ultimate strength is used as the
theoretical maximum, the factors presented in items 1 to 6
should be approximately doubled.
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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10. Where higher factors might appear desirable, a more

thorough analysis of the problem should be undertaken before
deciding on their use.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Dimension and Tolerances

The manufacture of interchangeable parts require precision.
Precision is the degree of accuracy to ensure the functioning of
a part as intended.
However, experience shows that it is impossible to make parts
economically to the exact dimensions. This may be due to,
(i) inaccuracies of machines and tools,
(ii) inaccuracies in setting the work to the tool, and
(iii) error in measurement, etc.
The workman, therefore, has to be given some allowable
margin so that he/she can produce a part, the dimensions of
which will lie between two acceptable limits, a maximum and a
minimum.
The system in which a variation is accepted is called the limit
system and the allowable deviations are called tolerances.
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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The relationships between the mating parts are called fits.

The study of limits, tolerances and fits is a must for
technologists involved in production.
The same must be reflected on production drawing, for
guiding the craftsman on the shop.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Dimension and Tolerances.

The following terms are used generally in dimensioning:
Nominal size. The size we use in speaking of an element. For
example,
we may specify a 40 mm pipe or a ½ in bolt. Either the
theoretical size or the actual measured size may be quite
different. The theoretical size of a 40 mm pipe is 47.5 mm for
the out-side diameter. And the diameter of the ½ in bolt, say,
may actually measure 0.492 in.
Limits. The stated maximum and minimum dimensions.
Tolerance. The difference between the two limits.
Bilateral tolerance. The variation in both directions from the
basic dimension. That is, the basic size is between the two
limits, for example, 25±0.05 mm. The two parts of the
tolerance need not be equal.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Unilateral tolerance. The basic dimension is taken as one of

the limits, and variation is permitted in only one direction,
for example, 25 +0.05-0.00 mm
Clearance. A general term that refers to the mating of
cylindrical parts such as a bolt and a hole. The word
clearance is used only when the internal member is smaller
than the external member. The diametral clearance is the
measured difference in the two diameters. The radial
clearance is the difference in the two radii.
Interference. The opposite of clearance, for mating
cylindrical parts in which the internal member is larger than
the external member.
Allowance. The minimum stated clearance or the maximum
stated interference for mating parts.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Figure: Illustration of basic size deviations and tolerances

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Machine Design Project one

Pressure Vessel Design

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Table of Contents
 What is a Pressure Vessel
 What are the Types of Pressure Vessels?
 Inputs for Design of Pressure Vessels
 Pressure Vessel Design Formula
 Type of Pressure Vessel Supports
 Pressure Vessel Parts
 Design codes used for Pressure Vessel Design
 Pressure Vessel Internals
 Example of Pressure Vessel
 Material of Construction of Pressure Vessel
 Applications of Pressure Vessel

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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What is a Pressure Vessel

A pressure vessel is a closed leak-tight container (normally
cylindrical or spherical) designed to hold fluids (i.e, gases
or liquids) at a pressure substantially different (higher or
lower) from the ambient pressure.
They are usually made from carbon steel or stainless steel
and assembled from plates by welding method. However,
other materials like Aluminium, copper, non-metals, etc also
find usage as pressure vessel material in some specific
situations.
Even though most of the pressure vessels are basically a long
cylinder with two heads at both ends, they can take the
shape of a sphere or cone.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Examples of few widely used pressure vessels are columns,

boilers, separators, knock out drums, Towers, Bullet Tanks,
Reactors, and Heat Exchangers.
All these pressure vessels are extensively used in the oil and
gas, petroleum refining, and chemical/petrochemical
processing industries and power plants have varying
operating pressure and temperatures.
However, note than an atmospheric storage tank is not a
pressure vessel. Fig. 1 shows a typical pressure vessel used in
the oil & gas industry.

Fig. 1: pressure
vessels used in a
process plant

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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What are the Types of Pressure Vessels?

Based on their installation they are classified into the
following two groups.
1.Vertical pressure vessel
2.Horizontal Pressure Vessel

Various methods are used to support pressure vessels, like

 Lug Support  Skirt Support  Saddle Support
 Ring Support  Leg Support
Types of end attached to the vessels are
• Dish ends
• Conical ends
• Flat Ends

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Inputs for Design of Pressure Vessels

The design of pressure vessels must be done with utmost
care as these operate under immense pressure. A ruptured
pressure vessel can cause serious irreversible harm to
mankind and properties.
Normally the ASME Sec VIII code governs the design of
pressure vessels.
The following inputs are required for pressure vessel design
• Internal Design Pressure / External Design Pressure
• Test Pressure
• Design temperature
• Material of constructions
• Type of support
• Type of loading (wind load/seismic loading/snow loading)

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Brief Explanation of Major Pressure
Vessel Parts
Pressure Vessels are one of the most important Static or
stationary equipments for any process plant. We can not
think about any chemical plants or Refineries or
Petrochemical complex which runs Without any Pressure
Vessel. Major chemical processes happen inside pressure
vessels. These may be vertical or horizontal and are known
by various names like column, drum, reactor, exchanger, etc.
They can carry or process fluids of various temperature and
pressure range. Most of the times these are designed
following ASME BPVC code. In this article, major component
vessel parts will be explained in brief.
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 and conical
in shape, which are discussed in detail on chapter 3 of
this book.
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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Head (Fig. 1): The end enclosures of a vessel. They can be

semi-elliptical, spherical, or dished.
All pressure vessel shells must be closed at the ends by
heads (or another shell section). Heads are typically
curved rather than flat.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Curved configurations are strong er and allow the heads to

be thinner, lighter, and less expensive than flat heads.
Heads can also be used inside a vessel.
These “intermediate heads” separate sections of the
pressure vessel to permit different design conditions in
each section.
Heads are usually categorized by their shapes. Ellipsoidal,
hemispherical, torispherical, conical, toriconical and flat
are the common types of heads which are discussed in
detail on chapter 4 of this book.
Figure 1-7 shows various types of heads. Ellipsoidal (2:1)
would be the most common type of heads, which is used
during the designing of pressure vessels.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Figure 1-7: Typical Types of Heads [4]

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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Nozzle (Fig. 1): A nozzle is a cylindrical component that

penetrates the shell or heads of a pressure vessel. The nozzle
ends are usually flanged to allow for the necessary
connections and to permit easy disassembly for maintenance
or access. Nozzles are used for the following applications:
Attach piping for flow into or out of the vessel.
Attach instrument connections, (e.g., level gauges,
thermowells, or pressure gauges).
Provide access to the vessel interior at manways.
Provide for direct attachment of other equipment items,
(e.g., a heat exchanger or mixer).
Nozzles are also sometimes extended into the vessel
interior for some applications, such as for inlet flow
distribution or to permit the entry of thermowells.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Design of openings and nozzles would be discussed on

chapter 5 of this book.
Nozzle orientation: The angular arrangement of nozzles
around the perimeter of a vessel’s shell.
Nozzle projection: Used to establish the distance from the
vessel’s centerline to the nozzle’s face of the flange.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Support
The type of support that is used depends primarily on the
size and orientation of the pressure vessel. In all cases, the
pressure vessel support must be adequate for the applied
weight, wind, and earthquake loads.
Calculated base loads are used to design of anchorage and
foundation for the pressure vessels. Supporting design would
be discussed in detail on the following slides of this
presentation. Typical kinds of supports are as follow:

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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a) Skirt
Tall, vertical, cylindrical pressure vessels (e.g., the tower
and reactor shown in Figure 1-4 and Figure 1-5
respectively) are typically supported by skirts.
A support skirt is a cylindrical shell section that is welded
either to the lower portion of the vessel shell or to the
bottom head (for cylindrical vessels). Skirts for spherical
vessels are welded to the vessel near the mid-plane of the
shell.
The skirt is normally long enough to provide enough
flexibility so that radial thermal expansion of the shell does
not cause high thermal stresses at its junction with the skirt.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Figure 1-5: Vertical Reactor Figure 1-4: Tall Vertical Tower

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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b) Leg
Small vertical drums (See Figure 1-3) are typically sup-
ported on legs that are welded to the lower portion of the
shell. The maximum ratio of support leg length to drum
diameter is typically 2:1. The number of legs needed
depends on the drum size and the loads to be carried.
Support legs are also typically used for spherical pressurized
storage vessels (See Figure 1-6).
The support legs for small vertical drums and spherical
pressurized storage vessels may be made from structural
steel columns or pipe sections, whichever provides a more
efficient design. Cross bracing between the legs, as shown in
Figure 1.6, is typically used to help absorb wind or earth-
quake loads [3].

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Figure 1-3: Vertical Drum on Leg Support

Figure 1-6: Spherical Pressurized Storage Tank
Leg Support

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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c) Saddle
Horizontal drums (See Figure
1-8) are typically supported at
two locations by saddle supports.
A saddle support spreads the
weight load over a large area of
the shell to prevent an excessive
local stress in the shell at the
support points.
The width of the saddle, among
other design details, is
determined by the specific size
and design conditions of the
pressure vessel.
Figure 1-8: Typical Scheme
One saddle support is normally of Saddle
fixed or anchored to its
foundation.
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Figure 1-8: Typical Scheme of Saddle

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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d) Lug
Lugs that are welded to the
pressure vessel shell, which are
shown on Figure, are also used
to support vertical pressure
vessels.
The use of lugs is typically
limited to vessels of small to
medium diameter (1 to 10 ft.)
and moderate height-to-
diameter ratios in the range of
2:1 to 5:1.

Figure : Typical Scheme of lug

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lug supports are often used

for vessels of this size that
are located above grade
within structural steel.
The lugs are typically bolted
to horizontal structural
members to provide stability
against overturning loads;
however, the bolt holes are
often slotted to permit free
radial thermal expansion of
the drum .

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Fig. 1: Typical Vessel Parts

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Base plate: A flat, metal ring welded to the bottom of a

vessel’s supporting skirt that rests on a concrete foundation.
Holes around the perimeter of the metal ring make it
possible to position it over anchor bolts and secure it to the
foundation.
Skirt (Fig. 1): A cylinder-shaped support for a vertical
vessel. One end is welded to the base plate allowing it to rest
on the foundation and the other end is welded to the bottom
head of a vertical vessel.
Skirt access opening: An 18’’ ID hole 2’-6’’ above the
foundation that allows workers entrance for inspection and
maintenance.
Skirt vents: Equally spaced holes approximately 3 to 4 in
diameter bored near the top of the vessel skirt that allows
toxic and explosive gases to escape.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Skirt fireproofing: Generally brick or granite, fireproofing is

applied around the interior and exterior walls of a vessel
skirt. It is necessary to prevent damage to the vessel skirt in
case a fire occurs.
Reinforcing pad (Fig. 2): A plate contoured to the shape of
a vessel shell. It is positioned around nozzles and provides
additional strength in the areas where metal was removed
from the shell.
Manholes (Fig. 2): Similar to large nozzles that allow
workers entry points into a vessel. They generally are 18 ID
and are accessible by ladders and platforms. When not in
use, the manhole is sealed with a blind flange.
Manhole hinge (Fig. 2): A hinge that creates a pivot point
allowing the blind flange attached to the manhole to be
easily removed for worker entrance.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Fig. 2: Typical Saddle, Manhole and reinforcing PAD

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Trays: Flat metal plates spaced approximately 18 to 24 apart

inside a vertical vessel. They can be bolted or welded to the
vessel shell. Trays are perforated to allow rising vapors and
falling liquids to pass through with the aid of a valving
mechanism called a cap.
Weir: A dam-like plate welded on a tray that allows a
fractionated by-product to collect and be extracted by a
nozzle.
Down comers: Openings adjacent to a tray that allows
liquids flowing over a weir plate to fall to the tray below and
begin the fractionation process over again.
Insulation rings: Continuous circular rings welded to the
exterior of a vertical vessel that supports a vessel’s
insulation. They are typically spaced on 12–0 centers.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Seal pan: A tray installed below the bottom tray in a vessel

to prevent liquids from bypassing the trays.
Lifting lugs: donut-shaped rings welded to the vessel’s shell
or head that allow the vessel to be raised and positioned
during installation.
Saddles (Fig. 2): U-shaped supports welded on horizontal
vessels and exchangers. Saddles are bolted to concrete
foundations and create cradle-like support in which the
vessel can rest.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Design codes used for Pressure Vessel
Design
There are various codes which are used for pressure vessel
design, construction and maintenance purposes. Few of them
are listed below:
• EN 13445: The current European Standard, harmonized with
the Pressure Equipment Directive (97/23/EC). Extensively
used in Europe.
• ASME Code Section VIII, in addition, supported by Sections
II (materials), V (NDT/NDE), and IX (welding). Published by
the American Society of Mechanical Engineers.
• ASME Code Section VIII Division 1: US standard, design by
the formula. Almost exclusively used in North America,
widely used worldwide.
• ASME Code Section VIII Division 2: Alternative Rules, design
by analysis.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

• ASME Code Section VIII Division 3: Alternative Rules for

Construction of High-Pressure Vessel
• BS 5500: Former British Standard, replaced in the UK by EN
13445 but retained under the name PD 5500 for the design
and construction of export equipment.
• AD Merkblätter: German standard, harmonized with the
Pressure Equipment Directive.
• EN 286 (Parts 1 to 4): European standard for simple pressure
vessels (air tanks), harmonized with Council Directive
87/404/EEC.
• BS 4994: Specification for design and construction of vessels
and tanks in reinforced plastics.
• IS 2825-1969 (RE1977): code unfired Pressure vessels

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Pressure Vessel Design Formula

The basic formula for designing the cylindrical shell is
σ = PD/2t
Therefore,           t = PD/2σ
Where,
t = thickness of the shell
P = internal pressure
D = diameter of the shell
σ = tensile stress
This basic formula is modified in international design codes.
ASME pressure vessel design code

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Fig. 2: General Configuration of a typical pressure Vessel

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

For ASME Sec VIII, the thickness of the cylinder is calculated

by the following formula (Fig. 3)

Where,
t = thickness of the shell
P = internal pressure
R = radius of cylinder
S = tensile stress
E = joint efficiency
Fig. 3: Formula for calculation of pressure vessel shell
thickness
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

Refer ASME Sec VIII Div 1 for design formulas for all sections
of the vessel/cylinder. The following figure provides a typical
flow chart for pressure vessel design steps.

Fig. 4: Flow Chart for Pressure Vessel Design Steps

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

Type of Pressure Vessel Supports

Based on how the pressure vessels are supported, they can
be of the following types.
Vessel Supported on Lug Support (Fig. 5)
Vessel Supported on Skirt(Fig. 5)
Vessel Supported on Leg(Fig. 5)
Vessel Supported on Saddle(Fig. 6)

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Pressure Vessel Parts

A pressure vessel constitute of the following
parts
• Shell, head
• Nozzles
• Flanges
• Gaskets
• Internals
• Platforms & ladders
• Skirt or saddles
• Baseplate
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

Pressure Vessel Internals

Internals are used to separate the liquid from a mixture of
liquid & vapour. Refer Fig. 6

Fig. 6: Pressure Vessel Internals.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Material of Construction of Pressure Vessel

For industrial applications, the following materials are
widely used for pressure vessel construction. However
custom made pressure vessel fabrication is possible
depending on requirements.
• Carbon steel and Cladding Plates
• Low and High Alloy Steels
• Stainless Steel
• Manganese Steel
• Duplex Stainless steel
• Aluminum, Copper, Nickel Alloys
• Fibre Glass Reinforced Plastic

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Applications of Pressure Vessel

Pressure Vessels are most widely used in the
following sectors
 Refinery and Petro-chemical
 Fertilizer
 Oil and Gas
 Chemical
 Power Plants
Regular inspection of pressure vessels is very
important to avoid pressure vessel failures. API 510
provides guidelines for pressure vessel inspection.
Few more Resources for you.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Material Selection for Pressure Vessel
Construction
The goal of this chapter is to give knowledge to engineers to
select and specify the most economic material for pressure
vessels considering requirement of the codes.
There are many parameters which may be investigated by
practice, calculations and tests, shall be considered in the
selection of suitable material for pressure vessels.
These parameters are including the following aspects:
 Strength for design condition
 Strength for desired service life
 Resistance to corrosion in service environment for desired life
 Capabilities for fabrication processes
 Market availability
 Maintenance and repair
 Cost (first investment and operation cost)
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161 Material Selection for Pressure Vessel
Construction
Materials are generally selected by the user for whole
of the plant and specifically, by pressure vessel
designer/supplier according to the following criteria.
 Corrosive or noncorrosive service
 Contents and its special chemical/physical effects
 Design condition (temperature)
 Design life and fatigue affected events during the plant life
 Referenced codes and standards
 Low temperature service
 Wear and abrasion resistance
 Welding and other fabrication processes

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Mechanical design of pressure vessel

The purpose of this lecture is to present an
overview of simple concepts of mechanical design
of pressure vessels that must be understood by a
project engineer specifying and purchasing this
equipment.
Most pressure vessels used in the oil and gas industr
y are designed and inspected according to the Ame
rican Society of Mechanical Engineers’ Boiler and Pr
essure Vessel Code (ASME code).
In particular, Section VIII of the code, “Pressure
Vessels,” is particularly important as it is the most
widely used.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Design considerations
Design temperature
The maximum and minimum design temperatures for a vessel will
determine the maximum allowable stress value permitted for the
material to be used in the fabrication of the vessel.
Maximum temperature used in the design should not be less than
the mean metal temperature expected under the design operating
conditions.
The minimum temperature used in the design should be the lowest
expected in service except when lower temperatures are permitted
by the rules of the
ASME code.
lowest operating temperature, operational upset, auto-
refrigeration, ambient temperature, and any other source of
cooling.
The metal temperature should be determined by computation using
accepted heat transfer procedures or by measurement from
equipment in service
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

Design pressure
The design pressure for a vessel is called its
“maximum allowable working pressure” (MAWP) or
“working pressure”.
The MAWP determines the setting of the relief valve
and must be higher than the normal pressure of the
process contained in the vessel, which is called the
vessel’s “operating pressure.”
If the operating pressure is too close to the relief
valve setting, small surges in operating pressure
could cause the relief valve to activate prematurely.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Table 1:

Often, especially for small vessels, it is advantageous to use a

higher MAWP than is recommended in Table 1.
It may be possible to increase the MAWP at little or no cost and
thus have greater future flexibility if process changes (e.g.,
greater throughput) require an increase in operating pressure.
The MAWP of the vessel cannot exceed the MAWP of the nozzles,
valves, and pipe connected to the vessel, which are manufactured
in accordance with industry standard pressure rating classes.
Once a preliminary MAWP is selected, it is necessary to calculate a
wall thickness for the shell and heads of the pressure vessel.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161
Table 2

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Maximum allowable stress values

The maximum allowable stress values to be used in the
calculation of a vessel’s wall thickness are given in the ASME
code for many different materials.
These stress values are a function of temperature. Section
VIII of the ASME code, which governs the design and
construction of all pressure vessels with operating pressures
greater than 15 psig, is published in two divisions.
Each sets its own maximum allowable stress values. Division
1, governing the design by rules, is less stringent from the
standpoint of certain design details and inspection
procedures, and thus incorporates a higher safety factor.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

The 1998 edition incorporates a safety factor of 4

The 2001 and later editions incorporate a safety factor of
3.5.
The 2001 edition of the code yields higher allowable stresses
and thus smaller wall thicknesses.
For example, using a material with a 60,000-psi tensile
strength, a vessel built under the 1998 edition (safety factor =
4) yields a maximum allowable stress value of 15,000 psi while
a vessel built under the 2001 edition (safety factor = 3.5)
yields a maximum allowable stress value of 17,142 psi.
On the other hand, Division 2 governs the design by analysis
and incorporates a lower safety factor of 3.
Thus, the maximum allowable stress value for a 60,000-psi
tensile strength material will become 20,000 psi.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Many companies require that all their pressure vessels be

constructed in accordance with Division 2 because of the
more exacting standards.
Others find that they can purchase less expensive vessels by
allowing manufacturers the choice of either Division 1 or
Division 2. Normally, manufacturers will choose Division 1
for low-pressure vessels and Division 2 for high-pressure
vessels. (Otherwise wall may too thick for high pressure
vessels)
The maximum allowable stress values at normal temperature
range for the steel plates most commonly used in the
fabrication of pressure vessels are given in Table 3.
For stress values at higher temperatures and for other
materials, the latest edition of the ASME code should be
referenced.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

 Table 3
MEng3161

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

ASME code section VIII, Division 1

 Determining wall thickness where
S = maximum allowable stress value,
psi (kPa),
t = thickness, excluding corrosion
allowance, in. (mm),
P = maximum allowable working
pressure, psig (kPa),
r = inside radius before corrosion
allowance is added, in. (mm),
d = inside diameter before corrosion
allowance is added, in. (mm),
E = joint efficiency, see Table 6-4
(most vessels are fabricated in
accordance with type of joint no. 1),
α = half the angle of the apex of the
cone.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161
Figure: summarizes the formulas for pressure vessels
under internal pressure (ASME Section VIII, Division 1)

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Table 6-4 lists joint efficiencies that should be used in Eqs. (6-1) to (6-4).
This is Table UW-12 in the ASME code.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161 Table 6-5 lists some of the common material
types used to construct pressure vessels.
 Individual operating companies have their own standards,
which differ from
those listed in this table.

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Corrosion allowance
Typically, a corrosion allowance of 0.125 in (3.175 mm) for
non-corrosive service and 0.250 in (6.35 mm). for corrosive
service is added to the wall thickness calculated in Eqs. (6-1)
to (6-4).

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Design project of a Pressure Vessel Reservoir

Guidelines for design procedures and special calculation
methods related to the design projects of pressure vessel.
Design Project of a pressure vessel reservoir.
 Prepare a design report of the design of a pressure
vessel reservoir containing the assumptions,
considerations calculations and remarks.
 Classification of pressure vessels
 Properties of containing fluids and properties of
materials selection for vessels construction (tensile
stress, yield stress, corrosion resistance, weld ability).
 General design considerations (Design pressure,
temperature and load, material for the vessel, design
stress, welded joints, efficiency and corrosion
allowance).
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

Develop the calculation of the pressure vessel as follows.

Design of vessels under internal pressure (force
analysis, material selection, thickness determination,
cover heads selection, choice of closure, volume
analysis, combined loadings on vessels, checking for
buckling in vertical vessels).
Fittings and Nozzles (Design of the inlet and discharge
pipes, material selection, thickness determination, and
flanges selections. Design of outlet pipe and safety
valve, material selection, thickness determination and
flanges selections. Design of temperature and pressure
gauges holes).
Reinforcement of shells openings. Compensation for
openings. Calculation of the reinforcement required.
Design of welding reinforcements for opening.
- .
Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project
MEng3161

 Weld design (Materials, methods of welding. Calculation

of the welded joints of the cylinder, cover heads, fittings
and flanges. Force analysis. Stresses).
Threaded connections. Design principles. Design of
threaded parts.
Man and hand holes (Strength analysis. Gasket selections,
materials of gaskets. Design of coverts and yokes, bolt
design, materials, and forces acting).
Design of supports (Types. Strength and stiffness
considerations. Base plate. Construction calculations).

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Drawings of the vessel.

Construct the assembly drawing (three views) of the
Vessel in a proper scale (A-1 drawing paper format),
with details of:
 The stub – flange connection,
 Stub for the pressure gauge meter,
 The supports
 Section of the welded seam of the vessel and
 The drawing of the hand or manhole

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

MEng3161

Design of Pressure Vessel

1. Select type of pressure vessel
Horizontal
Vertical
Spherical
2. User’s input parameters

Volume of pressure vessel Joint efficiency facto

Length of pressure vessel Corrosion allowance
Design working press Temperature
Materials Type of fluid

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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3. Output
Volume Design of head
Length Design of flanges and covers
Radius Design of opening
Design of shell Design of supports

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project

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Machine Design Project

Project II
Jack Design

Lecture By: Besufekad G. (MSc. in Mechanical Design) Machine Design Project