ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINNERING
COURSE TITLE: CHEMICAL ENGINEERING APPARATUS DESIGN
COURSE CODE: ChEg 4191
GROUP PROJECT: NETWORK 6
PROJECT ON MECHANICAL DESIGN OF PRESSURE VESSEL
SECTION-TWO
NAME OF STUDENTS:
ID.NORET
1. Adanesh G/hiwet ..0075/06
2. Aregawi G/hear0155/06
3. Berhe Gidey0252/06
4. Desta Tadesse4203/06
5. Fisha Hailay0521/06
6. Fsaha Desta4194/06
7. Fsseha G/haweria4265/06
8. G/mariam Tesfay..0574/06
9. Kidu Welay0927/06
10. Teberh Mekonon1409/06

SUBMITTED TO: ZINABU HAILU (MSc)

SUBMISSION DATE: DECEMBER 12, 2016
PROJECT ON MECHANICAL DESIGN OF PRESSURE VESSEL

Declaration
This project is obliged to be designed before a month. And it exists all the design
procedures for the effective designation of pressure vessel. And this pressure
vessel design is helped with the AutoCAD design and mathematical expressions
for sac of societies problem .

Acknowledgment
First and for most we would like to say thanks for our teacher he gives the chance
to prepare this project by helping in giving information and prepared format. And
also for all members of network that gathered data for designing , for the source in
formation digital website, and for the person who helps by give the laptop
computer to prepared this project.

Executive summary
This final project presents design, analysis and manufacturing of pressure
vessel. In the design of pressure vessel safety is the primary consideration, due
the potential impact of possible accident. There have a few main factors to design
the safe pressure vessel. This writing is focusing on analyzing the safety
parameter for allowable working pressure. Allowable working pressures
arecalculated by using PV Elite which comply with the ASME VIII, Rules of
construction pressure vessel div 1. The failuretiy of the vessel are probability
occur at maximum pressure which is the element that only can sustain that
pressure. At the end of this project, a pressure vessel which is water reserver are
fabricated and theprocedure of manufacture are explained clearly..

List of figures

Figure 4-0-1 (a) Torispherical heads.............................................................................................

Figure 4-0-2 (b) standard ellipsoidal.............................................................................................
Figure 4-0-3:column section with increasing thickness................................................................
Figure 4-0-4: Selected Standard Flange........................................................................................
Figure 4-0-5: Standard ellipsoidal head measurements.................................................................
Figure 4-6:Schematic diagram of pressure vessel.........................................................................

Table 2.Column Specification........................................................................................................

Table 3Nozzles specification.........................................................................................................
Table 4.Sieve plate column specification......................................................................................
Table 5Specification for Column Wall Thickness.........................................................................
Table 6Specification for selection and sizing of vessel heads.......................................................
Table 7 Total weight.......................................................................................................................
Table 8: Typical Standard Flanges Nominal Size (mm)................................................................
Table 9.Summarization of all final parameter results:...................................................................

Acronyms
ASME-American Society Mechanical Engineering
ASTM-American Society for Testing and Materials
BPVC-Boiler and Pressure Vessel Code
NDT-Non Destructive Testing

Contents
1 INTRODUCTION........................................................................................................................
1.1Back ground of pressure vessels.............................................................................................
1.2 Statement of the problem.......................................................................................................
Objectives...................................................................................................................................
1.3.1Specific objectives..........................................................................................................
1.4 Significance of study..........................................................................................................
2. LITERATURE REVIEW...........................................................................................................
2.1 NATURE OF DESIGN........................................................................................................
2.2 Pressure vessel.....................................................................................................................
2.3 GENERAL DESIGN CONSIDERATIONS: PRESSUREVESSELS.................................
2.3.1 Design pressure............................................................................................................
2.3.2. Design temperature.......................................................................................................
2.3.3 Materials.......................................................................................................................
2.3.4. Design stress (nominal design strength).......................................................................
2.3.5 Welded joint efficiency, and construction categories....................................................
2.3.6. Corrosion allowance.....................................................................................................
2.3.7. Design loads.................................................................................................................
2.3.8. Minimum practical wall thickness...............................................................................
2.4 COMPONENT OF PRESSURE VESSEL..........................................................................
2.4.1 Shell...............................................................................................................................
2.4.2 Head...............................................................................................................................
2.4.3Nozzle.............................................................................................................................
2.5. Factors Considered in Designing Pressure Vessels.............................................................
3 Materials and Methods...............................................................................................................
3.1Materials Used......................................................................................................................
3.2 Methodesused(procedures)and Qualitatively.......................................................................
4 Result and Discussions...............................................................................................................
4.1 .1Column Specification........................................................................................................

4.1.2 Nozzles specification....................................................................................................

4.1.3 Sieve plate column specification...................................................................................
4.2 Column Wall Thickness.......................................................................................................
4.2.1 Required Specifications.................................................................................................
4.3 Minimum Column Wall Thickness.....................................................................................
4.3.1 Mean Thickness of Column Wall..................................................................................
4.4 Selection and Sizing of Vessel Heads..................................................................................
4.4.1 Required Specifications.................................................................................................
4.5 Comparison of Heads...........................................................................................................
4.5.1Type Of Heads and their Properties................................................................................
4.5.2Calculation Thickness of Heads.....................................................................................
4.6 Preliminary Design..............................................................................................................
4.7.0 Reinforcement 0f Openings..............................................................................................
4.7.1 Required Area of Reinforcement...................................................................................
4.8 Preliminary Calculations for thickness................................................................................

1 INTRODUCTION
Tanks, vessel and pipelines that carry, store or receive fluids are called pressure
vessel. A pressure vessel is defined as a container with a pressure differential
between inside and outside. The inside pressure is usually higher than the outside.
The fluid inside the vessel may undergo a change in state as in the case of steam
boiler or may combine with other reagent as in the case of chemical reactor.
Pressure vessel often has a combination of high pressure together with high
temperature and in some cases flammable fluids or highly radioactive material.
Because of such hazards it is imperative that the design besuch that no leakage
can occur. In addition vessel has to be design carefully to cope with the operating
temperature and pressure. Pressure vessel are used in a number of industries; for
example, the power generation industry for fossil and nuclear power, the
petrochemical industry for storing and

processing crude petroleum oil in tank

farms as well as storing gasoline in servicestation, and the chemical industry.

Their use has expanded throughout the world. Pressure vessel and tank are in fact
essential to the chemical, petroleum, petrochemical and nuclear industry. It is in
the class of equipment that the reaction, separation and storage of raw material
occur. In the same word, pressurized equipment is required for a wide range of
industrial plant for storage and manufacturing purpose. pressure vessels are
usually spherical or cylindrical with dome end. The cylindrical vessels are
generally preferred because of they present simple manufacturing problem and
make better use of the available space. Boiler, heat exchanger, chemical reactor
and so on, are generally cylindrical. Spherical vessels have the advantages of
requiring thinner walls fora given pressure and diameter than the equivalent
cylinder.

1.1Back ground of pressure vessels

The earliest documented design of pressure vessels is described in the book
Codex Madrid I, by Leonardo da Vinci, in 1495, where containers of pressurized
air were theorized to lift heavy weights underwater, however vessels resembling
what are used today did not come about until he 1800s where steam was
generated in boilers helping to spur the industrial revolution. However, with poor
material quality and manufacturing techniques along with improper knowledge of
design, operation and maintenance there. was a large number of damaging and
often fatal explosions associated with these boilers and pressure vessels, with a
death occurring on a nearly daily basis in the United States. Local providences
and states in the US beganenacting rules for constructing these vessels after some
particularly devastating vessel failures occurred killing dozens of people at a time,
which made it difficult for manufacturers to keep up with the varied rules from
one location to another and the first pressure vessel code was developed starting
in 1911 and released in 1914, starting the ASME Boiler and Pressure Vessel Code
(BPVC). In an early effort to design a tank capable of withstanding pressures up
to 10,000 psi (69 MPa), a 6-inch (150 mm) diameter tank was developed in 1919
that was spirallywound with two layers of high tensile strength steel wire to
prevent sidewall rupture, and the end caps longitudinally reinforced with
lengthwise high-tensile rods.
The need for high pressure and temperature vessels for petroleum refineries and
chemical plants gave rise to vessels joined with welding instead of rivets (which
were unsuitable for the pressures and temperatures required)and in 1920s and
1930s the BPVC included welding as an acceptable means of construction, and
welding is the main means of joining metal vessels today.
There have been many advancements in the field of pressure vessel engineering
such as advanced non-destructive examination, phased array ultrasonic testing and
radiography, new material grades with increased corrosion resistance and stronger
materials, and new ways to join materials such as explosion welding (to attach
one metal sheet to another, usually a thin corrosion resistant metal like stainless
steel to a stronger metal like carbon steel), friction stir welding (which attaches
the metals together without melting the metal), advanced theories and means of
more accurately assessing the stresses encountered in vessels such as with the use
of Finite Element Analysis, allowing the vessels to be built safer and more
efficiently. Today vessels in the USA require BPVC stamping but the BPVC is not
just a domestic code, many other countries have adopted the BPVC as their
official code. There are, however, other official codes in some countries (some of
which rely on portions of and reference the BPVC), Japan, Australia, Canada,
Britain, and Europe have their own codes. Regardless of the country nearly all
2

recognize the inherent potential hazards of pressure vessels and the need for
standards and codes regulating their design and construction.

1.2 Statement of the problem

During the the force or the load acting on the pressure vessel the device is
directly fractured .The failurity of pressure vessels are differ from one to another
depending on the strength of the material. And the failurtiy of the materials
happened when there is
Material- Improper selection of material; defects in material.
Design- Incorrect design data; inaccurate or incorrect design methods;
Inadequate
Fabrication- Poor quality control; improper or insufficient fabrication
procedures including welding; heat treatment or forming methods.
Mechanical properties-Not studying the mechanical properties of the
material.
Factors affecting-Not studying the factors affecting the materials.
Generally, by studying those problems and limitaions we are stand to
design standard pressure vessels i.e tanker.
Objectives
The purpose of this project is to study the implementation and practices of
pressure vessel designs, to identify the pressure vessel and to fabricate the
pressure vessel as per the reference standards. Designing pressure vessel was
carried out to ensure the safety of pressure vessels operating in the plant. And also
in order to facilitate and accelerate the process of designing pressure vessel.

1.3.1Specific objectives
The specific objectives of this project is to solve scarcity of drinking water in
adigrat town. Especially in adigrat university by placing the designed tankers in
central place of the university it can solve the problems faced by shortage of
water in all students. And the tankers are used as reserviour for long period of
time.
1.4 Significance of study
The significance study of pressure vessel is to solve the problem of the society by
designing the standardized pressure vessel quantitively and qualitatively.And also
study by identified specific problem of the customer demand.

2. LITERATURE REVIEW
2.1 NATURE OF DESIGN
Design is a creative activity, and as such can be one of the most rewarding and
satisfying activities undertaken by an engineer. It is the synthesis, the putting
together, of ideas to achieve a desired purpose. The design does not exist at the
commencement of the project. The designer starts with a specific objective in
mind, a need, and by developing and evaluating possible designs, arrives at what
he considers the best way of achieving that objective; be it a better chair, a new
bridge, or for the chemical engineer, a new chemical product or a stage in the
design of a production process.
2.2 Pressure vessel
A pressure vessel is a container designed to hold gases or liquids at a pressure
substantially different from the ambient pressure. The pressure differential is
dangerous, and fatal accidents have occurred in the history of pressure vessel
development and operation. Consequently, 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,
but involves parameters such as maximum safe operating pressure and
4

temperature, and are engineered with a safety factor, corrosion allowance,

minimum design temperature (for brittle fracture), and involve nondestructive
testing, such as ultrasonic testing, radiography, and pressure tests, usually
involving water, also known as a hydrotest, but could be pneumatically tested
involving air or another gas.
The preferred test is hydrostatic testing because it's a much safer method of
testing as it releases much less energy if fracture were to occur (water does not
rapidly increase its volume while rapid depressurization occurs, unlike gases like
air, i.e. gasses fail explosively). In the United States, as with many other
countries, it is the law that vessels over a certain size and pressure (15 PSI) be
built to Code, in the United States that Code is the ASME Boiler and Pressure
Vessel Code (BPVC), these vessels also require an Authorized Inspector to sign
off on every new vessel constructed and each vessel has a nameplate with
pertinent information about the vessel such as maximum allowable working
pressure, maximum temperature, minimum design metal temperature, what
company manufactured it, the date, its registration number (through the National
Board), and ASME's official stamp for pressure vessels (U-stamp), making the
vessel traceable and officially an ASME Code vessel.
2.3 GENERAL DESIGN CONSIDERATIONS: PRESSUREVESSELS
2.3.1 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. 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. Vessels likely to be subjected to vacuum should be designed for a full
negative pressure of 1 bar, unless fitted with an effective and reliable, vacuum
breaker.
2.3.2. Design temperature strength of metals decreases with increasing
temperature. So the 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 vessel wall temperatures.

2.3.3 Materials
Pressure vessels are constructed from plain carbon steels, low and high alloy
steels, other alloys, clad plate, and reinforced plastics. Selection of a suitable
material must take into account the suitability of the material for fabrication
(particularly welding) as well as the compatibility of the material with the process
environment. The pressure vessel design codes and standards includelists of
acceptable materials; in accordance with the appropriate material standards.
2.3.4. Design stress (nominal design strength)
For design purposes it is necessary to decide a value for the maximum allowable
stress (nominal design strength) that can be accepted in the material of
construction. This is determined by applying a suitable design stress factor
(factor of safety) to the maximum stress that the material could be expected to
withstand without failure under standard test conditions. The design stress factor
allows for any uncertainty in the design methods, the loading, the quality of the
materials, and the workmanship. For materials not subject to high temperatures
the design stress is based on the yield stress (or proof stress), or the tensile
strength (ultimate tensile stress) of the material at the design temperature. For
materials subject to conditions at which the creep is likely to be a consideration,
the design stress is based on the creep characteristics of the material: the average
stress to produce rupture after 105 hours, or the average stress to produce a 1 per
cent strain after 105 hours, at the design temperature.

2.3.5 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 nondestructive 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 J. 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. Typical values are shown in Table 13.3.
Taking the factor as 1.0 implies that the joint is equally as strong as the virgin
plate; this is achieved by radiographing 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.
6

The national codes and standards divide vessel construction into different
categories, depending on the amount of non-destructive testing required. The
higher categories require 100 per cent radiography of the welds, and allow the use
of highest values for the weldjoint factors. The lower-quality categories require
less radiography, but allow only lower joint-efficiency factors, and place
restrictions on the plate thickness and type of materials that can be used. The
highest category will invariably be specified for process-plant pressure vessels.
The standards should be consulted to determine the limitations and requirements
of the construction categories specified. Welded joint efficiency factors are not
used, as such, in the design equations given in BS PD 5500; instead limitations
are placed on the values of the nominal design strength (allowable design stress)
for materials in the lower construction category. The standard specifies three
construction categories:
Category 1: the highest class, requires 100 per cent non-destructive testing (NDT)
of the welds; and allows the use of all materials covered by the standard, with no
restriction on the plate thickness.
4
Category 2: requires less non-destructive testing but places some limitations on
the materials which can be used and the maximum plate thickness. Category 3:
the lowest class, requires only visual inspection of the welds, but is restricted to
carbon and carbon-manganese steels, and austenitic stainless steel; and limits are
placed on the plate thickness and the nominal design stress. For carbon and
carbonmanganese steels the plate thickness is restricted to less than 13 mm and
the design stress is about half that allowed for categories 1 and 2. For stainless
steel the thickness is restricted to less than 25 mm and the allowable design stress
is around 80 per cent of that for the other categories.

2.3.6. Corrosion allowance

The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion, or scaling (see Chapter 7). 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. For carbon and lowalloy steels, where severe corrosion is not expected, a minimum allowance of 2.0
mm should be used; where more severe conditions are anticipated this should be
increased to 4.0 mm. Most design codes and standards specify a minimum
allowance of 1.0 mm.
2.3.7. Design loads
A structure must be designed to resist gross plastic deformation and collapse
under all the conditions of loading. The loads to which a process vessel will be
subject in service are listed below. They can be classified as major loads, that
must always be considered in vessel design, and subsidiary loads. Formal stress
analysis to determine the effect of the subsidiary loads is only required in the
codes and standards where it is not possible to demonstrate the adequacy of the
proposed design by other means; such as by comparisonwith the known behaviour
of existing vessels.
2.3.7.1Major loads
1. Design pressure: including any significant static head of liquid.
2. Maximum weight of the vessel and contents, under operating conditions.
3. Maximum weight of the vessel and contents under the hydraulic test conditions.
4. Wind loads.
5. Earthquake (seismic) loads.
6. Loads supported by, or reacting on, the vessel.

2.3.7.2Subsidiary loads
1. Local stresses caused by supports, internal structures and connecting pipes.
2. Shock loads caused by water hammer, or by surging of the vessel contents.
3. Bending moments caused by eccentricity of the centre of the working pressure
relative to the neutral axis of the vessel.
4. Stresses due to temperature differences and differences in the coefficient
expansion of materials.
5. Loads caused by fluctuations in temperature and pressure. A vessel will not be
subject to all these loads simultaneously. The designer must determine what
combination of possible loads gives the worst situation, and design for that
loading condition.

2.3.8. Minimum practical wall thickness

There will be a minimum wall thickness required to ensure that any vessel is
sufficiently rigid to withstand its own weight, and any incidental loads. As a
general guide the wall thickness of any vessel should not be less than the values
given below; the values include a corrosion allowance of 2 mm:
2.4 COMPONENT OF PRESSURE VESSEL
There are three main Type are given below
1. Shell
2. Head
3. Nozzle

2.4.1 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.
2.4.2 Head
All pressure vessel shells must be closed at the ends by heads (or another shell
section). Heads are typically curved rather than flat. Curved configurations are
stronger and allow the heads to be thinner, lighter, and less expensive than flat
heads. Heads can also be used in side 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.
2.4.3Nozzle
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 application
Attach piping for flow into or out of the vessel.

Attach instrument connections, (e.g., level gauges, thermo wells, or

pressure gauges).

Provide access to the vessel interior at midways.

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
thermo wells

10

2.5. Factors Considered in Designing Pressure Vessels

Dimensions-Diameter, length and their limitations.
Operating conditions Pressure and temperature.
Available materials and their physical properties and cost.
Corrosive nature of reactants and products.
Theories of failure.
Types of construction i.e. forged, welded or casted.
Method of Fabrication.
Fatigue, Brittle failure and Creep.
Economic consideration

3 Materials and Methods

3.1Materials Used
Insulation material; mineral wool; 50mm thick
Material of construction; vessel stain less steel;
Nozzle as vessel , skirt carbon steel, silicon killed;
Water
50 sieve plates-Acess ladder with plat forms
3.2 Methods used (procedures)and Qualitatively
The minimum column wall thickness
Step 1: Determine the minimum column wall thickness of cylinder that withstand to the internal
pressure. From the specifications and requirement provided previously data, the column wall
thickness is then calculated using the Equation
11

e=

PiDi
+c
2 fJPi

Where,
e = minimum plate thickness (mm)
Pi = design pressure (N/mm2)
Di = internal diameter (mm)
J = joint efficient factor
f = maximum allowable working or design stress (N/mm2)
C = corrosion allowance (mm)
Selection and Sizing of Vessel Heads
Step 1: Select and size the vessel ends, using Torispherical and ellipsoidal heads.
The wall thicknesses of each heads are calculated as follows using Equation.
Torispherical head:
e=

PiRcCs
2 fJ + Pi(Cs0.2)

Where,
CS = Stress concentration factor for TorisphericalHeads

1
Rc
Cs= (3+
)
4
Rk
Where
12

Rc=crown radius
Rk= knuckle radius
Ellipsoidal head:
e=

PiDi
2 fJ0.2 Pi

Dimension of Ellipsoidal Heads

Figure 4.5.1 shows the standard ellipsoidal head dimension .It had been
mentioned before that standard ellipsoidal heads are manufactured with a
horizontal against vertical axis ratio of 2:1.

Figure 4.5.1(b) Standard Ellipsoidal Head

Diameter of the vessel, D = Di = 1500 mm
D 1500
Height of the vessel head, h= 4 = 4 =375 mm

Design Loads
Step 1: Determine dead weight of the vessel
For preliminary calculations the approximate weight of a cylindrical steel vessel
with domed ends, and uniform wall thickness, can be estimated from the
following equation:
Wv=240 CvDm ( Hv+0.8 Dm ) tave

13

Where,
Wv = Total weight of the shell.
Cv = A factor to account for the weight of nozzles, manways, internal supports
Dm = Mean Diameter,
Hv = Length of cylindrical section,
tave = Mean wall thickness,
Step 2: Determine dead weight of the plate.
Since vessel is filled with 50 sieve plates with the same diameter as the column,
which will cause additional weight to the vessel. The weight of the plate is given
by:
Weight of a plate includingliquid on it
=1.7 kN /m2
platearea

Ap= ( Di )
4

Step 3: Calculate the dead weight of insulation

The weight of the insulation given by the following equation,
WI=( insulation)(Vinsulation)
Vinsulation=xDixHvx ( tisulation ) x 10-3
Where,
WI= Weight of the insulation material, KN
insulation= Density of insulation materials, kg/m3=130 kg/m3
Vinsulation= Volume of the insulation materials m3
=Gravitational Force, m/s
tinsulation= Minimum insulation thickness
14

At the last the weight of insulation is double in order to allowance of attachment

fittings, sealing and moisture absorption.
Step 4. Calculate the total dead weight
Total weight = Wv+Wp+WI
Where, Wv=weight of the vessel
Wp=weight of the plate
WI=weight of the insulation
Wind Loading
Step 1: Determine wind loading per length.
The wind loading per length can be expressed by,
Fw=PwxDeff
An allowance of 0.4 m should be addedto the formula below to find the
effective column diameter for a caged ladder(Coulson and Richardsons
chemical engineering Vol. 6)
Deff =Di+ 2 ( tave+tinsu ) x 10-3
Where,
Fw = Wind loading per length (N/m)
Pw =Wind Pressure(N/m2)
Deff

= Effective column diameter (m)

Di = Diameter of the vessel (m)

tave = Mean thickness of column (mm)
tinsu = Minimum insulation thickness (mm)

Step 2: Determine the bending moment, Mx.

15

The bending moment, Mx can be calculated using the formula given below.
Fw x 2
2

Mx=

Where,
Mx
x

= Bending moment (Nm)

= Length of cylindrical section (m

Stress Analysis
Step 1: Determine the longitudinal and circumferential stress at the bottom
tangent
line due topressure.
L=

PiDi
4 tb

h=

PiDi
2tb

Where,
L =Longitudinal stress, N/ mm2
h = Circumferential stress, N/ mm2
Di =Internal diameter, mm
tb =Wall thickness at the bottom tangent line, mm

Step 2: Determine the dead weight direct stress.

The dead weight stress can be calculated by,
w=

Wt
( Di+tb ) tb

Where,
16

= Total Dead weight of empty vessel, KN

Wt

= Direct stress, N/ mm2

Step 3: Determine the bending stress.

The bending stress due to bending moment is given by,
b=

Mx Di
+tb
Iv 2

Do=Di+2 tb

Iv=

( Do 4 Di4 )
64

Where,
b

= Bending stress (N/mm2)

Iv

=Second moment of area (mm4)

Do =Outer Diameter, mm

Step 4: Determine the resultant longitudinal stress.

The resultant longitudinal stress can be calculated as follow.
z=L+ w b
w is compressive therefore it is negative.

Step 5: Check its satisfactory design and elastic stability (buckling).

If the greater difference in downwind stress or upwind stress is much more less
than the maximum allowable stress, f = 130

N /mm2

this design with metal

thickness is okay and satisfactory. Critical buckling stress can be calculated as:

17

c=2 10 4

( Dotb )

Reinforcement of Openings and Required Area of Reinforcement

Required Area of Reinforcement:
All process vessels will have openings for connections, man ways, and instrument
fittings. The presence of opening has its own drawback whereby it weakens the
shell and gives rise to stress concentrations. The stress at the edge of a hole will
be higher than the average stress in surrounding plate. Thus, in order to reduce
this stress it is important that the opening is compensated with increase of wall
thickness in the region adjacent to the opening. In other words, a reinforcement of
opening will be done towards the hole in order to cope with a sufficient stress that
countered the weakening effect of the opening without.
Notation:
A = total cross-sectional area of reinforcement required in the plane under
consideration
A1 = area in excess thickness in the vessel wall available for reinforcement
A2= area in excess thickness in the nozzle wall available for reinforcement
A3= area available for reinforcement when the nozzle extends inside the vessel
wall
S = design stress at design temperature
d = finished diameter of circular opening under consideration
E = joint efficiency factor F = correction factor that compensates for the variation
of in internal pressure stresses on different planes with respect to the axis of the
vessel
t = specified vessel wall thickness
ti= nominal thickness of internal projection of the nozzle wall
tn = nozzle wall thickness
tr= required thickness of seamless shell based on circumferential stress
tr.n.= required thickness of seamless nozzle wall
18

fr1= strength reduction factor ( S

n/Sv for nozzle wall inserted through the vessel wall)
fr2= Sn/ Sv
Sn= allowable stress in nozzle
Sv = allowable stress in vessel
P = design pressure
D = diameter of manhole/access port
Di,n= internal diameter of nozzle
K1= spherical radius factor
c = corrosion allowance
h = height of ellipsoidal head
UTP = pipe under tolerance
Ri,n= Radius of the internal section of the nozzle
Access Port (or Manhole):
For design of internal pressure, the total cross-sectional area of reinforcement A
required in any given plane through the opening for a shell or formed head under
internal pressure shall not be less than
A=dtrF +2tntrF(1-fr1)
Now , start with preliminary calculations for thickness (t r,, tr.n. , t, ti, tn) and
distance (h)
i)The minimum required thickness under circumferential stress t r for seamless
PR
PK 1 D
=
shell or head is determined by , tr= SE0.6 P SE0.6 P
Note: tr is the thickness required for a seamless sphere with radius o K1D
PiDi
A, tr.n= 2 fjPi
B, The vessel wall thickness, t, it is determined as:
19

PR
t= SE0.6 P + C
C, For the nominal thickness of internal projection of nozzle wall, ti, it is
determined as follows:
ti = tn-2C
D, Distance nozzle projects beyond the inner surface of the vessel wall is as
determined:
h=min(2.5t,2.5ti)
E, The diameter of the finished opening, d, is as determined
d=D+C
Note: The opening is in a corroded condition. Thus, a corrosion allowance is
added to the diameter of the opening.
Calculations of Area Required for Reinforcement
A=dtrF +2tntrF(1-fr1)
To determine whether additional reinforcement is necessary for the manhole, the
actual area available for reinforcement must be calculated and compare with the
area required for reinforcement. The following condition must be satisfied if no
additional reinforcement isrequired:
Check that, A < Ai

Where, A1+A2+A3+A41+A43

A1(Largest)
A1=d(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1)

f
130
where, fr1= f = 130 =1 ,(since both the

nozzle and the vessel are made up of the same material ) Then the term , 2t n(E1tFtr)(1-fr1) will be cancel out.
A1=2(t+ t n)( E1t-Ftr)
A2(smallest):
A2: First of all, assuming fr2= fr1= 1 since they both have the same formula (Sn /
Sv);
20

A2=5(tn-tr.n) fr2.t
A2: A2=5(tn-tr.n) fr2tn
A3 (smallest):
A3=5t (ti fr2)
Lastly by considering the condition

Ai

>A , if it is satisfy this condition

there is no additional reinforcement will be required

Standard Flanges
Nozzles and flanges can be categorized into several categories depending on their
sizes, types and other attachments to vessels. A nozzle is a relatively simple
device, a cylindrical component that penetrates the shell or heads of a pressure
vessel (Sinott 2008). The main function of nozzles on the plates is to transport
fluids and allow the liquids and gas to disperse throughout the towers as the fluids
flow through the nozzles. On the other hand, flanges improve the strength of a
structure and also apply as a guide for keeping a particular object in place (Sinott
2008). Different column design requires different standards and designs of the
nozzles and flanges. Flanges are used for connecting pipe and instruments to
vessels, for removable vessel heads and manhole covers.

Mechanical Design for Skirt Support

Dead weight stress for the test and operating conditions

21

Approximate weight =

Di
Hvwg
4

Total weight = wv + Approximate weight

For test condition, ws :
ws(test )=

Formula given by,

Wwater
( Ds+ ts ) ts

Where,
ws(test )= Dead weight stress in the skirt for test condition
Wwater= Total weight of the vessel with contents (water).

For operating condition, ws( operating) :

The formula given by,
ws(operating)=

Wvessel
( Ds+ts ) ts

Where,
ws( operating)= Dead weight stress in the skirt for operating condition
Wvessel= Total dead weight of vessel with heads

Resultant bending stress in the skirt.

For maximum:

For minimum:

s ( compresive )=bs+ ( test )

sting
ws ( tensil )=bs +w

Design criteria

22

If given the worst combination of both wind and dead-weight loading, the skirt
thickness should not exceed that of its design criteria, as shown below from the
specification table, =90
fs= 155 N/mm2
E = Youngs modulus =200,000 N/mm2
For the maximum:
Given the formula,

s (compresive) 0.125 E(

ts
) sins
Ds

For minimum:
Given the formula,

s ( tensil ) fsJsins

New skirt thickness, ts:ts= (Old thickness of the skirt) + (Corrosion allowance)
Base ring/flange and anchor bolt design
For DS = 1.5 m
Determine the number of bolts required, N bolts
Since the measurements for the pitch diameter were not given, it was assumed
that the measurement of column diameter would be used to make an assumption
for the pitch diameter. An estimation of 10% allowance was then added to the
pitch circle diameter column.Number of bolts required N bolts given by the
formula:
Nbolts=

Dp
600

Where;
Ds = Internal column diameter = 1.5 m
Dp = Pitch circle diameter = Ds + (10% Ds)
Bolt area, Ab
The required bolt area, A given by the formula:
23

Ab=

1
4 Ms
Wvessel
Nbolt fb Dp

Where,
Nbolt= Number of bolts required = 12 Bolts
fb= Bolt design stress = 125 N/mm2
Ms= Bending moment in skirt
Wvessel= Total dead weight of vessel with heads
Dp= Pitch circle diameter = 1.6 5m = 1,650 mm
Bolt root diameter, Dbolt
The bolt root diameter given by the formula
Dbolt =

4 Ab

Total compressive load on each base ring per unit length, Fbolt.
Fbolt=(

4 Ms Wvessel

)
Ds
Ds2

Where, Wvessel= Total dead weight of vessel with heads , Ms= Bending
moment in skirt

Ds= Internal column diameter

Minimum width of base ring, Lb.

Lb=

Fbolt
fc

Fbolt= Total compressive load on the base ring per unit length =
1,196.40N/mm

24

fc= Maximum allowable bearing pressure on the concrete foundation

padbearing pressure 5 N/mm2
skirt base angle, s .
Skirt base angle, s (With Ds =2.5 m) given by,
s=tan 1 (

D' s
)
0.5 ( D' sDs )

Bolt spacing
Bolt spacing given the formula:
bolt specing=

Dbolt '
Nbolt '

Where,
Dbol t ' = Bolt circle diameter
Nbolt '= Number of bolts
New required bolt area, Ab
Ab=

1
4 Ms
(
Wvessel )
'
'
Nbol t ( fb ) Dbol t

Wvessel= Total dead weight of vessel with heads

Ms= Bending moment in skirt
Nbolt '= Number of bolts required
Dbolt '= Bolt circle diameter
fb= Bolt design stress

total compressive load on each base ring per unit length, Fbolt.
25

Fbolt=(

4 Ms Wvessel
+
)
' 2
'
D s
D s

Where,
Wvessel= Total dead weight of vessel with heads
Ms= Bending moment in skirt
D' s= Flared skirt bottom diameter
minimum width of base ring, Lb
Given the formula:
Lb=

Fbolt
fc

fc= Maximum allowable bearing pressure on the concrete foundation

padBearing pressure = 5 N/mm2

actual bearing pressure on the concrete foundation,
Given the formula:

f ' c=

Fbolt '
Actual width

Actual width =Lr + ts + ti

Where,
ts = Skirt thickness = 19mm
ti = Insulation thickness = 50mm
Fbolt= Total compressive load on the base ring per unit length
Lr =Distance from the edge of the skirt to the outer edge of the ring = 178 mm
(Sinnott., Coulson & Richardson's Chemical Engineering 1999) :Using Bolt size
70 (BS 4190:1967)
base ring thickness, th
The base ring thickness given by the formula:
26

tb=Lr

3f 'c
fr

4 Result and Discussions

4.1 .1Column Specification
Table 1.Column Specification

Properties

Specification

Length of cylinder section,L

Internal diameter, Di
Heads

37m
1.5m
Standard
ellipsoidal
50 plate
150c0
2mm
1200KN/m2

Number of sieve plates, n

Design Temperature, T
Corrosion allowance, Co
Design pressure, pi

4.1.2 Nozzles specification

Table 2Nozzles specification

Properties
Feed
Vapour out

Specifications
At mid-point
200mm
At 0.7m below top of 250mm

Bottom product

cylindrical section
At center of vessel head 200mm
At 1.0m below top of 200mm
cylindrical section

4.1.3 Sieve plate column specification

Table 3.Sieve plate column specification
27

Properties
Specifications
Diameter of access ports or 0.6m

- At 1.0m Above the

(manholes)

bottom
- At 1.5m below the
top of the column
Carbon steel, silicon

Height of support skirt

2.5m

Thickness of insulation
Vessels
Nozzles
Skirts

killed
50mm
Mineral wool
Stainless steel, unstabilised (304)
Stainless steel, unstabilised (304)
Silicon killed

In order to develop a preliminary design, some assumptions are made and listed
below.
Assumptions
No significant loading from piping and external equipment

Plates and plate supports design is negligible

Material is double welded butt or equivalent and fully radiographed

Assume flanges are standard flanges
4.2 Column Wall Thickness
A column should be designed with a specific wall thickness to ensure it has
sufficient rigidity to be able to cope with the maximum amount of pressure which
it is expected to be susceptible to in operation .The minimum column wall
thickness needed to withstand the vessel weight itself as well as other incidental
loads such as internal pressure is calculated and shown in the following
calculation section.
28

4.2.1 Required Specifications

The specification to calculate the column wall thickness are tabulated in Table
below :
Table 4 Specification for Column Wall Thickness
Properties
Specifications
Design Pressure, Pi
1200kN/m2
Operating Temperature, 1500C

Unit conversions
1.2N/mm2
-

T
Internal Diameter, Di
Material

1.5m
Stainless

Corrosion allowance, Co
Joints welds

unstabilised (304)
2mm
Fully radiographed.

1500mm
steel,
2mm
1.0

Joint factor, J = 1.0

Typical Design stress, f

(Appendix A: Figure A.1)

130N/mm2

(Appendix B: Figure B.1)

4.3 Minimum Column Wall Thickness
With the specifications and requirement provided previously, the column wall
thickness is then calculated using Equation.
PiDi
e= 2 fjPi

Where,
t- minimum plate thickness (mm)
Pi- design pressure (N/mm2)
Di- internal diameter (mm)

29

J- joint efficient factor

f- maximum allowable working or design stress (N/mm2)
Co- corrosion allowance (mm)
e- minimum plate thickness (mm)

e=

( 1.2 )(1500)
2 ( 130 ) ( 1 )1.2

e=6.955mm
With addition of corrosion allowance ,Co=2mm
e = (6.955+2)mm=8.955mm9m

4.3.1 Mean Thickness of Column WallSince a vessel needs to withstand design

loads such as wind and the dead weight loads, the column wall has to be gradually
thicker from the top to the bottom.Therefore, the column wall is divided into 5
sections with an increase of 2mm for each section going downwards. The column
wall thickness from top to bottom is (9,11,13,15and17) mm. The mean thickness
of Column wall can then be calculated.
tave , wall=

9+11+13+15+17
5

=13mm

4.4 Selection and Sizing of Vessel Heads

4.4.1 Required Specifications
The specifications or requirements given for selection and sizing of vessel heads
are summarized in table.
Table 5Specification for selection and sizing of vessel heads
Properties
Design pressure, Pi

Specifications
1.2 N/mm2
30

Internal diameter, Di
Material of vessel
Corrosion allowance, Co
Joint welds, J

1500mm
Stainless steel, Unstablized (304)
2mm
Double-welded butt or equivalent
Fully radiographed. Joint factor, J =
1.0

Allowable design stress, f

(Appendix A: Figure A.1)

130 N/mm2

4.5.1Type Of Heads and their Properties

a Standard torispherical head
This is the most commonly used closure for vessels with operating pressures of up
to 15 bar. Its shape is formed from part of a torus and part of a sphere. It has a
similar shape to thatof an ellipse but is easier to fabricate. However, above 10 bar
the cost is much more than that of an equivalent ellipsoidal head.

Figure 4-0-1 (a) Torispherical heads

b, Standard ellipsoidal head
This type of head is usually manufactured with a major and minor axis ratio of
2:1. For operating pressure of above 15 bar, an ellipsoidal head would be the most
economical end closure to use. Therefore, it should be considered for the design
of a sieve plate column. Figure 4.5.1(b) shows the standard ellipsoidal head
dimension .It had been mentioned before that standard ellipsoidal heads are
manufactured with a horizontal against vertical axis ratio of 2:1. Therefore the
correlations based on Figure 4.5.1(b), Diameter of vessel,D=Di=1500mm
Height of vessel head,h

D
4

31

1500
4

=375mm

Figure 4-0-2 (b) standard ellipsoidal

4.5.2Calculation Thickness of Heads
Minimum thickness of torispherical heads

e=

PiRcCs
2 fj+Pi (Cs0.2)

Where,
1
Cs=stress concentration factor for torispherical heads= 4 (3+

Rc
Rk )

Rc-Crown radius
Rk-Kunkle radius
The ratio of the knuckle to crown radii should not be less than 0.06, to avoid
buckling; and the crown radius should not be greater than the diameter of the
cylindrical section
1
Rc
Cs= 4 (3+ Rk )

32

e=

( 1.2 ) ( 1500 ) (1.77062)

2 ( 130 ) (1)+1.2(1.770620.2)

e=12.169918mm
Minimum thicknes of ellipsoidal
PiDi
e= 2 fj0.2 Pi Where,

Pi- design pressure (N/mm2)

Di- internal diameter (mm)
J- joint efficient factor
f- maximum allowable working or design stress (N/mm2)
Co- corrosion allowance (mm)
e- minimum thickness of ellipsoidal (mm)

e=

( 1.2 ) (1500)
2 ( 130 ) ( 1 )(0.2)1.2

= 6.9295mm

Since,e-of ellipsoidal is less than e-of torispherical.Anellipsoidal head would be

the most economical end closure to use. Therefore, it should be considered for the
design of a sieve plate column.
4.6 Preliminary Design
To make preliminary design we should start from calculating the thickness
of the vessel,analysis of weight,analysis of stress and finally checking
weather our design procedure is correct or not.Thus since the vessel is
cylindrical the minimum thickness;
PiDi
e= 2 fjPi

33

Where,
t- minimum plate thickness (mm)
Pi- design pressure (N/mm2)
Di- internal diameter (mm)
J- joint efficient factor
f- maximum allowable working or design stress (N/mm2)
Co- corrosion allowance (mm)
e- minimum plate thickness (mm)

e=

( 1.2 )(1500)
2 ( 130 ) ( 1 )1.2

e=6.955mm
With addition of corrosion allowance, Co=2mm (6.955+2)mm=8.955mm9mm
At the base of vessel should be much thick to with stand
dead weight and wind load.Thus,first trial divide the
column into 5 section and increase thickness by 2mm per
section.
tave , wall=

9+11+13+ 15+17
5

9mm

34

=13mm

11mm

13mm

15mm

17mm

2.5m=2500mm

Figure 4-0-3: column section with increasing thickness

Dead weight of vessel
-To estimate dead weight taken mean thickness(13)mm
Wv=240*Cv*Dm(Hv+0.8*Dm)*tm
Dm=Di+tm=(1.5+0.013)m
Dm=1.513m
Where Wv-Dead weight of vessel
Dm-mean diameter
Di-internal diameter
35

Cv-afactor to account for the weight of nozzles

Wv=240*1.15*1.513(37+0.8.513)*13
Wv=207430.6587N
Wv=207.4306587KN
Weight of plate
Plate area

A=

D2
1.52

2
4 =
4 =1.767145868m

Weight plate=1.7KN/m2*1.767145868m2
=3.004147976KN
For 50 plate=50*3.004147976KN=150.2073988KN
Weight of insulation
Mineral wool,density=130Kg/m3
Volume,V *D*Hv*tin 1.5370.05
V=8.71792m3
Weight w= *g*v=130Kg/mm2*9.81m/s2*8.71792m3
W=11117.96338N=11.11796338KN
Double this dueto allow for fitting

(2*11.11796338)KN

W=22.23592675KN
TOTAL WEIGHT

Vessel;

207.4306587KN

Plate;

150.2073988KN

Insulation;

22.23592675KN

TOTAL

=379.8739842KN

36

Table 6 Total weight

Wind loading
Fw=Pw*Deff
where;
Fw-load per meter
Deff-effective diameter
the dynamic wind pressure will be given by;
Pw=0.05*Uw2
Where;
UW-Wind speed
Uw=160Km/hr
Pw=0.05*(160)2Pw=1280w/m
Deff=Di+2(tm+tin)*0.00
Deff=1.5+2(13+50)*0.001=1.626m
Fw=1280w/m2*1.626m=2081.28N/m
Bending moment at bottom tangent line =
Mx

W
2081.28
HV 2

3737=1424636.16
Mx
Nm
2
2

Longitudinal and circumferential stress: At bottom tangent line, the pressure

stresses are given by:
Longitudinal stress,
L

PiDi
4t

(N/mm ) =

Circumferential stress, h

1.21500
417

PiDi
2t

= 26.470588N/mm2

1.21500
217
37

=52.94117647N/mm2

Stress due to dead weight, ,

w

Wv
207430.6587
=
( Di+t ) t ( 1500+17 ) 17

= 2.560286532N/mm2(compressive)

Do = Di + 2 x t = 1500 mm + 2 (17 mm) = 1534 mm = outer diameter of the

column
Bending Stresses,

Iv

,b

Mx
Di

4
4
(
+t)
But
Iv
Iv
2
64 (D0 -Di )

4
4
10
4
64 (1534 -1500 ) = 2.330880913*10 mm

1424636.16
1500
(
+17) = 46.87909745N/mm
2330880913 0
2

Resultant longitudinal stress is given by,

z = L + wb
w is compressive therefore it is negative.
z(upwind) = 26.470588 + (- 2.560286532) + 46.87909745 = + 70.78939892
N/mm2
z(downwind) = 26.470588 + (-2.560286532) 46.87909745
= -22.96879598 N/mm2
70.78939892

22.9

52.9411

52.9411

38

Up wind

down wind

The greatest difference between the principal stress will be on the down wind side
i.e 52.94117647-(-22.96879598)=75.90997245N/mm2
Snice,75.90997245130N/mm2
It is well below from the allowable maximum design stress.
Check elastic stability(Buckling),
17
c=2*104( 1534 )=221.642764N/mm2
The maximum compressive stress occurs when the vessel is not under pressure
b+w=46.87909745+2.560286532
=49.43938398221.642764 since it is less than the critical
stress. Therefore,the design pressure was correct.

4.7.0 Reinforcement 0f Openings

4.7.1 Required Area of Reinforcement
When an opening and its reinforcement are in an ellipsoidal head, and located
entirely within a circle, the centre of which coincides with head. The diameter of
the circle is equal to 80% of the shell diameter. tr is the thickness required for a
seamless sphere of radius K1D, where D is the shell internal diameter and K1 is
0.9 (Steward and Lewis 2013). Assume no weld is used in the nozzle.
Notation:
A= total cross-sectional area of reinforcement required in the plane under
consideration
A1 = area in excess thickness in the vessel wall available for reinforcement
39

A2 = area in excess thickness in the nozzle wall available for reinforcement

A3 = area available for reinforcement when the nozzle extends inside the vessel
wall
S = design stress at design temperature
d = finished diameter of circular opening under consideration
E = joint efficiency factor
F = correction factor that compensates for the variation of in internal pressure
stresses on different planes with respect to the axis of the vessel
t = specified vessel wall thickness
ti = nominal thickness of internal projection of the nozzle wall
tn = nozzle wall thickness
tr = required thickness of seamless shell based on circumferential stress
tr.n. = required thickness of seamless nozzle wall
fr1 = strength reduction factor
( Sn/Sv for nozzle wall inserted through the vessel wall)
fr2 = Sn / SvSn = allowable stress in nozzle
Sv = allowable stress in vessel
P = design pressure
D = diameter of manhole/access port
Di,n = internal diameter of nozzle
K1 = spherical radius factor
c = corrosion allowance
h = height of ellipsoidal head
UTP = pipe under tolerance
Ri,n = Radius of the internal section of the nozzle
4.8 Preliminary Calculations for thickness (tr ,tr.n., t, ti, tn) & distance (h)
40

1) The minimum required thickness under circumferential stress, tr, for seamless
shell or head is determined by:
tr=

PR
PK 1 D
, tr=
SE0.6 P =
SE0.6 P =

Note:tr is the thickness required for a seamless sphere with radiusof K1D
Given
S = 130Nmm-2
E=1
P = 1.2 Nmm-2
D = 600 mm = 0.6 m
K1 = 0.90 as determined from Table UG-37
when D/2h = 2.0,
where;
D = 1500 mm I.D. (shell internal diamet
tr=

PK 1 D
1.20.9600
=
SE0.6 P 11300.61.2

=5.012376mm 5mm

2) Actual thickness of nozzles ,tn=50mm

3) Theoretical thickness of nozzle ,tr,n,
,tr,n, =

PiDn
2 SEPi

,=

1.21500
213011.2

=6.955mm 7mm

4) For the vessel wall thickness, t, it is determined as:

t=

PR
SE0.6 Pi

+c

Given
S = 130 Nmm-2
41

P = 1.2 Nmm-2
R = D/2; D = 1500 mm I.D.
E=1
t=

1.2750
12010.61.2

+2 =8.9616mm 9mm

5) For the nominal thickness of internal projection of nozzle wall, ti, it is

determined as follows:
ti=tn-tc= 50-2*2=46mm
Nominal thickness ;46mm
6) Distance nozzle projects beyond the inner surface of the vessel wall is as
determined:
h=min(2.5t,2.5ti)
Given
t = 8.0 mm
ti = 10.0 mm
h=min(2.5*7),(2.5*46)=min(17.5),(115)
h=17.5mm
7) The diameter of the finished opening, d, is as determined
d=D+C=600+2=602mm
Note: The opening is in a corroded condition. Thus, a corrosion allowance is
added to the diameter of the opening.
The opening is in a corroded condition. Thus, a corrosion allowance is added to
the diameter of the opening.
Calculations of Area Required for Reinforcement
Given
42

d = D = 600 mm
t = 12.0 mm
ti = 10.0 mm
tr = 5.0 mm
tn = 18.26 mm
tr.n.= 8.26 mm
h = 20.0 mm
Assuming correction factor, F = 1 and d=D,
A=(600*5*1)+2(50*5*1)(1-1)=3000mm2
To determine whether additional reinforcement is necessary for the manhole, the
actual area available for reinforcement must be calculated and compare with the
area required for reinforcement. The following condition must be satisfied if no
additional reinforcement is required:
A <Ai
Where
Ai=A1+A2+A3+A41+A43
Thus, the following area (A1, A2, A3, A41, A43) is calculated as follows
. A1 (largest):
A1=d(E1t-Ftr)-2tn(E1t-Ftr)(1-Fr1)
Since

Fr1=

130 N /mm 2
130 N /mm 2 =1

(Since both the nozzle and the vessel are made of the same material)
Then, the term 2tn(E1t-Ftr)(1-fr1) will cancel out,
A1=d(E1t-Ftr)
Assuming E1 = E = 1 and F = 1,
43

A1=602((1*9)-(1*5))=2408mm2
A1=2(t+tn)(E1t-Ftr)=2(9+50)(1*9)-(1*5)
A1=470.584mm2

Since A1>A1,

Then A=A1=2408mm2
A2 (smallest): A2
First of all, assuming fr2 = fr1 = 1 since they both have the same formula (Sn /
Sv); Substituting the values,
A2=5(tn-tr,n)(fr1t)=5(50-7)(1*9)=1935mm2
Substituting the values,
A2=5(tn-tr,n)fr2tn=5(50-7)(1*50)=10750mm2
SinceA2 <A2 , then A2=A2=1935mm2
A3 (smallest):
A3=5t(tifr2)=5*9(46*1)=2070mm2
A3=5ti(tifr2)=5*46(46*1)=10580mm2
A3=2tn(tifr2)=2*17.5(46*1)
A3=1610mm2
Since A3A3A3 Then
A3=A3=1610mm2
For areas A41 and A43, they are not considered since the welds vary from fillet to
butt weld type thus,
A41 = A43 = 0 mm2
Summing up from A1 to A3,Given
A1 = 2408 mm2
A2 = 1935mm2
44

A3 = 1610 mm2
A41 = A43 = 0 mm2
Ai=(2408+1935+1610+0)mm2=5953 mm2
Comparing both the required area for reinforcement, A and the area available for
reinforcement,
A=3000mm2
Ai=5953mm2
Sinice, the condition Ai>A is satisfied.Therefore,no additional reinforcement
will be required.
4.9 Nozzles and Flange
Nozzles and flanges can be categorized into several categories depending on their
sizes, types and other attachments to vessels. Figure 4.9. shows the type of
standard flange selected for this design in respect to the specification.
Table 7: Typical Standard Flanges Nominal Size (mm)
Nominal Pipe
Flange
Raised face
boltin Drilling
Size
(mm)

outer

200
250

diameter
,
(mm)
219.1
273

Bos

d4

d1
320 20
375 22

44
44

258
312

45

3
3

M16
M16

s
d3

28

240

8
1

0
33

295

No

8
12

Figure 4-0-4: Selected Standard Flange

4.10 Skirt and Base
4.10.1. Skirt supports
4.10.1.1 Column supporting skirt and base ring
Height of the vessel, Hv
Given:
Length of cylindrical section = 37 m
Internal column diameter = 1.5 m
Height of each ellipsoidal head

Figure 4-0-5: Standard ellipsoidal head measurements

46

Since the ellipsoidal heads used for this design are of a standard measurement as
shown above in Figure 4.10.1.1, it is safe to assume that the heads are
manufactured with a major and minor axis ratio of 2:1 . Thus,
The height of each ellipsoidal head = (

1.4
4

) = 0.375 m

Height of vessel,Hv
The height of vessel,
Hv: Hv = (Length of cylindrical section) + (Height of the two ellipsoidal heads)
= 37 m + [(2) (0.375 m)]
= 37 m + 0.75 m = 37.75m
Bending Moment, Ms
For this design, a constant thickness was required. Thus the effect of bending
moment, Ms, was study and calculated by using the formula below.
Given the formula:
2

Ms=

Fw (Hv+ Hs)
2

Ms = Bending moment at the base of the skirt

Fw = Load per unit length = 2081.28 N/m =2.08128kN/m
Fw=Pw*Deff But Pw= 0.05(160)2s
Pw = 1280W/m2
Deff= Di+2(tm+tin)=1.5+2(0.013+0.05)=1.626m
Hs= Height of skirt = 2.5 m
Since: Hv+s = (Height of the vessel, Hv) + (Height of skirt, Hs) = 37.75 m + 2.5
m = 40.25 m = 40250 mm

47

2081.28 N /m(40.25 m)
=1685901.84 Nm
Thus, Ms=
2
Bending stress in the skirt,bs
Assume:
Bending stress Thickness of the skirt = Thickness of each ellipsoidal head
Given the formula:
bs

4 MS
( Ds+ts ) ( Dsts)

Where;
bs = Bending stress in the skirt
Ms = Bending moment at the base of the skirt 1685901.84 Nm
Ds = Internal column diameter = 1.5 m
ts = Thickness of the skirt = Thickness of each ellipsoidal head =8.9295mm
=0.0089295 m
41685901.84
2
Thus,bs= (1.5+ 0.0089295)1.50.0089295 =106207467.5N/ m
Step 4: Determine the dead weight stress for the test and operating conditions.
For test condition,ws(test):
Formula given by,

ws (test )=

Wwater
( Ds+ts ) ts

Where,
ws(test)=Dead weight stress in the skirt for test condition
Wwater= dead weight of the vessel with contents (water) is approximate weight

48

D Hvwg
1.5 3710009.81
Wwater=
=
=641420.9356N=64
4
4
1.4209356KN
Thus,

ws(test )=

Wwater
( Ds+ ts ) ts

641420.9356 N
=
ws(test)= (150+ 8.9295)8.9295
15.15294921N/mm2
For operating condition, ws(operating):
The formula given by,

ws (operating)=

Wvessel
( Ds+ ts ) ts

Where,ws(operating)=Dead weight stress in the skirt for operating condition

Wvessel= dead weight of vessel with heads.
Thus,

207.4306587 KN
=0.004900348663 K
ws(operating)= (1500+ 8.9295)8.9295

N/mm2
=4.90034663N/mm2
Determine the resultant bending stress in the skirt.
For maximum:s(compresive)= bs + w(test)
2
s(compresive)=106.2074675N/ mm +15.15294921N/mm2

=121.3604167 N/mm2
For minimum:ws(tensil)=bs+w(opersting)
2
ws(tensil)=106.2074675N/ mm + 4.90034663N/mm2= 111.1078141N/mm2

Design criteria:

49

If given the worst combination of both wind and dead-weight loading, the skirt
thickness should not exceed that of its design criteria, as shown belowFrom the
specification table,
=90
fs= 115 N/mm2=200,000 N/mm
E = Youngs modulus
For the maximum:
Given the formula, ws(compresive) 0.125E(ts/Ds)sins
121.36014167 N/mm20.125200,000(

8.9295
sin 90
1500 )

121.36014167 N/mm2s148.825(Fulfilled)
For minimum:
Given the formula, s(tensil)fsJsins
111.10781411151sin90
2

111.1078141N/ mm

115 (Fulfilled)

Since all the calculations and comparison above shows that the all design criteria
were fulfilled,add 2 mm for corrosion, gives a design thickness of new skirt
thickness, ts:New skirt thickness, ts:
ts= (Old thickness of the skirt) + (Corrosion allowance)
=8.9295mm + 2mm= 10.9295mm11mm
4.11 Base ring/flange and anchor bolt design
For DS = 1.5 m
Step 1 .Determine the number of bolts required, N bolts
Since the measurements for the pitch diameter were not given, it was
assumed that the measurement of column diameter would be used to make
an assumption for the pitch diameter. An estimation of 10% allowance was
then added to the pitch circle diameter column.Number of bolts required N
bolts given by the formula:
50

Dp
N bolts= 600
Where;
Ds = Internal column diameter = 1.5 m
Dp = Pitch circle diameter
= Ds + (10% Ds)
= 1.5 + 0.1 x 1.5
= 1.65 m
= 1,650 mm
Thus, Nbolts=

1650
=8.639379797
600

By taking the nearest multiple of 4, 12 iks the nearest value to the number of bolts
required, Nbolts.
Step 2: Determine the required bolt area, Ab
The required bolt area, A given by the formula:
1
4 Ms
Ab= Nboltfb ( Dp -Wv)
Where, N bolt=Number of bolts required = 12 Bolts.
fb = Bolt design stress = 125 N/mm2
Ms =Bending moment in skirt
Wvessel= dead weight of vessel with heads
Dp = Pitch circle diameter = 1.6 5m = 1,650 mm
1
4 Ms
Ab= Nboltfb ( Dp

- Wvessel)

1
41685901.84
-207430.6587) =
12125 (
1.650
51

=2586.402737 mm

Step 3: Determine the bolt root diameter, D bolt.

The bolt root diameter given by the formula:
D bolt =

4 Ab
=

42586.402737
=57.38562749mm

With the addition of base rings, the bolt should be sufficient enough to distribute
the total compressive load to the foundation.
Step 4: Determine the total compressive load on each base ring per unit length,
Fbolt.Given the formula: Fbolt=

4 Ms
2
Ds

Wv
DS

Where,

Wvessel=dead weight of vessel with heads

Ms=Bending moment in skirt = 1685901.84Nm
Ds=Internal column diameter = 1.5m
41685901.840
2
Fbolt=
1.5

207430.66
=998.0434382N/mm
1.5

Step 5: Determine minimum width of base ring, Lb.

Given by the formula:
Lb

Fb
fc

F bolt=Total compressive load on the base ring per unit length = 1,196.40N/m
fc=Maximum allowable bearing pressure on the concrete foundation pad bearing
2
pressure 5 N/ mm .

Lb=

998.0434382
=199.608687mm
5

Due to the large base ring width, a flared skirt shall be used as an alternative to
the design. Therefore, the requirements and assumptions for the new skirt are:
52

Flared skirt bottom diameter, Ds = 2.5 m = 2500 mm

Bolt circle diameter, Dolt= Ds+ (10% of Ds)
= 2.5 m + (1.5 0.1 = 2.5 m + 0.15 m
= 2.65 m (Assumed)
= 2,650 mm
Number of bolt,

Dp

Nbolt
= 600

= but , D'p=D's+(10% D s)

D'p=2.5+(10%2.5) = 2.75 m
= 2,750mm

Nbolt

2750
=14.39896633mm15mm
600

For Ds = 2.5m
Step 1: Determine the skirt base angle, s.
Skirt base angle, s (With Ds =2.5 m) given by,
sDs
D

Ds
s= 0.5()

1
tan
2.5
0.5(2.51.5)
s=
= 78.7

tan1
Step 2: Determine bolt spacing.
Bolt spacing given the formula:

53


Dbolt
Bolt specing =

Nbolt
Where, Dbolt'=Bolt circle diameter = 2650 mm
Nbolt'=Number of bolts =14.39896633l15mm
2650
Bolt specing=
=555.0147mm (satisfactory)
15
Step 3: Determine new required bolt area, Ab
Given by the formula:
1
4 Ms
Wvessel

Ab= Nboltfb
( Dbolt
)
Wvessel=dead weight of vessel with heads = 207430.66 N
Ms=Bending moment in skirt
Nbolt'=Number of bolts required = 15mm
Dbolt'=Bolt circle diameter = 2.650m = 2,650 mm
fb=Bolt design stress = 125 N/mm2
1
41685901.84 Nm
(
( 207430.66 N ) )
Ab= 15125
= 1246.574312mm2
2650
Step 4: Determine the total compressive load on each base ring per unit length,
Fbolt.
Given the formula:
4 Ms
Fbolt= Ds
2

Wv

+ Ds

Where,
W vessel= dead weight of vessel with heads = 207430.66 N
Ms= Bending moment in skirt = 1685901.84Nm
54

D's=Flared skirt bottom diameter=2.5m =2500mm

Fbolt
=

4168590.1840
+
2.52

207430.660
2.500 =369.8599945 N/mm

Step 5: Determine minimum width of base ring, Lb

Given the formula:

Fbolt
Lb= fc103
fc=Maximum allowable bearing pressure on the concrete foundation pad Bearing
pressure = 5 N/mm2
369.8599945
Lb=
= 73.9719989mm
5
Step 6: Determine the actual bearing pressure on the concrete foundation,
Given the formula:
f'c=Fbolt'/(Actual width)
Actual width =Lr + ts + ti Where,
ts = Skirt thickness = 11mm
ti = Insulation thickness = 50mm

Fbolt
= Total compressive load on the base ring per unit length
Lr =Distance from the edge of the skirt to the outer edge of the ring = 178 mm
Actual width = 178 + 11+50 = 239mm

Fbolt
369.8599945

=1.547531358 N/mm2
fc
= ActualWidth =
239
Step 7: Determine the base ring thickness, tb
The base ring thickness given by the formula:

55

tb = Lr

3fc
Fr

tb=178

31.547531358
=32.41427713 mm
140

tb= 32.41427713 mm

Table 8.Summarization of all final parameter results:

Parameters
Minimum
thickness

column

Quantity

wall

9mm

Average thickness of the

wall

13Mm

Thickness of tori spherical

head

12.169918mm

Thickness of ellipsoidal
head

6.9295mm

height of vessel head

375mm

Dead weight of vessel

207.430687kN
56

Mean diameter of vessel

1.513m

Weight of plate

150.2073KN

Dead weight of insulation

22.23592675KN

Weight of water

641.4209356KN

Total weight of cylindrical

section

379.8739842KN

Effective
vessel

1.626m

diameter

of

Loading per meter

2081.28N/m

Bending moment

1424636.16Nm

Longitudinal stress

26.470588N/mm2

Circumferental stress

52.94117647N/mm2

Stress due to dead weight

2.560286532N/mm2

Bending stress

46.87909745N/mm2

Up wind stress

70.78939892N/mm2

Downwind stress

-22.968795N/mm2

Maximum

49.43938398N/mm2

compressive
57

stress
221.642764N/mm2

Critical stress
Thickness required
seamless spare

for

5mm

Area
required
reinforcement

for

3000mm2

Area one

2408mm2

Area two

1935 mm2

Area three

1610 mm2

summation area

5953 mm2

skirt bending moment

1685901.84Nm

bending stress in the skirt

support

106207467.5N/m2

Dead weight stress skirt

test

15.15294921N/mm2

Dead weight stress skirt

operating

4.90034N/mm2

Compressive skirt stress

121.3604167 N/mm2

Tensile skirt stress

111.1078141N/mmm2

58

Number of bolts

12

Required bolt area

2586.402737 mm2

Bolt root diameter

57.38562749mm

Total compressive load

998.0434382N/mm

Minimum width of base

ring

199.608687mm

Skirt base ring angle

78.70

Bolt spacing

555.0147mm

New required bolt area

1246.574312 m2

Total compressive load

369.8599945 N/mm2

Minimum width of base

ring

73.9719989mm

Actual bearing pressure

1.54753 N/mm2

Base ring thickness

32.4087mm

59

60

Discussation
The overall pressure vessel schematic design is depend on the following given
dimensions:
Height of cylindrical section with 37m
Internal diameter with 1500mm
Heads with standard ellipsoidal
Feed at mid point with 200mm in side diameter
Vapour out at 0.7m below top of cylindrical section with 250mm in
side diameter
Bottom product at the center of the vessel head with 200mm inside
diameter reflux return
Bottom product at 1m below t op of cylindrical section with 200mm
inside diameter
Diameter of access ports (manholes) with 0.6m at 1m above the
bottom and at 1.5m below the top of column
Height of support skirt with 2.5m of carbon steel, silicon killed
5 Conclusions and recommendations
Conclusions
The design of a pressure vessel is more of a selection procedure, selection of its
components to be more precise rather designing each and every component.
Regarding storage of fluid for a pressure vessel system should be preferred due to
its simplicity, better sensitivity, higher reliability, low maintenance, compactness
for the same capacity. The storage of fluid at high pressure in the pressure vessel
is at the heart of its performance and is the first step towards the Design.

61

Recommendation
The designing of this pressure vessel it takes very long procedure to calculate the
values and consumes more time with day and night. And the pressure vessel is
very long in height and it is placed vertically .

References:

Conrexsteel.
DISHED
HEAD
CALCULATOR.
2012.
http://www.conrexsteel.com/calculator.php (accessed
30 October,
2015).
Density of Stainless Steel.2015. The Engineering ToolBox. 2 November
http://www.engineeringtoolbox.com/metal-alloys-densities-d_50.html
62

Sinnott, R.K. 2008. Coulson & Richardsons Chemical Engineering

Volume 6: Chemical Engineering Design, 3rd ed. Burlington, MA:
Butterworth-Heinemann Publications.

Ellipsoidal Head Dimensional Characteristics. 2013. Inspection 4

Industry LCC: Pressure Vessel Heads.(Accessed November 1)
http://www.inspection-for-industry.com/pressure-vessel-heads.html
MyChemE.
Types
of
Vessel
Head.
4
March,
2013.
http://www.mycheme.com/types-of-vessel-head/ (accessed 29 October,
2015). veristar. Dished heads subject to pressure on the concave (internal)
side. 2004. http://www1.veristar.com/veristar/bvrules/C_1_s3_3_4.htm
(accessed 29 October, 2015).

V.V.Wad kar.s.s.malgave.D.D.patil.H.S.Bhore.p.p.Gavade
analysis of pressure vessel

63

design

and

Vessel data sheet

Eq No. PV-1

Func. Pressure vessel

Customer

Sheet No. 1

ADIGRAT UNIVERSITY
Shell
Thickne
ss
DP

9mm

Torisphrical
12.314mm

1200N/mm2

1200kN/m2

DT

1500C

1500

Heads
Ellipsoidal
7mm

64

Supports

Flanges

15mm

26mm

1200kN/m2

1200kN/m2

10bar

1500

1500

1500

DS

130N/mm2

DC

1.0 (Fully
radiographed)

MC

Stainless

Diamet
er
Length

1500mm

1.0 (Fully
radiographed)

2mm

125N/mm
-

1.0 (Fully
radiographed)

Stainless

Carbon

steel,unstabilised(304)

steel,silicon

1500mm

1.0 (Fully
radiographed)

killed

37000mm

Nozzle
CA

steel,

unstabilised(304)

Water

130N/mm2

Joint
Factor

PM

130N/mm2

Stainless
steel

Water

1500mm

1500mm

395mm

750mm

2500mm

75mm

Design by: Network - 7

ID No. (0075, 0155, 0252, 4203,4194, 0521,
0574, 0927, 1409)/06
Section Two
Date: December 12, 2016
Checked by:

Appendices
Appendix A: Maximum Allowable Joint Efficiency

65

Figure A. 1: Maximum Allowable Joint Efficiency (Sinnott 2008

Appendix B: Typical Design Stresses for Plates

Figure B. 1: Typical Design Stresses for Plate (Sinnott 2008)

Appendix C: Typical Standard Flange Design

Table C: Typical Standard Flanges
66

Nominal

Pipe

Size

outer

(mm)

diamet
er,

200

Flange
D

h1

Raised

bolti

face
d4
F

ng
N

d2

Neck
k

d3

h2

240

16 1

d1

(mm)
219.1

Drilling

340

24

62

268

M20

22 295

250

273

395

26

68

300

M20

12 22 350

295

0
16 1

300

329.9

445

26

68

370

M20

12 22 400

344

2
16 1

350

355.6

505

26

68

430

M20

16 22 460

385

2
16 1

440

2
16 1

400

406.4

565

26

72

482

M24

16 25 515

450

457.2

615

28

72

532

M24

20 26 565

492

2
16 1

500

508

670

28

75

585

M24

20 26 620

542

2
16 1

600

600.6

780

28

80

685

M27

20 30 725

642

2
18 1

745

2
18 1

700

711.2

895

30

80

800

M27

24 30 840

800

812.8

1015

32

90

905

M30

24 33 950

850

2
18 1

900

914.4

1115

34

95

100

M30

28 33 105

950

2
20 1

1000

1016

1230

34

95

5
111

M33

0
28 36 116

105

2
20 1

38

11

0
133

M36

0
32 39 138

2
125

6
25 1

0
153

M39

0
36 42 150

5
146

6
25 1

1200

1020

1455

1400

1420

1675

42

5
12

1600

1620

1915

46

0
13

5
176

M45

0
40 48 185

0
166

6
25 1

1800

1820

2115

50

0
14

0
196

M45

2
44 48 202

5
186

6
30 1

67

2000

2020

2325

54

0
15

0
217

M45

0
48 48 223
0

5
207

6
30 1

Appendix D: Typical values for the density of insulating

materials
Density (kg/m3)

Insulating material
Foam glass
Mineral wool
Fiberglass
Calcium silicate
Table D.1: Typical values for the density
2005)

150
130
100
200
of insulating materials (R.K. Sinnott

Appendix E: Dimension with Different Bolt Size

Figure E.1 Anchor bolt chair design. (Coulson & Richardsons chemical engineering volume 6

68