BBBTTT 2

UNIVERSITY OF GONDAR
Institute of technology
Department of mechanical engineering
Machine design project
Submitted by:
1. Temesgen Eshetie 00609/10
2. Birtukan Anley 00347/10
Submitted to: Mr. Ayele
Submission date: 25 - march - 22
Gondar, Ethiopia
Design of vertical pressure vessel
ACKNOWLEDGMENT
Before all we would like to thank the Almighty God for Every opportunity that we got in life
through his endless mercy. Next we would like to express our great appreciation to all those
who provided us the possibility to complete this project. We would like to express the special
gratitude and sincere appreciation to Mr. Ayele (MSc.) for his guidance, follow-up, and
advice throughout the project period and helped us to coordinate our project. The last but not
the least we would like to express our sincere appreciation for all individual who invested
their time, energy and resources to help us to collect samples and other necessary guide
material for project.
ii
ABSTRACT
This project or term paper is given as a partial fulfillment of the course Machine Design
Project I. It is concerned with the design procedures that should be followed while designing
a vertical pressure vessel. This report covers the overall design procedures, limiting
conditions, and Considerations made while designing a pressure vessel. Many ASTM
standard tables are used a reference to select a standard element for the pressure vessel. It
also covers different internationally accepted types and selection criteria for flange
connections, support mechanisms, and sealing materials. At the end of this term paper or
report, the student is supposed to have the basic know-how on how to design a pressure
vessel and/or a similar mechanical component, and be familiar with the different codes and
standards that should be followed while designing. With the objective of designing a vertical
pressure vessels position with an ellipsoidal head by estimating the internal pressure and
temperature on its effect and having a material of low alloy steel and use medium of water
under the temperature of 1200c and pressure 3MPa and the method I am going to use is as
follows.
First by Selecting materials of shell, Find the thickness of shell and head on the basis of
compressions, steam property, find stress analysis of shell, Find the force on the shell and
then following design procedure of shell, heads, nozzles, skirt support with these the results
are as follows
iii
Table of contents
Contents
page
ACKNOWLEDGMENT.........................................................................................................ii
ABSTRACT..............................................................................................................................iii
Table of contents.......................................................................................................................iv
LIST OF SYMBOLS AND ABBREVIATIONS.....................................................................vi
LIST OF FIGURES................................................................................................................viii
LIST OF TABLES.....................................................................................................................9
CHAPTER ONE......................................................................................................................10
1.INTRODUCTION.............................................................................................................10
1.1. Historical Background of Pressure Vessel....................................................................13
1.1.1 History of ASME Boiler & Pressure Vessel Code..................................................14
1.1.2. Setting the Standard...........................................................................................15
1.2. Statement of The Problem............................................................................................15
1.3. Objective of The Design............................................................................................17
1.3.1. General Objective...............................................................................................17
1.3.2. Specific Objective..............................................................................................17
1.4. Scope of study...........................................................................................................17
1.5. Significant of the study..............................................................................................18
1.6. Limitation of the study..............................................................................................18
CHAPTER TWO.....................................................................................................................18
LITRATURE REVIEW...........................................................................................................18
2.1. Previous work related to pressure vessel design...........................................................18
2.2. Gaps between the models..............................................................................................21
2.3. Conceptual design with previous model.......................................................................25
2.3.1. Concept screening..................................................................................................25
2.3.2. Concept scoring......................................................................................................25
2.3.3. Reason to select the model.....................................................................................25
CHAPTER THREE..................................................................................................................26
METHODOLOGY...................................................................................................................26
3.1. Steps design process used in the design........................................................................26
iv
3.1.2. Definition of the problem...........................................................................................27

3.1.3. Analysis and optimization..........................................................................................27
3.2. Selection of material.....................................................................................................27
3.3. Design Specifications....................................................................................................29
3.4. Design procedure..........................................................................................................29
3.4.1. Using Method of (ASME Section II & VIII, Div1) Calculation............................30
3.5. Detail Design and Analysis...........................................................................................37
3.5.1. Design pressure......................................................................................................37
3.5.2 Design temperature.................................................................................................38
3.5.3. Design stress...........................................................................................................38
3.5.4. Welded joint efficiency, and construction categories............................................39
3.5.5. Corrosion allowance...............................................................................................39
3.6. Design of Component of vertical pressure vessel.........................................................40
3.6.1. Shell design............................................................................................................40
3.6.2. Head design............................................................................................................43
3.6.3. Nozzle design.........................................................................................................45
3.6.4. Design of manhole.................................................................................................54
3.6.5.Support design.........................................................................................................56
3.6.7. Selection of welded joint........................................................................................70
3.6.8. Flange design.........................................................................................................81
3.7. Developing prototype of the model...............................................................................83
3.8. General assembly design...............................................................................................83
3.9. Simulation analysis by solid work................................................................................83
CHAPTER FOUR....................................................................................................................84
RESULT AND DISCUSSION................................................................................................84
4.1. Result.............................................................................................................................84
4.2. Discussion.....................................................................................................................86
CHAPTER FIVE......................................................................................................................87
CONCLUSION AND RECOMMENDATION.......................................................................87
5.1. Conclusion....................................................................................................................87
5.2. Recommendation...........................................................................................................88
6. Reference..........................................................................................................................88
v
LIST OF SYMBOLS AND ABBREVIATIONS

Symbols
δ l = Longitudinal stress
δ t = Tangential stress
δ r = Radial stress
 = Circumferential stress
σ h = Hoop stress
Pi= Operating(internal) pressure
P D = Design pressure
SF = Straight factor
σ ws = Dead weight stress
CA = Corrosion allowance
δ bs= Bending stress
E = Joint efficiency
ts = Thickness of shell
tn = Thickness of nozzle
th = Thickness of head
VH = Volume of Hemisphere
Vs = Volume of shell
Vc = Volume of cone
Ms. = Maximum bending moments
Di = Internal diameter
Do = Outer diameter
Dm = Mean diameter
Ls = Length of shell
h = Height of cone
Sall = Allowable design stress
ST =Tensile stress
Ho = Outer head
vi
Hi = Inner head
di = Inner diameter of nozzle
do = Outer diameter of nozzle
Ws = Weight of shell
Wsf = Weight of shell fluid
Wh = Weight of head
Whf = Weight of head fluid
Wn = Weight of nozzle
Wnf = Weight of nozzle fluid
Wwn = Weight of wind
Mx = Momentum on the vessel due to weight
Wd = Design weight
δ d = Design stress
Fi = Force on a single bolt
dc = Minor (core) diameter of nut
dp = Effective (pitch) diameter of nut
d = Nominal (major) diameter of nut
Abbreviations
ASME - American Society of Mechanical Engineers
API - American Petroleum Institute
BPVC -Boiler and Pressure Vessel Code
LPG - Liquefied Petroleum Gas
CAD – Computer Aided Design
vii
LIST OF FIGURES
figure3. 1: Main parameters of nozzle.....................................................................................34
figure3. 2: Reinforced nozzle...................................................................................................46
figure3. 3: Nozzle Shell junction area (A) and main parameters for reinforcement (B).........46
viii
LIST OF TABLES
9
CHAPTER ONE
1.INTRODUCTION
Chemical engineering involves the application of sciences to the process industries, which
are primarily concerned, with the conversion of one material into another by a chemical or
physical means. These processes require the handling or storing of large quantities of materials
in containers of varied constructions, depending upon the existing state of the material, it's
physical and chemical properties and the required operations, which are to be performed. For
handling such liquids and gases, a container or vessel is used. It is called a pressure vessel, when
they are containers for fluids subjected to pressure. They are leak proof containers. They may be
of any shape ranging from types of processing equipment. Most process equipment units may be
considered as vessels with various modifications necessary to enable the units to perform certain
required functions, e.g. an autoclave may be considered as high-pressure vessel equipped with
agitation and heating sources.
A pressure vessel is leak proof container and their main purpose is to contain a given medium
under pressure and temperature with a pressure differential between inside and outside, or it is a
closed container designed to hold gases or liquids at a pressure substantially different from the
ambient (surrounding environment) pressure.
Finally, pressure vessel refers to those reservoirs and apparatus which work under internal
and external pressure and operate under the pressure The inside pressure is usually higher than the
outside, except for some isolated situations. The fluid inside the vessel may undergo a change in
state as in the case of steam boilers, or may combine with other reagents as in the case of a
chemical reactor. Pressure vessels often have a combination of high pressures together with high
temperatures, and in some cases flammable fluids or highly radioactive materials. Because of
such hazards it is imperative that the design be such that no leakage can occur. In addition, these
vessels have to be designed carefully to cope with the operating temperature and pressure. It
should be borne in mind that the rupture of a pressure vessel has a potential to cause extensive
physical injury and property damage.
They have a variety of applications in industry, including in oil refineries, nuclear reactors,
gas reservoirs, etc. An aircraft fuselage, a gas cylinder and a soda can, all are pressure vessels
which must be designed to meet very specific requirements of integrity. The human arteries
maintain pressure in the circulatory system much like a balloon maintains pressure on the air
within it. The arteries therefore act as pressure vessels by maintaining pressure. Pressure vessels
can be any shape, but shapes made of sections of spheres and cylinders are usually employed.
10
In the industrial sector, pressure vessels are designed to operate safely at a specific pressure and
temperature technically referred to as the "Design Pressure" and "Design Temperature"
vessel that is inadequately designed to handle a high pressure constitutes a very significant safety
hazard [1].
Pressure vessels are used in a number of industries; for example:

 The power generation industry for fossil and nuclear power;
 Pharmaceutical industry and for others;
 Food and beverage industry;
 The chemical industry; chemical reactors
 The petrochemical industry for storing, processing crude petroleum oil in tank
farms, storing gasoline in service stations
The gas or fluid that being stored may be through change of state inside the pressure
vessel, for example in case of steam boilers or it might combine with other reagents, such as a
chemical plant.
The pressure vessels must design with a perfect care because crack of pressure vessels
will cause an explosion which may cause of death and loss of property. The material that be used
to construct pressure vessels may be ductile such as mild steel or brittle such that cast iron.
a) Spherical pressure vessel b) Vertical pressure vessel
11
c) Horizontal pressure vessel
Figure 1.1:Typical Pressure vessels
Because they work under immense pressures, a ruptured pressure vessel can be incredibly
dangerous, leading to poison gas leaks, fires, and even explosions. For this reason, pressure
vessel safety is imperative. There are several standards and practices that cover the construction,
maintenance, and inspection of pressure vessels. Chief among these standards are ASME Section
VIII and API 510.
ASME Section VIII is the section of the ASME Boiler & Pressure Vessel Code (BPVC)
that covers pressure vessels. It gives detailed requirements for the design, fabrication, testing,
inspection, and certification of both fired and unfired pressure vessels.
API 510, "Pressure Vessel Inspection Code”: In-Service Inspection, Rating, Repair, and
covers the in-service inspection, repair, alteration, and rerating activities for pressure vessels and
the pressure relieving devices protecting these vessels.
When it comes to inspections, most pressure vessels should be examined once before
being placed into service and again every 5 years after every alteration or major repair. An
inspection can be internal, external, or both and should involve a thorough examination, a
thickness evaluation, a stress analysis, an inspection of the vessel’s pressure release valves, and a
hydrostatic pressure test. It is also important to perform a surface inspection, examine the
insulation and any structural connections, and finally inspect any welds or joints. [1]
12
1.1. Historical Background of Pressure Vessel
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 the 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 began enacting 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 spirally-
wound 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
13
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
recognize the inherent potential hazards of pressure vessels and the need for standards and codes
regulating their design and construction.
1.1.1 History of ASME Boiler & Pressure Vessel Code

ASME was founded in 1880 to provide a setting for engineers to discuss the concerns brought by
the rise of industrialization and mechanization.
The Society’s founders were some of the more prominent machine builders and technical
innovators of the late nineteenth century; led by prominent steel engineer Alexander Lyman
Holley, Henry Rossiter Worthington and John Edison Sweet.
Holley chaired the first meeting, which was held in the New York editorial offices of the
American Machinist, on February 16th, with thirty people in attendance. From this date onward,
the society ran formal meetings to discuss development of standard tools and machine parts as
well as uniform work practices. However, it wasn’t until 1905 that a major turning point gave
new definition to ASME’s purpose and impact on civilian life.
Steam powered the technology of the late 19th century. Despite their power, boilers and
pressure vessels were temperamental, requiring constant attention and maintenance. Although
there were numerous boiler explosions throughout the 19th century, there were no legal codes for
boilers in any state in the Union. Undoubtedly one of the most important incidents that proved
the need for developing boiler laws was the Grover Shoe Factory Disaster in Brockton,
Massachusetts on March 10, 1905.
An older boiler, used as a backup during maintenance on the newer model, exploded,
rocketing through three floors and the building’s roof. Broken beams and heavy machinery
trapped many workers who survived the initial explosion and collapse. Burning coals thrown
from the boiler landed throughout the crumbling superstructure, starting fires that were fed by
broken gas lines. The explosion resulted in 58 deaths and 117 injuries.
14
It was this catastrophe that gave Massachusetts the impetus to establish a five-man Board
of Boiler Rules, whose charge was to write a boiler law for the state; this board published its
boiler laws in 1908.
Having established the Boiler Testing Code in 1884, ASME formed a Boiler Code
Committee in 1911 that led to the Boiler & Pressure Vessel Code (BPVC) being published in
1915. The BPVC was later incorporated into laws in most US states and territories and Canadian
provinces.
ASME’s rich publication history—including standards, theory, and technical journals—

made a great deal of technical and biographical information available to engineers and policy
makers. These publications form a substantial and tangible connection to the past that proves
inspirational to ASME members to this day.
1.1.2. Setting the Standard

ASME is best known for improving the safety of equipment used in manufacturing and
construction, particularly boilers and pressure vessels. One founding interest was ensuring
reliability and predictability in machine design and mechanical production. Boilers and pressure
vessels were an innovation that advanced long-range transportation and heavy lifting in ways
that had never been possible before. However, the machinery was temperamental, and frequent
corner cutting and delayed servicing had disastrous consequences.
ASME published the Boiler & Pressure Vessel Code (BPVC) in 1915, which was later
incorporated into laws in most North American territories. In the years following the publication
of the first BPVC, ASME continued the proliferation of safety in industry, developing
engineering standards in numerous technical areas including pipeline production, elevators and
escalators, materials handling, gas turbines, and nuclear power. Today, ASME has more than 600
codes and standards available in print and online. [2]
1.2. Statement of The Problem
The failure of pressure vessel is very devastating &serious thing since it leads to several
economic losses, environmental pollution, and danger of life. If its failure leads to these effect
the cause of the failure is our focus to minimize it as much as possible.
15
The main intention behind this project is to determine stress level on the shell wall & two
different types of heads on a single pressure vessel. If the stress values are large enough & cross
the limitation of allowable stress values of material of vessel, we then check for the appropriate
thickness of shell wall at which the probability of failure of pressure vessel shell wall due to
stress are less.
Regardless of the nature of application of the vessels, a number of factors usually must be
considered in designing of the pressure vessel component. The most important consideration
often taken in the selection of the type of pressure vessels are:
 The operating pressure and temperature;
 Functions of the pressure vessel;
 Location of the pressure vessel;
 Nature of the working fluid that used in the pressure vessel which performs the
required services in the most satisfactory manner.
The pressure vessels that not follow any standard codes can be very dangerous. In fact, many
fatal accidents have occurred in the history of their operation and development.
The main causes of failure of a pressure vessel are as follows:
 Faulty Design
 Operator error or poor maintenance
 Operation above max allowable working pressures
 Over temperature
 Improper installation placement error
 Corrosion
 Cracking
 Welding problems
 Improper selection of materials or defects
In developing the design, a number of other criteria must be considered such as the properties
of material used, the induced stresses, the elastic stability, and the aesthetic appearance of the
unit. The cost of fabricated vessel is also important in relation to its service and useful life.
Designing of a perfect pressure vessel is almost impossible due to the large number of
influences listed above which can change the behavior of the pressure vessel. Although, it is
possible to decrease this influencing factors to a minimum, if the pressure vessel is used on a
proper way. In this project we will try to describe some problems, which influence the working
16
appearance of the pressure vessel. In order to reduce the above problems as much as possible it is
important to design the pressure vessel with in the given data accordingly.
1.3. Objective of The Design

1.3.1. General Objective
The main objective of our project is to design vertical pressure vessel position with conical
and hemispherical heads by the given design temperature and pressure on its effect medium of
working fluid of steam at the design temperature of 300◦C, design pressure of 3.5Mpa, corrosion
allowance of 1.4mm and with vertical vessel orientation and finally to conduct validation test for
the developed model.
1.3.2. Specific Objective

In this project the design will include the vertical position pressure vessel by, ellipsoidal
bottom head and tori spherical upper head, shell and nozzle and it has its own procedures to
design each component and to design the hole assembled of pressure vessels.
And our specific objective is to meet and,
 To know the standard of Thickness of column wall

 To understand the position of opening in a head or a shell
 To decrease the cost preferred material in our design
 To estimate the type of head, shell, support, opening and nozzles to compute stress
analysis and geometry analysis for each part
 Designing of each component and parts of pressure vessel
 To prepare each components of the pressure vessels and the assembly drawing
1.4. Scope of study

The scope of this project covers aspects like the introduction of pressure vessel, its
application, and classification. Moreover, the scope of the project is concerned with components
of pressure vessel. Taking time and resources taking in to account the scope of the project
includes material selections for each parts of the vessel component based on ASME Code, in
accordance with the given specifications. Finally, it covers the detail design of vertical pressure
vessel subjected to wind loading in addition to internal pressure and dead loads (weight of the
17
vessel which is full of steam). Detail design and numerical analysis up to 3D modeling of the
vertical pressure vessel with a medium of steam using AutoCAD software are included.
1.5. Significant of the study

As we have discussed in the above statement, this design significantly used to design a
vertical pressure vessel to store steam and keep its safety some of the rest significant are
 To store steam and keep it from evaporation
 To avoid man contact
 To made easy for transportation system
1.6. Limitation of the study
The uses of pressure vessel have become significant in many applications, so vast considerations
must be made while designing them. It has become mandatory to design each type of vessels
according to their standards properly so that we can ensure the safety of the equipment, the
environment and the personnel operating near or in the equipment.
But due to the following limitations we have been able to design Vertical type
pressure vessel and among the Limitations we faced during the study some are listed below:-
 shortage of time due to the load of other parallel courses
 Limitation of internet access
 shortage of available information and data about pressure vessel
CHAPTER TWO
LITRATURE REVIEW
2.1. Previous work related to pressure vessel design
18
1) Yogesh Borse and Avadesh K. Sharma [6]

Present the finite element modelling and analysis of pressure vessels with different end
connections i.e. Hemispherical, Ellipsoidal & Tori spherical. They describe its basic structure,
stress characteristics and the engineering finite element modelling for analysing, testing and
validation of pressure vessels under high stress zones. Their results with the used loads and
boundary conditions which remain same for all the analysis with different end connections
shows that the end connection with hemispherical shape results in the least stresses when
compared to other models not only at weld zone but also at the far end of the end-connection.
2) V.N. Skopinsky, A.B. SMETANKIN [7]

Presented work on modelling and stress analysis of nozzle connection in Hemispherical head
of pressure vessel under external loading, in this paper he used Timoshenko shell theory and the
finite element method, the effect of stress concentration in external loading has more effect than
in the internal pressure, there is an appreciable increase of the maximum stress for shell in the
interaction region even at the small level of nominal stress, non-radial and offset connection have
non-uniform distribution of stress on the interaction curve between the nozzle and the head, the
influence of angular parameter α for non-radial nozzle connection is shown in this paper, a
decrease of maximum effective stress as an angle α increase is more significant for non-central
connection, and in case of torsional moment loading, the angle affects the stress in opposite
manner, the stress in the shell increase as alpha angle increase.
3) M J Mungla [9]
Had conducted design and analysis of various components of pressure vessels like shell,
heads, flanges, and nozzle and support structures along using ASME code. Design of base ring
and skirt sections has not been covered under ASME code and their dimensions are calculated
19
with general design principles. Stress analysis of these components has been carried out with
combined load cases.
4) Modi A J, Jadav C.S [10]

Concluded that the radial stresses in case of hemispherical head pressure vessel is low
compared to other types of head, in this paper author study the comparative structural behaviour
of different types of geometry of pressure vessel, the head is under internal uniform pressure, the
analytical and finite element method used for finding stresses in pressure vessel, the aim is
finding best head for specific parameter with finite element analysis of thin cylindrical pressure
vessel, here three types of geometry consider like hemisphere, flat and ellipsoidal and
computation result compared with finite element analysis.
5) Mayank Nirbhay, OrashantTripathi & Vivek Kumar Gupta [12]
Present the design of a pressure vessel is carried out using ASME Codes. In this paper
designed the various components of the pressure vessel by calculating the necessary design
factors like thickness of the shell, head, stress analysis etc. To validate the design, result the
pressure vessel is modelled and analysed in ABAQUS. This proposed method is to conduct the
analysis is finite element method. Further the study in the variation of effective parameters in
design of pressure vessel is done. To study the variation different graphs are plotted. internal
pressure and diameter of shell. The applicability of various types of heads is also evaluated.
6) M. Jayakumar [15]
Researched on “Influence of residual stresses on failure pressure of cylindrical pressure
vessel”. Here main criteria is to study the effect of residual stresses on the pressure vessel.
Conclusion shows that there is a reduction in failure pressure due to UN favorable residual
stresses.
From the literature review we have seen that study of the different factors that affects the
design and overall life of pressure vessel and they have to be considered in different cases of
pressure vessel. Finite element analysis is an extremely powerful tool for the analysis of pressure
20
vessel. A structural analysis of the pressure vessel will be implemented. From above literature
review - Inclination angle, circular cross section with hemispherical ends and conical ends,
fatigue analysis, stress distribution, fracture analysis, optimization of location and size of
opening in a pressure vessel cylinder are the main criteria among all that have to be considered
on the design and analysis of pressure vessel to avoid any failure of pressure vessel.
2.2. Gaps between the models
Model 1
This paper deals with the Finite element modeling and Analysis of Pressure vessels with
different end connections (i.e. Hemispherical, Ellipsoidal & Toro spherical)
In this paper authors, describes its basic structure, stress characteristics and the engineering finite
element modelling for analyzing, testing and validation of pressure vessels under high stress
zones.
Advantages
 The equivalent von-misses’ stresses for different end connections are plotted.
 The different types of stresses and modeling of pressure vessel joints are also depicted in
ASME code in section.
 The difficulty of modeling the weld connection between the hemispherical end and
cylindrical shell was solved by providing the alternate shell thickness greater than that of
the base metal thickness, at the junction to provide it the strength of the weld.
 In this model analysis with different end connections shows that the end connection with
hemispherical shape results in the least stresses when compared to other models not only
at weld zone but also at the far end of the end connection. This can also be understood as
the maximum pressure taking capacity for the hemispherical type end connection with
least thickness (t/2 as per theory).
Disadvantage
 While due to restrictions of the cost of material, and optimization in demand via industry,
the use of ellipsoidal shape can be made with the increased thickness of the end
connection for same level of stresses.
21
 Tori spherical end type model where it was found the capability of undertaking pressure
force is least and thus the stresses exceeds the limit of ASME standard for the material
under the same loads and boundary conditions, still the same can be used with a little
increment in thickness
Model 2
This paper presents the structural modeling and stress analysis of nozzle connections in
ellipsoidal heads subjected to external loadings. Timoshenko shell theory and the finite element
method are used.
Advantages
 The features of the structural modeling of ellipsoid-cylinder shell intersections, numerical

procedure and SAIS special-purpose computer program are discussed.
 A parametric study of the effects of geometric parameters on the maximum effective
stresses in the ellipsoid-cylinder intersections under loading was performed.
 The results of the stress analysis and parametric study of the nozzle connections are
presented.
 A new method and numerical procedure for determining the plastic limit load in an
ellipsoid-cylinder intersection using the elastic-plastic finite element analysis are
presented.
 The proposed method is based on the maximum criterion of the rate of change of the
relative plastic work. For the elastic-plastic analysis of the nozzle connections the 2D
finite element method and plasticity theory with strain hardening are used.
 The results of the comparison of the plastic limit pressure obtained on the basis of
different known criteria and the proposed criterion are presented.
 A parametric study of ellipsoidal heads with a nozzle under internal pressure loading was
performed.
 The effects of non-dimensional geometric parameters of shell intersection on the plastic
limit pressure are also discussed.
 In this paper, results of the elastic-plastic stress analysis and determination of the plastic
limit pressure for ellipsoidal heads with cylindrical nozzles are presented.
 Some results obtained in the parametric study indicate the influence of various geometric
parameters on the plastic limit pressure and can be useful in pressure vessel design. In
22
future, it is proposed to extend the research scope of the nonlinear analysis of intersecting
shells.
Model 3
Advantages
 Pressure vessel components like shell, head, flange and nozzle are designed as per ASME
Section VIII Div-2, Edition 2001. Shell, head and skirt support dimensions are derived
based on various design conditions, viz., internal pressure, external pressure along with
wind / seismic effects. With the dimensions arrived at, the stresses have been verified to
be within allowable limits.
 Stress analysis of flange has been carried out as per appendix 3 of ASME Section VIII
Div.2, it has been determined that induced stresses (longitudinal, tangential and radial)
are within the corresponding given allowable limits.
Disadvantages
 Design of base ring and skirt sections has not been covered under ASME code and their
dimensions are calculated with general design principles.
 Stress analysis of these components has been carried out with combined load cases, it has
been found that stresses, produced due to combined loads, are within its allowable limits.
 If we assume that various load combinations are acting on support structures like skirt,
base ring etc. Various possibilities of failure for them (support structures) may be
occurred.
Model 4
This paper reviews some of the developments in the determination of stress concentration factor
in pressure vessels at openings, stress analysis of different types of end connections and
minimization stress with the help of optimize location and angle of nozzle on shell and head.
The literature has indicated a growing interest in the field of stress concentration analysis in the
pressure vessels. The motivation for this research is to analyze the stress concentration occurring
at the openings of the pressure vessels and the means to reduce the effect of the same.
23
Advantages
 Design of pressure vessels is governed by the ASME pressure vessel code. The code
gives for thickness and stress of basic components.
 In this paper the recent and past developments, theories for estimation of stress
Concentrations are presented and the scope for future studies is also presented.
 From this literature review it is seen that ASME and other code are providing solutions
for more general cases and required higher factor of safety.
 the position and location of the opening on cylinder is not studied in past by researcher
and there is no code provision for such design, here PVEleite software is used for
designing of pressure vessel.
 a review of the literature related to the stress concentration at opening in pressure vessel
is presented
 also the effect of the end cover on the position and size of the opening needs to be
studied.
Disadvantages
 limit load and stress concentration formulae are not available for nonstandard shape and
intersection and geometrical discontinuity.
Model 5
This paper deals with the Finite element modelling and Analysis of Pressure vessels with
different end connections (i.e. Hemispherical, Ellipsoidal & Toro spherical). Considering the fact
that required thickness of hemispherical head for internal pressure loading is only half of that
necessary for the cylindrical shell,
Advantages
24
 authors have tried to develop a finite element model taking due consideration on welding
involved at the end connections of cylinder to shell end in modelling using shell elements
to model cylinder.
 The larger the shell in diameter the more the economic benefits it achieves.
 In this paper authors, describes its basic structure, stress characteristics and the
engineering finite element modelling for analyzing, testing and validation of pressure
vessels under high stress zones.
 The equivalent von-misses’ stresses for different end connections are also plotted.
Model 6
In this project, a pressure vessel is designed by the stipulation recommended by ASME. Three-
dimensional modeling is carried out in Pro-e.
Advantages
 The analysis is carried out on the pressure vessel to verify the strength.
 Fatigue analysis is carried out for the entire structure of the pressure vessel, and from the
fatigue analysis report, it is clear that the fatigue life cycle is more than the required
period. Thereby it’s conclude that examined parts for fatigue are well within the
permissible limit set by ASME design code.
 The fatigue damage code factor experienced is less than unity, so the design is safe, by
this safety of pressure vessel is established well before production, and preventive
measures are taken to ensure a fatal accident doesn’t take place.
2.3. Conceptual design with previous model

2.3.1. Concept screening
2.3.2. Concept scoring
2.3.3. Reason to select the model
25
CHAPTER THREE
METHODOLOGY
Methodology is a general guide line or procedure which are used to solve problems to
design our project which is, design of unfired pressure vessel.
The methodology applied in this project is based on the project development phases that
commonly applied for all projects which each and every step are interlinked. Design
methodology will explain in detail on steps covered in conducting this project.
3.1. Steps design process used in the design
This project starts with the title selection that is provided by our supervisor according to
field of expertise. After determining introduction for the project, detailed background history
review is being carried out. Problem statement and objective of the topic was clearly defined,
articles related to the topic are being search from different sample papers and websites such as
Google Scholars by using the correct keywords. Keywords that are being used include: design of
pressure vessel and ASME standards of pressure vessel design. With all the papers and articles
available, the gap in the field is being determined and stated as the scope of study. All the related
materials which are being studied are cited in the references part of this report. Literature review
is also being carried out so that more knowledge about the topic can be obtained. Besides, design
parameters of pressure vessels such as the material, pressure and temperature were determined
based on priority which narrows down the scope to be applied. Mathematical derivation of
equations applied for design of pressure vessels also been worked out.
On the same time, studies and practices on the utilization of different software such as
Auto CAD also being performed so that we are familiar with the software and its functionalities.
With all the necessary information and equations for optimal design of pressure vessels obtained,
a calculation and finally validation test is conducted on the developed model for verification
purpose. The result of the project is then recorded and compiled into the report. Final
presentation about the findings of the project will be given to assure supervisor on the deadline.
The design methodology for this project depicted as in flow chart below:
26
3.1.2. Definition of the problem

We are asked to design vertical pressure vessel which has a capacity to store steam
without a great failures of material or parts.
3.1.3. Analysis and optimization
Selecting suitable material, Geometric, force and stress analysis for each component,
Such as: shell, head, nozzle, flange, bolt and skirt support, Checking the maximum principal and
shear stress with the permissible stress of material.
3.2. Selection of material

There are many consideration to select the material for designing purposes based on
considering the fluid/ medium, the working pressure (internal pressure) and the temperature at
the design pressure vessel. To select the proper material the following criterion should be
considered:-
 Availability of the material
 Suitability of the material for working consideration such as pressure, temperature
and strength.
 Mechanical properies of the material
 performance characteristics or mechanical properties
 processing (manufacturing) properties
 environmental profile
In detail the following are the most important characteristics to be considered when selecting a
material of constructions. These are: -
Mechanical properties: This includes the following properties.
Strength: - Tensile strength is required.
Stiffness: - The material should have high Elastic modulus (Young’s modulus).
Toughness: - Fracture resistance needed.
Hardness: - high wear resistance required
Corrosion resistance: - good corrosion resistance is required
27
Table 3.1: Typical design stresses for plate (taken from Coulson & Richardson volume 6 chap
13- table 13.2)
We select the material to be low allow steel because it has high working stress compared to
others, has high atmospheric corrosion resistance capacity, suitable to welding and also based on
the following criterias: -
 Performance characteristics (properties)
 Processing (manufacturing) properties
 Environmental profile
 Availability of the material
 Good corrosion resistance
By using design temperature and material type we read the design stress and tensile Strength
from the above typical design stress table:
Tensile strength:
δ t = 550 N/mm 2
Now we find the design stress at a given temperature by using interpolation.
28
Temperature Design stress
2
100° c 240 N/mm
130° c sall
2
150° c 240 N/mm
sall−240 130−100
=
150−100 240−240
Thus after interpolation the design stress (sall) is 240 N/mm2.
Table : Selected material for shell

Material Tensile strength Design stress at temprature 130° c
Low alloy steel 550Mpa 240Mpa
3.3. Design Specifications

table: The given design specifications
Parameters Values
Design pressure 3.5Mpa
Design temprature 130
Corrosion allowance 1.4mm
Length of cylinderical section 7m
Internal diameter of cylinderical section 3m
Working fluid Steam
Vessel orientation Vertical
3.4. Design procedure

 Determine the minimum plate thickness to resist the internal pressure
 Select the size and shape of vessel head (hemispherical, conical…)
29
 Increase the basic plate thickness to allow for the bending stress induced by the wind
loading at the base of the vessel and due to wind loading.
 Check the maximum combination stress at the base area with the design stress and check
that for critical buckling stress
 Decide which opening need for compensation
 Use standard flanges
 Design of the support type (skirt for our case)
 Design the base ring\
3.4.1. Using Method of (ASME Section II & VIII, Div1) Calculation

This code (standard) is used for designing vertical tanks (vessels), according to minimum
requirements of design without any failure of tank parts. The specialized code for the vessels
those used within range of (0.1 MPa to 20 MPa) and for this range most of vertical vessels are
selected. The cylindrical pressure vessel composed of: (Shell – Head – Nozzles – Base support).
Design pressure
From the internal pressure at the vessel the design pressure is calculated. - The design pressure is
taken from this given internal pressure of 5 to 10% above it.
Design temperature
For the purpose of design of pressure vessel, the temperature of the fluid and the given internal
temperature with the outside of the temperature must be balanced.
Design of stress
30
By considering the given temperature and the selected material the yield stress will be known.
We design by using yield stress of the material. In cylinder there are coordinate systems that
describe the state of stress
The hoop stress circumferential/tangential (𝜎𝐻)

The radial stress (𝜎r)
The longitudinal stress (𝜎𝐿)
Principal stress are the maximum or minimum order defined.
Analysis stress in the thin walled vessels; with internal pressure loading
A) Cylindrical (hoop/tangential/circumferential stress (𝜎H))
The total force(FT) acting on the longitudinal section
FT=intensity of pressure × projected area = (Pi) × (L × di) ……………...eq1
The total resisting force(FR)acting on the cylinder wall
FR= (tangential stress) × (area resisting the force) = 𝜎H (L.t) ×2 ………...eq2
*for equilibrium equation (1) is equal to equation (2)
FT=FR
(Pi) (L × di) = 𝜎H (L.t) × (2)
t =𝑃𝑖×𝑑𝑖/2 𝜎H
B) Longitudinal stress (𝜎L)

The total force acting on the transverse section due to pressure.
FT= (intensity of pressure) × (cross sectional area) = 𝑃𝑖×𝜋×𝑑𝑖 t/ 4
The total resistive force due to the material strength
FR= (𝜎L) × (area resisting the force) = (𝜎L) × (𝜋di t)
At equilibrium
FT=FR t =𝑃𝑖×𝑑𝑖/4𝜎L
Components
 Design of Shell
Consider the cylindrical shell and calculation or designing the parameter of the shell.
Thus design diameter, and thickness of shell. The shell is the primary component that contains
31
the pressure mainly. So, in order to design this shell, it is necessary to determine the values of
maximum allowable stress, tensile strength the internal pressure, design temperature, material
selection, welded joint efficiency and corrosion allowance.
The ASME codes presents basic rules while designing shells. It is clear that the thickness
of these shells is main consideration, the welding operation on vessels is necessary too. The used
thickness equations are:
 In case of circumferencial stresses (longitudinal welding).
PR Sall Et P (r +0.6 t)
ts ¿ + CA , Ps = , Sall =
Sall E−0.6 P R +0.6 t tE 1
 In case of longitudinal stresses (circumference welding).
PR 2 Sall Et
ts ¿ , Ps =
2 Sall E−0.4 P R−0.4 t
 Design of Head
All the pressure vessels must be closed at the ends by heads (or another shell section). Heads are
typically curved rather than flat. The reason is that curved configurations are stronger and allow
the heads to be thinner, lighter and less expensive than flat heads. Heads can also be used inside
a vessel and are known as intermediate heads. These intermediate heads are separate sections of
the pressure vessels to permit different design conditions. The ends of a cylindrical vessel are
closed by heads of various shapes. The principal Types used are:
● Flat Plates and Formed Flat Heads.

● Hemispherical Heads.
● Ellipsoidal Heads.
● Tori-spherical Heads.
● Conical Heads.
32
The ends of pressure vessel that confine the shell from below, above, and the sides. The ends of
the vessels are closed by means of head before putting them in to operation. In our design the
head is normally made from the same material as the shell and welded to the shell itself.
 The head geometry design is dependent up on the geometry of the shell as well as other
designs parameter such as operating temperature and the pressure. The geometry of the
head is selected based on the function as well as an economic consideration and methods
of forming and space requirements.
The thickness of both ends is given as below:
Hemispherical Head
PR 2 Sall Et P (r +0.2 t)
ts ¿ + CA , Ps = , Sall =
2 Sall E 1−0.2 P r +0.2 t 2 tE
Conical head
For α = 30o
PD 2 Sall EtCOS α
ts¿ + CA , Ps = , Sall =
2cos α ( Sall E−0.6 P) D+1.2 tcos α
P ( D+1.2tcos α)
2tEcos α
 Design of Nozzles
During providing the pressure vessels with nozzles, it is important to support these
nozzles to avoid or prevent any failure.
The pressure vessel need many opening for different purpose. Among this for inlet and
outlet of fluid drain, sample, manhole, pressure and temperature gauge. Therefore, for these
components or parts the opening is designed by compensation method, reinforcement of area
from the shell or head at the pressure vessel. We are going to design nozzle and reinforcement
area under considerations. Selection of nozzle pipe and sizing is applied from the standard table
listed below.
33
Table : Selection of nozzle pipe
Inside diameter of vessle Inspection of nozzle

12 in – 18 in Two – 1 and ½ in pipe size threades opening.
over 18 in - <36 Minimum 16 in I.D manhole or two 2 inch pipe size threaded
opening.
Over 36 Minimum 16 in I.D manholes or two 6 inch pipe size
nozzle.
figure3. 1: Main parameters of nozzle
PR
tn ¿ + CA
SsllE−0.6 P
Ar = dn ts f
As = Dn(TS – ts) – 2Tn(TS – ts)
An = 2[2.5(Ts) (Tn – tn)
Ar < (As + An)
ds = dn + 2(tn)
X = rn + Tn , y = 2.5Ts
dn = Dn – 2(Tn + CA)
34
 Design of Support
WE design skirt support and is designed by calculating the weight of fluid and the weight
of vessel. The contact angle should be less than 120o and will not normally greater than 150o.
Wear plate are often welded to the shell wall to reinforcement the wall over the area of contact
with the saddle. Design of bolt: -Design of bolting (bolt design) used for flanges to connect the
support with the ground. Design of skirt Support The skirt support must be designed to withstand
the load imposed by the weight of the vessel and contents. They are constructed of bricks or
concrete, or are fabricated from carbon steel plate.
During designing of support of a pressure vessel the main sources of load of the vessel
should be should be taken into consideration. These sources of load are the following:
1. Pressure
2. Dead weight of vessel and contents
3. Wind
4. Earthquake (seismic)
5. External loads imposed by piping and attached equipment
Primary stresses
1) The longitudinal and circumferential stresses due to pressure (internal or external), given by:
 The maximum stress is the circumferential stress, 
P Di
 =
2t
 The minimum stress is the radial stress, r
r = -P
2) The direct stress σw due to the weight of the vessel, its contents, and any attachments. The
dead-weight stress will normally only be significant, compared to the magnitude of the other
stresses, in tall vessels.
W
w = π ( Di+t) t , where W is the total weight which is supported by the
vessel wall at the plane considered.
35
3) Weight loads
Wv = CvmDmg(Hv + 0.8Dm)t × 10-3
Cv = 1.08 for vessels with only a few internal fittings
Cv = 1.15 for distillation columns or similar vessels with several man waysand with plate
support rings or equivalent fittings.
 Design of the bolt

In design materials the design of bolt is the basic thing because bolt is used to clamp or
connect two or more part together .in our design we use bolt for the attachment of flange with the
nozzle so in our design we have different nozzle with different internal diameter such as some
250mm, 600mm. then we will work our calculation on this two.
Then we will calculate the force acted on each indusial bolt
F
P i=
A
F = Pi × A
Fr
Then in single bolts the force can be calculated as follow F i=
n
 Discussion and Conclusion
Discuss and explain the result on the design of each component and draw conclusion
from the design in different angle.
 Recommendation
The design is carried out in order to prevent problems due to improper design as well as
improper selection of material which results failure and economical as well as energy loss. So in
order to prevent these problems and increase customer’s satisfaction the designer must consider
proper design procedure starts from good time management.
 Proto-type
36
Detail drawing and the assembly drawing is included in this design. The detail drawing
is drawn clearly and neatly so it is easy to read and manufacture.
 Reference
Finally state the reference books or any material which are used for the design of
pressure vessel.
3.5. Detail Design and Analysis
Table: Design specification and their corresponding values:
Design of column (vertical layout) pressure vessel

Parameters Value Unit
Design pressure 3.5 Mpa
Design temperature 130 0
c
Internal diameter 3 M
Length of cylinder 7 M
Corrosion allowance 1.4 Mm
Working fluid Steam
Vessel orientation Vertical
3.5.1. Design pressure
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.
10
PD=Pi+ Pi × ; Where Pi - Internal pressure
100
PD - Design pressure
PD=Pi+ 0.1 Pi
37
PD=1.1 Pi
Since the design pressure is given:
PD 3.5 Mpa
Pi= = =3.18 Mpa – Internal pressure
1.1 1.1
If internal is greater than 300psi or PD > 0.385×Sall E then the wall of the cylinder is
thick, otherwise PD< 0.385×Sall E or less than 300psi, the wall of the cylinder is thin.
1 psi=6894.8 Pa
So 3.5Mpa = 507.6psi > 300psi therefore thick walled pressure vessel is employed.
3.5.2 Design temperature
The strength of metals decreases with increasing temperature so the maximum allowable design
stress will depend on the material temperature. The design temperature at which the design stress
is evaluated should be taken as the maximum working temperature of the material, with due
allowance for any uncertainty involved in predicting vessel wall temperatures.
at T= 130℃
From typical design stress table (Table 3.1) the stresses for low alloy steel are: -
Design stress (sall) = 240 N/mm2 (calculated above using interpolation)
Tensile strength(ST) =550 N/mm2
3.5.3. Design stress
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. The design stress factor
38
allows for any uncertainty in the design methods, the loading, the quality of the materials, and
the workman ship.
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.
3.5.4. Welded joint efficiency, and construction categories
The strength of a welded joint will depend on the type of joint and the quality of the welding.
The soundness of welds is checked by visual inspection and by non-destructive testing
(Radiography). The possible lower strength of a welded joint compared with the virgin plate is
usually allowed for in design by multiplying the allowable design stress for the material by a
"Welded joint factor" 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.
Table 4.1: welded joint factor (table taken from Coulson & Richardson vol 6)
In our design we use joint efficiency value E = 1
Taking the factor as 1.0 implies that joint is equally as strong as a virgin plate.
39
3.5.5. Corrosion allowance
The additional thickness of metal added to allow for material lost by heat, corrosion and erosion
or scaling. The allowance to be used should be agreed between the customer and manufacturer’s
corrosion is complex phenomena, and it is not possible to give specific rules for the estimation of
corrosion allowance required for circumstances. The allowance should be based on the
experience with the material construction under similar surface conditions to those for the
purposed design.
For carbon and low alloy steel where sever corrosion is not expected the minimum allowance
given that 1.4mm should be used. i.e. CA = 1.4mm
3.6. Design of Component of vertical pressure vessel

3.6.1. Shell design
We have seen that, according to geometrical shapes, shells can be classified as spherical,
cylindrical and conical. Hence our design is concerned with cylinderical shell.
3.6.1.1. Column wall Thickness

 Calculate the thickness of shell, using the following formula:
t s = R×[
√ Sall E+ PD
SE−PD
−1] …….. If P D> 0.385Sall E
PD × R
ts = ……………….. If P D<0.385Sall E
SallE−0.6 PD
Where Sall = allowable design stress
E = joint efficiency……………. take E = 1
PD = design pressure
Material: - low alloy steel (SA-387) Grade 22 cl.2
Sall = 240Mpa , PD = 3.5Mpa , E=1
 Now check the first condition:
40
If P D> 0.385Sall E
3.5Mpa>0.385(240Mpa) (1)
3.5Mpa>92.4Mpa
Since 3.5Mpa is not greater than 92.4Mpa, the first condition is not appropriate to calculate the
thickness of shell.
 Now check the second condition:
If P D<0.385Sall E
3.5Mpa < 0.385(240Mpa) (1)
3.5Mpa < 92.4Mpa
Since 3.5Mpa < 92.4Mpa we use the second formula to find thickness of the shell.
R = Di/2 = 3m/2 = 1.5m
PD× R
ts = + CA ; where CA is corrosion allowance for safe design
Sall E−0.6 PD
3.5 Mpa ×1.5 m
= 240× 1−0.6 (3.5) + 1.4m
= 22.068mm + 1.4mm
= 23.468mm - Shell thickness
 Check the shell is thin or thick using thickness to diameter ratio.

t/d = 23.468mm/3000mm = 0.007823 < 1/10
Therefore, it is a thin shell.
 Outside diameter of shell ¿):
DO = Di+2ts
D O= 3m +2× 0.023468m
= 3.0469m
 Volume of shell ¿ ¿) is given by:
2
V s = π Di L s , Ls = 7m , where Ls is length of the cylindrical section(shell)
4
π ×(3 m)2
= ×7m
4
= 49.455 m3
41
3.6.1.2. Stress analysis of shell

 Circumferential or hoop stress
It is a tensile stress acting in the direction to the circumference or hoop.
The hoop stress is given by:
P i× D
σh = m
2t
Pi = Pd /1.1 = 3.5Mpa/1.1 = 3.18Mpa
D m = D + ts = 3 m+ 0.023468m ; where Dm is mean diameter
= 3.023468m or 3023.468mm
3.18 Mpa × 3.023468 m

σh = = 204.845Mpa
2× 0.023468 m
Know check hoop stress is less than design stress for safe design
σ h< Sall
Since 204.845Mpa < 240Mpa, the design is safe!
 Longitudinal stress
This is the tensile stress acting in the direction of the axis.
Longitudinal stress is given by:
P i× D
σl = m
4t
(3.18 Mpa)(3.023468 m)
σl = = 102.4227Mpa
4 (0.023468 m)
Know check longitudinal stress is less than the design stress for safe design
σ l< Sall
Since 102.4277Mpa < 240Mpa, the design is safe!
42
 Maximum shear stress (𝜏𝑚𝑎𝑥) is given by:
i IPD PD
1 = h = 2t = 204.845 Mpa and 2 = L = 4i t I = 102.4277 Mpa
1−2 204.845 Mpa−102.4277 Mpa
𝜏𝑚𝑎𝑥 = 2 = 2
= 51.21Mpa < 240Mpa
N.B: -Since all stresses calculated above are less than the design stress of 240Mpa, the design is
safe!
3.6.2. Head design
All pressure vessel shell must be closed at the end by heads. The ends of cylindrical
vessel are closed by head various shapes: -
 Flat plates head

 Hemispherical head
 Ellipsoidal head
 Conical head etc.
We have selected hemispherical and conical type heads because the radial stress on
hemispherical head is lower compared to the other types of heads and Conical ends are used to
facilitate the smooth flow and removal of solids from process; equipment; such as hoppers,
spray, dryers and crystallizers. Conical ends are also used as a drain for the vessel.
3.6.2.1. Design of Hemispherical head
Pd × D
 The thickness of hemispherical head is given by th ¿ + CA
2 Sall E−0.2 P
43
3.5 Mpa ×3 m
th ¿ + CA
2× 240 Mpa × 1−(0.2× 3.5 Mpa )
= 21.9069mm+ 1.4mm
= 23.30695mm
So this is approximately the same with the thickness of shell calculated above which is
equal to 23.0468mm.
Di 3m
H i= =¿ = 1.5m, H i = inner head of the hemisphere
2 2
D o 3.0469 m
Ho = = = 1.52345m , H o = outer head of the hemisphere
2 2
 volume of hemisphere
2 3 2 3
Vh = π r = π ×(1.5 m) = 7.065m3
3 3
3.6.2.2. Design of Conical head

The thickness of conical head is given by
PD
th¿ 2cos α ( Sall E−0.6 P) + CA, α = 30o
3.5 Mpa × 3 m
th¿ 2 cos 30 ¿ ¿ + CA = 25.482mm+ 1.4mm = 26.882mm
 Height of the cone is given by:

h = D/2 tan 60o = 1.5m× tan60o = 2.598 m
 Volume of cone
Radius of the cone is approximately equal to radius of the shell which is 1.5m.
1 2 1
Vc = π r h = π ¿ = 6.1183m3
3 3
 Slant height of cone

Use the Pythagorean theorem to find the slant height.
44
S 2 = h2 + r2 where: S= slant height of the cone

h = height of the cone
r = radius of the cone
S2 = (2.598m)2 + (1.5m)2
S = 2.99999m
3.6.2.3. Stress analysis at the center of the head

At the center of the head longitudinal stress has greater effect:
Pi Ri 2
Thus , L = where th is thickness of
2t h× Ho
hemisphere
3.18 Mpa ×(1.5 m)2
= Ho is outer head
2× 0.02330695 m×1.52345 m
= 100.755Mpa Ri is internal diameter
Check that the factor of safety, if the factor of safety greater than 1.5 our design is safe:
Design stress 240 Mpa
Fs=
Longitudinal stress
= 100.755 Mpa = 2.382
2.382 > 1.5 therefore, the design is safe!

Volume of the vessel
The total volume of the entire vessel is given by:
V = volume of hemisphere + volume of shell + volume of cone
3 2 2
2π r
V= + π Di Ls + π r h
3 4 3
45
2
2 3 π ×(3 m) 1
V= π ×(1.5 m) + ( × 7 m ) + ( π ¿)
3 4 3
V = 7.065m3 + 49.455 m3 + 6.1183m3
V = 62.6383m3
3.6.3. Nozzle design
The pressure vessel need many opening for different purpose. Among this for inlet and outlet of
fluid drain, sample, manhole, pressure and temperature gauge. Therefore, for these components
or parts the opening is designed by compensation method, reinforcement of area from the shell or
head at the pressure vessel. We are going to design nozzle and reinforcement area under
considerations.
Figure 4.1 Show the cross-sectional view of reinforced nozzle that indicates nozzle and shell
thickness area, reinforcement locations and weld paths, parallel and normal limits with its
equations.
figure3. 2: Reinforced nozzle
46
A B
figure3. 3: Nozzle Shell junction area (A) and main parameters for reinforcement (B)
We select our nozzle from the standard table listed below:
Inside diameter of vessle Inspection of nozzle

12 in – 18 in Two – 1 and ½ in pipe size threades opening.
over 18 in - <36 Minimum 16 in I.D manhole or two 2 inch pipe size threaded
opening.
Over 36 Minimum 16 in I.D manholes or two 6 inch pipe size
nozzle.
Table : Selection of nozzle pipe
First let us change our internal diameter of shell into inch
Since 1mm = 0.0393701in
3000mm¿ 118.1102∈¿ – internal diameter
Therefore, since our diameter (118.1102 in) which is in the range of over 36 in(914.4mm)
internal diameter.so the inlet pipe diameter will be 6 in.
Now let us change the inlet size into millimeter
Since 1mm= 0.0393701 in
6
D i= mm
0,0393701
=152.4mm
di 152.4 mm
Then the radius will be ri = = =76.2mm
2 2
47
3.6.3.1. Nozzle thickness
The formula that we are using to calculate the thickness is the same as thickness formula to
calculate for shell, the only difference is the diameter we use.
As we can see from table 4.1 for a vessel that has a diameter of greater than 36 in (914.4mm) use
6 in (152.4mm) pipe size nozzle.
P D× R
tn = +CA
Sall E−0.6 PD
3.5 Mpa ×0.0762 m
= + 1.4mm
240 Mpa × 1−0.6 × 3.5 Mpa
= 0.001121m + 1.4mm
= 1.121mm + 1.4mm
= 2.521mm – thickness of nozzle
3.6.3.2. The reinforcement area
For vessels under internal pressure the total cross-section area required for reinforcement of
opening shell not be less than:
A = d × 𝑡r Where, d = chord length at the mid surface of the thickness required
excluding the excess thickness available for reinforcement.
𝑡r = minimum required thickness of nozzle reinforcement
When the reinforcing limits do not extend outside of an area where the required thickness and
limits are available equally on each side of the opening centre line, the following equations may
be used to determine the area of reinforcement available:
Therefore, these are the same parameters that used to design opening.
48
A = d × 𝑡𝑟
d = di + 2 × CA = 152.4mm +( 2 × 1.4mm) = 155.2mm
minimum thickness of shell (𝑡r) is found by:
P D × Ri 3.5 ×1500
𝑡r = ts – CA or tr❑ = =
Sall E−0.6 PD 240−0.6 (3.5)
= 23.468mm – 1.4mm = 22.068mm = 22.068mm
The required minimum thickness of nozzle for inlet pipe:
P D × Rn
tr n = Rn = d/2 = 155.2mm/2 =77.6mm
Sall E−0.6 PD
3.5 ×77.6 mm
tr n = = 1.138mm
240−0.6 (3.5)
Area of reinforcement required
A = d × 𝑡𝑟
= 155.2mm × 22.068mm = 3424.95mm2
 Area available in vessel wall(A1), is the larger of: A1= d (t −𝑡𝑟) or A1= 2(t −𝑡𝑟) (𝑡𝑛 − t)
A1 = d (t −𝑡𝑟) = 155.2mm (23.468mm – 22.068mm) =217.28mm2
A1 = 2(t −𝑡𝑟) (𝑡𝑛 − t)) = 2(23.468mm – 22.068mm) (2.521mm – 23.468mm) =58.6516mm2
Take the larger area which is A1 = 217.28mm2
 Area available in nozzle wall(A2), is smaller of: A2 = 5t (𝑡𝑛 −CA) or A2 = 5𝑡𝑛 (𝑡𝑛 − CA)
A2 = 5 × 23.468mm (2.521mm – 1.4mm) = 131.538mm2
A2 = 5 × 2.521mm (2.521mm – 1.4mm) = 14.13mm2
Take the smaller area which is A2 = 14.13mm2
 Area available in inward nozzle, A3
49
A3 = 5tn (𝑡𝑛 - CA) = 5 × 2.521mm × (2.521 – 1.4mm) =14.13mm2

 Area of welds, A4
A4= 2(0.5) (t2) = 2 × 0.5 × (23.468mm)2 = 550.747mm2
The total area of reinforcement is:
AT = A1 + A2 + A3 + A4
= 217.28mm2 + 14.13mm2 + 295.814mm2 + 550.747mm2 = 1077.971mm2
Since 𝐴𝑇 < A that is 1077.971mm2 < 3363.1632mm2 therefore the opening is adequately not
reinforced so that our design is not safe
We need additional reinforcement by taking 𝑡𝑤 = 4mm thickness of the pad for good welding
Area available in an element
𝐴1 = (Dp − d – (2 × 𝑡𝑛) × tw but, Dp = 2d +2 tw ; where tw = thickness of pad.
Dp = 2×155.2mm +(2 ×4mm) = 318.4mm DP = diameter of pad
Check weather our calculation is right or wrong
Since thin diameter does not extend beyond the outer limit of the permitted reinforcement zone
2d <Dp
since 302.4 < 318.4 our design is acceptable.
Since the required reinforcement area is less than the available area therefore it needs additional
reinforcement or filler material for welding.
Figure 3.3: Reinforcement limits

Parallel to the shell surface, the horizontal limits are greater of x = d and x = 0.5d + t + 𝑡n
x = d and x = 0.5d + t + 𝑡n
x = 155.2mm and x = 0.5 × 155.2mm + 23.468mm + 2.521mm = 103.589mm
50
Take the greater values which is x = 155.2mm.

Perpendicular to the shell surface, the vertical limits are smaller of Y = 2.5t and Y = 2.5tn
Y = 2.5t and Y = 2.5tn
Y = 2.5 × 23.468mm and Y = 2.5 × 2.521mm
Y = 58.67mm and y = 6.3025mm
Take smaller value which is Y = 6.3025mm
tr 22.068 mm
From the above figure tan θ=¿ ¿= = 01421907
x 155.2mm
θ = 8.09°, by using this angle, read F from pressure vessel design manual-2-book in figure 2-48
below.
Figure 3.4: Chart for determinig the value of F

For the angle value of force will be, F≈ 0.8 and,
Design stress of nozzle 240 Mpa
f r 1= = =1
Design stress of shell 240 Mpa
Use same material in order to have a good welding take the angle of the fillet 45° and thickness
of weld 𝑡𝑤 = 1.5mm.
Now read all area formulas from machine design data book. The area of reinforcement required
is given by:
51
Ar = (d × tr × F) +( 2 × tn × tr × F × (1 – fr1))
A = (155.2mm × 22.068mm × 0.8) + (2 × 2.521 × 22.068× 0.8(1 – 1)) = 2740mm2
The area available in cylindrical shell is whichever is maximum of:
A1 = d (Ext − F×𝑡𝑟) − 2tn (Ext − F𝑡𝑟) (1− fr1) or
A1 = 2(t −𝑡𝑛) (Ext − F𝑡𝑟) − 2tn (Ext − F𝑡𝑟) (1− fr1)
But F = 0.8, fr1 = 1, E = 1
𝐴1 = 155.2(1× 23.468 – (0.8 × 22.068)) – (2 × 2.521)( (1 × 23.468) – (0.8 × 22.068)) (1 − 1))
= 902.3𝑚𝑚2 or
A1 = 2(t −𝑡𝑛) (t −𝑡𝑟) = 2(23.468 – 2.521) (23.468 – 22.068) = 58.652mm2
Take the largest one A1= 902.3mm2
the area available in the nozzle projecting out ward is whichever is minimum of:
A2 = 5(𝑡𝑛−𝑡𝑟𝑛) ×𝑓𝑟1×t = 5(2.521-1.13) × 0.8× 23.468mm = 130.57mm2 or
A2 = 5(𝑡𝑛−𝑡𝑟𝑛) ×𝑓𝑟1𝑡𝑛 = 5(2.521 – 1.13) × 0.8 × 2.521mm = 14mm2
Take the smaller one A2 = 14mm2.
The area available in inward nozzle:
A3 = 2(𝑡𝑛− CA) 𝑓𝑟1 × Y = 2 × (2.521 – 1.4) × 0.8 × 6.3025 = 11.3mm2
The area available in outward weld:
We take thickness of pad (𝑡𝑤) = 4mm.
A41 = (tw)2 × fr1 = (4mm)2 × 1 = 16mm2
The area available in inward weld: 𝑡𝑤=4mm
A43 = (tw)2 × fr1 = (4mm)2 × 1 = 16mm2
Now the total available area is given by:
AT = A1 + A2 + A3 + A41 + A43 = (902.3+ 11.3+ 11.3 + 16+ 16) 𝑚𝑚2
=957 mm2
AT < A……….957mm2 < 2740 mm2 , it is not safe.
Let’s take the thickness of reinforcing pad (te) = 10mm
The area of reinforcement required is A = 2740 mm2
The area available in the cylinder shell A1 = 902.3mm2
The area available in nozzle projecting out ward is changed and is given by
A2 = 5(𝑡n−𝑡𝑟𝑛) × 𝑓𝑟1t = 5(2.521 – 1.13) × (0.8 × 23.468mm2)
52
= 130.57mm2 or
A2 = 2(𝑡n−𝑡𝑟𝑛) (2.5tn –𝑡e) 𝑓𝑟1 = 2(2.521 – 1.13) (2.5× 2.521 - 10) × 0.8 = 8.23mm2
For safe design take smaller one A2 = 8.23mm2
The area available inward nozzle is the same as above A3 = 11.3mm2
The area available outward nozzle is given by:
A41 = te 2 × fr1 = (10mm)2 ×1 = 100mm2
but fr2=fr1, For the same material is added
The area available in outward weld is given by
A42 = te 2 × fr1 = (10mm)2 × 1 = 100mm2 but fr1 = fr2 = fr3
The area available in inward weld is given by
A43 = te 2 × fr1 = (10mm)2 × 1 = 100mm2
The area available in element is given by. A5
𝑑𝑝= 2d + 2te = 2 × 155.2 + 2 × 10 = 350.4 mm. Where: - 𝑑𝑝 = diameter of pad (fillet material)
A5 = ((𝑑𝑝− d − 2tn) × 𝑡e× 𝑓𝑟3 = (350.4 – 155.2 – 2 × 2.521) × 10 × 1) mm2 = 1701.6mm2
Total available area is given by:
AT = A1 + A2 + A3 + A41 + A42 + A43 + A5
= (902.3mm2 + 5.12mm2 + 11.3mm2 + 100mm2 +100mm2 +100mm2 +1701.6mm2)
=2923.4mm2
Since the total reinforcement area is greater than area reinforcement required (2923.4mm2
>2740mm2). Therefore, our design is safe!
3.6.3.3. Stress analysis of nozzle

Now we find the stress analysis of the nozzle by finding of the hoop (𝜎ℎ) and longitudinal (𝜎𝑙)
stresses using the following formulas:
P d Di P d Di
σ h= and σ l=
2tn 4 tn
3.5 Mpa × 0.1524 m
σ h=σ 1 = = 105.79Mpa
2× 0.002521m
3.5 Mpa × 0.1524 m
σ l=σ 2 = = 52.89Mpa
4 ×0.002521 m
Find the maximum shear stress (𝜏𝑚𝑎𝑥)
53
σ 1 −σ 2 105.79−52.89
τ max= = 2
= 26.447Mpa
2
Then, check it is safe by comparing it with design stress.
26.447Mpa < 240Mpa
Therefore, the design is safe
Also we can know either the design is safe or not by using factor safety but, we take working
stress is radial stress (hoop stress) in the nozzle, because hoop stress has more effect at the
nozzle.
Design stress 240 Mpa
Fs= = = 2.268
Work stress 105.79 Mpa
Since the factor of safety is greater than 1.5 and less than 5(i.e.1.5 < 2.268 < 5), the design is
safe!
3.6.4. Design of manhole
In our design we take the inlet pipe diameter (Dm)

Dm =16in = 406.4mm
Ri = Di/2 = 406.4mm/2 = 203.2mm
P D × Ri
tn = + CA
Sall E−0.4 P D
3.5× 203.2 mm
tn = +1.4 mm = 4.38mm
240−0.4 (3.5)
The outer diameter of manhole is given by: -
do = d+2tn but, d =di +2CA =406.4mm+2*1.4mm=409.2mm
= (409.2mm+2*4.39mm)
= 418mm
The required minimum thickness of nozzle for inlet pipe is given by: -
P D × Rn
t mn = but, Rn =d/2 = 409.2mm/2 =204.6mm
Sall E−0.6 PD
3.5× 204.6 mm
=
240−0.6(3.5)
= 3mm
The required minimum thickness of shell is given by: -
54
P D × Ri
t rs = but, Ri =di/2 = 3000mm/2 =1500mm
Sall E−0.6 PD
3.5× 1500 mm
=
240−0.6(3.5)
= 22.068mm
In our design we take thickness of weld = 4mm for good welding.
Area of reinforcement required
A = d×trs
= 409.2mm(22.068mm)
= 9030mm2
Area available in the cylindrical shell
A1 = (t - trs)d = (23.468 - 22.068)409.2 = 573mm2 or
A2 = 2(t+tn) (t-trs) =2(23.468+4.38)(23.468 - 22.068) = 78mm2
For safe design we take the largest value A1=573mm2
Area available in outward nozzle wall
A2 =5t (tn - trn) = 5(23.468) (4.38 - 2.98) =164.3mm2 or
A2 =5tn(tn-trn) =5(4.38) (4.38 - 2.98) = 30.66mm2
We take the smaller value that is A2 =30.66 mm2
Area available in inward nozzle
A3 = 5tn (tn-CA) =5(4.38) (4.38 - 1.4) =65.3mm2
55
Area of weld
A4 =( te)2 = (4)2 = 16 mm2
At = A1 + A2 + A3 + A4
= (573 + 30.66 + 65.3 + 16) mm2= 685 mm2
Total area reinforcement available must be greater than area of reinforcement required to achieve
safe design but in our design (At<Ar) or (685mm 2<9030 mm2), so we need additional
reinforcement pad for safe design.
Area of reinforcing pad (Ap) =Area reinforcement required –Area reinforcement available
Ap = (9030 - 685) mm2
Ap = 8345mm2
Reinforcing pad diameter (Dp) = n× Dm = 2×406.4 =812.8mm
Ap = (Dp - Dm) × tpad
Ap
tpad =
( D p−D m)
8345 mm 2
=
(812.8 mm−406.4 mm)
= 20.5mm
Therefore, the man hole will be reinforced by reinforcing pad diameter =812.8 mm with
thickness pad =20.5mm.
3.6.5.Support design
The vessel support is intended to support the pressure vessel on the support base. The
support has to be designed with stand the dead weight from the pressure vessel and to limit the
56
heat flow from the vessel walls to the base. The pressure vessel support should be able to with
stand the dead weight of the vessel, internals and the contained fluid without experiencing
permanent deformation.
In our case, the support of the pressure vessel is skirt and we choose a 5.8(carbon steel)
material for support design because 5.8(carbon steel) has excellent fatigue resistance, good
temperature resistance, it is tougher and has high strength.
Material Tensile strength in (N/mm2) 0.2%yield strength (N/mm2)

4.6 (carbon steel) 414 248
5.8 (carbon steel) 510 393
8.8 (alloy steel) 828 635
10.9 (alloy steel) 1035 897
A2-70 (stainless steel) 700 450
Table: Standard material for support design
In order to design skirt support, the dead weight of vessel must be considered. The major
sources of dead weight loads are
 The vessel shell load

 The vessel head load
 The vessel fitting, manhole and nozzle load
 Wind load Weight of fluid
3.6.5.1. Weight of shell
It is the sum of the weight of shell material and the fluid stored on it.
 Weight of shell material
The material is low alloy steel we take its density(𝜌) = 7850kg/m3
Weight of shell is given by: 𝑊𝑠 = π𝐷𝑚 𝑡𝑠 ρ L g

where: - Dm = mean diameter of shell
57
g= acceleration due to gravity taken as 9.81m/s2
ts=thickness of shell
L= vessel length
D0
L = Ls + + h + tc where h = height of cone
2
tc = thickness of the cone head
Do = outer diameter of the shell
D O = Di+2t
D O= 3000mm +2×23.468 mm=3046.936mm = 3.046936m
h = D/2 tan 60o = (1.5m) tan60o = 2.598m
3m
L = 7m + + 2.598m + 0.026882m
2
L= 11.125m
Dm= Di + ts
Dm= 3000 mm+ 23.468mm = 3023.468mm = 3.023468m
Ws = π Dm 𝑡𝑠 𝜌 L g
Ws = π×3.023468m× 0.023468m × 7850kg/m3 × 11.123m × 9.81m/s2
𝑊𝑠 = 190,873.68N = 190.874kN
 Weight of shell fluid
Wsf = 𝑚𝑓×g
but mf = 𝜌×𝑣𝑓 where 𝑣𝑓 =volume of the fluid on the shell
Vf =Ls ( )
π D2
4
58
2
π ×(3 m)
= 7 m( ) = 49.455m3
4
The mass of the shell fluid
msf = 𝜌 × 𝑣f
= 1000kg∕m3 × 49.455m3
= 49455kg
Thus the weight of the shell fluid can be determined as:
Wsf = msf × g
= 49,455kg × 9.81m/s2
= 485,153.55N = 485.152kN
3.6.5.2. Weight of head:
It is the sum of the weight of head material and the fluid stored on it.
 Weight of head material
The material is low alloy steel we take 𝜌 = 7850kg/m3
Wh = 1.084Dm2 × 𝑡ℎ × 𝜌 × g Where Dm = mean diameter of hemispherical head
g = acceleration due to gravity taken as 9.81m/s2
𝑡ℎ = thickness of head
59
Wh = 1.084𝐷𝑚2 × 𝑡ℎ × 𝜌 ×g
= 1.084 × (3.023468m)2 × 0.023468m × 7850kg/m3 × 9.81m/s2
= 17,908.3N = 17.91kN
 Weight of head fluid
Whf = mhf × g
Volume of the fluid in the head
π Di3
V hf = where Vhf = volume of the fluid on the head and Di = 1.5m
12
π ×(1.5 m)3
¿
12
= 0.883m3
Now the mass of the fluid in the head is as follow:
𝑚ℎ𝑓 = 𝜌 × 𝑣𝑓
= 1000kg/m3 × 0.883m3
= 883kg
Thus the weight of the fluid in the head is determined by:
Whf = mhf × g
= 883kg × 9.81m/s2
= 8662.23N = 8.662kN
60
3.6.5.3. Weight of the discharge nozzle
It is the sum of the weight of nozzle material and the fluid stored on it.
 Weight of the discharge nozzle material
The material is low alloy steel we take 𝜌 = 7850kg/m3
Wn = mn×g where mn is the mass of nozzle
But mn = 𝜌×𝑣𝑛 where vn is volume of nozzle material and given by
2 2
π (do −di )
V n= L where do = outlet nozzle diameter
4
𝑑𝑖 = inlet nozzle diameter
L = length of nozzle
𝑟𝑖 = 𝑑𝑖/2 = 152.4𝑚𝑚/2 = 76.2 mm and 𝑅𝑖 = 𝐷𝑖/2 = 3000𝑚𝑚/2 = 1500mm
C=Ri−√ Ri −ri
2 2
where C = length of part of the nozzle entering to shell
¿ 1500 mm− √ (1500 mm)2 −(76.2 mm)2
= 1.95mm
The length of nozzle is given by:
L = C+ ts + length of part of the nozzle leaving the shell
61
Let′s take the length of the nozzle leaving the shell 300mm then
L = 1.95mm + 2.521mm + 300mm
= 304.47mm
di = 152.4mm and do = di + 2tn = 152.4mm + 2(2.521mm) = 157.442mm
Now the volume the nozzle material is:
π (do 2−di 2 )
V n= L
4
2
π (157.442mm ¿ ¿ ¿ 2−(152.4 mm) )
¿ × 304.47mm
4
= 373,385.365mm3 = 0.000373385m3
Now calculate the mass of nozzle
mn = 𝜌×Vn
=7850 kg/m3 × 0.000373385m3
= 2.93kg
Thus the weight of nozzle can be calculated as:
Wn = mn×g
= 2.93kg × 9.81m/s2
= 28.754N
 Weight of the fluid in discharge nozzle
The weight of fluid in the nozzle is determined by:
62
Wnf = mf ×g but mf = 𝜌×Vf where Vf = volume of the fluid on the nozzle
mf = mass of the fluid
the volume of fluid is calculated as:
2
π di
Vf= L
4
2
π ×(152.4 mm)
¿ × 304.47mm
4
= 2,781,514.7mm3 = 0.0027815m3
The mass of fluid is given by:
mf = 𝜌×𝑣𝑓 We take density of water ρ =1000kg/m3
= 1000kg/m3 × 0.0027815m3
= 2.7815kg
Now calculate the weight of the fluid in the discharge nozzle.
Wnf = mf ×g
= 2.781 kg × 9.81m/s2
= 27.3 N
3.6.5.4. Weight of Wind (wind load)
The atmospheric pressure varies from place to place thus we take the mean atmospheric pressure
in Gondar as Patm = 1011N/m2.
Wwn = Patm ×Af where Patm = mean atmospheric pressure
63
Af = projected area
The projected area is determined as:
Af = D0 × Htotal
The total height of the vessel is: -
Htotal = Lshell + Hhead , hemi + Hcone+ Lskirt
𝐻ℎ𝑒𝑎𝑑, hemi = 𝐷𝑂/4 = 3046.94mm/4 = 761.7mm
we take length of the skirt (Lskirt) = 700mm
Htotal = 7000mm + 761.7mm + 2598mm + 700mm
Htotal = 11,059.7mm =11.0597m
Af = D0 × Htotal
= 3.04697m × 11.0597m
=33.7 m2
Now calculate the weight of wind
Wwn = Patm ×Af
= 1011N/m2 × 33.7 m2
= 34069N = 34.07kN
The wind effect has its own role in pressure vessel design. When we design pressure vessel with
greater height, we have to consider this effect on the vessel. The moment on the vessel due to
wind is calculated as:
64
2
x
Mx =w ; Where Mx = moment due to wind ,X is the distance measured from the
2
free end(approximately equal to total height of the vessel = 11.0597m) and, w = the load per
unit length (Newton Per meter) and calculated as follows:
Dm = Di + t where Dm = mean diameter of vessel
= 3000mm + 23.468mm
= 3023.468mm = 3.023468m and,
w = Dm × Patm
= 3.023468m ×1011N/m2
= 3056.7N/m
Now the moment due to wind is:
2
x
Mx = w
2
(11.0597 m)2
=3056.7 N /m×
2
= 186,944.7N.m = 186. 9447kN.m
65
Figure:3.5: Bending moment diagram under wind load
Now we can find the total weight as follows:
Wnet = Wtmaterial + Wtfluid + Wwn
Wtmaterial = 𝑊𝑠 + 𝑊ℎ + 𝑊𝑛
= 190.874kN+17.91kN+28.754kN
= 237.538kN
66
Wtfluid = Wsf + Whf + Wnf
= 485.152k𝑁 + 8.662k𝑁 + 0.0273kN
= 493.84kN
Now the net weight of the vessel is determined as:
Wnet = Material + Wtfluid + Wwn
= 237.538kN + 493.84k N + 34.07kN
= 765.45kN
Then the design weight is determined as follows:
Wd = Wnet + Wnet ×10 %
= 765.45kN + 765.45kN × 10/100
= 841.995kN
3.6.5.5 Skirt thickness
The skirt thickness must be sufficient to withstand the dead-weight loads and bending Moments
imposed on it by the vessel; it will not be under the vessel pressure. Mostly it sets 80° from the
horizontal.
3.6.5.6. Design considerations
Support structures have to be designed on the criteria of combined load considerations. Several
loads such as Wind/Seismic loads, External loads on nozzles due to piping joints, operating
67
weight of vessel etc. are acting on support structures simultaneously. With these combinations of
loads, stresses are analysed in structures.
If we assume that various load combinations are acting on support structures like skirt, base ring
etc. Various possibilities of failure for them (support structures) must be considered, which are
listed as per followings. A Skirt may fail in following conditions:
a) Induced tensile stress due to uneven expansion of different materials at skirt to shell
junction where temperature gradient along skirt length is very high,
b) Induced compressive stress due to operating weight of entire vessel along with
Seismic/Wind bending moments,
c) If the length of skirt is considerably long, it may lose its elastic stability, and buckle
under (self-weight) load of the vessel and/or external loads.
To design skirt is an iterative method. In which, first assume thickness of skirt; with this
thickness analyse stresses corresponding to above load combinations. If stresses, induced due to
above combined loads are not with in the allowable limits, increase the thickness and repeat it till
it satisfies the condition.
Figure3.6: skirt base ring geometry
68
We can give the thickness and diameter of skirt using its standard by considering shell diameter.
Base angle of conical skirt (θ) =80°
Assume from the above notation skirt thickness (ts = 50mm)
Internal diameter of shell is 3000mm
Height of cylinder is 19268 mm Height of skirt support is assumed to be 700mm
Internal diameter of skirt at lower part (𝐷𝑠) is given by:
Ds = Do + 2 th + 2𝐿sk/𝑡𝑎𝑛80
= 3046.936mm + 2(23.30695mm) + (2×700mm)/𝑡𝑎𝑛80 = 3340.4mm
Take thickness of skirt (ts) =50mm = 0.05m and check if our stress analysis of skirt works on this
thickness.
3.6.5.7. Stress analysis of skirt support
σs (Tensile) = σ𝑏𝑠 – σ𝑤𝑠 And σs (compressive) = σ𝑏𝑠 + σ𝑤s
where σ𝑏𝑠 = Bending stress on the skirt
σ𝑤𝑠 = dead weight stress in the skirt
σs = tensile(compressive) stress
4 Mx
σ bs = but we have 𝑀𝑥 = 186. 9447kN.m
π (D s +t s) D s t s
4 ×186.9447 kN .m
¿
π ( 3.34 m+0.05 m ) 3 .34 m ×0.05 m
= 420.65kN/m2
= 420.65kPa
69
The Dead weight stress in the skirt (σ𝑤𝑠) is calculated as:
WT
σ ws=
π (D s +t s )t s
Where 𝑀𝑠 = Maximum bending moment evaluated at the base of the skirt (Due to wind loading)
Ds = Inside diameter of the skirt at the base
ts = Skirt thickness
𝑊𝑇 = Total weight of the vessel and contents (WT =765.45kN)
WT
σ ws=
π (D s +t s )t s
765.45 kN
¿
π (3.34 m+ 0.05 m) 0.05 m
= 1438.2kN/m2
= 1438.2kpa = 1.4382Mpa
The resultant tensile stress on the skirt:
σs (Tensile) = σ𝑏𝑠 – σ𝑤𝑠
= 420.65k N/m2 – 1438.2kN/m2
= 1017.5kN/m2 = 1.0175Mpa
The resultant compressive stress on the skirt:
70
σs (Compressive) = σ𝑏𝑠 + σ𝑤𝑠
= 420.65kN/m2 + 1438.2kN/m2
= 1858.85kN/m2 = 1.85885Mpa
Since both σs (Tensile) and σs (Compressive) are less than the allowable or design stress that is
σd = 510Mpa the design is safe!
3.6.7. Selection of welded joint
A welded joint is a permanent joint which is obtained by the fusion of edge of two parts to be
joined together with or without the application of pressure and filler material. Electric arc
welding is extensively used because of greater speed of welding.
The main considerations involved in the selection of weld type are:
 The shape of welded component required

 The thickness of the plates to be welded
 The direction of force to be applied
We Select butt joint especially square butt joint for the connection of both head and shell but for
the connection of nozzle to the shell part we select corner joint.
3.6.7.1. Stresses for Welded Joints
The stresses in welded joints are difficult to determine because of the variable and unpredictable
Parameters like homogeneity of the weld metal, thermal stresses in the welds, changes of
physical Properties due to high rate of cooling etc. The stresses are obtained, on the following
assumptions:
71
 The load is distributed uniformly along the entire length of the weld, and
 The stress is spread uniformly over its effective section.
The following table shows the stresses for welded joints for joining ferrous metals with mild
steel electrode under steady and fatigue or reversed load.
Table: Standard for weld design
Since the stress in the weld material is to be 81Mpa our electrode is mild steel electrode. The
recommended minimum size of weld is 14mm size of weld between 25mm- 55mm
2 2
π (do −di )× σm
F= where d𝑜 = outside diameter of the nozzle
4
do = di +2CA +2tn di = inside diameter of the nozzle
= 152.4mm +2(1.4mm) +2(2.521mm)
= 160.4mm
2 2
π (do −di )× σm
F=
4
¿ π ¿¿
= 0.0078m2σm …………………… (1)
72
And
2
P D × π ×di
FR=
4
3.5 Mpa × π ×(0. 1524 m)2

¿
4
= 63812.77N
¿ 63.81277kN…………………… (2)
By equating equation 1 and 2 we calculate σm as follows:
Since FR = F
0.0078m2σm = 63.81277kN
63.845 kN
σm = = 8125kN/m2 = 8.125Mpa
0.0078 m2
3.6.7.2. Selection of bolted flange joints
Bolt joints are one of the most common elements in construction and machine design. They
consist of fasteners that a capture and join other part and are secure with the mating of bolt joints
designs or screw threads.
There are two main type of bolted joint design:
1) Tension joint
2) Shear joint
In the tension joint the bolt and clamped component at the joint are designed to transfer the
external tension load through the joint by away of clamped component through the design of
73
proper balance of joint and bolt stiffness. The second type of bolted joint transfer the applied
load in a shear on the bolt shank and relies on shear strength of the bolt, tension loads on such
joints are only identically.
We select mild steel material to design bolted flange joints because of easily workable, very
hard, yet malleable, good for construction, easy to shape and machine and very flexible and can
be harden.
Steel grade Measured direction Yield strength (MPa) Tensile strength (MPa)
HT50 A 542 591
HT80 A 693 830
Mild steel A 452 497
HT50 B 501 562
HT80 B 657 779
Mild steel B 439 471
HT50 C 531 587
HT80 C 665 811
Mild steel C 447 478
74
Table: Material selection for bolt design
Use the following formula to find the size and number of bolt.
Let, Di = internal diameter of cylinder
Dp = design pressure in the cylinder
dc = core diameter of the bolt
σtb= permissible tensile stress of the bolt
n = number of bolt
Here we know that the upward force acting on the cylinder cover is:
2
P D × π × Di
F= ……………………………………………….. (1)
4
This force is resisted by n number of bolt and the resisting force offered by n number of bolts
2
π ×σtb ×n × dc
FR= …………………………………………. (2)
4
From equation (1) the upward force acting on cylinder cover is:
P D × π ×di 2
F=
4
2
3.5 Mpa × π ×(3 m)
F=
4
F = 24,727.5kN
75
From equation (2) the resisting force by the bolt is:
2
π ×σtb ×n × dc
FR=
4
The material for the bolt is mild steel and σtb= 497N/mm2 the core diameter is from the table by
taking standard M16 size.
From the table we take dc =13.546mm
π ×σtb ×n × dc2
FR=
4
2
π × 497 N /mm 2× n ×( 13.546 mm)
¿
4
= 71589.3n N
= 71.5893n kN
Since, F = FR
71589.3n N =24,727.5kN
n = 24,727.5kN/71.5893kN
n = 345.4 ≈ 346
Nominal or major diameter of nut and bolt (d = D) = 16mm
76
Table 4.6: Standard bolt dimension
The total length of bolt and thread length of bolt can be calculated as follows:
Let us take L < 125mm, d < 152.4mm
Lt = 2(16) + 6𝑚𝑚
Lthreaded = 2 × 16mm + 6mm
Lthreaded =38mm
𝐿𝑢𝑛𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑 = 𝐿 − 𝐿𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑
𝐿𝑢𝑛𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑 = 100mm − 38mm
𝐿𝑢𝑛𝑡ℎ𝑟𝑒𝑎𝑑𝑒𝑑 = 62 mm
77
78
Table 4.7: Standard bolt and nut dimension
3.6.7.3. Stress analysis of bolt
The total force acted in the whole 346 bolts is F = 24,727.5kN
79
Thus the force in a single bolt can be calculated as follow:
𝐹𝑖 = 𝐹/𝑛 = 24,727.5kN /346𝑏𝑜𝑙𝑡𝑠 = 71.467kN
Then we will calculate the stress acted on each bolt.
Let’s take standard bolt size of M16
Stress on a bolt = 𝐹𝑖 𝑏𝑜𝑙𝑡/𝐴𝑏𝑜𝑙𝑡where Abolt – is the area of the bolt
𝐴𝑏𝑜𝑙𝑡 = 𝜋𝐷𝑖2/4
= 𝜋 (16mm)2/4
= 200.96mm2
Now the stress on each bolt is calculated as:
Stress on a bolt = 𝐹𝑖 𝑏𝑜𝑙𝑡/𝐴𝑏𝑜𝑙𝑡
= 71.467kN /200.96mm2
= 355.63𝑀𝑃𝑎
The tensile strength of M16 bolts is σtb = 497N/mm2 = 497Mpa.
Since 355.63Mpa < 497Mpa the design is safe!
80
3.6.7.4. Selection of Nut
We select mild steel material to design nut the same as bolted flange joint because of easily
workable, very hard, yet malleable, good for construction, easy to shape and machine and
very flexible and can be harden.
Steel grade Measured direction Yield strength (MPa) Tensile strength (MPa)
HT50 A 542 591
HT80 A 693 830
Mild steel A 452 497
HT50 B 501 562
HT80 B 657 779
Mild steel B 439 471
HT50 C 531 587
HT80 C 665 811
Mild steel C 447 478
81
Table: Material selection for the nut design
By reading from the above standard table we get:
 minor or core diameter of nut (dc) = 13.835mm

 effective or pitch diameter of nut (dp) = 14.701mm
 nominal or major diameter of nut and bolt (d=D) = 16.000mm
Table : Nut standard dimension
3.6.8. Flange design
Flanged joints are used for connecting pipes and instruments to vessels, for manhole covers, and
for removable vessel heads when ease of access is required. Flanges may also be used on the
vessel body, when it is necessary to divide the vessel into sections for transport or maintenance.
Flanged joints are also used to connect pipes to other equipment, such as pumps and valves.
Standard flanges will be specified for most applications. Special designs would be used only if
no suitable standard flange were available; or for large flanges, such as the body flanges of
vessels, where it may be cheaper to size a flange specifically for the duty required rather than to
accept the nearest standard flange, which of necessity would be over-sized 9.
82
3.6.8.1. Standard flanges
Standard flanges are available in a range of types, sizes and materials; and are used extensively
for pipes, nozzles and other attachments to pressure vessels. The proportions of standard flanges
are set out in the various codes and standards. A typical example of a standard flange design is
shown below. The relevant British Standards are BS 1560, Part 3 and BS 4504, Part 3, which
cover flanges for pipes, valves and fittings; in carbon and alloy steels.
Figure 3.7: Standard flange
Table: Flange standard dimension
Now as we design the bolt before the bolt is 𝐌𝟏𝟔 standard size
83
For this reason, our flange design parameters are in the first row of the table above.
Thus, d1 = 200mm
d2 = 18mm
d3 = 240mm
d4 =258mm
h =44mm
b = 20mm
D = 320mm
f = 3mm
K= 280mm
Bolt M16
3.7. Developing prototype of the model

3.8. General assembly design
3.9. Simulation analysis by solid work
84
CHAPTER FOUR
RESULT AND DISCUSSION
The following table shows the overall geometry of vertical pressure vessel that we have
calculated and analysed in the project.
4.1. Result
Components Dimension
1. Shell 𝐷i = 3000mm
Do = 3046.936mm
Dm = 3023.468mm
ts = 23.468mm
Ls = 7000mm
Vs = 49.455m3
2. Head Hemispherical Head Di = 3000mm
Do = 1336.827mm
Hi = 656.6mm
Ho = 668.41
85
th = 11.8mm
Vh = 0.5929m3
2.2 Conical Head 𝐷i = 3000mm
Do = 1340.027mm
Dm = 1326.627mm
h = 2598mm
th = 26.88mm
S = 2990mm
3 Nozzle Di = 152.4mm
tn = 2.521mm
do = 157.4mm
tr = 22.068mm
4 Bolt flanged Joint dc= 13.546mm
M16
N = 346
Lthreadedpart = 38mm
Lunthreaded part = 62mm
D = d = 16mm
5 Nut Dc =13.835mm
dp = 14.701mm
D = d = 16mm
86
6 Flange d1= 200mm
d2= 18mm
d3= 240mm
d4=258mm
h=44mm
b= 20mm
D= 320mm
f= 3mm
K= 280mm
Bolt M16
7 Vessel Support Lskirt = 700mm
Ds = 3340.4mm
ts = 50mm
Table: Result
4.2. Discussion
In this pressure vessel design report we have designed a total inside volume (V= 10m 3) Pressure
vessel for steam storing application. In this process we have designed shell, head, inlet and outlet
nozzle, bolt flanged joint, flange, hand hole and vessel support. All of these components are
designed by using appropriate formulas for each and their factor of safety are checked for
strength to avoid failures.
87
CHAPTER FIVE
CONCLUSION AND RECOMMENDATION

5.1. Conclusion
We conclude from this pressure vessel design the pressure with nominal volume 10𝑚3which is
used to store steam at 3.5 𝑀𝑃𝑎and 300℃ designed above is designed to satisfy all the required
requirements to be able to work under the given parameters. A corrosion allowance of 2mm is
applied in order to prevent failure due to corrosion and fatigue conditions. Our pressure vessel is
made with low alloy steel for all parts or components of pressure vessel and carbon steel for skirt
design due to have higher than to those of the plain carbon steels for given applications. This
means it has higher strength, hardness, hot hardness, wear resistance, toughness, and more
desirable combinations of these properties.
During designing of this project we have got so many problems are happened like in calculating
of area of reinforcement actually in the required area of the nozzle. In our design of pressure
vessel, the required area less than available area. So, we can use the reinforcement pad.
The design of pressure vessel in initialized with the specification requirements in terms of
standard technical specifications along with numerous requirements that lay hidden from the
market.
The storage of fluid at higher pressure in the pressure vessel is at the heart of its performance and
it is the first step towards the design. The pressure vessel components are merely selected, but
the selection is very critical. A slight change in selection will lead to a different pressure vessel
altogether from what is aimed to be designed.
88
It is observed that all the pressure vessel components are selected on basis of available ASME
standards and the manufactures also follow the ASME standards while manufacturing the
components.
Selection of pressure vessels components should be according to standards rather than

customizing the design. The standards lead to;
 A universal approach
 Less time consumption
 Easy replacement
 So less overall cost.
5.2. Recommendation
We designed a pressure vessel having different end closes that is hemispherical and
conical. At the very beginning of our design, we planned to design a pressure vessel with
hemispherical top end and conical bottom end, but, since our vessel support is of skirt type it is
not suited to make the bottom end conical shape. So we found that it is better to make the upper
(top) end of our pressure vessel of conical type and the bottom end of hemispherical type. The
reason we couldn’t use leg support is because of the overall height of our pressure vessel that is
11,125mm which is considerably tall and it is known that skirt type is better to use for such case.
We recommended the next designer to use leg support for conical bottom end pressure vessel
using optimum length of the pressure vessel.
6. Reference
[1] https://en.wikipedia.org/wiki/ASME_Boiler_and_Pressure_Vessel_Code
89
[2] https://en.wikipedia.org/wiki/Pressure_vessel
90

BBBTTT 2

Uploaded by

Copyright:

Available Formats

BBBTTT 2

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BBBTTT 2

Uploaded by

Copyright:

Available Formats

UNIVERSITY OF GONDAR

1. Temesgen Eshetie 00609/10

2. Birtukan Anley 00347/10

Submitted to: Mr. Ayele

Submission date: 25 - march - 22

3.1.2. Definition of the problem...........................................................................................27

LIST OF SYMBOLS AND ABBREVIATIONS

Pressure vessels are used in a number of industries; for example:

a) Spherical pressure vessel b) Vertical pressure vessel

c) Horizontal pressure vessel

Figure 1.1:Typical Pressure vessels

1.1. Historical Background of Pressure Vessel

1.1.1 History of ASME Boiler & Pressure Vessel Code

ASME’s rich publication history—including standards, theory, and technical journals—

1.1.2. Setting the Standard

1.2. Statement of The Problem

1.3. Objective of The Design

1.3.2. Specific Objective

And our specific objective is to meet and,

 To know the standard of Thickness of column wall

1.4. Scope of study

1.5. Significant of the study

1.6. Limitation of the study

1) Yogesh Borse and Avadesh K. Sharma [6]

2) V.N. Skopinsky, A.B. SMETANKIN [7]

4) Modi A J, Jadav C.S [10]

5) Mayank Nirbhay, OrashantTripathi & Vivek Kumar Gupta [12]

2.2. Gaps between the models

 The features of the structural modeling of ellipsoid-cylinder shell intersections, numerical

2.3. Conceptual design with previous model

3.1. Steps design process used in the design

3.1.2. Definition of the problem

3.1.3. Analysis and optimization

3.2. Selection of material

Temperature Design stress

Table : Selected material for shell

3.3. Design Specifications

3.4. Design procedure

3.4.1. Using Method of (ASME Section II & VIII, Div1) Calculation

The hoop stress circumferential/tangential (𝜎𝐻)

B) Longitudinal stress (𝜎L)

 In case of circumferencial stresses (longitudinal welding).

 In case of longitudinal stresses (circumference welding).

● Flat Plates and Formed Flat Heads.

The thickness of both ends is given as below:

Table : Selection of nozzle pipe

Inside diameter of vessle Inspection of nozzle

figure3. 1: Main parameters of nozzle

 The minimum stress is the radial stress, r

vessel wall at the plane considered.

 Design of the bolt

 Discussion and Conclusion

3.5. Detail Design and Analysis

Table: Design specification and their corresponding values:

Design of column (vertical layout) pressure vessel

3.5.1. Design pressure

Since the design pressure is given:

3.5.2 Design temperature