TABLE OF CONTENTS

S. NO TITLE
PAGE NO
1. INTRODUCTION TO PRESSURE VESSELS
4
1.1. BASIC TERMINOLOGIES USED 5
1.2 CYLINDERS AND SPHERS 19
2. ANALYTICAL DESIGN OF METHANATOR
26
2.1 GIVEN DATA 28
2.2 REQUIRED DIMENTIONS OF METHANATOR 29
2.3 METHANATOR AS A THIN CYLINDER 30
2.4 THICNESS OF SHELL 32
2.5 THICNESS OF 2!1 ELLIPSOIDAL HEAD 34
1
2." OPENING IN THE PRESSURE VESSELS 35
2.# SELECTION OF FLANGES 3#
2.8 THICNESS OF SIRT OR DESIGN OF SUPPORTS 39
2.9 LOADINGS 44
2.10 STRESSES IN RESPONSE TO DIFFERENT LOADS 45
a) INTERNAL PRESSURE
45
b) WEIGHT
46
c) WIND LOAD
49
d) SEISMIC LOAD
54
2.11 COMBINATION OF STRESSES 5#
2.12 COMPARISION 58
2.13 DESIGN OF ANCHOR BOLTS 58
2.14 $ELDING OF PRESSURE VESSELS "2
3. ANALYSIS BY ANSYS
67
3.1 ANSYS "8
3.2 ANSYS INPUT METHODS "9
3.3 SHELL 51 #0
3.4 ANALYSIS OF METHANATOR UNDER INTERNAL PRESSURE USING
SHELL 51 #1
3.5 ANALYSIS OF METHANATOR TO COMMAND $INDO$ #2
3." ANALYSIS OF METHANATOR THROUGH GUI #2
3.# TO FIND THE HOOP AND LONGITUDINAL STRESS ON ANSYS 88
3.8 DISPLACEMENTS OF NODES 91
2
4. COMARISION AND CONCLUSION
92
4.1 MEMBRENE STRESSE IN METHANATOR 93
4.2 COMARISION OF ANSYS AND ANALYTICAL SOLUTION 94
4.3 CONCLUSION 9"
REFERENCES%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%
TABLES %%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%%




3
INTRODUCTION
TO
PRESSUREVESSE
LS
4
1.1 BASIC TERIMINOLOGIES USED
VESSEL:
A container or structural envelope in which materials are processed,
treated, or stored; for eample, pressure vessel, reactor vessel, a!itator
vessel, and stora!e vessels "tan#s$%
&'ESS('E VESSEL:
A metal container !enerall) c)lindrical or spheroid, capa*le or
withstandin! various loadin!s%
S+'A,-:
An) forced chan!e in the dimensions of a *od)% A stretch is a tensile
strain; a shortenin! is a compressive strain; an an!ular distortion is a shear
strain% +he word strain is commonl) used to connote unit strain%
S+'ESS:
,nternal force eerted *) either of two ad.acent parts of a *od) upon
the other across an ima!ined plane of separation% /hen the forces are
parallel to the plane, the stress is called shear stress; when the forces are
normal to the plane the stress is called normal stress; when the normal stress
is directed toward the part on which it acts is called compressive stress;
when it is directed awa) from the part on which it acts it is called tensile
stress.
0
S+'ESSES ,- &'ESS('E VESSEL:
Lon!itudinal S1 stress%
1ircumferential "hoop$ S2 stress%
S1 and S2 called mem*rane "diaphra!m$ stress
2or vessel havin! a fi!ure of revolution
3endin! stress
Shear stress
4iscontinuit) stress at an a*rupt chan!e in thic#ness or
Shape of the vessel
+E-S,LE S+'E-5+6:
+he maimum stress a material su*.ected to a stretchin! load can
withstand without tearin!%
+E-S,LE S+'ESS:
Stress developed *) a material *earin! tensile load%
+ES+ &'ESS('E:
+he re7uirements for determinin! the test pressure *ased on
calculations are out lined in (5899"c$ for the h)drostatic test and (581::"*$
for the pneumatic test% +he *asis for calculated test pressure in either of
these para!raphs is the hi!hest permissi*le internal pressure as determined
*) the desi!n formulas, for each element of the vessel usin! nominal
thic#ness with corrosion allowances included and usin! the allowa*le stress
values for the temperature of the test% "1ode (A8;:$
;
+6E'<AL S+'ESS:
A self8*alancin! stress produced *) a non uniform distri*ution of
temperature or *) differin! thermal coefficients of epansion% +hermal stress
developed in a solid *od) whenever a volume of material is prevented from
assumin! the si=e and shape that it normall) should under a chan!e in
temperature%
+6,1>-ESS ?2 VESSEL /ALL:
1% +he @re7uired thic#nessA is that computed *) the formulas in this
division, *efore corrosion allowance is added%
2% +he @desi!n thic#nessA is the sum of the re7uired thic#ness and the
corrosion allowance%
3% +he @nominal thic#nessA is the thic#ness selected as commerciall)
availa*le, and as supplied to the manufacturer; it ma) eceed the
desi!n thic#ness%
(-,+ S+'A,-:
(nit tensile strain is the elon!ation per unit len!th; unit compressive
strain is the shortenin! per unit len!th; unit shear strain is the chan!e in
an!le "radians$ *etween two lines ori!inall) at ri!ht an!les to each other%
(-,+ S+'ESS:
+he amount of stress per unit of area%
/EL4 <E+AL:
+he metal resultin! from the fusion of *ase metal and the filler metal%
B
/EL4,-5:
+he metal .oinin! process in ma#in! welds%
,n the construction of vessels the weldin! process is restricted *) the
code "(/82B$ as follows;
1% Shielded metal arc, su*mer!ed arc, !as metal arc, !as tun!sten arc,
atomic h)dro!en metal arc, o) fuel !as weldin!, electro8sla!, and
electron *eam%
2% &ressure weldin! process: flash, induction, resistance, pressure
+hermit, and pressure !as%
C,EL4 &?,-+:
+he lowest stress at which strain increases without increase in stress%
2or some purpose it is important to distin!uish *etween the upper )ield
point, which is the stress at which stress8stain curve first *ecome hori=ontal,
and the lower )ield point, which is the somewhat lower and almost constant
stress under which the metal continues to deform% ?nl) a few materials
ehi*it a true )ield point; for some materials the term is sometimes used as
s)non)mous with )ield stren!th%
S&E1,2,1 5'AV,+C:
+he ratio of the densit) of a material to the densit) of some standard
material, such as water at a specified temperature, for eample, 4
D
1 or ;:D2%
?r "for !ases$ air at standard conditions of pressure and temperature%
E
S+A3,L,+C ?2 VESSEL:
"Elastic sta*ilit)$ +he stren!th of the vessel to resist *uc#lin! or
wrin#lin! due to aial compressive stress% +he sta*ilit) of a vessel is
severel) affected *) out of roundness%
S6ELL:
Structural element made to enclose some space% <ost of the shells are
!enerated *) the revolution of plane curve%
S6EA' S+'ESS:
+he component of the stress tan!ent to the plane of reference%
'A4,(S ?2 5C'A+,?-:
+he radius of !)ration of an area with respect to !iven ais is the
s7uare root of the 7uantit) o*tained *) dividin! the moment of inertia of the
area with respect to that ais *) the area%
'ES,4(AL S+'ESS:
Stress remainin! in a structure or mem*er as a result of thermal or
mechanical treatment, or *oth%
'ES,S+A-1E /EL4,-5:
A pressure weldin! process wherein the heat is produced *) the
resistance to the flow of an electric current%
9
SE1?-4A'C S+'ESS:
A normal stress or a shear stress developed *) the constraint of
ad.acent parts or *) self8constraint of a structure% +he *asic characteristic of
a secondar) stress is that it is self8limitin!% Local )ieldin! and minor
distortions can satisf) the conditions which cause the stress to occur and
failure from one application of the stress is not to *e epected% Eamples of
secondar) stress are: !eneral thermal stress; *endin! stress at a !ross
structural discontinuit)%
&?,SS?-SF'A+,?:
+he ratio of lateral unit strain to lon!itudinal unit strain, under the
conditions of uniform and uniaial lon!itudinal stress within the
proportional limit%
&?S+/EL4 6EA+ +'EA+<E-+:
6eatin! a vessel to a sufficient temperature to relieve the residual
stresses which are the result of mechanical treatment and weldin!%
&ressure vessels and parts shall *e post weld heat treated%
&'E6EA+,-5:
6eat applied to *ase metal prior to weldin! operations%
&'ESS('E 'EL,E2 VALVE:
A valve which relieves pressure *e)ond a specified limit and recluses
upon return to normal operatin! conditions%
1:
&'ESS('E /EL4,-5:
A !roup of weldin! processes wherein the weld is completed *) use
of pressure%
&',<A'C S+'ESS:
A normal or shear stress developed *) the imposed loadin! which is
necessar) to satisf) the simple laws of e7uili*rium of eternal and internal
forces and moments% +he *asic characteristic of a primar) stress is that it is
not self8limitin!% &rimar) stresses which considera*l) eceed the )ield
stren!th will result in failure or at least, in !ross distortion% A thermal stress
is not classified as primar) stress% &rimar) mem*rane stress is divided into
local and !eneral cate!ories% A !eneral primar) mem*rane stress is one
which is so distur*ed in the structure no redistri*ution of load occurs as a
result of )ieldin!% Eamples of primar) stress are: !eneral mem*rane in a
circular c)lindrical or a spherical shell due to internal pressure or to
distri*uted live load; *endin! stress in the central portion of a flat head due
to pressure%
?&E'A+,-5 &'ESS('E:
+he pressure at the top of a vessel at which it normall) operates% ,t
shall not eceed the maimum allowa*le wor#in! pressure and it is usuall)
#ept at a suita*le level *elow the settin! of the pressure relievin! devices to
prevent their fre7uent openin!% "1ode (A8;:$
?&E'A+,-5 +E<&E'A+('E:
+he temperature that will *e maintained in the metal of the part of the
vessel *ein! considered for the specified operation of the vessel% "1ode (A8
;:$
11
-E(+'AL AG,S:
+he line of =ero fi*er stress in an) !iven section of a mem*er su*.ect
to *endin!; it is the line formed *) the intersection of the neutral surface and
the section%
<?<E-+ ?2 ,-E'+,A ?2 A- A'EA "SE1?-4 <?<E-+ ?2 A-
A'EA$
+he moment of inertia of an area with respect to an ais is the sum of
the products o*tained *) multipl)in! each element of the area *) the s7uare
of its distance from the ais% +he moment of inertia ",$ for thin walled
c)linder a*out its transverse ais; , H I r
3
t
/here
r H mean radius of c)linder
t H wall thic#ness
<?4(L(S ?2 ELAS+,1,+C "C?(-5FS <?4(L(S$:
+he rate of chan!e of unit tensile or compressive stress with respect
to unit tensile or compressive strain for the condition of uniaial stress
within the proportional limit% 2or most, *ut not all materials, the modulus of
elasticit) is same for tension and compression% 2or nonisotropic materials
12
such as wood, it is necessar) to distin!uish moduli of elasticit) in different
directions%
<?4(L(S ?2 ',5,4,+C:
+he rate of chan!e of unit shear stress with respect to unit shear strain,
for the condition of pure shear within the proportional limit%
<AG,<(< ALL?/A3LE S+'ESS VAL(E:
+he maimum unit stress permissi*le for an) specific material that
ma) *e used in the desi!n formulas !iven in the code% "(5823$
<AG,<(< ALL?/A3LE /?'>,-5 &'ESS('E:
+he maimum !a!e pressure permissi*le at the top of a completed
vessel in its operatin! position for a desi!ned temperature% +his pressure is
*ased on the wea#est element of the vessel usin! nominal thic#ness
eclusives of allowances for corrosion and thic#ness re7uired for loadin!
other than pressure% "1ode (A8;:$
<E<3'A-E S+'ESS:
+he component of normal stress which is uniform all) distri*uted and
e7ual to the avera!e value of stress across the thic#ness of the section under
consideration%
,S?+'?&,1:
6avin! same properties in all directions% ,n discussion pertainin! to
stren!th of materials, isotropic usuall) means havin! the same stren!th and
elastic properties%
13
J?,-+ E22,1,E-1C:
A numerical value epressed as the ratio of the stren!th of a riveted,
welded, or *ra=e .oint to the stren!th of the parent metal%
L?A4,-5:
Loadin! "loads$ are the results of various forces% +he loadin!s to *e
considered in desi!nin! a vessel : internal or eternal pressure, impact loads,
wei!ht of the vessel, wind and earth7ua#e, superimposed loads, local load,
effect of temperature !radients%"1ode (5822$%
L?/8ALL?C S+EEL:
A harden a*le car*on steel !enerall) containin! not more than a*out
1K car*on and one or more of the followin! components; L "less than$ 2K
man!anese, L 4Knic#el, L 2Kchromium, :%;K mol)*denum, and
L :%2Kvanadium%
6EA+ +'EA+<E-+:
6eat treatin! operation performed either to produce chan!es in
mechanical properties of the material or to restore its maimum corrosion
resistance% +here are three principle t)pes of heat treatment; annealing,
normalizing, and post weld heat treatment
.
6C4'?S+A+,1 +ES+:
+he completed vessel filled with water shall *e su*.ected to test
pressure which is e7ual to 1 M times the maimum allowa*le wor#in!
14
pressure to *e mar#ed on the vessel or 1 M the desi!n pressure *)
a!reement *etween the user and the manufacturer% "1ode (5899$
,<&A1+ S+'ESS:
2orce per unit area imposed to a material *) a suddenl) applied force%
,<&A1+ +ES+:
4etermination of the de!ree of resistance of a material to *rea#in! *)
impact, under *endin!, tensile and torsion loads, the ener!) a*sor*ed is
measured *) *rea#in! the material *) a sin!le *low%
5A5E &'ESS('E:
+he amount *) which the total a*solute pressure eceeds the am*ient
atmospheric pressure%
2,LLE' <E+AL:
<aterial to *e added in ma#in! a weld%
2,3E' S+'ESS:
A term used for convenience to denote the lon!itudinal tensile or
compressive stress in a *eam or other mem*er su*.ect to *endin!% ,t is
sometimes used to denote this stress at the point or points most remote from
the neutral ais, *ut the term stress in extreme fiber is prefera*le for this
purpose% Also, for convenience, the lon!itudinal elements or filaments of
which a *eam ma) *e ima!ined as composed are called fibers.
10
2A1+?' ?2 SA2E+C:
+he ratio of the load that would cause a failure of a mem*er or
structure, to the load that is imposed upon it in service%
2A+,5(E:
+endenc) of materials to fracture under man) repetitions of a stress
considera*l) less than the ultimate static stren!th%
E1E-+',1,+C:
A load or component of a load normal to a !iven cross section of a
mem*er is eccentric with respect to that section if it does not act throu!h
centroid% +he perpendicular distance from the line of action of the load to
either of principle central ais is the eccentricit) with respect to that ais%
E22,1,E-1C ?2 A /EL4E4 J?,-+:
+he efficienc) of the welded .oint is epressed as a numerical 7uantit)
and is used in the desi!n of a .oint as a multiplier of the appropriate
allowa*le stress value% "1ode (A8;:$
ELAS+,1:
1apa*le of sustainin! stress without permanent deformation; the term
is also used to denote conformit) to the law stress8strain proportionalit)% An
elastic stress or elastic strain is a stress or strain within the elastic limit%
1;
ELAS+,1 L,<,+:
+he least stress that will cause permanent set%
4ES,5- &'ESS('E:
+he pressure used in determinin! the minimum permissi*le thic#ness
or ph)sical characteristics of the different parts of the vessel% "1ode (58;:$
4ES,5- +E<&E'A+('E:
+he mean metal temperature "throu!h the thic#ness$ epected under
operatin! conditions for the part considered% "1ode (582:$
1'EE&:
1ontinuous increase in deformation under constant or decreasin!
stress% +he term is usuall) with reference to the *ehavior of metal under
tension at elevated temperatures% +he similar )ieldin! of a material under
compressive stress is usuall) called plastic flow or flow.
1?''?S,?-:
1hemical erosion *) motionless or movin! a!ents% 5radual
destruction of a metal or allo) due to chemical process such as oidation or
action of a chemical a!ent%
1LA4 VESSEL:
A vessel made from plate havin! a corrosion resistant material
inte!rall) *onded to a *ase of a less resistant material% "1ode (A8;:$
1B
ALL?C:
An) of a lar!e no% of su*stances havin! metallic properties consistin!
of two or more elements; with few eceptions, the components are usuall)
metallic elements%
1E
1.2 CYLINDERS AND SPHERES:
Vessels such as steam *oilers, air compressors, stora!e tan#s,
accumulators and lar!e pipes are su*.ected to internal fluid pressure which is
uniforml) distri*uted% All the a*ove mentioned vessels are classified as
c)linders or spheres%
+6,- 1CL,-4E':
,f the ratio of the thic#ness to the internal diameter i%e% tNd is less than
a*out 1N2:, the c)linder is assumed to *e thin c)linder%
+6,1> 1CL,-4E':
,f the ratio of thic#ness to the internal diameter i%e% tNd is !reater than
1N2:, the c)linder is assumed to *e thic# c)linder%
S+'ESSES ,- 1CL,-4E'S:
+he followin! stresses are illustrated in fi!% "1$ and fi!% "2$
1,'1(<2E'E-+,AL ?' 6??& S+'ESS:
+he stress which acts tan!ent to the circumference and perpendicular
to the ais of the c)linder is called circumferential or hoop stress% ,t is
denoted *) f
h%
19

L?-5,+(4,-AL S+'ESS:
+he stress which acts normal to circumference and parallel to the ais
of the c)linder is called lon!itudinal stress% ,t is denoted *) f
l
%

'A4,AL S+'ESS:
+he stress which acts in a direction perpendicular to the internal
surface is called radial stress% ,t is denoted *) f
r
% 'adial stress is ver) small
as compared to f
l
and f
h
in case of thin c)linder and is therefore i!nored%
2:
A-ALCS,S ?2 +6,- 1CL,-4E':
1onsider the e7uili*rium of half c)linder of len!th OLF sectioned
throu!h a diameteral plane as shown in fi!, "3$

Let the internal diameter *eOdF and the thic#ness OtF; OpF is the applied
internal pressure, fh the hoop stress and fl the lon!itudinal stress%
6??& S+'ESS:
1onsider the elemental rin! of the c)linder su*tendin! an an!le PQ%
Let ds H arc len!th of elemental rin! H r%
2orce actin! on elemental rin! H p Rarea
H prPQL
Vertical component of this force H prPQL SinQ
+otal vertical force HprL
:
S
1E:
SinQPQ
H 8prl "cos 1E: T 1os :$ H 2prL
H pdL e7%"1$
3ut
dL H hori=ontal pro.ected area%
21
So
+otal vertical force H pdL H intensit) of pressure R hori=ontal
pro.ected area%
+his force tries to *urst the c)linder into two halves and is called
O*urstin! forceF%
3urstin! force H 2 H pdL
And
'esistin! force H stress R resistin! area
H f
h
R 2tL
2or e7uili*rium of c)linder
3urstin! force H 'esistin! force
pdL H f
h
R2tL
f
h
H pdN2t e7%"A$
L?-5+(4,-AL S+'ESS:
1ross sectional area HI N4 d
2

+otal force at the end of c)linder H pR IN4 d
2

+his force tries to *urst the c)linder at the ends of c)linder and is
called O*urstin! forceF%
3urstin! force H 2 H pR IN4 d
2
'esistin! force H stress R resistin! area
H f
l
R Idt
for e7uili*rium of c)linder
3urstin! force H resistin! force
&R IN4 d
2
H f
l
R Idt
22
2
l
H pdN4t e7% "3$
1omparin! "A$ and "3$
2
l
H1N2 f
h
+6,- S&6E',1AL S6ELL:
,n case of spherical shell also, the radial stress will *e ne!lected and
the circumferential or hoop stress will *e assumed to *e constant%

As shown in the fi!% the two stresses are e7ual to due to s)mmetr)% i%e%
f
h
H f
l
H f
1ross8sectional area H I N4d
2

3urstin! force H pR I N4d
2
'esistin! force H stress R resistin! area
H f R dt
2or e7uili*rium of shell
3urstin! force H resistin! force
& R I N4d
2
H f R dt
f H pdN4t
23
1CL,-4E',1AL S6ELL /,+6 6E<,S&6E',1AL E-4S:
As shown in the fi!% let t
1
*e the thic#ness of the c)linder and t
2
*e the
thic#ness of the hemisphere, the internal diameter *ein! assumed the same
for *oth%
S+'ESSES ,- +6E 1CL,-4E',1AL &?'+,?-:
,f the shell is su*.ected to an internal pressure p, stresses in the
c)linder will *e;
6oop stress, f
h
H pdN2t
1
And
Lon!itudinal stress, f
l
HpdN4t
1
6oop strain,U
h
H f
h
NE T V f
l
NE H 1NE "f
h
T V f
l
$
H1NE "pdN2t
1
8 pdN4t
1
$ H 1NE ""2pd 8 pdN4t
1
$$
U
h
H pdN4t
1
E "2 8 V$
Lon!itudinal strain, U
l
H f
l
NE 8 fhNE H pdN4t
1
E 8 pdN2t
1
U
l
H pdN4t
1
E "1 T 2V$
24
S+'ESSES ,- +6E S&6',1AL &?'+,?-:
2or the hemispherical ends havin! thic#ness t
2,
we have
f
h
W

H f
l
W

H f H pdN4t
2
+herefore, hoop stress, f
h
H pdN4t
2
And
Lon!itudinal stress, f
l
H pdN4t
2
+hen
6oop strain, U
h
W
H f
h
NE T f
l
NE H pdN4t
2
E T pdN4t
2
E
U
h
W

H pdN4t
2
E "1 8V$
Lon!itudinal strain,U
l
W
H f
l
W
NE 8 V f
h
W
NE H pdN4t
2
E 8 VpdN4t
2
E
U
l
W
H pdN4t
2
E "1 8V$
+herefore for spherical portion
U
h
W H U
l
W
At the .unction of c)lindrical and spherical portion
U
h
H U
h
W
&dN4t
1
E "2 8V$ H pdN4t
2
E "1 8V$
t
2
Nt
1
H "1 8V $N"2 8V $
for steel,H :%3
+herefore,
t
2
Nt
1
H BN1B
+he maimum hoop stress will then occur in the ends, i%e%
f H pdN4t
2
H "1BNB$ "pdN4t
1
$
/hich is !reater than the hoop stress fh in the c)linder% 2or e7ual maimum
stress t
2
should e7ual to :%0%
20
ANALYTICAL DESIGN
OF METHANATOR
2;
2.1 GIVEN DATA
PARAMETETS!%
2B
/or#in! temperature H 3;4 D1
4esi!n temperature H 404 D1
/or#in! pressure H 3E: &si%!
4esi!n pressure H 430 &si%!
DIMENSIONS!%
,nside diameter H 1:2X H 209:%E mm
+an!ent to tan!ent len!th H 10:X H 3E1:mm
+)pe of dished ends H 2:1 semi ellipsoidal
6)drostatic test pressure H E:; &si%!
/elded .oint efficienc) H 1:: K
1orrosion allowance H 1%; mm
MATERIAL!%
AS+< A3EB 511
CODE RECOMMENDED
AS<E Section E division 1
2E
2.2 REQUIRED DIMENSIONS OF
METHANATOR
+he 7uantities or dimensions that are to *e determined for desi!nin! are
listed *elow
I +hic#ness of shell "accordin! to (5 82B"c$$
II +hic#ness of 2:1 semi ellipsoidal head "accordin! to (5832"d$$
III ?penin!s in the pressure vessel as per re7uirement "accordin! to
(583; "*$ "1$ "2$$
IV Selection of flan!es "accordin! to (5844 Y (5811 "a$ "2$$
V +hic#ness of s#irt or desi!n of supports%"accordin! to (5804 Y
appendi 5$
VI Specif) different #inds of loads "(5822$
VII 2ind stresses in response to different loads%
VIII 1om*ination of stresses%
I& 1omparison of stresses with allowa*le stress of material%
& ?penin!s in s#irt
&I 4esi!n of anchor *olts
&II 4esi!n of *ase rin!%
&III /eldin! specification for <ethanator
29
2.3 METHANATOR AS A THIN
CYLINDER
As we #now that if the ratio of thic#ness to internal diameter i%e% tNd is less
than a*out 1N2: ":%:0$, the c)linder is assumed to *e thin c)linder otherwise
it would *e thic#%
2or methanator this ratio will *e
tNd H 1%43EN1:2 H :%:14 Z :%:0
So we treat methanator as thin c)linder

So incase of methanator the radial stresses can *e ne!lected% And there will
*e onl) circumferential or hoop stress Y lon!itudinal stress in the
methanator% 2urther the !overnin! stress will *e the !reater of the two Y we
*ase our desi!n on it%
3:
31
2.4 THICNESS OF SHELL
Accordin! to specifications in (582B "c$ which deals with the thic#ness of
shells under internal pressure and clause @cA with the c)lindrical shells,
!ives formulae for the thic#ness *ased on either lon!itudinal .oint or
circumferential .oint%
a$ 1,'1(<2E'-+,AL S+'ESS "L?-5,+(4,-AL J?,-+S$
,t means that the !overnin! stress will *e the
circumferential stress "hoop stress$ in the lon! seam% 2or this it has to satisf)
that & does not eceed :%3E0SE %,n which case we shall use the followin!
formulae for thic#ness of shell
t H &'N "SE 8:%;&$
*$ L?-5,+(4,-AL S+'ESS "1,'(<2E'E-+,AL J?,-+S$

,t means that the !overnin! stress will *e the lon!itudinal
stress in the circumferential .oint% 2or this it has to satisf) that & does not
eceed 1%20SE% ?' if the circumferential .oint efficienc) is less than than M
the lon!itudinal .oint efficienc)% ,n which case we use the formula for
thic#ness is
t H &'N "2SE [%4&$
As for methanator

& Z :%3E0SE
32
430 Z :%3E0"1;394%9;;$ "1%:$
430 Z ;312%:; Satisfied
therefore hoop stress will *e !overnin! therefore desi!n is *ased on the
lon!itudinal .oint Y we find the thic#ness as follows
t H &' N "SE T :%;&$
/here
t H min% re7uired thic#ness of shell, in
& H internal desi!n pressure, psi
' H inside radius of shell, in
S H ma% Allowa*le stress, psi
E H .oint efficienc) "min$
&uttin! the values in the a*ove e7uation for methanator%
Allowa*le stress for the material to *e used is also !iven "1;394%9;; psi$
t H "430$ "01$ N ""1;394%9;;$ "1%:$ T ":%;$ "430$$
t H 1%3B0X
t H 1%3B0X [ corrosion allowance
t H 34%9 [ 1%; mm
t H 3;%0 mm
t H 1%43EBX
we shall ta#e a plate of 1 MX for safet)
33
2.5 THICNESS OF 2:1
ELLIPSOIDAL HEAD
,t will *e found *) (5832 "d$ which states
+he re7uired thic#ness of a dished head of semi ellipsoidal form, in
which half the minor ais "inside depth of the head minus the s#irt$e7uals
one8forth of the inside diameter of the head s#irt, shall *e determined *)

t H &4 N "2SE T :%2&$
An accepta*le approimation of a 2: 1 Ellipsoidal head is one with a #nuc#le
radius of :%1B4 and a spherical radius of :%9:4%
2or methanator

t H "430$ "1:2$ N "2"1;394%9;;$ "1%:$ T ":%2$ "430$$
t H 1%30;BX [ corrosion allowance
t H 1%30;BX [ "1%; R :%394X$
t H 1%419BX
34
>nuc#le radius H :%1B4 H 1B%34X
Spherical radius H :%9:4 H 91%EX

/here 4 H internal diameter in inches

2." OPENINGS IN A PRESSURE VESSEL
+he clause of the code concernin! with the desi!n of openin!s is (583;"a$
"*$
a$ shape of openings

1$ ?penin!s in c)lindrical or conical portions of vessels, or in formed
heads, shall prefera*l) *e circular, elliptical or round openin! eceeds twice
the short dimensions, the reinforcement across the short dimensions shall *e
increased as necessar) to provide a!ainst ecessive distortion due to twistin!
moment% "+he openin! made *) a pipe or a circular no==le, the ais of which
is not perpendicular to the vessel wall or head, ma) *e considered as
elliptical openin! of desi!n purposes$
30
2$ ?penin!s ma) *e of other shapes than those !iven in "1$ a*ove, and all
corners shall *e provided with a suita*le radius% /hen the openin!s are of
such proportions that their stren!th cannot *e computed with assurance of
accurac), or when dou*t eists as to the safet) of a vessel with such
openin!s, the part of the vessel affected shall *e su*.ected to a proof
h)drostatic test as prescri*ed in (581:1%
*$ size of openings
1$ &roperl) reinforced openin!s in c)lindrical shells are not limited as to
si=e ecept with the followin! provisions for desi!n% +he rules in (583;
throu!h (5843 appl) to openin!s not eceedin! the followin!: for vessels
;: in% in diameter and less, one half vessel diameter, *ut not to eceed 2: in%;
for vessel over ;: in% in diameter, one third the vessel diameter, *ut not to
eceed 4: in% 2or openin!s eceedin! these limits, supplement rules of 18B
shall *e satisfied in addition to (583; throu!h (5843%
2$ &roperl) reinforced openin!s in formed heads and spherical shells are
not limited in si=e% 2or an openin! in end closure, which is lar!er than one
half of inside diameter of the shell, various alternatives to reinforcement
ma) also *e used%
2?' <E+6A-A+?'
As we #now that openin!s in a vessel are made as per re7uirement, *ut the
the factor to *e considered in is its si=e, which will re7uire various de!rees
of reinforcements as stated a*ove%
3;
As there are five openin!s in the methanator all of them are in its heads% +wo
of them are elliptical Y three are circular%
As for methanator there is the maimum openin! is of si=e 24X Y
24 Z 1N3"1:2$
24 Z 34 to4:
So we use (583; for openin!%
2.# SELECTION OF FLANGES
/e #now that openin!s of si=e 2%0X or lar!er shall *e flan!ed Y we shall use
flan!es with raised face%
2or methanator , all the flan!es would *e of ratin! ;::l* which are selected
from the pressure8temperature ratin! "A-S, 31;%0819E1$ 2or desi!n
pressure of 430 psi%! Y desi!n temperature of E:;D2, which will *e rounded
off to E0:2 Y 030psi%! ta*le attached%
?ther specification of the flan!es accordin! to their pipe si=es are !iven
"hi!h li!hted$ for ;::l* flan!es in the ta*le attached%
3B
LE-5+6 ?2 S+(4 3?L+S
3E
2.8 THICNESS OF SIRT OR DESIGN OF
SUPPORTS
A s#irt is the most fre7uentl) used and the most satisfactor) support for
vertical vessels% ,t is attached *) continuous weldin! to the head and usuall)
the re7uired si=e of this weldin! determines the thic#ness of the s#irt%
39

2i!ures A and 3 show the most common t)pe of s#irt to head attachment% ,n
calculations of the re7uired weld si=e, the values of the .oint efficienc) !iven
*) the 1ode "(/ 12$ ma) *e used%"(5804 YA&&E-4,G 5$
t H 12 <
+
N '
2
R I RSE [ / N 4ISE
/here
4 H ?utside diameter of s#irt, in
E H efficienc) of s#irt to head .oint%
":%; for *utt weld, fi! A, :%40 for lap weld, fi!% 3$
<
+
H moment at s#irt to head .oint, ft% l*
' H outside radius of s#irt, in
S H stress value of the head or s#irt material whichever is
smaller, psi
t H re7uired thic#ness of s#irt, in
/ H wei!ht of tower a*ove the s#irt to head .oint, in
operatin! condition% l*
NOTE!%
4:
(sin! etremel) hi!h s#irt, the stresses at the *ase ma) !overn% +o calculate
the re7uired thic#ness of s#irt, in this case the a*ove formula can *e used%
+he moment and wei!ht shall *e ta#en into consideration at the *ase and
.oint efficienc) will *e ta#en as 1%:%
2or methanator the wei!ht of the vessel used is as approimated later% And
we are ta#in! into account the moments due to two forces firstl) due to
earth7ua#e
And secondl) due to wind% /hichever is !reater should *e used%
As the moment at the s#irt to head .oint due to seismic load is !reater as
indicated *) the calculations later% so we shall use < due to earth7ua#e
2?' <E+6A-A+?'
4 H 1:4%EB0X
E H :%;
<
+
H B;:09%0E l*ft
' H 02%43EX
S H 1;394%9;; l*ft
t H\
/ H 41EBB%;B; l*
So minimum thic#ness of s#irt
t H 12RB;:09%0E N 02%43E
2
R3%14R1;394%9;;R%; ] earth7ua#e
[
41EBB%;B; N 1:4%EB0R3%14R1;394%9;;R:%; ] wei!ht
t H :%:1:B4 [ :%:1292
t H :%:23;;X
41
+he a*ove calculations are from the @Pressure vessel hand book by
Megyesy
+o verif) our calculations we also used the formula from another *oo# of
@Dennis R. Mossthese calculations are as under
THICNESS REQUIRED AT OPENING OF SIRT
+here are five openin!s in the methanator s#irt *ut the *i!!est openin! is of
24X in dia% +herefore the desi!n is *ased on this openin!
5 H width of openin! in inches H 24X
4 H width of s#irt H 1:4%EB0X
<
*
H moment at *ase, in8l* H B932B%39E; l*ft "earth7ua#e$
/
*
Hwei!ht of vessel at *ase, l* H 41EBB%;B;l*
2
)
H minimum specific )ield stren!th, psi H 349EE%430psi
f
*
H *endin! stress, psi H \
f
*
H 1 N "I4835$ R ^4E<
*
N4 [ /
*
_

-ow after puttin! the values in a*ove formula Y solvin! we !et the value of
*endin! stress as follows
f
*
H 1E02%94B0 psi
-ow the thic#ness of s#irt can *e found *) two formulae the !reater of the
two values must *e ta#en
42
t
s#
H f
*
N ER2
)
H 1E02%94B0 N ER349EE%430
t
s#
H ;%;E8;
?'

t
s#
H "f
*
N 4;4:,:::$
1N2
t
s#
H :%:19X
+he !reater value should *e ta#en%":%:19$
/hich nearl) e7ual to the thic#ness found earlier
DETERMINE ALLO$ABLE LONGITUDANAL STRESSES!%
+E-S,?-,
S
t
H lesser of :%;2
)
or 1%33S
S
t
H :%;2
)
or S
t
H 1%33S
H :%;R349EE%430 H 1%33R 1;394%9;;
S
'
( 20993.0" H 21E:0%3:4
1?<&'ESS,?-,
S
c
H :%3332
)
or H 1%33S "whichever is less$
H :%333R349EE%430 or H 21E:0%3:4
S ( 11"51.148
THICNESS REQUIRED AT BASE DUE TO M
)
!%
43
L?-5,+(4,-AL 2?'1ES
2
lt
H ^4ER<
*
N IR4
2
_ T ^/
*
N IR 4_

2
lt
H 1323%:3B T 12B%1;E
2
lt
H 1190%E;E l*Nin
2
lc
H "8$ `2
lt
]
2
lc
H 8 140:%2:0 l*Nin
+herefore s#irt thic#ness re7% at *ase
t
s#
H 2
lt
N S
t
?' H 2
lc
N S
c
H 1190%E;E N 2:993%:; ?' H 140:%2:0 N 11;01%14E
H :%:0;X ?' H :%12X
+he !reater of the two values is ta#en i%e% :%12X
2.9 METHANATOR IS TO BE SUB*ECTED TO THE
FOLO$ING INDS OF LOADINGS
2rom the list of the loadin!s on a pressure vessel !iven in (5822,
methanator is lia*le to *e su*.ected to the followin! loads%
,nternal pressure
44
/ei!ht of the vessel and normal contents under operatin! or test
conditions"this includes additional pressure due to static head of
li7uids$
/ei!hts of various attachments
/ind Y seismic reactions
2.10 STRESSES IN RESPONSE TO DIFFERENT LOADS
a$ 4(E +? ,-+E'-AL &'ESS('E

As we are treatin! methanator as a thin c)linder so the values of hoop
stress Y lon!itudinal stress are calculated as under
+herefore radial stresses are i!nored "ver) small$ so we consider the
followin! primar) mem*rane stresses%
6oop Stresses
Lon!itudinal Stresses
6??& S+'ESSES "S
1
$
2
h
H &d N2t
H "430$ "1:2$ N 2"1%43E1$
H 1042;%; l*Nin
2
L?-5,+(4,-AL S+'ESS "S
2
$
40
2
l
H &d N 4t
H "430$ "1:2$ N 4"1%43E1$
H BB13%3:2 l* N in
2
As hoop stress is !reater so desi!n is *ased on hoop stress%
)+ STRESS DUE TO $EIGHT OF VESSEL ,
ATTACHMENTS
,t is assumed that wei!ht of the vessel and its attachments results in
compressive stress onl) Y eccentricit) doesnFt eists and the resultin! force
coincides with the ais of the vessel%
+he wei!ht shall *e calculated for the various conditions of the tower as
follows%
A% Erection wei!ht
3% ?peratin! wei!ht
1% +est wei!ht
+he compressive stress due to the wei!ht is !iven *)
S H / N ct 888888888888888888888888888888888888888888888 "a$
/here
S H unit stress, psi
/ H wei!ht of vessel a*ove the section under consideration, l*
c H circumference of shell or s#irt on the mean diameter, in
t H thic#ness of shell or s#irt, in
+he wei!hts of different vessel elements are !iven in the ta*les attached%
$EIGHT OF METHANATOR
4;
A+ ERECTION WEIGHT
1$ S6ELLH10EER12%0"++L$ H19850 lb
2$ SE<, ELL,&S?,4AL 6EA4S H 0003R2 H11106 lb
3$ 2LA-5ES ";$ H 2a "S,bE$ H wt% of weld nec# [wt% of slip on
[studs
A "24X$ H 9BB [ EB; [ 3;0
A
a
"12X$ H 22; "/ -$
A+ Y 3+ "2X$ H 4"1:$ [ 2"4%0$ `/%- [ S+(4S]
3 "12X$ H 22; "/-$
1 ";X$ H B3[E;[3:
+?+AL /E,56+ ?2 ; 2LA-5ES H 2908 lb
4$ &,&ES "assumin! S16% 1;:$
El*ow "12X$ H40:l*
2 pipes "1MX$ H 2R4%9 l*Nft R 1;c
&ipe "2X$ H B%0 l*Nft R "9N12$c
&ipe ";X$ H 40%3 R "1:0N12$c
+?+AL /E,56+ 4(E +? &,&ES Y EL3?/ H 1008.775 lb
0$ &LA+ES
"+here are 4 plates in the methanator upper manhole Y which
are 4X wide Y MX thic# Y also 3c lon!$

/ei!ht of one plate H ;%E:R3
/ei!ht of 4 plates H 2:%4R4 H E1%; l*%
4B
;$ ,-S(LA+,?-
"/e shall use an insulation of mineral wool of thic#ness 2MX%
+he wei!ht of insulation !iven in the ta*le is in pounds per cu*ic feet so in
order to !et the wei!ht of insulation we will have to calculate the volume of
insulation to *e used on methanator% 2or that we will 1
st
have to find the
circumference of the vessel *ased on eternal diameter%
Volume of insulation on shell H ++L [ circumference [ thic#ness
H 12%0c [ I R 4
o
[ :%2:E3c
H 12%0 [ 2B%44 [:%2:E3
H B1%44;9%ft
3
Volume of insulation on the heads H 1%:9 R 4
2
Rthic#ness R2
H 1%:9 R E%B39d2R:%2:E3R2
H 34%;E3E ft
3
+?+AL V?L(<E ?2 ,-S(LA+,?- +? 3E (SE4 ?- +6E
<E+6A-A+?' H 1:;%13:BF e 11: ft
3
+herefore
+?+AL /E56+ ?2 ,-S(LA+,?- "<,-E'AL /6??L$ H E:l*Nft
3
R11:
H EE: l*%
Addin! all the a*ove wei!hts H 30E34%3B0 l*
2or over wei!hts of plates Y weldin! wei!hts add ;K of the a*ove wei!hts
to total wei!ht%
+otal wei!ht H 30E34%3B0
;K of total wei!ht H 210:%:;20
4E
+herefore, the erection wei!ht H3B9E4%43Bl*
3$ ?&E'A+,-5 /E,56+
E'E1+,?- /E,56+ H 3B9E4%43B l*
/E,56+ 2?' ?&E'A+,-5 L,f(,4 H 0K ?2 +6E E'E1+,?-
/E,56+
H 1E99%22 l*
+?+AL ?&E'A+,-5 /E,56+ ?2 <E+6A-A+?'
H41877.676 lb
STRESS DUE TO WEGHT OF METHANATOR
&uttin! values in the formula "a$
/here,
c H I R 4
mean
H 3%14 "1:3%43E$ H324%B9 in
t H 1%43E
S
w
H 41EBB%;B; N 324%;B;R1%43E H89.88 -./ 0123-45../65+%%%%%%%%%%
01$
1+ STRESS DUE TO $IND LOAD!
+owers under wind pressure are considered as uniforml) loaded cantilever
*eams% +he computation of wind is *ased on standard A-S, A0E%1819E2%
/here terrain features and local records indicate that 0: )ears at standard
hei!ht are hi!her than those shown in the map, those hi!her values shall *e
the minimum *asic wind speed%
49
+he minimum *asic wind speed for determinin! desi!n wind pressure shall
*e ta#en from the map of wind speed%
4esi!n wind pressure shall *e determined *) the followin! formula:8
& H 7
s
R1
e
R1
7
/here,
&H 4esi!n wind pressure, psf
7
s
H /ind sta!nation pressure at the standard hei!ht of 3: feet as
ta*ulated:
B7./1 8/9: .-55:; 3-<.
B: E: 9: 1:: 11: 12: 13:
P45..=45 >0.+; -.?
13 1B 21 2; 31 3B 44
1
7
H &ressure coefficient "shape factor$:
'ound or elliptical towers8888888888888888888888888888:%E
1
e
H 1om*ined hei!ht, eposure and !ust factor coefficient as ta*ulated:
6ei!ht a*ove !round,
ft%
1oefficient 1"e$
Eposure 1 Eposure 3
:82: 1%2 :%B
2:84: 1%3 :%E
4:8;: 1%0 1%:
;:81:: 1%; 1%1
1::810: 1%E 1%3
10:82:: 1%9 1%4
Eposure 1888888888888888888888+he most severe eposure
Eposure 3 888888888888888888888,ntermediate eposure
0:
2or the methanator we will ta#e a wind speed of 13: mph, so the value of
7
s
H44psf
1
e
H :%E88888888888888888888888882or circular vessel
1
7
H :%E 888888888888888888888888,ntermediate eposure Y vessel hei!ht of
2Eft
+here fore the value of wind pressure usin! the a*ove formula will *e;
& H 2E%1; psf
/e will ta#e the wind pressure 3: psf%
f(A-+,+,ES 2?'<(LAS
Shear VH &
w
R4
1
R6
1
<oment at *ase <H&
w
R4
1
R6
1
Rh
1
<oment at hei!ht h"t$ <
t
H <8 h
t
`V8:%0&
w
4
1
h
t
]
Stress SH 12<
t
N '
2
RIRt
/here,
4
1
H width of the vessel with insulation, ft H 9%10 ft
E H Efficienc) of the welded .oints H 1%:
h
1
H lever arm, ft H 6 N 2 H 12%;;c
01
h
t
H distance from *ase to section under consideration, ft H 12%E
6 H len!th of vessel section, ft H20%33c
< H <aimum moment "at the *ase$, ft8l*
<
t
H <oment at hei!ht h
t
, l*ft
&
w
H /ind pressure, l*% N ft
2
H 3:c
' H <ean radius of vessel, in H01%BX
S H Stress due to wind, psi H\
V H +otal shear, l*
t H +hic#ness of shell ecludin! corrosion, in H 1%430X
+he values of shear, moment at *ase Y moment at s#irt .oint are calculated
as under and then the stress developed in response to the moment <"t$ usin!
the formulae listed in the ta*le a*ove% 3) puttin! the values of the
parameters listed a*ove for methanator

02
Shear H V H 3:R9%10R20%33
V H ;903%:E0 l*
<oment "at *ase$ < H 3:R9%10R20%33R12%;;
HEE:2;%:0;1 l*ft
<oment at head to s#irt .oint

<
t
H < T 12%E33`V T :%0R3:R9%10R12%E33]
<
t
H 214::%204;0 l*ft
Stress due to wind H 12R<
t
N "01%B$
2
RIR1%430
S (wind) = 21.32 psi
:+ STRESS DUE TO SEISMIC LOAD

a$ &E',?4 ?2 V,3'A+,?-
As a result of wind tall towers develop vi*ration% +he period
of vi*ration should *e limited, since lar!e natural periods of vi*ration can
lead to fati!ue failure% +he allowa*le period has *een computed from the
maimum permissi*le deflection%
f(A-+,+,ES 2?'<(LAS
&eriod of vi*ration,+ sec +H:%::::2;0"6 N 4$
2
R"w4 Nt$dM
<aimum allowa*le period of
vi*ration,+
a
sec
+
a
H:%E:"/6 NV!$
M
s
03
/here,
4 H ?utside diameter of vessel, ft% HE%B0l*
6 H Len!th of vessel includin! s#irt, ft% H 2B%41;; ft
5 H 32%2 ft% N sec
2
acceleration
+ H +hic#ness of s#irt at the *ase, in% H:%::1X
V H +otal shear, l*%, H 32:3%;4 l* "calculated ahead$
/H /ei!ht of tower, l*% H 41EBB%;B; l*

wH wei!ht of tower per foot of hei!ht, l*% H 10EEl* "from ta*le$
&uttin! values to !et period of vi*ration for methanator
+ H :%::::2;0"2B%41;; N E%B0$
2
R"10EERE%B0N%::1$
M
+ H :%9; sec
-ow allowa*le period of vi*ration
+
a
H :%E: `wR6 N VR!]
M
+
a
H 2%;;E sec
As O+F is less than O+
a
F hence the condition is satisfied
STRESS DUE TO EARTHQUAE
+he loadin! condition of the tower under seismic forces is similar to that
of the cantilever *eam when the load increases uniforml) towards the
free end
04
2?'<(LAS
Shear <oment
VHb,>1S/ <H^2
t
6["V82
t
$"26 N3$_
<

H <"N6$
/here
1H -umerical coefficient
H 1N10"+$
@
H :%:;BN "++
@
(0.:;E"should not *e more than :%12$
E H Efficienc) of welded .oints H 1%:
2
t
H +otal hori=ontal seismic force at the top of the vessel, l*
H :%:B+V "2
t
shall not eceed :%20V$
H :, for + Z :%B
6 H Len!th of vessel includin! s#irt, ft H 2B%41;;c
, H ?ccupanc) importance coefficient "use 1%: for vessels$
> H 6ori=ontal force factor "use 2%: for vessels$
< H <aimum moment at the *ase, l*ft
<

H <oment at distance , ft8l*

S H -umerical coefficient for site structure resonance
H 1%0 if + Z 2%0
+he product 1S shall not eceed :%14
/ H /ei!ht of the vessel, l*
b H Seismic factor
H :%3B0 for methanator
Shear H :%3B0R1R2R:%:;ER1%0R41EBB%;B;
V H 32:3%;4l*
2
t
H :%:BR+RV H210%2E4
00
:%20V H E::%91
As condition is that 2
t
should not eceed :%20V so it is satisfied for
methanator
+herefore,
<oment < H ^210%2ER2B%41;;["32:3%;48210%2E$R"2R2B%41;;N3$
< H 1;2493%49;2l*ft
<oment at s#irt to head .oint
<
t
H <"N6$ where H12%E33
M
t
= 76059.58748 lbft

0;
+herefore stress due to earth7ua#e

S
e7
H 12R <
t
N '
2
RIR t
H 12RB;:09%0E N "01%B$
2
R3%14R1%430
S
eq
= 75.74 psi
2.11 COMBINATION OF STRESSES
+he stresses induced *) the previousl) descri*ed loadin!s shall *e
investi!ated in com*ination to esta*lish the !overnin! stresses%
,t is assumed that wind and earth7ua#e loads do not occur simultaneousl)
+hus the tower should *e desi!ned for either wind or earth7ua#e load
/hichever is !reater\
,n case of methanator the stress due to internal pressure is the hoop stress
"mem*rane stresses$, the stress due to earth7ua#e "!reater$ Y stress due to
wei!ht "compressive$ is considered

1om*ination of stresses will *e as follows
A.'45.. :=5 '2 574'<>=7B5
A.'45.. :=5 '2 /9'5497C -45..=45
%.'45.. :=5 '2 85/D<'
2rom the previous calculations puttin! the values of stresses
[1042;%; l*Nin
2
[B0%B4 psi
8E9%99 psi
0B
1om*ined stress at the head to s#irt .oint on the vessel in operatin!
conditions = 15412.46 psi
2.12 COMPARISON
+he !overnin! stress will *e tensile as shown *) the positive si!n, which is
lesser than allowa*le stress of the !iven material at that particular
temperature
+herefore the desi!n is safe.
2.13 DESIGN OF ANCHOR BOLTS
Vertical vessels, must *e fastened to the concrete foundation, s#id or other
structural frame *) means of anchor *olts and the *ase "*earin!$ rin!%
+6E -(<3E' ?2 A-16?' 3?L+S
+he anchor *olts must *e in multiple of 4 and for tall towers it is
preferred
to use minimum E *olts%
SPACING OF ANCHOR BOLTS
+he stren!th of too closel) spaced anchor *olts is not full) developed in
concrete foundations% it is advisa*le to set the anchor *olts not closure than
a*out 1EX %to hold this minimum spacin!, in the case of small diameter
vessel the enlar!in! of the *olt circle ma) *e necessar) *) usin! conical
s#irt or wider *ase rin! with !ussets%
4,A<E+E' ?2 A-16?' 3?L+S
1omputin! the re7uired si=e of *olts the area within the root of the
threads onl) can *e ta#en into consideration% +he root areas of the *olts are
0E
shown *elow in ta*le A% for corrosion allowance 1NE of an inch should *e
added to the calculated diameter of anchor *olts%
2or anchor *olts and *ase desi!n is descri*ed for methanator
1$ An approimate method which ma) *e satisfactor) in a num*er of cases%
2$ A method which offers closer investi!ation when the loadin! conditions
and other circumstances ma#e it necessar)%
R Source &ressure Vessel 6and 3oo# *)
/e will use the approimate method
+he desi!n of anchor *olts is to assume the *olts replaced *) a
continuous rin! whose diameter is e7ual to the *olt circle%
09
+he re7uired area of the *olts shall *e calculated for empt) condition
of tower%
2?'<(LAS
<aimum tension l*% Nlin% ,n% + +H12<NA
*
8/N1
*
'e7uired area of one *olt S7%8in% 3
a
3
a
H+1
*
NS
*
-
Stress in Anchor 3olt psi% S
*
S
*
H+1
*
N3
a
-
/here,
A
*
H area within the *olt circle, s7% 8 in%
1
*
H 1ircumference of *olt circle in%
< H <oment at the *ase due to wind or earth7ua#e, ft% T l*%
- H-um*er of anchor volts
S
*
H maimum allowa*le stress value of *olt material psi%
/H /ei!ht of the vessel durin! erection, l*%
4iameter of *olt circle H 1:2 [ 2"1%43E$ [2"l "2$$

Let us assume l "2$ H 3%3B0

4iameter of *olt circle H 1:2[2R1%43E[2R3%3B0
H 111%;2X
2rom ta*le 3
minimum no% of *oltsH1;
maimum no% of *oltsH2:
*olt si=e H 2 gX
;:
*olt root area H 4%;1E s7% in

2rom ta*le 1
specimen no%HSA 1933B
ma% allowa*le stress H 1;,::: psi
2or chec#in! stress in anchor *olts
5iven,

3olt circle dia% H 111%;2X
Area with in the *olt circle H A
*
H I r
2
H9BE:%33 s7%in
1ircumference of *olt circle H I 4 H 30:%;X
<oment at *ase due to earth7ua#e H1;2493%49;2l*ft
/ei!ht durin! errectionH/ H 41EBB%;B; l*
<a% allowa*le stressH S
*
H 1;,::: psi
- H1;
Area within one *olt H 4%;1E s7%in
<aimum tension + H 12R1;2493%49;2N9BE:%33 8 41EBB%;B;N30:%;
+ H 199%3B2;8119%420
+HB9%94 e E: l*Nin
Stress in anchor *olts
S"*$ H E: R 30:%; N 4%;1E R1;
S"*$ H 3B9%;: psi
/hich is less than the allowa*le stress so it is satisfied
2.14 !ELDING OF PRESSURE VESSELS:
;1
+here are several methods to ma#e welded .oints% ,n a particular case
the choice of a t)pe from the numerous alternatives depend on:
1% +he circumstances of weldin!%
2% +he re7uirements of the code%
3% +he aspect of econom)%
+6E 1,'1(<S+A-1ES ?2 /EL4,-5:
,n man) cases the accessi*ilit) of the .oint determines the t)pe of
weldin!% ,n a small diameter vessel "under 1E824 inches$ from the inside,
no manual weldin! can *e applied% (sin! *ac#in! strip it must remain in
plate% ,n lar!er diameter vessels if a man wa) is not used, the last "closin!$
.oint can *e welded from outside onl)% +he t)pe of weldin! ma) *e
determined also *) the e7uipment of the manufacturer%
1?4E 'Ef(,'E<E-+S:
'e!ardin! the t)pe of .oint the 1ode esta*lishes re7uirements *ased on
service, material and location of the weldin!% +he weldin! processes that
ma) *e used in the construction of vessels are also restricted *) the 1ode%
+he 1ode8re!ulations are ta*ulated on the followin! pa!es under the
titles:
"a$% +C&ES ?2 /EL4E4 J?,-+S:
"Joints permitted *) the code, their efficienc) and limitations of their
applications%$ +a*le (/812
"*$% 4ES,5- ?2 /EL4E4 J?,-+S:
;2
"+)pes of .oints to *e used for vessels in various services and under
certain desi!n conditions%$ (/82, (/83
"c$%J?,-+ E2,1,E-1,ES A-4 S+'ESS 'E4(1+,?-S:
"Efficiencies of .oints at certain locations and reduced allowa*le stress
to *e used in calculations of vessel components%$
+he data of the ta*le are *ased on the followin! 1ode re!ulations:
2ull, spot, partial radio!raphic eamination or no radio!raph) of A, 3, and 1
.oints% (/811
2or lon!itudinal stress calculation the efficienc) of partiall) radio
!raphed .oints is the same as for spot radio !raphed .oints%
Seamless vessel sections and heads with 1ate!or) 3,1 or 4 *utt .oints
that are spot radio !raphed shall *e desi!ned for circumferential stress usin!
a stress value e7ual to E0K of the allowa*le stress value of the material;
(/812"*$
/hen the .oints are not radio !raphed and for .oint efficienc), E the
value in column of ta*le @+)pes of welded .ointsA are used, in all other
desi!n calculation, a stress value e7ual to E:K of the allowa*le stress value
of material shall *e used ecept for unsta)ed flat heads, etc% (/812"c$
+6E E1?-?<C ?2 /EL4,-5:
,f the two precedin! factors allow free choice, then the aspect of
econom) must *e the decidin! factor%
Some consideration concernin! the econom) of weldin!:
V8ed!e preparation, which can *e made *) torch cuttin!, is alwa)s
more economical than the use of J or ( preparation%
4ou*le V preparation re7uires onl) half the deposited weld metal
re7uired for sin!le V preparation%
;3
,ncreasin! the si=e of a fillet weld, its stren!th increases in direct
proportion, while the deposited weld metal increases with the s7uare of its
si=e%
Lower 7ualit) weldin! ma#es necessar) the use of thic#er plate for
the vessel% /hether usin! stron!er weldin! and thinner plate or the
opposite is more economical, depends on the si=e of vessel, weldin!
e7uipment, etc% this must *e decided in each particular case%
/EL4,-5 ?- <E+6A-A+?':
+o the .oints under certain conditions special re7uirements appl)%
+hese special re7uirements which are *ased on service, material, thic#ness%
Accordin! to the desi!ned conditions, service environment, material, and
desi!n thic#ness it is recommended to use a dou*le V8t)pe *utt .oint% +his
dou*le V8t)pe *utt .oint can *e applied with out a *ac#in! strip, thus
reducin! the cost of material% +he .oint efficienc) of each ever) .oint in the
vessel should *e one accordin! to radio!raph)% A dou*le V8t)pe *utt .oint is
shown in the fi!% *elow%
+here will *e a circumferential .oint at each shell head .unction%
+here will *e another circumferential .oint in the middle havin! a
lon!itudinal seam on each side% As evident from the fi!%
;4
;0
ANALYSIS
BY
ANSYS
;;
3.1 ANSYS
A-SCS is software of 2EA "2inite Element Anal)sis$ which !ives )ou a
wa) to test )our model *efore manufacturin!% )ou can calculate stress,
strain, displacement, thermal stresses, resonance, also optimum desi!n
parameters, points where our model *ecomes unsta*le and much more% An)
of seven anal)sis t)pes offered in A-SCS:
S+A+,1
<?4AL
6A'<?-,1
+'A-S,E-+
S&E1+'(<
E,5E-VAL(E 3(1>L,-5
S(3S+'(1+(',-5
124 "1?<&(+A+,?-AL 2L(,4 4C-A<,1S$
All of these anal)sis t)pes help us in desi!n optimi=ation to a !reat
etent% /hether the pro*lem is linear or non8linear i%e% isotropic or
orthotropic, we can solve it with the help of this software% 4esi!n
optimi=ation also helps )ou in findin! suita*le desi!n parameters of a
failed structure% So, in short, A-SCS is a complete anal)sis tool which
can !ive )ou all what )ou want%
;B
3%2 ANSYS INPUT METHODS
GUI "Gap!i"al #se intefa"e#
COMMAND !INDO!
INPUT"$ata# FILE
;E
3%3
;9
3.4 ANALYSIS OF METHANATOR UNDER
INTERNAL PRESSURE USING $SHELL 51%
B:
3.5 ANALYSIS OF METHANATOR THROUGH COMMAND
!INDO!
&PREP7
&TITLE' METHANATOR

ANTYPE'STATIC
ET'1'SHELL51
R'1'1.43(
MP'E)'1'3*E6
MP'NU)Y'1'.3
N'1'51
N'2'51'1*
E'1'2
CP'1'U)'1'2 + COUPLE RADIAL DIRECTION
D'1'UY'''''U,'ROT,
D'2'ROT,
F'2'FY'35545*7.( + CAP FORCE
SFE'1'1'PRES''435 + INTERNAL PRESSURE
FINISH
&SOLU
OUTPR'ALL'1
SOLVE
FINISH
&POST1

ETABLE'STRS-HOOP'NMISC'6..........", DIR#
ETABLE'STRS-LONGI'NMISC'7........."Y DIR#
3.6 ANALYSIS OF METHANATOR THROUGH GUI
Since the material of methanator is same throu!hout therefore we will use
istroptropic material for structural anal)sis% +he units specified in 3,-
"3+($ %
B1
MAIN MENUE / PREFERENCES / STRUCTURAL
,n order to !ive title to our modal%
2,LEh16A-5E +,+LEh<E+6A-A+?'
B2
MAIN MENU /SOLUTION / NE! ANALYSIS / STATIC
DEFINIG THE ELEMENT TYPE
As we are usin! @Shell 01A for the anal)sis of methanator therefore, define
thhe element t)pe as follows,
MAIN MENU/PREPROCESSOR/ELEMENT TYPE /ADD&EDIT&DELETE/SHELL51
B3
DEFINING REAL CONSTANTS
,n @shell 01A we will onl) ta#e two nodes of the vessel material % as it is a a
24?2 case therefore the thic#ness of the vessel could *e entered in the real
constants% Since the shell is of uniform thic#ness and the dished ends are of
comparativel) less thic#er than the shell "as calculated in anal)tical desi!n$,
to compensate for the increase in stren!th due to *endin!% +herefore, the
thic#ness remains the same throu!hout the vessel%i%e% 1%43E in%
B4
MAIN
MENU/PREPRCESSOR/REALCONSTANTS/1.43(0
DEFINIG MATERIAL PROPERTIES
2or isotropic materials, the properties remains the same in ever) direction%
6ere we have entered the )oun!Fs modulus "3:e;$, the densit) of material is
":%2E$, the posionFs ratio ":%3$% all of these values are !iven in the ta*le of
material for the methanator%
MAIN MENU/PREPRCEESOR/MATERIAL PROP/CONSTANT.ISOTROPIC
B0
+he two nodes are plotted at a distance of 01 inches from the ori!in which is
infact, the radius of methanator% +hr hei!ht of element is ta#en at 1: inches%
M123 4536/78595853:5;/:851<5/3=>5;/I3 1:<2?5 CS
B;

CREATING ELEMENT
MAIN MENU/PREFERENCES/CREATE/ELEMENTS/THRU
NODES
BB

APPLYING CONSTRAINTS
MAIN MENU/SOLUTION/APPLY/DISPLACEMENT
BE

B9

APPLYING LOADS
E:
,n order to see the effect of lon!itudinal component of pressure which causes
the lon!it)udinal stress in the shell mem*rane, lon!itudinal force is applied
as caculated earlier in addition to the internal pressure which is 430 psi%
MAIN MENU/SOLUTION/APPLY/FORCE&MOMENT/FY
E1
E2
after creatin! element of the methanator material% And after appl)in! the
*oundar) conditions Y loads % +he element is read) for the solution% As
shown on the previous pa!e%
solve the element as shown *elow%
MAIN MENU/SOLUTION/SOLVE.CURRENT LS
E3
POSTPROCESSING
,t is the environment where the results of the anal)sis can *e listed or ploted%
2or our case the resuts are ploted as follows% As we are interested in the
stress therefore we have listed or plotted the e7uivalent stress or von mises%
MAIN MENU/ GENERAL POSTPROCESSOR/LIST
RESULTS/NODAL SOLU/STRESS.COMPONENTS

RESULTS

E4
MAIN MENU/GENERAL POST PROCESSOR/LIST
RESULTS/NODAL SOLU/STRESS.PRINCIPALS
RESULTS
E0
MAIN MENU/GENERAL POSTPROCESSOR/PLOT
RESULTS/NODAL SOLU/STRESS.VON MISES

E;
3.7 TO FIND THE HOOP AND LONGITUDINAL STRESS
H22- .'45.. 8/CC )5 7C29D '<5 E%7F/. , C29D/'=:/97C .'45.. 8/CC )5 7C29D GH7F/..
S'74'/9D ?423 37/9359= '<5 ?2CC28/9D -7'< /. ?2CC285: '2 .55 '<5 <22- 79:
C29D/'=:/97C .'45..5..
GEN. POSTPROC/ELEM. TABLE/DEFINE TABLE/STRESS.HOOP.NMISC'6
888888888888888888888888888888888888 /STRESS-LONG.NMISC.7
EB
TO SEE THE STRESSES "HOOP @LONG#
GEN.POSTPROC/LIST RESULTS/ELEM. SOLN/BY SEAUENCE.NMISC'6
BY DOING THIS HOOP STRESS IS OBTAINED.
EE
TO SEE THE LONGITUDINAL STRESS
............................................../BY SEAUENCE.NMISC'7
THE LONGITUDINAL STRESS IS OBTAINED.
E9
3.( DISPLACEMENTS OF THE 4 DOFB;

9:
COMPARISON
&
CONCLUSION
91
4.1 MEMBRANE STRESSES IN
METHANATOR
+he mem*rane stresses i%e hoop Y lon!itudinal stresses ploted are in pound
per s7uare inch%

92
4.2 COMPARISON OF ANSYS @ ANALYTICAL
SOLUTION
As it is evident from the chart that our lon!itudinal stress is eactl) the same
*ut the circumferential stress varies sli!htl) owin! to roundin! off data%

CONCLUSION
F=8 131CD<2:1C >5;2E3 F5 G1?5 6;5> <G5 ASME SECTION.(
>2?2;2=3 1 FG2:G E2?5; <G5 6C<241<5 >5;2E3 :1C:6C1<2=3;. A; F5
G1?5 E=< <G5 ;145 ?1C65; 98=4 <G5 ;=9<F185 <G5859=85 ANSYS 2;
1 85C21HC5 ;=9<F185.
93
REFERENCES
SECTION VIII RULES FOR CONSTRUCTION OF PRESSURE
VESSELS DIVISION 1
PRESSURE VESSEL HANDBOO 0Seventh Edition !"
!"# $. M"%&%
#RESSURE $ESSE% DESIGN MANUA%
by DENNIS R& MOSS

94
90
9;
9B
9E
99
1::
1:1
1:2
1:3
1:4



1:0