A REPORT

ON
PRESSURE VESSEL DESIGN AND ANALYSIS
BY
Alok Saxena (2010A4PS319G)
(B.E (Hons.)Mechanical)
Bhavik Kakka (2010A4PS237G)
(B.E (Hons.)Mechanical)

Under the guidance of:

Dr. D.M. Kulkarni
(Dept. of Mechanical Engineering, BITS Pilani K.K. Birla Goa Campus)

Prepared in partial fulfilment of the Computer Oriented Project;

Course No: BITS C331
AT
BITS Pilani K.K Birla Goa Campus

ACKNOWLEDGEMENT
A Project of any kind is a boon for budding engineers. It
develops work ethic and orients students towards a career in
applied research. I am lucky to have an opportunity to carry
out a computer oriented project. Compiling this report has
been a great learning curve and a satisfying one. This report
was made possible due to the great help of certain people i
would like to acknowledge.
Dr. D.M. Kulkarni for giving me such an interesting project
and for his valuable inputs.
My friend Ravi Teja for helping with the technical difficulties
faced during modelling.

ABSTRACT
The significance of the title of the project comes to front
with designing structure of the pressure vessel for static
loading and its assessment by ANSYS. This project is to
develop an interactive system to design pressure vessels
besides the understanding of the algorithm in designing
pressure vessel. Results generated by the system were to
compare with manual calculations using ASME VIII-1
design code. Besides that, a finite element model was
created using the results generated by the system and the
maximum stress value in finite element analysis was
compared with theoretical calculation. This project
includes comparison studies to compare self-defined
material with material library and self-defined load. As a
conclusion, designing pressure vessel using computer
aided tool is easier and interactive.

Table of Contents
Pg no.
Stress

Loadings

Failures in pressure vessel

Strength theories

10

Nozzle openings and

reinforcements

13

Design of shell and its

components

14

Design calculations

14

Model

19

Ansys analysis

21

Problems encountered

28

Design Summary

29

INTRODUCTION
The pressure vessels (i.e. cylinder or tanks) are used to store
fluids under pressure. The fluid being stored may undergo a
change of state inside the pressure vessel as in case of steam
boilers or it may combine with other reagents as in a chemical
plant. The pressure vessels are designed with great care because
rupture of pressure vessels means an explosion which may cause
loss of life and property. The material of pressure vessels may be
brittle such that cast iron or ductile such as mild steel.
Cylindrical or spherical pressure vessels (e.g., hydraulic cylinders,
gun barrels, pipes, boilers and tanks) are commonly used in
industry to carry both liquids and gases under pressure. When
the pressure vessel is exposed to this pressure, the material
comprising the vessel is subjected to pressure loading, and hence
stresses, from all directions. The normal stresses resulting from
this pressure are functions of the radius of the element under
consideration, the shape of the pressure vessel (i.e., open ended
cylinder, closed end cylinder, or sphere) as well as the applied
pressure.
Two types of analysis are commonly applied to pressure vessels.
The most common method is based on a simple mechanics
approach and is applicable to thin wall pressure vessels which
by definition have a ratio of inner radius, r, to wall thickness, t, of
r/t10. The second method is based on elasticity solution and is
always applicable regardless of the r/t ratio and can be referred
to as the solution for thick wall pressure vessels. Both types of
analysis are discussed here, although for most engineering
applications, the thin wall pressure vessel can be used.

STRESS
Types of Stresses
Tensile, Compressive Shear, Bending, Axial Discontinuity
Membrane Tensile
Tangential Load induced
Strain induced Circumferential
Longitudinal
Radial
Normal
Classes of stress
Primary Stress
General:
Primary general membrane stress
Primary general bending stress
Local:
Primary local stress,
Secondary stress:
Secondary membrane stress.
Secondary bending stress
Peak stress
PRIMARY GENERAL STRESS:
These stress act over a full cross section of the vessel. Primary
stress are generally due to internal or external pressure or
produced by sustained external forces and moments. Primary
general stress are divided into membrane and bending stresses.
Calculated value of a primary bending stress may be allowed to go
higher than that of a primary membrane stress.
Primary general membrane stress
Circumferential and longitudinal stress due to pressure.

Longitudinal stress due to the bending of the horizontal

vessel over the saddles.
Membrane stress in the centre of the head.
Membrane stress in the nozzle wall
Axial compression due to weight.
LOCAL PRIMARY MEMBRANE STESS
Membrane stress at local discontinuities:
Head-shell juncture
Nozzle-shell juncture
Shell-flange juncture
Membrane stresses from local sustained loads:
Support legs
Nozzle loads
Beam supports
Major attachments
SECONDARY STRESS
Secondary membrane stress
Axial stress at the juncture of a flange and the hub of the
flange
Membrane stress in the knuckle area of the head.
Secondary bending stress
Bending stress at the gross structural discontinuity: for eg:
nozzle
The non-uniform portion of the stress distribution in a thickwalled vessel due to internal pressure.
The stress variation of the radial stress due to internal
pressure in thick-walled vessels.
Peak Stress

Stress at the corner of discontinuity.

Stress due to notch effect. (stress concentration).

LOADINGS
Loadings or forces are the causes of stress in pressure vessels.
Loadings may be applied over a large portion (general area) of the
vessel or over a local area of the vessel. General and local loads
can produce membrane and bending stresses. These stresses are
additive and define the overall state of stress in the vessel or
component.
The stresses applied more or less continuously and uniformly
across an intersection of the vessel are primary stresses.
The stresses due to pressure and wind are primary membrane
stresses.
On the other hand, the stresses from the inward radial load
could be either a primary local stress or secondary stress. It is
primary local stress if it is produced from an unrelenting load or a
secondary stress if produced by a relenting load.
If it is a primary stress, the stress will be redistributed; if it is a
secondary stress, the load will relax once slight deformation
occurs.
Loading can be outlined as follows:
Categories of loadings
General loadsApplied more or less continuously across a
vessel section.
Pressure loadsInternal or external pressure (design,
operating, hydro test, and hydrostatic head of liquid).
Moment loadsDue to wind, seismic, erection,
transportation.
Compressive/tensile loadsDue to dead weight, installed
equipment, ladders, platforms, piping and vessel contents.
Local loadsDue to reactions from supports, internal,
attached Piping, attached equipment, i.e., platforms, mixers,
etc.

a. Radial loadInward or Outward.

b. Shear loadLongitudinal or circumferential.
c. Torsional load.
d. Tangential load.
e. Moment loadLongitudinal or circumferential.

FAILURE IN PRESSURE VESSELS

Categories of Failures:
Material--Improper Selection of materials; defects in
material.
DesignIncorrect design data; inaccurate or incorrect
design methods; inadequate shop testing.
Fabrication Poor quality control; improper or insufficient
fabrication procedure including welding; heat treatment or
forming methods.
ServiceChange of service condition by the user;
inexperienced operations or maintenance personnel; upset
conditions.
TYPES OF FAILURES
Elastic deformationElastic instability or elastic buckling,
vessel geometry, and stiffness as well as properties of materials
are protecting against buckling.
Brittle fractureCan occur at low or intermediate temperature.
Brittle fractures have occurred in vessels made of low carbon
steel in the 40-50 F range during hydro test where minor flaws
exist.
Excessive plastic deformationThe primary and secondary
stress limits as outlined in ASME Section VIII, Division 2, are
intended to prevent excessive plastic deformation and
incremental collapse.
Stress ruptureCreep deformation as a result of fatigue or
cyclic loading, i.e. progressive fracture. Creep is a time-dependent
phenomenon, whereas fatigue is a cyclic-dependent phenomenon.

10

Strength Theories
The majority of material strength data is based on uniaxial tensile
test results. Usually, we have to work with is the yield strength Sy
and/or the ultimate tensile strength Su.
This is fine if we only have the one normal stress component
present : this is true for simple tension or compression members
and for parts loaded only in bending.

In this case, failure (defined as the onset of plastic deformation)

occurs when
x = 1 =Sy/FOS
FOS is the factor of safety.
In many loading cases, we have more than just one normal stress
component.
E.g. in torsion, we have a single shear stress component:

Or,

combined

bending

and

torsion

in

shaft:

These cases can all be reduced to a simple biaxial case by finding

the principal stresses,
1 and 2

11

For ductile materials there are two commonly used

Strength theories - the Maximum Shear Stress (MSS) or Tresca
theory and the von Mises Stress criterion
Strength Theories
1. Maximum Shear Stress:
This states that failure occurs when the maximum shear
stress in the component being designed equals the
maximum shear stress in a uniaxial tensile test at the yield
stress:
This gives max = Sy/2FOS or
| 1 2 | = Sy/FOS or | 2 3 | = Sy/FOS or
Sy/FOS

| 3 1 | =

Which ever of the last three leads to the safest result. The latter
usually involves 3 being zero, i.e. plane stress, and both 1 and
2 having the same sign.

12

2. Von Mises Theory:

This states that failure occurs when the von Mises stress e in the
component being designed equals the von Mises stress e in a
uniaxial tensile test at the yield stress:
This gives: e = 2/2 [(1 2)2 + (2 3)2+ (3 1)2]0.5 =
Sy/FOS
In the plane stress case we have 3 = 0 and hence:
e = [12 12 + 22]0.5 = Sy/FOS
This is the most commonly used of the strength equations.
A third theory, the Maximum Normal Stress theory is similarly
defined. It must NEVER be used for design with ductile materials.
A modified version of this theory is sometimes used with brittle
materials

13

NOZZLES, OPENINGS AND REINFORCEMENTS

Nozzles and openings are necessary components of pressure
vessels for the process industries. Openings in a cylindrical shell,
conical section or closure may produce stress concentrations,
adjacent to the opening and weaken that portion of the vessel. In
order to minimize such stress concentrations, it is preferable that
the opening be circular in shape. As a second choice the openings
may be made elliptical, as a third choice they may be made
around. An around opening has two parallel sides and two semicircular ends. Openings of other shapes are permissible if the
vessel is tested hydrostatically. If the opening in a closure of
cylindrical vessel exceed one-half the inside diameter of shell, the
opening and closure should be fabricated. Others require
reinforcement. Small sizes of openings welded or brazed to a
vessel do not require reinforcement.
In the case of shell, opening requiring reinforcement in vessel
under internal pressure the metal removed must be replaced by
the metal of reinforcement. In addition to providing the area of
reinforcement, adequate welds must be provided to attach the
metal of reinforcement and the induced stresses must be
evaluated.
Materials used for reinforcement shall have an allowable stress
value equal to or greater than of the material in this vessel wall
except that, when such material is not available, lower strength
material may be used; provided, the reinforcement is increased in
inversed proportion to the ratio of the allowable stress values of
the two materials to the ratio of the two materials to compensate
for the lower allowable stress value of any reinforcement having a
higher allowable stress value than that of the vessel wall.

14

DESIGN OF SHELL AND ITS COMPONENTS

The pressure vessel considered here is a single unit when
fabricated. However, for the Convenience of design, it is divided
into the following part: (1) Shell; (2)head or cover; (3) nozzles;
(4) support; Most of the components are fabricated from plates or
sheets. Seamless or welded pipes can also be used. Parts of
vessels formed are connected by welded or riveted joints. In
designing these parts and connections between them, it is
essential to take r into account, the efficiency of joints. For welded
joints, the efficiency may be taken as 100% if the joint is fully
checked by a radiograph and taken as 85%, even if it is checked at
only a few points. If the radiographic test is not carried out 50 to
80%, I efficiency is taken. Efficiencies vary between 70 to 85% in
the case of riveted joints. All these are made for pressure vessels
operating at pressures less than 200kg/kmA2. Design procedure
is primarily based on fabrication by welding.

Design Calculation
Given data

Internal pressure (P) = 10 Mpa

Internal Diameter (Di) = 500mm
Corrosion Allowance (CA) = 3mm
Joint Efficiency for shell = 1
a=500mm ( Major axis of elliptical head )
b=250mm (Minor axis of elliptical head)

15

Thickness Calculation (ASME CODE)

Pi Di K

Head Thickness (t): t=2 .2 +

Pi Di K

Cylinder shell thickness (T): T=2 +

1

K=6 [2 + (2 )]
a=semi-major axis of ellipsoidal head
b=semi-minor axis of ellipsoidal head
CA=corrosion allowance; K=stress intensity factor
Pi=pressure in MPa; Di=internal diameter of cylinder
=joint efficiency; t=allowable stress.

a=500mm, b=250mm
1

5002

K=6 [2 + (2 )]
=6 [2 + (2502 )] =1

Pi =10 MPa, Di=1000mm, K=1, Syt=350 MPa, FoS=2

=1(double welded butt joint with full penetration, fully
radiographed)
CA=3mm

16

Using Max. Shear stress criteria:

t=0.5

Syt
2

(where Factor of safety=2)=87.5 MPa

Pi Di K

t=2 .2 + (ASME design code)

=

(10) (1000) (1)

2(87.5) (1).2(10)

+3

61mm
Pi Di K

(10)(1000) (1)

T=(2 + )= 2(87.5) (1)10 + 3 64mm

Nozzle reinforcement calculations:

trs= required shell thickness, ts=shell thickness,
trn=required nozzle thickness, tn=nozzle thickness (a
reference thickness), d=internal diameter of nozzle,
d0=external diameter,
Rs= Internal radius of the
cylindrical shell

17

tn=27.75mm, ts=64mm, d=154mm, P=10 Mpa, Rs=500mm

Design by ASME code:
Rs

(10)(500)

Rn

(10)(77)

trs=t.6P=87.5(.6)(10)=61.35mm
trn=t.6P=87.5(.6)(10)=9.44mm
Now,
(a) ts+tn+.5d=168.5mm
(b)
d=154mm

The limit parallel to the

surface of the shell is the
larger of two
quantities = 168.5mm

Also,
(a)2.5 ts=160mm
(b)2.5 tn=69.375mm

The limit normal to the

surface of the shell is the
smaller of
quantities=69.375mm

The reinforcement area required is :

Ar=dXtrs=9447.9mm2

The reinforcement area available in the shell:

A1=(2a-d)( ts-trs)
Where a=

=466.5mm2

Greater of

d+2CA=160mm &
(d/2 +ts +tn -3CA)=157.75mm

The reinforcement area available in nozzle wall is available

in two parts :
A2=2(2.5 ts)( ts- trn)=17459.2mm2
A3=2(2.5 ts) ts=20480mm2
The total area available for reinforcement :

18

At=A1+A2+A3=38405.7mm2
At > A r

Result: The available reinforcement At therefore exceeds the

reinforcement required Ar and the method is acceptable. Hence
padding is not necessary.

Height of nozzle outside the vessel:

H1=2.5(ts-CA)=152.5mm
OR
H1=2.5(tn-CA)=62mm

Smaller of the two values is

chosen as H1.
So H1=62mm

The extension of nozzle inside the vessel:

H2 18mm
Determined experimentally as discussed in the problems
encountered section

19

MODEL
Material Used
AISI
Steel,
rolled

Properties

1020
Cold

Main Components
1) Ellipsoidal head (a:b=2),
a=500mm, b=250mm.
Thickness=61mm
a=major axis
b=minor axis

2) Cylindrical shell
Internal radius=500mm
Thickness=64mm

20

3) Nozzle and flange

Internal
diameter
=154mm
Thickness = 27.75mm
H1=62mm
H2=18mm

CUT SECTION FOR ANALYSIS

21

Analysis layout:

22

MESHING
Fine Mesh
49322 nodes
27628 elements
Element type and size
program controlled.

Fixed support and loads

23

24

Max Shear stress criteria

Max allowable stress

87.5Mpa ((.5Syt)/2) where

Syt=350 Mpa, FoS=2

Max stress from analysis

85.48 Mpa

Min stress from analysis

Result : Design Passed

64797 pa
Since max stress < max
allowable stress

25

26

Von-Mises stress Criteria:

Max allowable stress
Max stress from analysis
Min stress from analysis
Result: Design Passed

175 Mpa ,((Syt)/2), Fos=2

Syt=350 Mpa
162.3 Mpa
123300 pa
Since Max stress at any
point < Max allowable stress

27

28

Problems Encountered
The main problem faced during the analysis was near the
openings of the pressure vessel i.e. near the welding at the
extension of nozzle inside the vessel. Here, for both
strength criteria 1) Maximum shear stress criterion 2) Von
mises criterion, the stress exceeded the allowable stress.
Therefore H2 i.e. length of extension of nozzle inside the
pressure vessel was varied starting from minimum 15mm
to 20mm for which H2=18mm gave accepted stress value
that was less than the maximum allowable stress.

Maximum allowable shear stress =

87.5N/mm2
H2
(mm)
15
16
17
18
19
20

Max
Shear
stress(N/mm2)
97
105
146
85.48
93
158

Pass/Fail
Fail
Fail
Fail
Pass
Fail
Fail

29

Summary
Pressure vessel requirement Design a pressure vessel of
capacity 10 MPa to carry
compressed air at room
temperature with allowance
for corrosion.
Material used and its
Elastic Modulus in X
properties
205000 N/mm^2
(AISI 1020 steel, cold
Poisson's Ration in XY
rolled)
0.29 N/A
Shear Modulus in XY
80000 N/mm^2
Mass Density
7870
kg/m^3
Tensile Strength in X
420 N/mm^2
Yield Strength
350 N/mm^2
Thermal Expansion
1.17e-005/K
Thermal Conductivity
51.9 W/(mK)
in X
Specific Heat
486 J/(kgK)
Type and components
Pressure vessel with semi
ellipsoidal head(major axis
to minor axis ratio of the
ellipse =
2:1,thickness=61mm) with
cylindrical
body(thickness=64mm)

30

Criteria used to test for

failure

Results

Components: semiellipsoidal head caps,

cylindrical body, supports
and nozzle(thickness
27.75mm,extension
outside=62mm,extension
inside=18mm)
Von misces stress:
Max stress: 162.3N/mm^2
Min stress: .12330 N/mm^2
Max shear stress :
Max stress: 85.48N/mm^2
Min stress: .064797N/mm^2
The maximum stresses
obtained from analysis are
below the maximum allowed
stresses given by the above
mentioned theories.
Hence design is safe.