1

PROJECT ON CHEMICAL ENGINEERING

APPARATUS DESIGN
Course code: (ChEg4191)
PROJECT TITLE:- PRESSURE VESSEL DESIGN
PREPARED BY:-NETWORK -6th
SECTION -1Year 4
Semester 1st

List Name of Network Members

ID

1) Fanus Alemu.............RET 0485/06

2) Letebrhan Bahta............................................RET 0963/06
3) Rgbey Kiday.............................................RET 1242/06
4) Teame Gebretsadik.......RET 1406/06
5) Teklehaimanot Abraha.............RET 1443/06
6) Wasie Kebire................................................RET 1578/06

Submitted to Instructor
Zinabu H. (Msc)

Submission Date

December 12/2016 G.C

TABLE CONTENT
Contents

Page

List of figures.II
List of Tables.II
Acronyms...II
Declaration...III
Acknowledgment.IV
Executive summary...V
Chapter One.1
Introduction.............1
1.1. Background...1
1.2. Problem of statement2
1.3. Significant of study...2
1.4. Objective...3
1.4.1. General objectives............3
1.4.2. Specific objectives3
Chapter Two.4
Literature Review...4
2.1. Nature of Design..4
2.1.1. Pressure vessel...4
2.1.2. Design Parameters of pressure vessel...4
2.2. Skirt and base...7
Chapter Three..........8
Materials and Methods...8
3.1. Materials...8
3.1.1. Assumptions...8
3.2. Methodology....8
3.2.1. Sieve plate column design specification....8
Chapter Four..17
Result and Discussion......17
4.1. Calculations17
4.2. Reinforcement of openings22
4.2.1. Required Area of Reinforcement.22
4.3. Nozzles and Flanges...25
4.4. The Design of skirt-support for the vessel.26
4.5. Discussion......35
Chapter Five...36
Conclusion and recommendation.....36
5.1. Conclusion..36
5.2. Recommendation36
Reference.. ...37
Appendix...38
Appendix A: Maximum allowable joint efficiency38
Appendix B: The wall thickness of any vessel...............38
Appendix C: Typical design stress for any plate39
Appendix D: Standard flange.39

List of Figures
Page

Figures

Figure4.1. Selected standard flange.25

Figure4.2. Standard ellipsoidal head26
Figure4.3. Schematic pressure vessel diagram.34

List of Tables
Page

Lists

Table3.1. Column specification..8

Table3.2. Nozzles specifications.9
Table3.3. Other sieve plate column.9
Table4.1. Standard flange...................25
Table4.2. Final results of the data sheet..33

Acronyms
1. ASME.American society mechanical engineering
2. BPVCBoiler and pressure vessel code
3. D.P....Design Pressure
4. D.TDesign Temperature
5. MAWP.Maximum allowable working pressure
6. MDMT.....Maximum and Minimum design temperatures
7. PsiPound square inch

II

Declaration
We hereby declare that the report submitted are entirely our own work and have not been
Copied from any other student or past year reports. Relevant work was referred to and
Appropriate citations were made to acknowledge the author of such a work. . We also declare that we
have adhered to all principles of academic honesty and integrity and have not misrepresented or
falsified any idea, source in our submission.

III

Acknowledgment
We would like to extend our deepest appreciation to our remarkable instructor Zinabu H.
We have made it possible to write a project. In particular, we sincerely thank our god and the
Network six members, who help to develop ideas. Who have completed this project all of us
and We apologies for any errors and omissions.

IV

Executive summary
This technical paper can teach the concept of design, and analysis of pressure vessel. High
pressure rise is developed in the pressure vessel and pressure vessel has to withstand severe
forces. In the design of pressure vessel safety is the primary consideration, due the potential
impact of possible accident. Analyses were carried out on head, shell, nozzle and saddle. The
input parameters are type of material, pressure, temperature, diameter, and corrosion
allowance. Analysis performed the calculations of internal and external pressure, weight of
the element, allowable stresses, vessel longitudinal stress check, nozzle check and saddle
check.

Chapter -1
Introduction
Pressure vessels are leak proof containers, as the name implies, their main purpose is to contain a
given medium under pressure and temperature. Pressure vessels are commonly used in industry to
carry both liquid and gases under required pressure and temperature limit. This pressure and
temperature comes from an external source or by the application of heat from a direct or indirect
source or any combination of them. Pressure vessels; commonly have the cylindrical, spherical,
ellipsoidal, conical or a combination of these shapes. However, some pressure vessels are named after
the type of function they required to perform. For example, the distillation column is a vessel used in
oil and petroleum refining process. The heat exchanger used in many types of industries to transfer
heat from one fluid to another fluid. Also, reactor is a vessel, which is used for chemical reaction of
contained substance. The material comprising the vessel is subjected to pressure loading and hence
stresses from all direction. The normal stresses resulting from this pressure are functions of diameter
of the elements under consideration, the shape of the pressure vessel as well as the applied pressure.
Pressure vessels are usually spherical or cylindrical with dome end. The cylindrical vessels are
generally preferred because of they represent simple manufacturing problem and make better use of
the available space. Boiler, heat exchanger, chemical reactor and so on, are generally cylindrical.

1.1. Back ground

The earliest design of pressure vessels is described 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 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 Sieve plate column is one of the distillation
columns with cross-flow trays, which is widely used in various mass transfer operations, for instance,
modern industrial nitric acid plant. Sieve plates offer high capacity and efficiency, low pressure drop,
ease of cleaning and therefore, low capital cost.
A column should be designed with a specific wall thickness to ensure it has sufficient rigidity to be
able to cope with the maximum amount of pressure which it is expected to be susceptible to in
operation. The minimum column wall thickness needed to withstand the vessel weight itself as well as
other incidental loads such as internal pressure is calculated and shown in the following calculation
section The design pressure for vessels under internal pressure is conventionally taken as the pressure
where the relief device is set. This is usually about 5-10 % above the regular working pressure. This is
done to avoid spurious operation during minor process upsets.
A cylindrical pressure vessel shell must be enclosed at both ends by heads. Flat plates, formed flat
heads, hemispherical heads, torispherical heads and ellipsoidal heads are several principal types of
heads used . Hemispherical, torispherical and ellipsoidal are categorised as domed heads where the
formation is by pressing or spinning with large diameters fabricated from formed sections.
Torispherical heads, on the other hand also referred to as dished ends.

Pressure vessels can theoretically be almost any shape, but shapes made of sections of spheres,
cylinders and cones are usually employed. More complicated shapes have historically been much
harder to analyze for safe operation and are usually far harder to construct. Theoretically a sphere
would be the optimal shape of a pressure vessel. Unfortunately the sphere shape is difficult to
manufacture, therefore more expensive, so most of the pressure vessels are cylindrical shape with 2:1
semi elliptical heads or end caps on each end. Smaller pressure vessels are arranged from a pipe and
two covers. Disadvantage of these vessels is the fact that larger diameters make them relatively more
expensive. Many pressure vessels are made of steel. To manufacture a spherical pressure vessel,
forged parts would have to be welded together. The design of pressure vessels is an important and
practical topic which has been explored for decades. Optimization techniques have been extensively
applied to design structures in general; few pieces of work can be found which are directly related to
optimal pressure vessel design. These few references are mainly related to the design optimization of
homogeneous and composite pressure vessels. The pressure vessel meets international safety
standards, carefully selected steel with a high impact resistance & corrosion resistant material.
1.2 Statement of Problem
Vessels failure can be grouped into the following major categories, which describe why a vessel
failure occurs. Failures also grouped into types of failures, which describe how the failure occurs
mean each failure contains its failure history, why and how it occurs. There are many reasons of
vessels failure such as:
Improper material selection, defected material.
Incorrect design data, incorrect or inaccurate design method or process, inadequate shop
testing.
Improper fabrication process, poor quality control, insufficient fabrication process including
welding, heat treatment and forming methods.
In order to meet a safe design, a designer must be familiar with the above mentioned failure and
its causes. There have a few main factors to design safe pressure vessel. This study is focusing on
analysing the safety parameters for allowable working pressure.

1.3 Significant of studies

For design of pressure vessel the selection of Code are important as a reference guide to
achieve the safety pressure vessel. The primary purpose of the preliminary column design, materials
of construction, fabrication, inspection, and testing. Improper vessel design and maintenance increase
the risk of vessel failure and may lead to serious safety hazard. Thus a mechanical design of the
column is highly important in essence of keeping the safety hazard and maintenance cost at minimum.

The significance of the study is not only the calculation of the detailed dimensions of a
member but rather is an all-inclusive term, incorporating:
1.
2.
3.
4.
5.
6.
7.

The selection of pressure vessel orientation.

The selection of pressure vessel end closers.
The selection of suitable flanges.
The selection of suitable pressure vessel support.
The method of stress analysis employed and significance of results.
The selection of materials type and its environmental behaviour.
Understanding the application of the pressure vessel in different industry.
2

1.4 Objectives
1.4.1 General objective
To design pressure vessel according to input data and analyse the safety parameters of each
component for its allowable working pressure.

1.4.2 Specific objectives

i. To build an interactive system using auto cad design system to design pressure vessel.
ii. To compare results of design analysis in the system of design pressure calculation.
iii. To validate the results in the system using theoretical calculation.

Chapter -2
Literature review
2.1. NATURE OF DESIGN
Design is a creative activity, and as such can be one of the most rewarding and satisfying
activities undertaken by an engineer. It is the synthesis, the putting together, of ideas to achieve a
desired purpose. The design does not exist at the commencement of the project. The designer starts
with a specific objective in mind, a need, and by developing and evaluating possible designs, arrives
at what he considers the best way of achieving that objective; be it a better chair, a new bridge, or for
the chemical engineer, a new chemical product or a stage in the design of a production process.

2.1.1. Pressure vessel

The term pressure vessel referred to those reservoirs or containers, which are subjected to
internal or external Pressure. The pressure vessels are used to store fluids under pressure.
The fluid being stored may undergo a change of state inside vessels as in case of steam
boilers or it may combine with other reagents as in chemical plants. High pressure is
developed in pressure vessel so pressure vessel has to withstand several forces developed due
to internal pressure, so selection of pressure vessel is most critical. ASME is most widely
used code for design & construction of pressure vessel. It does not consider harmonic
analysis. Consider biaxial state of stress combined in accordance with maximum stress
theory. When pressure of operating fluid increases, increase in thickness of vessel. These
increases in thickness beyond a certain value possess fabrication difficulties and stronger
material for vessel construction.
The material of pressure vessel may be brittle such as cast iron or ductile such as mild steel.
Failure in Pressure vessel occurs due to improper selection of material, defects in material,
incorrect design data, design method, shop testing, improper or insufficient fabrication
process including welding. To obtain safety of pressure vessel and to design Pressure vessel
the selection of code is important. Corrosion allowance is the main consideration in vessel
design. Corrosion occurring over the life of the vessel. During service, pressure vessel may
be subjected to cyclic or repeated stresses. Fatigue in pressure vessel occurs due to:
a) Fluctuation of pressure
b) Temperature transients,
c) Restriction of expansion or contraction during normal temperature variations,
d) Forced vibrations,
e) Variation in external load
2.1.2. DESIGN PARAMETER OF PRESSURE VESSEL
The following are design parameters of pressure vessel;

1. Design temperature
Design temperature is the temperature that will be maintained in the metal of the part of the
vessel being considered for the specified operation of the vessel. The strength of metals decreases
with increasing temperature so the maximum allowable design stress will depend on the material
temperature. For most vessels, it is the temperature that corresponds to the design pressure. However,
4

there is a maximum design temperature and a minimum design temperature (MDMT) for any given
vessel. The MDMT shall be the lowest temperature expected in service or the lowest allowable
temperature as calculated or the individual parts. Design temperature for vessels under external
pressure shall not exceed the maximum temperatures.

2. Design pressure
In the pressure vessels, three terms related to pressure are commonly used

Maximum Working pressure is the maximum pressure to which the pressure vessel is
Subjected.
Design pressure is the pressure for which the pressure vessel designed.
Hydrostatic test pressure is the pressure at which the vessel is tested. The pressure vessel is
finally tested by the hydrostatic test before it is put into operation.

The pressure use in the design of a vessel is called design pressure. It is recommended to design a
vessel and its parts for a higher pressure than the operating pressure. A design pressure higher than the
operating pressure with 10%, whichever is the greater, will satisfy the requirement. The pressure of
the fluid will also be considering. The maximum allowable working pressure (MAWP) for a vessel is
the permissible pressure at the top of the vessel in its normal operating position at a specific
temperature. This pressure is based on calculations for every element of the vessel using nominal
thicknesses exclusive of corrosion allowance. It is the basis for establishing the set pressures of any
pressure relieving devices protecting the vessel.

3. Corrosion Allowance
The corrosion allowance is the additional thickness of metal added to allow for material lost
by corrosion and erosion, or scaling. The allowance to be used should be agreed between the
customer and manufacturer. The walls of the pressure vessel are subjected to thinning due to
corrosion which reduces the life of the pressure vessel. The corrosion in pressure vessel is due
to the following reasons:

Chemical attack by reagents on the inner wall surface of the

vessel.
Rusting due to atmospheric air and moisture.
High temperature oxidation.

Erosion due to flow of reagent over the wall surface at high velocities.
Every attempt should be made avoid the corrosion. However, this may not be always possible. An
allowance is, therefore, required to be made by suitable increase in wall thickness to compensate for
the thinning due to corrosion. Corrosion allowance is an additional thickness of the pressure vessel
wall over and above that required to withstand the internal pressure.

4. Materials
Several of materials have been use in pressure vessel fabrication. The selection of material is
based on the appropriateness of the design requirement. The materials used in the manufacture of the
receivers shall comply with the requirements of the relevant design code, and be identifiable with mill
sheets. The selection of materials of the shell shall take into account the suitability of the materials
with the maximum working pressure and fabrication process.
5

Pressure vessels are constructed from plain carbon steels, low and high alloy steels, other alloys, clad
plate, and reinforced plastics. Selection of a suitable material must take into account the suitability of
the material for fabrication (particularly welding) as well as the compatibility of the material with the
process environment. The pressure vessel design codes and standards include lists of acceptable
materials; in accordance with the appropriate material standards.

5. Design stress (nominal design strength)

For design purposes it is necessary to decide a value for the maximum allowable stress (nominal
design strength) that can be accepted in the material of construction. This is determined by applying a
suitable design stress factor (factor of safety) to the maximum stress that the material could be
expected to withstand without failure under standard test conditions. The design stress factor allows
for any uncertainty in the design methods, the loading, the quality of the materials, and the
workmanship.

6. 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. The use of lower joint factors in design, though saving costs on
radiography, will result in a thicker, heavier, vessel, and the designer must balance any cost savings
on inspection and fabrication against the increased cost of materials.
The standard specifies three construction categories.
Category 1: the highest class requires 100 per cent non-destructive testing of the welds; and allows
the use of all materials covered by the standard, with no restriction on the plate thickness.
Category 2: requires less non-destructive testing but places some limitations on the materials which
can be used and the maximum plate thickness.
Category 3: the lowest class, requires only visual inspection of the welds, but is restricted to carbon
and carbon-manganese steels, and austenitic stainless steel; and limits are placed on the plate
thickness and the nominal design stress.

7. Design loads
A structure must be designed to resist gross plastic deformation and collapse under all the
conditions of loading. The loads to which a process vessel will be subject in service are listed below.
They can be classified as major loads that must always be considered in vessel design and subsidiary
loads. Formal stress analysis to determine the effect of the subsidiary loads is only required in the
codes and standards where it is not possible to demonstrate the adequacy of the proposed design by
other means; such as by comparison with the known behaviour of existing vessels.

A. Major loads
1. Design pressure: including any significant static head of liquid.
2. Maximum weight of the vessel and contents, under operating conditions.
3. Maximum weight of the vessel and contents under the hydraulic test conditions.
4. Wind loads.
5. Earthquake (seismic) loads.
6. Loads supported by, or reacting on, the vessel.
6

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

8. Minimum practical wall thickness

There will be a minimum wall thickness required to ensure that any vessel is sufficiently rigid to
withstand its own weight, and any incidental loads. As a general guide the wall thickness of any
vessel should not be less than the values given below; the values include a corrosion allowance of 2
mm:

2.2. Skirt and Base

Column supporting skirt and base ring
One of the most essential components of a distillation column would be its supports. By convention,
there are four types of vessel support structures which are typically used as saddle supports for heat
exchangers, skirt support for vertical columns, leg support for spherical vessels, and lug/bracket
support for other applications. These supporting columns would have to be designed to handle the
weight of the pressure vessel and its contents, superimposed loads such as pressure and temperature as
well as wind loads while taking into account practicality factors like size and dimensions, location and
setup, attachments of fittings and flanges, as well as ease of access for inspection and maintenance.
This assignment demonstrates the guidelines required to design a skirt support for a vertical column
which was welded in place to the bottom of the pressure vessel, taking into account the design of the
skirt itself, base ring and the anchoring bolts.

Skirt supports
In this design, it was assumed that the skirt support used would consist of a conical shell welded to the
bottom dome of the pressure vessel. The flange, which was located at the bottom of the skirt,
transmits forces from the skirt itself to the foundation. Openings in the skirt made with the purpose of
creating access and pipe connections that would later be reinforced. To ensure a safe design of the
skirt, it was important to take into account the load per unit length, bending moment, bending stress,
and dead weight loading stress without water.

Base ring/flange and anchor bolt design

The bottom of the skirt must be anchored to a concrete foundation by the means of anchor bolts
embedded in the concrete that help to prevent overturning from any sort of bending moment that
might induced by either wind and seismic loads. When either a compressive or tensile load is applied
to the anchor bolts, the load would be dispersed from the steel through its bond to the concrete the
materials used for the skirt was made entirely of carbon steel, silicon killed. Meaning, the anchor bolt
formed from the steel rounds should be clean and free of oil; ensuring that it will bond to the
embedded surface of steel.

Chapter -3
Materials and Methods
3.1. Materials
Materials that used to design this project are;

Stainless steel vessel, unsterilized (304).

Stainless steel nozzle, unsterilized (304).
Carbon Steel skirt support, silicon killed.
50 sieve plate
Access ladder with plat form.
Insulation mineral wool.

3.1.1 Assumptions
In order to develop a preliminary design, some assumptions are made and listed below.

No significant loading from piping and external equipment.

Plates and plate supports design is negligible.
Material is double welded butt or equivalent and fully radiographed.
Assume flanges are standard flanges.
Earth quake loading need not be considered.

3.2 METHODOLOGY
3.2.1. Sieve Plate Column Design Specifications
The design specifications and requirements for column, nozzle, material of construction and other
specification are specified in Table below;
Required Specifications
The specification to calculate the column wall thickness is tabulated in Table 3.1. below;
Table 3.1 Column Specification
Properties

Specifications

Length of cylindrical section, L

Internal diameter, Di
Heads
Number of sieve plates, n
Design temperature, T
Design pressure, Pi
Corrosion allowance, C

37 m
1.5 m
Standard ellipsoidal
50
150 0C
1200 KN/m2
2 mm

Table3.2. Nozzles Specification

Properties
Feed
Vapor out

Specifications
At mid-point
At 0.7 m below top of cylindrical
Section
At Centre of vessel head

Bottom
Product

200 mm inside diameter

250 mm inside diameter
200 mm inside diameter

At 1.0 m below top of cylindrical

section

200 mm inside diameter

Table 3.3 other sieve plate column specifications

Properties

Specifications

Diameter of Access ports

(manhole)

0.6 m

Height of support skirt

Thickness of insulation

2.5 m
50 mm thick

At 1.0 m above the

bottom
At 1.5 m below the top of
the
Column

Design procedure steps

The minimum plate thickness to resist the internal pressure.
(1)

Where,
e = minimum plate thickness (mm)
Pi = design pressure (

Di = internal diameter (mm)

J = joint efficient factor
f = maximum allowable working or design stress (

minimum wall thickness of torispherical and ellipsoidal heads

For ellipsoidal; e
Torispherical;

......................................................................................(2)
.(3)

Where,
Cs is stress concentration factor for torispherical heads Cs

) (4)

=crown radius,
= knuckle radius.
J=joint factor
f=maximum allowable design stress
e=minimum wall thickness torispherical head

Dead Weight
For a steel vessel
Wv = 240 CvDm (Hv + 0.8 Dm)t..(5)
Dead weight of the plate
(6)

Where,
= Weight of the plate, kN
= Number of plate
= Area of the plate m2
= Pressure of liquid loading, kN/m2

Dead weight of the insulation materials

The weight of the insulation can be calculate by,
g
Whereby,
= Weight of the insulation material, kN
= Density of insulation materials,

=Volume of the insulation materials,

g=gravitational force,
Wind Loading Per linear,

and the bending moment

(7)
=
Where

(8)
= Bending moment (Nm)
Wind Pressure(N/m2)
10

X = Length of cylindrical section (m)

Deff = Effective column diameter (m)

Stress Analysis
In the stress analysis of the column, , direct stress due to weight of vessel and bending stress are
considered. The resultant longitudinal stress and direct stress of cylindrical vessel with water are
also calculated. Coulson & Richardsons CHEMICAL ENGINEERING VOLUME 6 Book was
used as reference for the formula used in this section.
Longitudinal and circumferential stress:
At bottom tangent line, the pressure stresses are given by:
Longitudinal stress, L= (N/mm2) .(9)
where,
L = Longitudinal stress,

2)

=Design Pressure(N/mm

Internal Diameter, mm
= Wall thickness, mm
2

Circumferential stress, h= (N/mm ) .(10)

Stress due to dead weight,

.............................................................................(11)
Bending Stresses,

).(12)
.(13)
(14)
Where
=Bending stress (

=The bending moment (N.m)

Internal Diameter(mm)
=Bottom Tangent line thickness (mm)
= Second moment of area (

11

Internal Diameter in mm
= Outer Diameter in mm
Resultant longitudinal stress is given by,

(15)
Critical buckling stress can be calculated as:
(16)
The maximum resultant compressive stress will occur when the vessel is not under pressure
given by,
(17)

The bending moment, in skirt.

The effect of bending moment of skirt, Ms, can be calculated as follow.
..(18)
...(19)
Where,
MS = Bending moment at the base of the skirt
FW = Load per unit length
HS = Height of skirt
H V = Height of the vessel

The bending stress in the skirt.

.(20)

The bending stress in the skirt is given by;

Where, Ds =Internal column diameter,
ts = Thickness of the skirt

Bending stress in the skirt

12

 The dead weight stress for the test and operating conditions.
For test condition,

..(21)

Is given by,

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

: is given by;
..(22)

Where,
Dead weight stress in the skirt for operating condition
Total dead weight of vessel with heads.

The resultant bending stress in the skirt.

) ..(23)

For maximum:For minimum:-

)(24)
Number of bolts required N bolts given by the formula:
(25)
Where;

= Internal column diameter

= Pitch circle diameter

The new required bolt area,

(
Where:

is given by :

(26)
Number of bolts required
Bolt design stress
Bending moment in skirt
Total dead weight of vessel with heads
Pitch circle diameter
13

The bolt root diameter

Is given by the formula;

.(27)

The total compressive load on each base ring per unit length,
is Given by:
).(28)
Where,
Total dead weight of vessel with heads
Bending moment in skirt
Internal column diameter

The minimum width of base ring,

Given by the formula:

Where:

.(29)

Total compressive load on the base ring per unit length

=maximum allowable bearing pressure on the concrete foundation pad

The skirt base angle:

Skirt base angle,

given by,

.(30)

The bolt spacing.

Bolt spacing is given by the formula:
(31)
Where,

Bolt circle diameter

Number of bolts

The total compressive load on each base ring per unit length, Fbolt.
Given the formula:
14

..(32)
Where,
Total dead weight of vessel with heads
Bending moment in skirt
Flared skirt bottom diameter
The actual bearing pressure on the concrete foundation,
Given the formula:
(33)
Actual width =Lr + ts + ti(34)
Where,
ts = Skirt thickness
ti = Insulation thickness
Fbolt = Total compressive load on the base ring per unit length
Lr =Distance from the edge of the skirt to the outer edge of the ring = 178 mm (Sinnott.,
Coulson & Richardson's Chemical Engineering 1999) : Using Bolt size 70 (BS 4190:1967)

The base ring thickness, tb.

The base ring thickness given by the formula:

..(35)

Where,

Lr =Distance from the edge of the skirt to the outer edge of the ring = 127 mm (Sinnott., Coulson &
Richardson's Chemical Engineering 1999) : Using Bolt size 70 (BS 4190:1967)
= Allowable design stress in the ring material = 140 N/mm2 (Typically)
= Actual bearing pressure on the concrete foundation

Effective Column Diameter

To find the effective column diameter,
.(36)

Where, Deff = Effective column diameter (m)

Ds= Diameter (m)
15

= Average thickness of cylinder vessel wall (m)

= Thickness of insulation (m)

compensation area required

design skirt support
Approximate weight =

).(37)

Total weight=
.......................(38)
Bending moment at the base of skirt
,

(39)

Where
.(40)
Where
Dead weight stress in the skirt
..(41)
Where

= dead weight stress in the skirt

.(42)

Required Area of Reinforcement

)..(43)
(44)

=d(

where: A = total cross-sectional area of reinforcement required in the plane under consideration
A1 = area in excess thickness in the vessel wall available for reinforcement
A2 = area in excess thickness in the nozzle wall available for reinforcement
A3 = area available for reinforcement when the nozzle extends inside the vessel wall
S = design stress at design temperature
d = finished diameter of circular opening under consideration
E = joint efficiency factor
F = correction factor that compensates for the variation of in internal pressure stresses on
different planes with respect to the axis of the vessel
t = specified vessel wall thickness
ti = nominal thickness of internal projection of the nozzle wall tn = nozzle wall thickness
tr = required thickness of seamless shell based on circumferential stress
trn. = required thickness of seamless nozzle wall fr1 = strength reduction factor.
16

Chapter -4
Result and discussion
Mechanical design of the sieve plate column with;
Inner diameter of the column, Di = 1.5 m = 1500 mm
Design temperature = 150
Design stress of the material at 150 = 130 N/mm2
Material of construction = stainless steel 18Cr/8Ni unestablished (304).
Design stress of the material = 130 N/
.
Youngs modulus = 200000 N/
Design pressure = 1.2 N/
Corrosion allowance = 2 mm
Inner diameter of the column = 1500 mm
Height of the column between the two tangent lines = 37000 mm
Skirt height = 2500 mm
No of plates = 50
Insulation = 50 mm thick
Mineral wool density = 130 kg/m3
Maximum wind velocity = 160KM/h
Access ladder with platforms = 1.7 k N/
area,
1
2
3
4
5

Thickness calculation for the cylindrical shell

Selection and sizing calculation
Pressure calculation for the ellipsoidal shell and torispherical heads
Calculation for nozzle
Calculation for legs and supports

4.1. Calculation
Thickness of Heads
Step1, determine Calculation of the minimum thickness
the column wall thickness to resist internal pressure
then Calculated using

6.955mm

Rounding off to 7 mm Take into consideration of 2 mm of corrosion allowance.

Therefore the final thickness is,
T 7mm

17

Domed head
Step2, determine Calculation of the minimum thickness of the ellipsoidal and
torispherical head
Most standard ellipsoidal heads are manufactured with a major and minor axis ratio of 2:1. For this
ratio, the following equation can be used to calculate the minimum thickness required:
e
e

6.93mm

Where, Cs is stress concentration factor for torispherical heads Cs

=crown radius,
= knuckle radius.
The ratio of the knuckle to crown radii should not be less than 0.06, to avoid buckling;and the crown
radius should not be greater than the diameter of the cylindrical section.
Crown radius,

Di

Knuckle radius

1.5 m

6%

0.09 m

A head of this size would be formed by pressing: no joints, so J

Cs
e

1.

1.77m
12.1657mm

So an ellipsoidal head would probably be the most economical.

Step3: Select the ellipsoidal head because it has minimum wall thickness.
Mean Thickness of Column Wall
Since a vessel needs to withstand design loads such as wind and the dead weight loads, the
column wall has to be gradually thicker from the top to the bottom Thus, the pressure at the vessel
base is maintained at maximum and this requires greater thickness of the column wall and also
larger diameter for the column. This is crucial to prevent the vessel from collapsing as well as to
increase its capability to endure wind loading and dead weight of vessel and content that
contributed to the high stress from increase in pressure. Therefore, For stability of the shell the
column wall is divided into 5 sections with an increase of 2mm for each section going
downwards. The column wall thickness from top to bottom of the shell is 7mm , 9 mm, 11 mm,
13 mm and 15mm respectively. The mean thickness of Column wall can then be calculated.

18

7
9

11
11
For all other calculations, the average thickness is used.

13

Step4: Dead weight of vessel

15

For a steel vessel

Take Cv = 1.15, vessel with plates
Dm = 1.5 + 11 x 10-3 = 1.511m
Hv = 37 m
t = 11 mm
Wv = 240 CvDm (Hv + 0.8 Dm) t
Wv = 240 X 1.15 X 1.511 (37 + 0.8 X 1.511) 11
= 175,279 N
= 175.279kN

Step5: Weight of plates

Plates area = /4 X 1.52 = 1.77 m2
Access ladder with platforms=1.7kN/m2 X 1.77 m2 = 3.009kN
50 plates = 50 X 3.009KN = 150.45kN

Step6: Weight of insulation

Mineral wool density = 130 kg/m3
Approximate volume of insulation = x 1.5 x 37 x 50 x 10-3 = 8.72 m3
Weight = 8.72 m3 x 130 kg/m3 x 9.81 m/s2 = 11,121 N
Double this to allow for fitting, etc. = 22.241 kN

Total weight:
Shell
Plates & contents
Insulation

175.279kN
150.45kN
22.241kN

Total

347.97kN

19

Step7: Wind loading

Take dynamic wind pressure as 1280 N/m2,corresponding to 160kph (100 mph) for preliminary
design studies.
Mean diameter including thickness and insulation

= Di + 2(ts +tins) x 10-3

= 1.5 + 2(11+50) x 10-3 =1.622 m

Loading (per linear meter),

= 1280 N/m2 x 1.622 m = 2076.16 N/m

Bending moment at bottom tangent line = Mx =

= 1421131.52Nm

Step8: Analysis of stress

Longitudinal and circumferential stress:
At bottom tangent line, the pressure stresses are given by:
Longitudinal stress,
L= (N/mm2) =

(N/mm2) = 30N/mm2

Circumferential stress,
h= (N/mm2) =

(N/mm2) = 60N/mm2

Stress due to dead weight,

Do = Di + 2 t = 1500 mm + 2 (15 mm) = 1530 mm = outer diameter of the column

Bending Stresses,

mm

= 53.084N/mm2

20

Resultant longitudinal stress is given by,

Is compressive therefore it is negative.

(up wind) =
(down wind) =
(Upwind)
80.63 N/mm2

25.535 N/mm2

60 N/mm2

60 N/mm2

(Downwind)
The greatest the difference between the principal stress will be on the down -wind side
60

N/mm2

Since both upwind (80.63 N/mm2) and downwind stress (25.535 N/mm2) are much more less than the
maximum allowable stress, S = 130 N/mm2 this design with metal thickness of 15 mm is okay and
satisfactory.

Step9: Check elastic stability (buckling).

Critical buckling stress can be calculated as:

= 196.078 N/mm2
The maximum resultant compressive stress will occur when the vessel is not under pressure given by,

55.539N/mm2
Since the maximum resultant compressive resultant stress (55.539 N/mm2) less than that of critical
buckling stress(196.078 N/mm2). So the design of the vessel is satisfactory.

21

4.2. Reinforcement of Openings

4.2.1. Required Area of Reinforcement
Pressure Vessel, for design of internal pressure, the total cross-sectional area of reinforcement A
required in any given plane through the opening for a shell or formed head under internal pressure
shall not be less than

Preliminary Calculations for thickness (

A) The minimum required thickness under circumferential stress, tr, for seamless shell or head is
determined by:
=
S = 130 N/mm2

Given

E=1
P = 1.2 N/mm2
D = 600 mm = 0.6 m
K1 = 0.90
=5.012mm
B) a nozzle wall thickness of:
C) For the vessel wall thickness, t, it is determined as;
R= =

= 750mm

t=

= 6.96

D) For the nominal thickness of internal projection of nozzle wall,

it is determined as follows:

= 50
D) Distance nozzle projects beyond the inner surface of the vessel wall is as determined:
H = min(2.5t,

t = 7mm
ti = 46 mm
=min(2.5

,2.5

=min(22.5,115)

E) The diameter of the finished opening, d, is determined as,

22

d=D
Note: The opening is in a corroded condition. Thus, a corrosion allowance is added to the
diameter of the opening.

Calculations of Area Required for Reinforcement

Given
d = D = 600 mm

t = 9 mm
= 46 mm

= 5.0123 mm
= 50mm
= 7 mm
h = 12.5 mm
Assuming correction factor, F = 1 and d=D,
=600

50

To determine whether additional reinforcement is necessary for the manhole, the actual area available
for reinforcement must be calculated and compare with the area required for reinforcement.
The following condition must be satisfied if no additional reinforcement is required:
A

Where,

Thus, the following area (A1, A2, A3, A41, A43) is calculated as follows.

A1 (largest):

=d(

where

Since both the nozzle and the vessel are made up of the same material, Then the term
will be cancel out.
d(

,
d(

23

Since A<A, then A=

Then substituting the values,

Since

=1935

Substituting the values,

, Then,
For areas

and

they are not considered since the welds vary from fillet to butt weld type

By comparing both the required area for reinforcement, A and the area available for reinforcement,
A=3007.38

5953

Then there is no additional reinforcement will be required.

24

4.3. Nozzles and flanges

Nozzles and flanges can be categorized into several categories depending on their sizes, types and
other attachments to vessels. A nozzle is a relatively simple device, a cylindrical component that
penetrates the shell or heads of a pressure vessel. The main function of nozzles on the plates is to
transport fluids and allow the liquids and gas to disperse throughout the towers as the fluids flow
through the nozzles. On the other hand, flanges improve the strength of a structure and also apply as a
guide for keeping a particular object in place. Different column design requires different standards
and designs of the nozzles and flanges. Flanges are used for connecting pipe and instruments to
vessels, for removable vessel heads and manhole covers.
For this particular design, then nozzle and flanges design is strictly based on specification of nozzles
provided in the project specification sheet. The nozzles connecting the feed to column at the midpoint
has a 200mm inside diameter and vapour outlet diameter of 250 mm. The bottom product and reflux
return have inside diameter of 200mm.
Table4.1. Standard flanges
Nominal

Pipe

Flange

Size

Output
diameter(mm)

65

76.1

160

20

273

375

bolting

Raised
face
d4
f

14

32

110

22

44

312

Drilling
No

d2

d3

M12

130

100

M12

20

18

335

295

Typical Standard Flanges;

Figure4.1. Selected Standard flange

25

boss

4.4. Design of skirt support for the vessel

The height of the vessel including height of each ellipsoidal head.

Height of the vessel,

Given:
o Length of cylindrical section = 37 m
o Internal column diameter = 1.5 m

Height of each ellipsoidal head, h

Since the ellipsoidal heads used for this design are a standard measurement as shown below
in Figure 4.2, it is safe to assume that the heads are manufactured with a major and minor
axis ratio of 2:1(Coulson and Richardsons chemical engineering Vol.6).

Figure4.2.Standard ellipsoidal head

The height of each ellipsoidal head, h =

The height of vessel,

= (Length of cylindrical section) + (Height of the two ellipsoidal heads)
= 37+2(0.375) = 37.75m
Height of the vessel, Hv =length of cylindrical section + height of the two ellipsoidal
head 37 m +20.375 m =37.75 m
Approximate weight =(

Total weight=
As a first trial, take the skirt thickness as the same as that of the bottom of section
of the vessel,

26

Step1: The bending moment, in skirt.

The effect of bending moment of skirt, Ms, can be calculated as follow.

Where,

MS = Bending moment at the base of the skirt

FW = Load per unit length
HS = Height of skirt
H V = Height of the vessel

KNm

Step2: The bending stress in the skirt.

The bending stress in the skirt is given by;
Assume as a first trial, take the skirt thickness as the same as that of the bottom
section of the vessel, 15 mm.
Where, Ds =Internal column diameter, =1.5m
ts = Thickness of the skirt = Thickness of the bottom section, =15mm
Bending stress in the skirt

62.812N/mm2

Thus,

Step3: The dead weight stress for the test and operating conditions.
For test condition,

Is given by,

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

9.166N/mm2

Thus,

27

For operating condition

: is given b

Where,
Dead weight stress in the skirt for operating condition
Total dead weight of vessel with heads.
2.455 N/mm2

Thus,

Step4: The resultant bending stress in the skirt.

For maximum:

)
71.978N/mm2

For minimum:

)
60.357N/mm2

Step5: Design criteria:

A straight type skirt support is selected, where = 90 Material of construction used is plain
2
carbon steel maximum allowable design stress, S =115 N/mm and Youngs modulus,
E=200,000N/mm2 at ambient temperature. The welding efficiency, E =0.85.
Maximum
dead-weight load on the skirt will occur when the vessel is full of water. Since hydrocarbon materials
has density that is lower than water, then we use density of water to complete our calculations.

For the maximum:

Given the formula,
(
(correct)
For minimum:
Given the formula,

28

(correct)
Since all the calculations and comparison above shows that all design criteria were correct,
add 2 mm for corrosion allowance, gives a design thickness of new skirt thickness,
New skirt thickness,
= (Old thickness of the skirt) + (Corrosion allowance)
=15mm + 2mm = 17mm

Step6: Design Base ring/flange and anchor bolt

For

=1.5

Determine the number of bolts required, N bolts

Since the measurements for the pitch diameter were not given, it was assumed that the
measurement of column diameter would be used to make an assumption for the pitch
diameter. An estimation of 10% allowance was then added to the pitch circle diameter
column.
Number of bolts required N bolts given by the formula:
Where,

= Internal column diameter = 1.5 m

= Pitch circle diameter

+ (10

= 1.5 + 0.1 x 1.5 = 1.65 m = 1,650 mm

Thus,
By taking the closest multiple of 4, 12 is the nearest value to the number of bolts required,
.

Determine the required bolt area,

This is given by:
(
Where,

Number of bolts required = 12 Bolts

Bolt design stress = 125
Bending moment in skirt = 1681.63KNm
29

Total dead weight of vessel with heads = 175.3KN

Pitch circle diameter = 1.6 5m = 1650 mm
(
=2600.9mm2
The bolt root diameter

Is given by the formula:

=57.546 mm

With the addition of base rings, the bolt should be sufficient enough to distribute the total
compressive load to the foundation.

The total compressive load on each base ring per unit length,
Is Given by:

Where,

Total dead weight of vessel with heads = 175.3KN

Bending moment in skirt =

Nm

Internal column diameter = 1.5m

)=988.878N/mm

The minimum width of base ring,

Given by the formula:

Total compressive load on the base ring per unit length = 988878N/m
=maximum allowable bearing pressure on the concrete foundation pad bearing pressure
5 N/mm2
197.8 mm=0.1978m
30

Due to the large base ring width, a flared skirt shall be used as an alternative to the design.
Therefore, the requirements and assumptions for the new skirt are:
Flared skirt bottom diameter, = 2.5 m
Bolt circle diameter, Dolt = + (10% of )

= 2.5 m + (1. 0.1) = 2.5 m + 0.15 m = 2.65 m = 2650 mm

Number of bolt,

= 2.75 m = 2750mm
14.39

The skirt base angle:

Skirt base angle,

(With
(

=2.5 m) given by,

78.69 0

The bolt spacing.

Bolt spacing is given by the formula:
Where,

Bolt circle diameter = 2650 mm

Number of bolts =14.39
578.542 mm (satisfactory)

The required bolt area,

Is given by the formula:
Total dead weight of vessel with heads = 175.3KN
Bending moment in skirt
Number of bolts required = 14.39
Bolt circle diameter = 2.650m = 2650 mm
Bolt design stress = 125 N/mm2

31

256mm2

The total compressive load on each base ring per unit length, Fbolt.
Given the formula:
Where,
Total dead weight of vessel with heads =175.3KN
Bending moment in skirt = 1681.63kNm
Flared skirt bottom diameter =2.5m =2500mm

364.89 N/mm=364890N/m

The minimum width of base ring,

Given the formula:

Maximum allowable bearing pressure on the concrete foundation pad Bearing pressure
= 5 N/mm2
72.978mm

The actual bearing pressure on the concrete foundation,

Given the formula:
Where,

= Skirt thickness = 17mm,

Actual width =Lr + ts + ti

ti = Insulation thickness = 50mm

Fbolt = Total compressive load on the base ring per unit length
Lr =Distance from the edge of the skirt to the outer edge of the ring = 178 mm (Sinnott.,
Coulson & Richardson's Chemical Engineering 1999) : Using Bolt size 70 (BS 4190:1967)
Actual width = 178 + 17 +50 = 245 mm
1.4893 N/mm2

The base ring thickness, tb.

The base ring thickness given by the formula:

31.798mm

32

Data sheet

Equipment No
Pv-1

Fun. sieve plate column

Sheet No.1
Customer: ADU
Shell

Thickness

Heads

supports

Flanges

torispherical

ellipsoidal

9mm

12.17mm

7mm

17mm

25mm

1200

1200

1200

1200

10 bar

150

150

150

150

150

ASME

ASME

ASME

ASME

ASME

Stainless steel
(304)

Stainless
steel(304)

Stainless steel
(304)

carbon

Stainless
steel (304)

Diameter

water
1500mm

water
1500mm

water
1500mm

water
1500mm

Water
395mm

Length

37000mm

0.75

Design by: Network 6

Nozzle

Skirt carbon
steel

Silicon killed

D. pressure

D.
temperature
Design code

Material
construction

Process
material

Corrosion
allowance

2mm

ID No:(0485,0963,1242,1406,1443,1578)/06
Section: 1

Date: 12/12/2016
Checked by: Zinabu H.

Table4.2. Final results of the data sheet

33

Distillate

Feed

Bottom
Figure4.3. Schematic Pressure vessel diagram

34

4.5. Discussion
Since a vessel needs to withstand design loads such as wind and the dead weight loads, the column
wall has to be gradually thicker from the top to the bottom Thus, the pressure at the vessel base is
maintained at maximum and this requires greater thickness of the column wall and also larger
diameter for the column. This is crucial to prevent the vessel from collapsing as well as to increase its
capability to endure wind loading and dead weight of vessel and content that contributed to the high
stress from increase in pressure.
The ellipsoidal head is chosen to satisfy the specifications mentioned earlier. However, there were
also other factors considered when chosen the vessel head. Essentially, the best vessel head should be
able to withstand maximum stress with the least materials and economically feasible (Sinott 2008)
.From the calculated thickness of both heads previously, Ellipsoidal head with smaller thickness
compared to that of torispherical Head may suggested an economically feasible head. The head
resembles an ellipse with its radius varying continuously in its cross section. The varying radius
results in a smooth transition between the dome and cylindrical section of the vessel. Its head is
deeper than a comparable torispherical head. When an opening and its reinforcement are in an
ellipsoidal head, and located entirely within a circle, the centre of which coincides with head. The
diameter of the circle is equal to 80% of the shell diameter. tr is the thickness required for a seamless
sphere of radius K1D, where D is the shell internal diameter and K1 is 0.9 (Steward and Lewis 2013).
Assume no weld is used in the nozzle. The required reinforcement area is needed to compare with the
total area of nozzle in feed, vapour out, bottom product, 1 m above the bottom of the column and 1.5
m below the top of the column to ensure the nozzle got reinforcement. To obtain the total area, the
area of excess thickness in shell or head, area available in nozzle projecting outward and area
available in nozzle projecting inward are determined. If,
.Opening is adequately reinforced;
if
Therefore , there will no additional reinforcements needed.

35

Chapter -5
CONCLUSION AND RECOMMENDATION
5.1. Conclusion
Generally, the design of pressure vessel is initialized with the specification requirements in
terms of standard technical specifications along with numerous requirements that lay hidden
from the market. The design of a pressure vessel is more of a selection procedure, selection of
its components to be more precise rather designing each and every component. Regarding
storage of fluid for a pressure vessel system should be preferred due to its simplicity, better
sensitivity, higher reliability, low maintenance, compactness for the same capacity. The
storage of fluid at high pressure in the pressure vessel is at the heart of its performance and is
the first step towards the design.
For pressure vessels, finite element analysis provides an additional tool for use in analysis.
However, it must be compared to other available data, not taken as being correct just because
it looks right. Used with this understanding, finite element analysis offers great insight into
the complex interactions found in pressure vessel design. With the help of finite element
analysis, we can study the actual maximum stress distributions in the different components of
pressure vessel and the actual behavior of pressure vessel.

5.2. Recommendation
To do this project many problems have been occurred. Those are the courses which are related
to AutoCAD, project writing, shortage of materials such as computer, shortage of knowledge about
how can we design, it takes many times to practice and understand.
So for next it should be given the courses of introduction to project, AutoCAD and more practice of
the course of chemical apparatus design before such big project is given and simple projects must be
given before doing such it.

36

References
Vessel Design Handbook, AZBEL, D. S. and CHEREMISINOFF, N. P. (1982) Chemical and
Process Equipment Design: vessel design and selection (Ann Arbor Science).
BEDNAR, H. H. (1990) Pressure 2nd edn (Krieger).
BHATTACHARYYA, B. C. (1976) Introduction to Chemical Equipment Design, Mechanical
Aspects (Indian Institute of Technology).
BERGMAN, D. J. (1963) Trans. Am. Soc. Mech. Eng. (J. Eng. for Ind.) 85, 219. Temperature
gradients for skirt supports of hot vessels.
BIRCHALL, H. and LAKE, G. F. (1947) Proc. Inst. Mech. Eng. 56, 349. An alternative form
of pressure vessel of novel construction.
MyChemE. Types of Vessel Head. 4 March, 2013. http://www.mycheme.com/types-of-vesselhead/ (accessed 29 October, 2015).
http://www.inspection-for-industry.com/pressure-vessel-heads.html
Sinnott, R.K. 2008. Coulson & Richardsons Chemical Engineering Volume 6: Chemical
Engineering Design, 3rd ed. Burlington, MA: Butterworth-Heinemann Publications.
Section VIII, Division 1: Rules for Construction of Pressure Vessel, ASME Boiler and
Pressure Vessel Codes, 2010 edition, The American Society of Mechanical Engineers (New
York, NY: ASME, 2010): pg. 13, 19, 38-43 & 54, accessed November 5, 2015,
http://www.slideshare.net/AbdulKhalikMuhammadF/asme-section-viii-div1-2010

37

Appendix
Appendix A: maximum allowable joint efficiency
Type of joint

degree of radiography
100persent

-double welded butt or

spot

non

1.0

0.85

0.7

0.9

0.8

0.65

Equivalent
-single weld butt joint
With bonding

Appendix B
The wall thickness of any vessel should not be less than the values given below.
Vessel diameter

Minimum thickness

1to2

2to2.5

9
10

2.5to3
12
3to3.5

38

Appendix C Typical design stress for plate

Material

Design stress at temperature (

tensile
Strength (

0 to5 100 150 200 250 300 350 400 450 500

Carbon steel(silicon killed)

360

135 125 115 105 95 85 80 70

Carbon manganese steal

460

180 170 150 140 130 115 105 100

Carbon steel molybdenum

450

180 170 145 130 120 110 110 110

Low alloy steel (Ni,Cr,Mo)

550

240 240 240 235 230 230 190 170

Stainless steel unstablized(304) 510

165 145 130 115 110 105 100

95 90

Stain lesssteel tistablized(321)

540

165 150 140 135 130 125 120 120 115

Stain less steel (316)

520

175 150 135 120 115 110 105 105 100

Appendix D
Standard flange
Nominal

Pipe

Flange

Size

Output
diameter(mm)

65

76.1

160

20

273

375

39

bolting

Raised
face
d4
f

14

32

110

22

44

312

Drilling

boss

No

d2

d3

M12

130

100

M12

20

18

335

295