Pressure Vessel Designe by Natneal

DEBRE BERHAN UNIVERSITY
DESIGN OF UNFIRED HORIZONTAL PRESSURE VESSEL
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL
ENGINEERING
2010
MACHINE DESIGN PROJECT-I

Design of unfired pressure vessel
Name Id no Group 10
Natneal Asrate-------------------------------0894/08
Mulusew Asrie-------------------------------0884/08
Gosa Sintayehu------------------------------0602/08
Kibrom Zeray--------------------------------0702/08
Submitted to Mr. Habtamu Molla
DEBRE BERHAN UNIVERSITY 1

Acknowledgments
After the completion of this work, we would like to give our sincere thanks to all those
who helped us to reach our goal. It’s a great pleasure and moment of immense
satisfaction for us to express our profound gratitude to our guide instructor Habtamu
Mola whose constant encouragement enabled us to work enthusiastically. His perpetual
motivation, patience and excellent expertise in discussion during progress of the project
work have benefited us to an extent, which is beyond expression.
Last but not the least I would also like to thank all the staffs of DEBRE BERHAN
UNIVERSITY Campus (Mechanical Engineering Department) for their valuable
guidance with their interest and valuable suggestions brightened us.

Abstract
This paper reviews research of different researchers on the failure and optimization of
pressure vessels. The study includes various reasons for failure of vessel as stress
concentration at junctions, excessive deformation due to improper support, reinforcing,
end connections and so on. The literature reviewed shows growing interest in
optimization. The motivation for this research is to optimize the pressure vessel by
changing support location and nozzle location. Pressure vessel design is carried out as
per the standards set by ASME in pressure vessel code. It is Clint’s decision to select
appropriate analytical data for determination of thickness of the walls. In this paper
some of recent and past research carried on the pressure vessel design and analysis.

Nomenclature
P = internal pressure, psi
Di, Do =inside and outside diameter, in
S = allowable or calculated stress, psi
E = Joint efficiency
Ri, Ro = inside and outside radius, in
K, M = coefficients
δx = longitudinal stress, psi
δØ = circumferential stress, psi
Rm = mean radius of shell, in
t = thickness or thickness required of shell, head or cone, in
S = allowable stress, psi

E = joint efficiency
P1 , P2 = equivalent internal pressure, psi
δ1 , δ2 = circumferential membrane stress, psi
c = code correction factor
M1 , M2 = longitudinal bending moment at elevation, in-lb
* = multiplication
List of Abbreviation
 ASME = American society of mechanical engineering

 MWAP= Maximum working allowable pressure
 WAP = Working allowable pressure
 AISI = American Iron And Steel Institution

Contents
Chapter One
1. Introduction ....................................................................................................................... 7
1.1 Background History ................................................................................................... 7
1.1.1 Definition of Pressure Vessel ............................................................................. 8
1.1.2 Classification of Pressure Vessel........................................................................ 9
1.1.3 Application of Pressure Vessel .......................................................................... 9
1.1.4 Component of Pressure Vessel........................................................................ 10
1.1.5 Failures in Pressure Vessels ............................................................................. 12
1.2 Statement of Problem ............................................................................................. 14
1.3 General Objective .................................................................................................... 14
1.3.1 Specific Objective ............................................................................................ 14
1.4 Scope of the Study................................................................................................... 14
2 Literature ......................................................................................................................... 16
2.1 Literature Review .................................................................................................... 16
2.2 Identified Gaps in the Literature’s........................................................................... 18
3 Methodology and Design Consideration ......................................................................... 19
3.1 Design methodology of the project......................................................................... 19
3.2 Material Selection Factors ....................................................................................... 20
3.3 Decision Matrix........................................................................................................ 20
3.4 Selected Material .................................................................................................... 21
3.5 ASME SA516 Grade 60 - Chemical Composition ..................................................... 22
3.6 ASME SA516 Grade 60 - Mechanical Properties ..................................................... 23
3.7 Physical property of SA-516 .................................................................................... 23
3.8 Design Consideration............................................................................................... 23
3.9 Selection of Type of Vessel ...................................................................................... 24
3.9.1 Reason of Selection of Horizontal Pressure Vessel ......................................... 24
3.9.2 Supports for Vessel .......................................................................................... 24
3.10 Design Loading......................................................................................................... 24
3.11 Categories of Loadings ............................................................................................ 25
3.12 Operating and Design Scenarios to Consider .......................................................... 26
3.13 Stress ....................................................................................................................... 27
3.13.1 Types of Stress ................................................................................................. 27
3.14 Maximum Allowable Stress ..................................................................................... 28
3.15 Welded Joint Efficiency ........................................................................................... 28

3.16 Considered fluid for the design ............................................................................... 28

4 Design Analysis ................................................................................................................ 29
4.1 Design of Shell ......................................................................................................... 29
4.2 Design of Head ........................................................................................................ 34
4.3 Design of Nozzle ...................................................................................................... 36
4.4 Design of Saddle Support ........................................................................................ 40
4.5 Result of the design ................................................................................................. 46
5 Conclusion and Recommendation................................................................................... 47
5.1 Conclusion ............................................................................................................... 47
5.2 Recommendation .................................................................................................... 48
6 Appendix I ........................................................................................................................ 56
7 Appendix II ....................................................................................................................... 57
8 Appendix III ...................................................................................................................... 60
9 Appendix IV ..................................................................................................................... 61
10 Reference ........................................................................................................................ 62

CHAPTER ONE
1. Introduction
1.1 Background History
By 1911 it was apparent to manufacturers and users of boilers and pressure vessel that
the lack of uniformly in these regulations between states made it difficult to construct
vessel for interstate commerce. A group of these interested parties appealed to the
Council of the American Society of Mechanical Engineers to assist in the formulation
of standard specification for steam boiler and pressure vessels. (The American Society
of Mechanical Engineers was organized in 1880 as an education and technical society
of mechanical engineers) [1]. After years of development and public comment, the first
edition of the code, ASME rules of construction of stationary Boilers and for allowable
Working Pressure, was published in 1914 and formally adopted in the spring of 1915.
The first code rules for pressure vessels, entitled rules for the construction of unfired
pressure vessels, followed in 1925. From this simple beginning the Code has now
evolved into present eleven section document, with multiple subdivisions, parts,
subsection, and mandatory and non-mandatory appendices [1].
The earliest documented design of pressure vessels is described in the book Codex
Madrid I, by Leonardo da Vinci, in 1495, where containers of pressurized air were
theorized to lift heavy weights underwater,[2] however vessels resembling what are used
today did not come about until the 1800s where steam was generated in boilers helping
to spur the industrial revolution[2]. 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 [2].
Local providences and states in the US began enacting rules for constructing these
vessels after some particularly devastating vessel failures occurred killing dozens of
people at a time, which made it difficult for manufacturers to keep up with the varied
rules from one location to another and the first pressure vessel code was developed
starting in 1911 and released in 1914, starting the ASME Boiler and Pressure Vessel
Code (BPVC).[2] In an early effort to design a tank capable of withstanding pressures

up to 10,000 psi (69 MPa), a 6-inch (150 mm) diameter tank was developed in 1919
that was spirally-wound with two layers of high tensile strength steel wire to prevent
sidewall rupture, and the end caps longitudinally reinforced with lengthwise high-
tensile rods[2].
The need for high pressure and temperature vessels for petroleum refineries and
chemical plants gave rise to vessels joined with welding instead of rivets (which were
unsuitable for the pressures and temperatures required) and in 1920s and 1930s the
BPVC included welding as an acceptable means of construction, and welding is the
main means of joining metal vessels today [2].
1.1.1 Definition of Pressure Vessel

A pressure vessel is a container having a pressure differential with respect to the
atmosphere. The purpose of a pressure vessel is to store or process a high pressure high
temperature fluid. The fluid can be toxic such as chemicals as well as nontoxic such as
steam. In other words, pressure vessel is a closed container designed to hold gases or
liquids at a pressure substantially different from the gauge pressure.
Generally, pressure vessel is a metallic or nonmetallic container, generally cylindrical

or spheroid, capable of withstanding various loadings and in which materials are
processed, treated, or stored is said to be pressure vessel.
Fig-1 pressure vessel

1.1.2 Classification of Pressure Vessel

The pressure vessels may be classified as follows:
According to the dimensions the pressure vessels, according to their dimensions, may
be classified as thin shell or thick shell. If the wall thickness of the shell (t) is less than
1/10 of the diameter of the shell (d), then it is called a thin shell. On the other hand, if
the wall thickness of the shell is greater than 1/10 of the diameter of the shell, then it is
said to be a thick shell.
According to the end construction the pressure vessels, according to the end
construction, may be classified as open end or closed end. A simple cylinder with a
piston, such as cylinder of a press is an example of an open end vessel, whereas a tank
is an example of a closed end vessel. In case of vessels having open ends, the
circumferential or hoop stresses are induced by the fluid pressure, whereas in case of
closed ends, longitudinal stresses in addition to circumferential stresses are induced.
According to construction pressure vessels can be classified in to three main group

Horizontal, Vertical and Spherical
According to service pressure vessel classified into two major parts those are Fired
and Unfired pressure vessel
1.1.3 Application of Pressure Vessel

A pressure vessels are used in number of industry like power generation industry for
fossil and nuclear power, the petrochemical industry for storing and processing crude
petroleum oil in tank forms as well as storing gasoline in surface situation and the
chemical industry (in chemical reactors). The pressurized equipment for wide range of
industrial plant for storage and manufacturing process.
Generally, Pressure vessels have many application areas in the real world. They are
majorly used in chemical industry, processing plants, nuclear power plants, and oil
refining industries.
The size and geometric form of pressure vessel vary greatly from large cylindrical
vessel used for high pressure gas storage to the small size used as hydraulic units for
air craft. Some are buried in the ground or deep in the ocean but most are positioned on
ground or supported in plate form.

1.1.4 Component of Pressure Vessel

Pressure vessel has several components but the main parts are: shell, nozzle, head, and
support
Shell: is the primary component that contains the pressure. Pressure vessel shells in
the form of different plates are welded together to form a structure that has a common
rotational axis. Horizontal drums have cylindrical shells and are constructed in a wide
range of diameter and length. The shell sections of a tall tower may be constructed of
different materials, thickness and diameters due to process and phase change of process
fluid. Shells are either cylindrical, spherical or conical in shape.
Fig-2 shell
Nozzle: is a cylindrical component that penetrates into the shell or head of pressure
vessel. The nozzle ends are usually flanged to allow for the necessary connection and
to permit easy disassembly for maintenance for access. And they are used to Attach
piping for flow into or out of the vessel, Attach instrument connection (level gauges,
Thermos wells, pressure gauges) etc.
Fig-3 nozzle

Head: A component design is a cylinder with end caps called heads. Heads are typically
curved rather than flat for several reasons. Hence in this project we will use semicircular
type of head.
Fig-4 head
Support: The type of support that is used depends primarily on the size and orientation
of the pressure vessel support must be adequate for the applied weight, wind, and earth
quack loads. It is considered to be the non-pressurized part of the vessel.
Common type of supports are Skirt support, Leg support, saddle support, lug support
Skirt Support: tall, vertical, cylindrical pressure vessel are typically supported by skirts.
A support is a cylindrical shell section that is welded either to the lower portion of the
vessel shell or to the bottom head (for cylindrical vessels). Skirts for spherical vessels
are welded the vessel near the mid plan of the shell. The skirts are normally long enough
to provide enough flexibility so that radial thermal expansion of the shell does not cause
high thermal stress at its junction with the skirt.
Leg Support: Small vertical drums are typically supported on legs that are welded the
lower portion of the shell. The maximum ratio of support leg length to the drum
diameter is typically 2: 1.the number of legs needed depends on the drum size and load
to carried support legs are also typically used for spherical pressurized storage vessels.
Saddle Support: Horizontal drums are typically supported two locations by saddle
supports. A saddle support spreads the weight load over the long area of the shell to
prevent an excessive local stress in the shell at the support points. The width of the
saddle, among other design details, is determined by a specific size and design

conditions of the pressure vessel one saddle support is normally fixed anchored to its
foundation.
Lug Support: Lugs that are welded to the pressure vessel, may also be used to support
pressure vessels. The use of lugs a typically limited to vessels at small to medium
diameter (1 to 10 f t). And moderate height to diameter ratios in the range of 2:1 to 5:1
lug support are often used for vessels of this size that are located above grade with
structural steel. The lugs are typically bolted to horizontal structural members to
provide stability against overturning loads; however, the bolt holes are often slotted to
permit free radial thermal expansion of the drum.
Fig-5 supports
1.1.5 Failures in Pressure Vessels

Vessel failures can be grouped into four major categories, which describe why a vessel
failure occurs. Failures can also be grouped into types of failures, which describe how
the failure occurs. Each failure has a why and how to its history. It may have failed
through corrosion fatigue because the wrong material was selected! The designer must
be as familiar with categories and types of failure as with categories and types of stress
and loadings. Ultimately they are all related. Then Vessel failures are: Material, Design,
Fabrication, and Service.
Material-Improper selection of material; defects in material.
Design-Incorrect design data; inaccurate or incorrect design methods; inadequate shop

testing.
Fabrication-Poor quality control-improper or insufficient fabrication procedures

including welding; heat treatment or forming methods.

Service-Change of service condition by the user; inexperienced operations or

maintenance personnel; upset conditions. Some types of service which require special
attention both for selection of material, design details, and fabrication methods are as
follows: Lethal, Fatigue (cyclic), Brittle (low temperature), High temperature, High
shock or vibration, Vessel contents
As described above this are cause to occur failure; now we will consider what type of
failure to happen in different conditions.
Brittle Fracture-Can occur at low or intermediate temperatures. 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 deformation-The primary and secondary stress limits as outlined in

ASME Section VIII, Division 2, are intended to prevent excessive plastic deformation
and incremental collapse.
Stress Rupture-Creep deformation as a result of fatigue or cyclic loading, i.e.,

progressive fracture. Creep is a time-dependent phenomenon, whereas fatigue is a
cycle-dependent phenomenon.
Plastic Instability-Incremental collapse; incremental collapse is cyclic strain

accumulation or cumulative cyclic deformation. Cumulative damage leads to instability
of vessel by plastic deformation.
High Strain-Low cycle fatigue is strain-governed and occurs mainly in lower-strength

high-ductile materials.
Stress Corrosion-It is well known that chlorides cause stress corrosion cracking in
stainless steels; likewise, caustic service can cause stress corrosion cracking in carbon
steels. Material selection is critical in these services.
Corrosion Fatigue-Occurs when corrosive and fatigue effects occur simultaneously.

Corrosion can reduce fatigue life by pitting the surface and propagating cracks. Material
selection and fatigue properties are the major considerations.
In dealing with these various modes of failure, the designer must have at his disposal a
picture of the state of stress in the various parts. It is against these failure modes that
the designer must compare and interpret stress values.

1.2 Statement of Problem
Vessel failures can be grouped into four major categories, which describe why a vessel
failure occurs. Failures can also be grouped into types of failures, which describe how
the failure occurs. Each failure has a why and how to its history. It may have failed
through corrosion fatigue because wrong material was selected! The designer must be
as familiar with categories and types of failure as with categories and types of stress
and loadings. Ultimately they are all related.
● Material- Improper selection of material; defects in material.
● Design- Incorrect design data; inaccurate or incorrect design methods; inadequate
shop testing.
● Fabrication- Poor quality control; improper or insufficient fabrication procedures
including welding
1.3 General Objective

The general objective of this project is to design thin, unfired horizontal pressure vessel.
1.3.1 Specific Objective

 To design pressure vessel with ASME code.
 To design each Component of pressure vessel.
 To compare the design with the ASME code and Check failures.
 To sketch the designed components.
 To determine safe design method with enhanced factor of safety.
 To know the proper process.
 To know the proper material selection process for our design.
1.4 Scope of the Study

In sophisticated pressure vessels encountered in engineering construction; high
pressure, extremes of temperature and severity of functional performance
requirements pose exciting design problems. The word "DESIGN" does not mean
only the calculation of the detailed dimensions of a member, but rather is an all-
inclusive term, incorporating: The reasoning that established the most likely mode of
damage or failure; The method of stress analysis employed and significance of
results; The selection of materials type and its environmental behavior.

The ever-increasing use of vessel has given special emphasis to analytical and
experimental methods for determining their emphasis to analytical and experimental
methods for determining their operating stresses of equal importance is the
appraising the significance of these stresses. This appraisal entails the means of
determining the values and extent of the stresses and strains, establishing the
behavior of the material involved, and evaluating the compatibility of these two
factors in the media or environment to which they are subjected. Knowledge of material
behavior is required not only to avoid failures, but also equally to permit
maximum economy of material choice and amount used. Then in our design we will
use solidwork to model our vessel.

CHAPTER TWO
2 Literature
2.1 Literature Review
Shafique M.A. Khan (Stress Distributions in A Horizontal Pressure Vessel and the
Saddle Supports) Author analyzed and got the result of stress distribution in a
horizontal pressure vessel and the saddle support. The results are obtained from a three
dimensional finite element analysis. A quarter of the pressure vessel is modeled with
realistic details of saddle support. Physical reasons for favoring of a particular value of
ratio of distance of support from the end of the vessel to the length of vessel are outlined
[3]
.
Adithya M, M. M. M. Patnaik horizontal pressure vessel supported on saddles is

designed and analyzed. The FEA for different configurations of pressure vessel on
saddle supports is done using ANSYS. The stress intensities in various cases are
analyzed and the optimal location when the saddles are placed away from heads is
considered as the most suitable design for the large horizontal vessels. The effect of
stiffening is also considered in three cases. The reduction in stress intensity is found for
one of the cases. For this the optimization of thickness was done which resulted huge
reduction of weight [4].
Sagar P. Tiwatane analysis throws light on various stresses encountered in the skirt to
dished junction which makes its design critical. After this analysis optimum parameters
considered which can minimize stresses in junction. This helps in increasing life of
pressure vessel & reduces its cost. He concluded that stress and other parameters are
also decreased by changing weld size of skirt to dished end junction [5].
Vinod Kumar he did comparative study on stresses by using mathematical approach

and by ANSYS software. He did modifications in present design, reduced maximum
stress value at critical zone and optimizes the cost of equipment. Some modifications
are done like inserted wear plate between saddle and vessel, made saddle support radius
greater than vessel outer radius and made it flexible at the saddle horn [6].
V. V. Wadkar He did analysis of cylindrical pressure vessels with hemispherical head

type. By ANSYS he calculated maximum equivalent stress and compared results

With theoretical values. In his paper he concluded that smaller values of equivalent
stresses are appearing in pressure vessel with hemispherical heads and equivalent stress
distribution is advantageous in case of head geometry [7].
Bandarupalli Praneeth, T.B.S. Rao (Finite Element Analysis of Pressure Vessel and
Piping Design) Features of multilayered high pressure vessels, their advantages over
monoblock vessels are discussed in this paper. Various parameters of solid pressure
vessel are designed and checked according to the principles specified in American
Society of Mechanical Engineers (ASME) Section VII Division 1. The stresses
developed in solid wall pressure vessel and multilayer pressure vessel is analyzed by
using ANSYS. The solid wall thickness is 12mm and of layers’ thickness is 6mm. The
theoretical values and software values are compared for both solid wall and multilayer
pressure vessel [8].
R.C. Carbonari (Design of Pressure Vessels using Shape Optimization: An

Integrated Approach) The paper discusses shape optimization of axisymmetric
pressure vessel considering an integrated approach in which entire pressure vessel
model is used in conjunction with a multi-objective function that aims to minimize the
von-misses mechanical stress from nozzle to head. Representative examples are
examined and solution obtained for the entire vessel considering temperature and
pressure loading. The different shapes from usual one are obtained. Even though such
different shapes may not be profitable considering present manufacturing processes,
they may competitive for future manufacturing technologies and contribute to better
understanding of the actual influence of shape in the behavior of pressure vessels [9].
Shyam R. Gupta, Ashish Desai have designed a horizontal pressure vessel using PV
Elite industrial software. For designing the vessel very few parameters such as design
pressure, design temperature, inside diameter, volume, material, fluid properties, etc.
are required. PV Elite gives the thickness of the shell, head dimensions as per our
selected head, nozzle calculations based on diameter given by us, loadings on pressure
vessels, support design and calculations and all the parameters required to manufacture
a pressure vessel. The stress generated in the vessel due to pressure loading and at
discontinuities is obtained in the report from PV Elite. PV Elite does the calculations
as per the code selected by the user and the stresses are calculated as per Welding
Research Council (WRC) 107. The results obtained from the software are accurate and

complying with the standard codes. Use of the software will help reduce design time
and can give precise calculations and required data [10].
Ahmed Ibrahim*, Yeong Ryu, Mir Saidpour have discussed about stress developed in
thin walled pressure vessels by doing a case study on a soda can by measuring the
elastic strains of the surface of the can with help of strain gauges attached to the can.
Generalized equations for stress and strain obtained by Hook’s law ware used to find
the longitudinal stress, hoop stress and internal pressure. The change in longitudinal
strain and hoop strain were used to calculate the internal pressure in the can. Small
variations were seen in internal pressures calculated form longitudinal strain and hoop
strain [11].
Yogesh Borse and Avadesh K. Sharma Basics of pressure vessel and its structure is
explained. Stress Characteristics are mentioned in the paper. Finite element modeling
and analysis done for different ends of pressure vessel. The different ends are
Hemispherical, Ellipsoidal & Tori spherical. Loads and boundary conditions for
different ends are kept same and were found that hemispherical end have least stress
[12]
.
2.2 Identified Gaps in the Literature’s

The literature reviewed includes study of stresses, non –linear analysis, fatigue analysis,
thermal analysis. Major focus of the researchers is on stress analysis due to pressure
generated in the vessel. Hence it is found that none of the researcher focused on the
optimization for support location and nozzle location. It is essential to study the effect
of nozzle location and support location due to which stresses generated in the shell. The
location of support affects the stress concentration. Location of the nozzle will help to
reduce the concentration of the stress at particular location. Hence this gap causes to
focus on the area optimization of structure by nozzle location and support location.
 Shape of pressure vessel changes. Now it like a water or oil tanker.

 Analysis has been carried out with two saddle support and with three
saddle support.
 Analysis has been carried out also for three vertical leg and four vertical
leg.
 Axisymmetric analysis has been carried out.

CHAPTER THREE
3 Methodology and Design Consideration

3.1 Design methodology of the project
In this section Design methodology is discussed. The design methodology is the
methods to be used to finish one project or to accomplish ones goal.so in our design of
the pressure vessel we are planning to follow the following methods to complete our
design. The methodology is most of the time used in flow chart method and it is as
shown below.
Start
Input parameter of head, shell and nozzle
Selecting of material of element
Calculation of thickness and pressure on head, shell and nozzle
Calculation results
Input parameter for saddle

support
Calculation of stress on saddle
Calculation results on saddle, longitudinal and circumferential stresses
Calculation results on vessel, shell, head, nozzle and other elements
Detailed drawing of the designed

material
Stop

3.2 Material Selection Factors

Primary factors that affect pressure vessel material selections are:
Strength
Corrosion Resistance
Resistance to Hydrogen Attack
Fracture Toughness
Fabricability
Referenced codes and standards
Product availability
Cost
Service life
Machinability
Operating Temperature, the operating temperature is the temperature which prevails

inside the pressure vessel during any intended operation. The maximum operating
temperature is the highest temperature which provides sufficient flexibility for the
control of the intended operation.in our design we consider the operating temperature
is at room temperature (25oc)
Corrosion Allowance in our design is considered as 1.6mm per 1 year therefore our
design must withstand this highly corrosive behavior.
3.3 Decision Matrix

We have the following materials that are usually used for pressure vessel construction
and we will select one of them based on different criteria and we will decide which
material is used to manufacture it.
Usually pressure vessel materials are
 Aluminum
 Carbon steel
 Stainless steel
Property Aluminum Carbon steel Stainless steel

Extrudablity Very good Not practical Very limited
Waldability Fair Good Good

Cost by weight $1.5/lb. $0.3/lb. $1.4/lb.

Cost by volume $0.14/in3 $0.084/in3 $0.42/in3
Cost index 2.5 1 4.7
Corrosion resistance Good Fair Very good
Tensile,yield 35Ksi 36 to 50 Ksi 45Ksi
strength
Stiffness 10000Ksi 29000Ksi 27000Ksi
Elongation 8-10% 20% 30%
Density 0.098lb./in3 0.283lb./in3 0.284lb./in3
Strength to weight 2.8 1 to 1.41 2
ratio
Table-1 comparison of d/t material
Then from the above table carbon steel is better for our design conditions. After this we
will select which carbon steel is used from ASME code.
3.4 Selected Material

The material selected for this design from American society of mechanical engineering
code section VIII division 1 is carbon steel (SA-516 grade 60)
The selected material has the following property that fulfill the design consideration
Specification for Pressure Vessel Plates, Carbon Steel, for Moderate- and
Lower-Temperature Service.
ASME A516 specification covers plate of carbon steel

Principal Design Features for moderate and lower temperature use in pressure
vessels. The Grade 60 alloy is basically the same as AISI
steel 1330.
Applications Used for weld fabrication of pressure vessels that require

improved notch toughness for lower than ambient
temperature service.
Machinability Machinability of Grade 60 steel is good, being the
equivalent of AISI 1330 steel.
Forming Forming capability is good as the steel has good
ductility.

Welding Grade 60 steel is intended for fabricating by welding.

Thus its welding characteristics are good by
conventional methods.
Heat Treatment The steel is supplied in the as-rolled condition or as

normalized or stress relieved annealed, as specified by
the purchaser. Subsequent heat treatment is not covered
by this specification. See also "Tempering".
Forging Material is supplied as plate and not subsequently

subjected to forging.
Hot Working Grade 60 steel may be hot worked if necessary. Contact
the steel supplier for information.
Cold Working Cold works readily by bending an shaping as with the
plain carbon steels.
Annealing Annealing, if necessary, is done at 1600 F and slow
furnace cooled.
Aging Not applicable.
Tempering Notch toughness can be improved by quenched cooling

from hot rolling or normalizing by the supplier. If such
a faster cooling rate is agreed upon between purchaser
and supplier then the steel is also to be tempered at 1200
F.
Hardening The steel hardens by cold worked and also can be heat
treated and quenched for hardness. However this
specification does not deal with heat treated material.
Other Comments Grade 60 steel has a tensile strength in the 60 to 80 ksi
range with 25% elongation. Its physical and mechanical
properties are basically similar to AISI 1330 steel.
3.5 ASME SA516 Grade 60 - Chemical Composition
Composition Percentage % Composition Percentage %
C 0.18 Cu 0.3
Si 0.4 Ni 0.3
Mn 0.95/1.5 Mo 0.08

P 0.015 Nb 0.01
S 0.018 Ti 0.03
Al 0.02 V 0.02
Cr 0.3
Table-2 chemical composition of SA516

3.6 ASME SA516 Grade 60 - Mechanical Properties
Property Value
Tensile strength (N/mm2) 415/580
Yield strength (N/mm2) 265
Table-3 mechanical property of SA516

3.7 Physical property of SA-516
Density (lb / cu. in.) 0.284
Specific Gravity 7.9
Specific Heat (Btu/lb/Deg F - [32-212 Deg F]) 0.107
Melting Point (Deg F) 2750
Thermal Conductivity 360
Mean Coeff Thermal Expansion 6.7
Modulus of Elasticity Tension 30
Modulus of Elasticity Torsion 11
Good strength
High toughness over a wide temperature range and oxidation resistance to
over 950ºF/510ºC
Excellent resistance to corrosion
Very good resistance to various types of stress corrosion cracking
Very good ductility
Good weld ability
Excellent formability
3.8 Design Consideration

Regardless of the nature of application of the vessels, a number of factors usually must
be considered in designing the unit. The most important consideration often is the
selection of the type of vessel that performs the required services in the most
satisfactory manner. In developing the design, a number of other criteria must be
considered such as the properties of material used, the induced stresses, the elastic

stability, and the aesthetic appearance of the unit. The cost of fabricated vessel is also
important in relation to its service and useful life.
3.9 Selection of Type of Vessel

The first step in the design of any vessel is the selection of the type best suited for the
particular service in question. The primary factors influencing this choice are,
The operating temperature and pressure.

Function and location of the vessel.
Nature of fluid.
Necessary volume for storage or capacity for processing.
It is possible to indicate some generalities in the existing uses of the common types of
vessels. For storage of fluids at atmospheric pressure, cylindrical tanks with flat
bottoms and conical roofs commonly used. Spheres or spheroids are employed for
pressure storage where the volume required is large. For smaller volume under pressure,
cylindrical tanks with formed heads are more economical.
3.9.1 Reason of Selection of Horizontal Pressure Vessel

In general, functional requirements determine whether the vessel shall be vertical
or horizontal. E.g. Distilling columns, a packed tower, which utilizes gravity, require
vertical installation. Heat exchanges and storage vessels are either horizontal or vertical.
If the vessel to be installed outdoor, wind loads etc., are to be calculated to prevent
overturning, thus horizontal is more economical. However, floor space, ground area
and maintenance requirements should be considered.
3.9.2 Supports for Vessel

Cylindrical and other types of vessels have to be supported by different methods. And
horizontal vessels usually supported with saddles support. Beside it have better advantage in
distribute the vessel stress to the ground effectively therefor in increase the service life of the
vessel over the other supports.
3.10 Design Loading

Loadings or forces are the “causes” of stresses in pressure vessels. These forces and
moments must be isolated both to determine where they apply to the vessel and when
they apply to a vessel. Categories of loadings define where these forces are applied.
Loadings may be applied over a large portion (general area) of the vessel or over a local
area of the vessel. Remember both 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. Stresses from local loads must be added to stresses from general
loadings. These combined stresses are then compared to an allowable stress.
For different loadings we have to consider several problems such as
For steady loads, the vessel must support these loads more or less continuously during
its useful life. As a result, the stresses produced from these loads must be maintained to
an acceptable level.
For non-steady loads, the vessel may experience some or all of these loadings at
various times but not all at once and not more or less continuously. Therefore, a
temporarily higher stress is acceptable.
For general loads that apply more or less uniformly across an entire section, the
corresponding stresses must be lower, since the entire vessel must support that loading.
For local loads, the corresponding stresses are confined to a small portion of the vessel
and normally fall off rapidly in distance from the applied load. As discussed previously,
pressurizing a vessel causes bending in certain components. But it doesn’t cause the
entire vessel to bend. The results are not as significant (except in cyclic service) as those
caused by general loadings. Therefore, a slightly higher allowable stress would be in
order.
3.11 Categories of Loadings

general loads
local loads
non-steady loads
steady loads
1. General Loads-Applied more or less continuously across a vessel section.
a. Pressure Loads-Internal or external pressure (design, operating, hydro
test. and hydrostatic head of liquid).
b. Moment Loads-Due to wind, seismic, erection, transportation.
c. Compressive/tensile Loads-Due to dead weight, installed equipment,
ladders, platforms, piping, and vessel contents.
d. Thermal Loads-Hot box design of skirt head attachment.

2. Local Loads-Due to reactions from supports, internals, attached piping, attached

equipment, i.e., platforms, mixers, etc.
a. Radial Load-Inward or outward.
b. Shear Load-Longitudinal or circumferential.
c. Torsional load.
3. Steady Load-Long-term duration, continuous.
a. Internal Vs external pressure.
b. Dead weight.
c. Vessel contents.
d. Loadings due to attached piping and equipment.
e. Loadings to and from vessel supports.
f. Thermal loads.
g. Wind loads.
4. No steady Loads-Short-term duration; variable
a. Shop and field hydro tests.
b. Earthquake.
c. Erection.
d. Transportation.
e. Upset, emergency.
f. Thermal loads.
g. Start up, shut down
3.12 Operating and Design Scenarios to Consider
Operating Temperature, the operating temperature is the temperature which prevails

inside the pressure vessel during any intended operation. The maximum operating
temperature is the highest temperature which provides sufficient flexibility for the
control of the intended operation. Therefore, for our design we consider the operating
temperature is at room temperature (25oc).
Operating Pressure, the pressure which is required for the process, served by the
vessel, at which the vessel is normally operated. Operating pressure of our pressure
vessel is 2.8Mpa.

Design Temperature, the design temperature is the highest temperature at which

equipment may be subjected to the upper and/or lower design pressure. The design
temperature is typically 15°C above the operating temperature. Therefore, the design
temperature becomes 40ºc.
Design Pressure, the pressure which uses designs the vessel. It is recommended to
design a vessel and its parts higher than the operating pressure. A design pressure higher
than the operating pressure with 10 percent, whichever is the greatest, will satisfy this
requirement. The pressure of the fluid and other content of the vessel should also be
taken care consideration for designing the vessel. The design pressure of our pressure
vessel is 3.08Mpa which is 10% of 2.8Mpa.
3.13 Stress
3.13.1 Types of Stress
There are many names to describe types of stress. Enough in fact to provide a confusing
picture even to the experienced designer. As these stresses apply to pressure vessels,
we group all types of stress into three major classes of stress, and subdivision of each
of the groups is arranged according to their effect on the vessel. The following list of
stresses describes types of stress without regard to their effect on the vessel or
component. They define a direction of stress or relate to the application of the load.
Stress to be consider are
 Tensile
 Compressive
 Shear,
 Bending,
 Bearing,
 Axial,
 Discontinuity,
 Membrane,
 Principal,
 Thermal,
 Tangential,
 Load induced,

 Strain,
 induced,
 Circumferential,
 Longitudinal,
 Radial,
 Normal stress.
3.14 Maximum Allowable Stress

The maximum allowable stress is obtained by applying a safety factor to the maximum
stress that the material can withstand under standard testing conditions. This allows for
possible deviations from ideal material properties and ideal vessel construction. The
maximum allowable stress is obtained by applying a safety factor to the maximum
stress that the material can withstand under standard testing conditions. This allows for
possible deviations from ideal material properties and ideal vessel construction.
3.15 Welded Joint Efficiency

Weld joint efficiency (E) accounts for the quality of a welded joint and for the
concentration of local stress. This higher local stress is due to local material or structural
discontinuities. The strength of welded joint will depend on the type of joint and the
quality of the welding .the soundness of the welding is checked by visual inspection
and by nondestructive testing (radiography).the possible lower strength of a welded
joint compared with the virgin plate is usually allowed for in design by multiplying the
allowed design stress for the material by “welded joint factor” J. j=1
3.16 Considered fluid for the design

For the design purpose we assume the fluid that the pressure vessel can hold is gasoline
and its chemical and other properties.

CHAPTER FOUR
4 Design Analysis
4.1 Design of Shell
Equipment shell
Code ASME Section VIII Div. I
Material SA516Gr 60
Design Pressure, P 3.08Mpa,446.77psi
Design Temperature, T 40ºc,104oF
Internal pressure 2.8Mpa
Operating temperature 25oc
Joint efficiency (E) 1mm
Density of carbon steel 𝛒=7861.092kg/𝑚3
Corrosion allowance, c 1.6mm,0.0016m
Inner diameter 1.4m
𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
Allowable stress= 𝑓.𝑠
80𝑘𝑠𝑖
S= 2.35
S=34.0425ksi
S=234.7mpa
From the following table we can find the l/d ratio with the design pressure of 446.77psi
Pressure (Psi) 𝐿/𝐷
0 – 250 3
250 – 500 4
> 500 5

Therefore, the l/d ratio is 4 since pressure is between 250-500psi
Then from this ratio we can find the length if the shell
𝑙
=4
𝑑
L=4d
L=4*1.4m
L=5.6m
For circumferential stress thin cylinder
Pd ∗ 𝑅𝑖
𝑡= +C
𝑆𝐸 − 0.6Pd
3.08 ∗ 106 ∗ 0.7

t= + 0.0016𝑚
234.7 ∗ 106 ∗ 1 − 0.6 ∗ 3.08 ∗ 106
2.156𝑚𝑝𝑎
𝑡 = 232.852𝑚𝑝𝑎 + 0.0016𝑚
t=0.0108m
𝑡 = 10.8𝑚𝑚
For longitudinal stress thin cylinder
Pd ∗ 𝑅𝑖
𝑡= +C
2𝑆𝐸 + 0.4Pd
3.08 ∗ 106 ∗ 0.7

𝑡= + 0.0016𝑚
2 ∗ 234.7 ∗ 106 ∗ 1 + 0.4 ∗ 3.08 ∗ 106
2.156𝑚𝑝𝑎
𝑡= + 0.0016𝑚
470.63𝑚𝑝𝑎
𝑡 = 0.00618𝑚
𝑡 = 6.18𝑚𝑚
Now we will choose the value which have the maximum value for safety purpose
therefor the thickness will be t=10.8mm

Stress Calculation and Checking
A. Circumferential Or Hoop Stress
Is the tensile stress acting in a direction tangential to the circumference, is called

circumferential or hoop stress for the material of the cylindrical shell.
Where (p) internal pressure.
(d) internal diameter of cylindrical shell.
(l) length of the cylindrical shell.
(t) thickness of the cylindrical shell.
The total force acting on a longitudinal section along the diameter of the shell is equal
to The intensity of internal pressure by the projected area= pdl
Total resisting force acting on the cylinder wall = t12tl
𝑝𝑑
From both equations we have [ t12tl  pdl ] or [t =2 1 ]
𝑝𝑑
 1 = 2t
3.08𝑚𝑝𝑎∗1400𝑚𝑚
= 2∗10.8𝑚𝑚
4312
= 21.6 mpa
=199.63mpa
234.7mpa>199.63mpa then our design is safe

B. Longitudinal Stress
Tensile stress acting in the direction of the axis is called longitudinal stress. It is the
tensile stress acting in the transverse or circumferential section or on the ends of the
vessel.
( t 2 ) longitudinal stress. Total resisting force =  t2dt
Total force acting at the transverse section, equal to the intensity of pressure by cross
𝜋
sectional area by this the total force will be: total force=p 4 d2
𝑝∗𝑑
From equations we have: [l1= 4𝑡 ]
𝑝∗𝑑
l1= 4𝑡
3.08𝑚𝑝𝑎∗1400𝑚𝑚
l1= 4∗10.8𝑚𝑚
l1=99.81mpa
234.7mpa>99.81 therefore our design is safe in longitudinal too
Radial Stress
Radial stress is considered for thick cylinders, but it is negligible for thin cylinders.
Therefore, there is no need of calculating radial stress.

Volume of the Fluid the Shell Hold’s
To find the weight of the shell first we need to find first the volume of the shell and to
find the volume we need to calculate F2
𝑆𝐸
F2 = C ( 𝑃 − 0.6)
234.7𝑚𝑝𝑎
= 0.0016m (3.08𝑚𝑝𝑎∗1 − 0.6)
=0.120m=4.72in
We know that l/d ratio is 4. Now using factor 2and l/d ratio, from the following chart
we can find the volume of fluid that the shell can hold.
F21 = 2in V21 = 40𝑓𝑡 3
F2 = 4.72 in V2 =?
F23 = 5in V23=600𝑓𝑡 3

F23 − F2 V23 − V2
=
F2 − F21 V2 − V21
Vf=547.7𝑓𝑡 3 =15.5m3
Mass of the shell
Density = 0.284 lb / in3=7861.09kg/m3
Vshell = mshell/ρ
Vs=(𝜋d2/4)*l
=𝜋*(1.41082-1.42/4)5.6
=0.1335 m3
Ms=0.1335 m3*7861.09kg/m3
=1049.57 kg
4.2 Design of Head

Design of head
Equipment head
Material SA516Gr 60
Inner diameter 1.4m

ultimate stress
Allowable stress= f.s
80𝑘𝑠𝑖
S= 2.35
S=34.0425ksi
S=234.7mpa
As per Clint order we have to design hemispherical head
𝑃𝑅𝑖
𝑡= +𝐶
2𝑆𝐸 − 0.2𝑃𝑑
3.08𝑚𝑝𝑎∗0.7m
𝑡 = 2∗234.7𝑚𝑝𝑎∗1−0.2∗3.08𝑚𝑝𝑎 +0.0016m
2.156mpa
𝑡= + 0.0016𝑚
468.784𝑚𝑝𝑎
𝑡 = 0.00619𝑚
𝑡 = 6.199𝑚𝑚
Mass of the head
Vs=15.5m3
𝜋
𝑣ℎ = (12) (𝐷𝑜3 − 𝐷𝑖 3 )

𝜋
𝑣ℎ = (12) ∗ 0.064
=0.0167m3
M=0.0167m3 * 7861.09kg/m3
=131.7kg
Mass of fluid that the head hold
𝜋
Vf=(12)di3
𝜋 3 3
= *1.4 =0.718m
12
4.3 Design of Nozzle

Design of nozzle
Equipment nozzle
Material SA516Gr 60
Inner diameter 1.4m
𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑠𝑠
Allowable stress= 𝑓.𝑠
80𝑘𝑠𝑖
S= 2.35
S=34.0425ksi=234.7mpa

Since we are dealing with circular nozzle the diameter of the nozzle can be determined
by the following table
Inside diameter of vessel Inspection opening required

Over 12inch less than 18 inch I.D Two - 1 1⁄2 in pipe size threaded
opening
18inch to 36 inch (inclusive) I.D Min 15 in I.D man hole two – 2 in, pipe
size threaded opening.
Over 36 inch I.D Min, 15 in I.D for man hole, or
two- 6 in, pipe size for nozzle
I.D.=1.4m=55.118in
Then the internal shell diameter is greater than 36 therefor we will use inside diameter
of the nozzle is dn=6in=0.1524m
Now from the following formula we can find the thickness of the nozzle
𝑃𝑑 ∗ 𝐷𝑛
𝑡𝑛 = +𝐶
2𝑆𝐸 − 0.2𝑃𝑑
3.08𝑚𝑝𝑎 ∗ 0.1524𝑚
= + 0.0016𝑚
2 ∗ 234.7𝑚𝑝𝑎 ∗ 1 − 0.2 ∗ 3.08𝑚𝑝𝑎
0.4694𝑚𝑝𝑎 ∗ 𝑚
= + 0.0016𝑚
468.784𝑚𝑝𝑎
= 2.601𝑚𝑚
Stress Analysis On A Nozzle
𝑃∗𝐷𝑛
𝜎𝐻 = 2𝑡𝑛
3.08𝑚𝑝𝑎 ∗ 0.1524𝑚
𝜎𝐻 =
2 ∗ 0.002601𝑚
=90.233mpa

Hence, 90.233mpa<234.7mpa so our design is safe
Now to decrease the stress concentration around the nozzle we need to calculate the
reinforcement, then the reinforcement area is
𝐴𝑟 = 𝐷𝑛 ∗ 𝑡𝑟
Where, tr =required thickness shell without

corrosion allowance.
𝑝𝑑 ∗ 𝑅
𝑡𝑟 =
𝑆𝐸 − 0.6𝑃𝑑
3.08𝑚𝑝𝑎∗0.7𝑚
=234.7𝑚𝑝𝑎∗1−0.6∗3.08𝑚𝑝𝑎
=9.2mm
𝐴𝑟 = 0.1524𝑚 ∗ 0.0092𝑚
𝐴𝑟 = 0.001402𝑚2 = 1402.08𝑚𝑚2
Area of reinforcement on shell becomes, from chart by using pipe diameter 6in from
table, nominal thickness of nozzles (tn=2.601mm) and nominal thickness of shell
(t=10.8mm)
𝐴1 = 𝐷𝑛(𝑡 − 𝑡𝑟)
𝐴1 = 152.4𝑚𝑚(10.8𝑚𝑚 − 9.2𝑚𝑚)
𝐴1 = 243.84𝑚𝑚2
The reinforcement area available in nozzle is
𝑃∗𝐷𝑛
𝐴2 = 5𝑡𝑛(𝑡𝑛 − 𝑡𝑟𝑛) 𝑡𝑟𝑛 = 2𝑆𝐸−0.2𝑃
3.08𝑚𝑝𝑎 ∗ 0.1524𝑚
=
2 ∗ 234.7𝑚𝑝𝑎 ∗ 1 − 0.2 ∗ 3.08𝑚𝑝𝑎
= 1.0012𝑚𝑚
𝐴2 = 5 ∗ 2.601𝑚𝑚(2.601𝑚𝑚 − 1.0012𝑚𝑚)
𝐴2 = 20.8𝑚𝑚2

Limit of reinforcement
Parallel to shell surface
𝑋 = 152.4𝑚𝑚 , 𝑋 = 0.5𝐷𝑛 + (𝑡 + 𝑡𝑛)
𝑋 = 0.5 ∗ 152.4𝑚𝑚 + (10.8 + 2.601)
𝑋 = 89.601𝑚𝑚
Take the maximum value of X= 152.4mm
Perpendicular to shell surface
𝑌 = 2.5𝑡 , 𝑌 = 2.5𝑡𝑛
𝑌 = 2.5 ∗ 10.8𝑚𝑚 𝑌 = 2.5 ∗ 2.601𝑚𝑚
𝑌 = 27𝑚𝑚 𝑌 = 6.5025𝑚𝑚
Take the minimum value Y = 27mm
Area of extension of nozzle inside
𝐴3 = 2𝑌𝑡𝑛
𝐴3 = 2 ∗ 27𝑚𝑚 ∗ 2.601𝑚𝑚
𝐴3 = 140.454𝑚𝑚2
Area of weld
𝐴4 = (2 ∗ 0.5)𝑡𝑟 2
𝐴4 = 2 ∗ 0.5 ∗ 9.22
𝐴4 = 84.64𝑚𝑚2
The total areas become

𝐴𝑡 = 𝐴1 + 𝐴2 + 𝐴3 + 𝐴4
= 243.84 + 20.8 + 140.454 + 84.64
= 489.734mm2
𝐴𝑡 < 𝐴𝑟 Therefore, additional reinforcement is not required
Design of Manhole
to design man hole using table inspection of opening, whose diameter of the shell is
greater than 36in.then the corresponding diameter of man hole (Dm) is;
𝐷𝑚 = 15𝑖𝑛 = 381𝑚𝑚
Thickness of manhole is

𝑃∗𝑅𝑚
𝑡𝑚 = 𝑆𝐸−0.6𝑃 + 𝐶
3.08 ∗ 190.5
𝑡𝑚 = + 0.0016𝑚
234.7𝑚𝑝𝑎 ∗ 1 − 0.6 ∗ 3.08𝑚𝑝𝑎
𝑡𝑚 = 4.123𝑚𝑚
Stress Analysis of Manhole
P ∗ Dm
𝜎h =
2 ∗ tm
3.08 ∗ 10^6 ∗ 0.381m

𝜎h =
2 ∗ 0.00648mm
𝜎h = 90.546Mpa
90.546Mpa < 234.7mpa which is safe
Mass of the nozzle
𝑚𝑛 = 𝑉𝑛 ∗ 𝜌𝑛
𝜋∗(𝐷𝑜 2 −𝐷𝑖 2 )∗𝐿

𝑉𝑛 = 4
𝜋∗(0.1552 −0.15242 )𝑚2

𝑉𝑛 = ∗ 0.0274𝑚
4
𝑉𝑛 = 0.00001719𝑚3
𝑚𝑛 = 0.135𝑘𝑔
4.4 Design of Saddle Support

Design of saddle support
Equipment saddle support
Material SA516Gr 60

Inner diameter 1.4m
To find all the dimension of the saddle we will use the following table using the inside
dimension of the shell di=1.4m=4.5931ft=55.120in
di=4ft+0.5931ft
di=4ft+0.120in
the required dimensions are

Now the di=4ft+0.120in is between 4-6 ft.-in and now from the table the value of the
dimensions are
𝐴 = 3𝑓𝑡 + 11𝑖𝑛 = 3𝑓𝑡 + 0.92𝑓𝑡 = 3.92𝑓𝑡 = 1194.816𝑚𝑚
𝐵 = 3𝑓𝑡 + 0𝑖𝑛 = 3𝑓𝑡 = 914.4𝑚𝑚
𝐶 = 6𝑖𝑛 = 152.4𝑚𝑚
𝐷 = 11𝑖𝑛 = 279.4𝑚𝑚
𝐸 = 1𝑓𝑡 + 6𝑖𝑛 = 1𝑓𝑡 + 0.5𝑓𝑡 = 1.5𝑓𝑡 = 457.2𝑚𝑚
3
Base plate thickness G=4 𝑖𝑛 = 19.05𝑚𝑚
3
Web flange ribs H=8 𝑖𝑛 = 9.525𝑚𝑚
3
Wear K=8 𝑖𝑛 = 9.525𝑚𝑚
And the maximum weight that the saddle can hold is 282,000𝑙𝑏 = 127913.04834𝑘𝑔
The distance from shell end to the center of the saddle is
𝐴 = 0.2 ∗ 𝐿 = 0.2 ∗ 5.6 𝑚 = 1.12𝑚
The distance between the two saddle (𝑙) is

𝑙 = 𝐿 − 2 ∗ 𝐴 = 5.6𝑚 − 2 ∗ 1.12𝑚 = 3.36𝑚
Stress Analysis on the Saddle Support
First determine the reaction force that applied to the two saddles
Outer diameter (Do) = Di + 2t =1.4m + 2*0.0108 m = 1.4216 m
Internal diameter (Di) = 1.4m
Density of stainless steel= 7861.092kg/𝑚3
Density of refrigerant fluid 𝜌
Length of shell (L) = 5.6 m
Gravity=9.81𝑘𝑔/𝑠 2
We know all the mass of the shell head and nozzle so we can find the weight of
components
Mshell=1049.57 kg
Mhead=131.7kg *2=263.4kg
Mnozzel=0.135𝑘𝑔
We can find the mass of the fluid too, and we know that too the overall volume of fluid
the vessel can hold
Vtotal=Vshell+Vhead
=15.5m3+2*0.1335 m3
=15.767m3
If we take the fluid to be gasoline 𝜌GASOLINE=719.7kg/m3
Mfluid=Vtotal*𝜌𝑓𝑙𝑢𝑖𝑑
=15.767m3*719.7kg/m3
=11347.5kg

Total Weight calculation
W=mg
Wshell=10296.28N
Whead=2583.95N
Wnozzel=1.32N
Wfluid=111319.07N
WTOTAL= 𝑊𝑠 + 𝑊ℎ + 𝑊𝑓 + 𝑊𝑛
=10296.28N+2583.95N+1.32N+111319.07N
=124200.62N
Scince the tolal weight is less than the maximum weight the saddle hold
124200.62N<282000N then it is safe
Load per saddle
𝑊𝑡
𝑄=
2
=124200.62N/2
=62100.31N
Stress analysis
we can Annalise the stress based on two stress conditions this are Longitudinal bending,
Tangential shear The cylindrical shell acts as a beam over the two supports to resist
bending by the uniform load of the vessel and its contents. The total weight of the vessel
and its contents is equal to 2Q. If the vessel is composed of a cylindrical shell with a
formed head (i.e. tori spherical, elliptical, or hemispherical) at each end that is
supported by two saddle supports equally spaced and with A ≤ 0.25 L, then the moment
at the saddle, M1, the moment at the center of the vessel, M2, and the shear force at the
saddle, T, may be computed using the following equations [14].
1.12𝑚<0.25*5.6m

1.12m<1.4m then we can use the following equations
The longitudinal membrane plus bending stresses in the cylindrical shell between the
supports are given by the following equations. Longitudinal stress at top of the shell:
𝐴 𝑅2 −𝐻^2
1− +
𝐿 2∗𝐴∗𝐿
M1=-Q*A(1- 3𝐻 )
1+
4𝐿
1.12𝑚0.7𝑚2 −0.7𝑚^2
1− +
5.6𝑚 2∗1.12𝑚∗5.6𝑚
=62100.31N*1.12𝑚(1- 30.7𝑚 )
1+
45.6𝑚
=-18679.7kgf-m
2∗(𝑅2 −𝐻^2)
𝑄∗𝐿 1+ 𝐿^2
M2 =
4
( 3𝐻 )
1+
4𝐿
2∗(0.7𝑚2 −0.7𝑚^2)
62100.31N∗5.6𝑚 1+ 5.6𝑚^2
= 4
( 30.7 )
1+
45.6
=79488.4 kgf-m
𝑝∗𝑅𝑚 𝑀2
𝜎 1= − 𝜋𝑅𝑚^2𝑡
2𝑡
Rm=Ro+Ri/2=1.4108+1.4/2=1.4054m
3.08𝑚𝑝𝑎∗1405.4mm 79.4884mpa
= − 𝜋14054mm2∗10.8𝑚𝑚
2∗10.8𝑚𝑚
= 200.4mpa
Longitudinal stress at the bottom of the shell:

𝑝∗𝑅𝑚 𝑀1
𝜎 1= + 𝜋𝑅𝑚^2𝑡
2𝑡
3.08𝑚𝑝𝑎∗1405.4mm 18.679mpa
= − 𝜋14054mm2∗10.8𝑚𝑚
2∗10.8𝑚𝑚
= 200.4mpa
200.4mpa<234.7mpa then our design is safe

4.5 Result of the design

Shell
Length of the shell 5.6m
Thickness of the shell 0.0108m
Inner diameter of the shell 1.4m
Head
Thickness of the head 6.199𝑚𝑚
Inner diameter of the head 1.4m
Height of the head 0.7m
Nozzle
Inside diameter of the nozzle 0.1524m
Thickness of the nozzle 2.601𝑚𝑚
Saddle
𝐴 = 1194.816𝑚𝑚
𝐵 = 914.4𝑚𝑚
𝐶 = 152.4𝑚𝑚
𝐷 = 279.4𝑚𝑚
𝐸 = 457.2𝑚𝑚
G=19.05𝑚𝑚
H=9.525𝑚𝑚
K=9.525𝑚𝑚

CHAPTER FIVE
5 Conclusion and Recommendation

5.1 Conclusion
When we conclude this pressure vessel design project: From the shell design the
longitudinal, circumferential and radial stresses value is less than that of allowable
stress of selected material. Therefore, shell design is safe. From the head design
longitudinal and circumferential stress is below the allowable stress, therefore design
of head is safe. In the case of support design, the stress developed by the load of pressure
vessel is very small relative to the allowable stress of support materials. Generally, this
pressure vessel properly functions pressure less than 3.05 MPa with its maximum
thickness 10.8mm. Unless pressure vessel fails. From this project work we conclude
that in addition to up grading or updating the theoretical knowledge, we are able to refer
so many things which necessary for our project, how to design, how to select material,
so we know also how to design the mechanical component, and of course how to apply
the knowledge matter of mechanical engineering in order to design effectively,
economical, durable equipment for the desired requirement or function.
The Horizontal Pressure Vessel has been designed and analyzed and optimized
Successfully Accordingly, we conclude that all evaluation points for fatigue are within
allowable limits specified by code. The maximum fatigue damage fraction observed
which less than unity as required by code. These paper has led to numerous conclusions.
, major conclusions are as below:
 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.
 The pressure vessel components are merely selected, but the selection is very
critical, a slight change in selection will lead to a different pressure vessel al-
together from what is aimed to be designed.
 It is observed that all the pressure vessel components are selected on basis of
available ASME standards and the manufactures also follow the ASME
standards while manufacturing the components. So that leaves the designer free

from designing the components. This aspect of Design greatly reduces the
Development Time for a new pressure vessel.
5.2 Recommendation
In this project we recommend that to check the design using ANSYSE to know how
the design fail to the future. Therefor using this software we can determine the weak
spot of the vessel for better service life.
On the other hand we also recommend that some of the calculations are rounded to the
nearest standard value for the sake of factor of safety.
And also we recommend that the outlet nozzle can be at the bottom of the vessel for
better flow of the fluid but it is mandatory that it should be checked the stress
concentration and moment around it.








6 Appendix I
Material selection guide
Material selection guide
Composition Percentage % Composition Percentage %
C 0.18 Cu 0.3
Si 0.4 Ni 0.3
Mn 0.95/1.5 Mo 0.08
P 0.015 Nb 0.01
S 0.018 Ti 0.03
Al 0.02 V 0.02
Cr 0.3
chemical composition of SA516

Property Value
Tensile strength (N/mm2) 415/580
Yield strength (N/mm2) 265

mechanical composition of SA516

7 Appendix II
Design standards
List of Desired formula table
Pressure (Psi) 𝐿/𝐷
0 – 250 3
250 – 500 4
> 500 5
l/d ratio table

Factor 2 table volume of fluid shell can hold
Inside diameter of vessel Inspection opening required

Over 12inch less than 18 inch I.D Two - 1 1⁄2 in pipe size threaded
opening
18inch to 36 inch (inclusive) I.D Min 15 in I.D man hole two – 2 in, pipe
size threaded opening.
Over 36 inch I.D Min, 15 in I.D for man hole, or
two- 6 in, pipe size for nozzle
Nozzle inspection table

Saddle measurement inspection table

8 Appendix III
Unit conversion relation
Metric conversion

9 Appendix IV

10 Reference
[1] Nilsen, Kyle. (2011) "Development of low pressure filter testing vessel and
analysis of electrospun nanofiber membranes for water treatment"
[2] Ingenious Coal-Gas Motor Tank, Popular Science monthly, January 1919, page
27, Scanned by Google
Books: http://books.google.com/books?id=HykDAAAAMBAJ&pg=PA13
[3] Bandarupalli Praneeth,” Finite Element Analysis of Pressure Vessel and Piping
Design”, International Journal of Engineering Trends and TechnologyVolume3 Issue5-
2012.
[4] Adithya M, M. M. M. Patnaik, “Finite element of horizontal reactor pressure vessel

supported on saddles” International Journal of Innovative Research in Science,
Engineering and Technology, Vol. 2, Issue 7 July 2013
[5] Sagar P. Tiwatane, “Finite Element Analysis of Skirt to Dished junction in a

Pressure Vessel” International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol. 3, Issue. 4, Jul - Aug. 2013
[6] Vinod Kumar, “Design of Saddle Support for Horizontal Pressure Vessel”
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and
Manufacturing Engineering Vol. 8, 2014
[7] V. V. Wadkar, “DESIGN AND ANALYSIS OF PRESSURE VESSEL USING

ANSYS” Journal of Mechanical Engineering and Technology (JMET) Volume 3, Issue
2, July-Dec 2015
[8] L. Xue, G. E. O. Widera, Z. Sang,” Parametric FEA Study of Burst Pressure of

Cylindrical Shell Intersections”, Journal of Pressure Vessel Technology by ASME June
2010, Vol. 132
[9] R.C. Carbonari,” Design of pressure vessels using shape optimization: An integrated
approach”, International Journal of Pressure Vessels and Piping volume 88 pp 198-212

[10] S y m R Gupt , As s D s , “D s n o Horizontal Pressure vessel us n PV El t so

tw r ”, IJIRST–International Journal for Innovative Research in Science & Technology|
Vol. 1, Issue 1, June 2014|Page No. 58-63. ISSN(online): 2349-6010.
[11] Ahmed Ibrahim m*, Y on Ryun, M r S pour “Stress Analysis of Thin-W ll

Pressure Vessels”, Morn Mechanical Engineering, 2015, Vol. 5, Published Online
February 2015 in SciRes. Page No.1-9 http://dx.doi.org/10.4236/mme.2015.51001.
[12] Yougush Borsem n Av s S rm “Mo l n o Pressure Vessels with Different

End connections using Pro M n ”, Int rn t on l Journal of Engineering, Research and
Applications (IJERA) –Vol.2. Issue 3, May-Jun 2012, Page-No.(1493-
1497).ISSN:22489622
www.wikipedia.com.
R.S. khurmi and J.K Gupta,”A text book of machine design” first multiple color edition.
www.machine design.com/basics-design/design consideration.

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DEBRE BERHAN UNIVERSITY

DESIGN OF UNFIRED HORIZONTAL PRESSURE VESSEL

MACHINE DESIGN PROJECT-I

DEBRE BERHAN UNIVERSITY 1

DEBRE BERHAN UNIVERSITY 2

DEBRE BERHAN UNIVERSITY 3

Di, Do =inside and outside diameter, in

S = allowable or calculated stress, psi

Ri, Ro = inside and outside radius, in

δx = longitudinal stress, psi

δØ = circumferential stress, psi

Rm = mean radius of shell, in

t = thickness or thickness required of shell, head or cone, in

S = allowable stress, psi

M1 , M2 = longitudinal bending moment at elevation, in-lb

 ASME = American society of mechanical engineering

DEBRE BERHAN UNIVERSITY 4

DEBRE BERHAN UNIVERSITY 5

3.16 Considered fluid for the design ............................................................................... 28

DEBRE BERHAN UNIVERSITY 6

DEBRE BERHAN UNIVERSITY 7

1.1.1 Definition of Pressure Vessel

Generally, pressure vessel is a metallic or nonmetallic container, generally cylindrical

Fig-1 pressure vessel

DEBRE BERHAN UNIVERSITY 8

1.1.2 Classification of Pressure Vessel

According to construction pressure vessels can be classified in to three main group

1.1.3 Application of Pressure Vessel

DEBRE BERHAN UNIVERSITY 9

1.1.4 Component of Pressure Vessel

DEBRE BERHAN UNIVERSITY 10

DEBRE BERHAN UNIVERSITY 11

1.1.5 Failures in Pressure Vessels

Material-Improper selection of material; defects in material.

Design-Incorrect design data; inaccurate or incorrect design methods; inadequate shop

Fabrication-Poor quality control-improper or insufficient fabrication procedures

DEBRE BERHAN UNIVERSITY 12

Service-Change of service condition by the user; inexperienced operations or

Brittle Fracture-Can occur at low or intermediate temperatures. Brittle fractures have

Excessive plastic deformation-The primary and secondary stress limits as outlined in

Stress Rupture-Creep deformation as a result of fatigue or cyclic loading, i.e.,

Plastic Instability-Incremental collapse; incremental collapse is cyclic strain

High Strain-Low cycle fatigue is strain-governed and occurs mainly in lower-strength

Corrosion Fatigue-Occurs when corrosive and fatigue effects occur simultaneously.

DEBRE BERHAN UNIVERSITY 13

1.2 Statement of Problem

1.3 General Objective

1.3.1 Specific Objective

1.4 Scope of the Study

DEBRE BERHAN UNIVERSITY 14

DEBRE BERHAN UNIVERSITY 15

Adithya M, M. M. M. Patnaik horizontal pressure vessel supported on saddles is

Vinod Kumar he did comparative study on stresses by using mathematical approach

V. V. Wadkar He did analysis of cylindrical pressure vessels with hemispherical head

DEBRE BERHAN UNIVERSITY 16

R.C. Carbonari (Design of Pressure Vessels using Shape Optimization: An

DEBRE BERHAN UNIVERSITY 17

2.2 Identified Gaps in the Literature’s

 Shape of pressure vessel changes. Now it like a water or oil tanker.

DEBRE BERHAN UNIVERSITY 18

3 Methodology and Design Consideration

Input parameter of head, shell and nozzle

Selecting of material of element