Assignment 2 MATERIALS PROPERTIES AND APPLICATIONS, CPE641 Sept 2013-Jan 2014 Design on sieve column metal thickness, column

head and bottom cover metal thickness and column support

As a chemical engineer you are to do a preliminary design for a sieve plate column. The specification for the sieve plate column is as given. Your design should include the following, a) A suitable column wall thickness b) Selection and sizing of vessel head and bottom- end cover c) The column support skirt material of construction, support material thickness, and design on the skirt support to the base concrete d) You should also prepare a dimensioned sketch of your designed column DO NOT include the design of plates and plate supports. However, you have to consider the following design loads a) Internal pressure b) Wind loading c) Dead weight of vessel and contents (vessel is full of water) Note that there is no significant loading from piping and other external equipment attached. Earth quake loading need not be considered. The column specifications are as follows, a) Length of cylindrical section: 37 m b) Internal diameter: 1.5 m c) Selected Head & Botton cover design: standard ellipsoidal type d) There are 50 sieve plates e) Nozzles: Feed at mid-point, 50 mm inside diameter, Vapour out: 0.7 m below top of cylindrical section, 250 mm inside diameter Bottom product: centre of vessel head, 50 mm inside diameter Reflux return: 1.0 m below top of cylindrical section, 50 mm inside diameter f) g) h) i) j) k) l) m) n) o) Two 0.6 m diameter access ports (manholes) situated 1.0 m above the bottom and 1.5 m below the top of the column Support skirt of 2.5 m high Access ladder with platforms Insulation, mineral wool, 50 mm thick Materials of construction: vessel stainless steel, unstabilised 304 type, Take the welding efficiency =1 Nozzles material is the same as vessels material Skirting material is carbon steel, silicon killed( Elastic modulus= 200,000 N/mm 2 and the welding efficiency for the support joint is 0.85) Design pressure: 1200 kN/m2 Design temperature: 150oC Corrosion allowance: 2 mm

You are to submit in 1 week time, on individual basis. This assignment will carry 10 % of the total final marks for this course. Please hand in your script with your name, ID, course identification and university logo, and type written script is encouraged.

MECHANICAL DESIGN OF THE SIEVE PLATE COLUMN

Inner diameter of the column, Di = 1.5 m = 1500 mm Design pressure = 1200 kN/m2 = 1.2 N/mm2 Design temperature = 150oC Material of construction of the shell and the covers is Stainless steel 18Cr/8Ni unstabilized (304) Design stress of the material at 150oC = 130 N/mm2 Design of the covers of the column: Standard ellipsoidal head with major and minor axis ratio of 2:1 (ASME BPV Code Sec. VIII D.1 Part UG-32): this equation can be used to calculate the minimum thickness required,

Pi = Design pressure = 1.2 N/mm2 Di = inner diameter of the column = 1500 mm S = the design stress of the material of construction = 130 N/mm2 E = the weld joint efficiency = 1.0 The weld joint is double welded butt or equivalent joint and 100 percent degree of radiography.

round off and add corrosion allowance of 2 mm = 9 mm

STRESS ANALYSIS OF THE VESSEL Material of construction = stainless steel 18Cr/8Ni unstabalized (304). Design stress of the material = 130 N/mm2 Youngs modulus = 200000 N/mm2 Design pressure = 1.2 N/mm2 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 = 160 KM/h Plate loading including liquid = 1.2 kN/m2 of plate area

CALCULATION OF THE MINIMUM THICKNESS OF THE SHELL ASME, Minimum thickness required for pressure loading

mm rounding off to 7 mm For stability of the shell the column is divided into five parts and thickness is increased from top to bottom of the shell, as 7 mm, 9 mm, 11 mm, 13 mm and 15 mm respectively. For all other calculations, the average thickness is used. The average thickness = ts = 11 mm

STRESS ANALYSIS Dead weight of vessel Stress due to the dead weight of the vessel: For a steel vessel Take Cw = 1.15, vessel with plates Dm = 1.5 + 11 x 10-3 = 1.511m Hv = 37 m t = 11 mm Wv = 240 Cw Dm (Hv + 0.8 Dm) t Wv = 240 X 1.15 X 1.511 (37 + 0.8 X 1.511) 11 = 175,279 N = 175.3 kN Weight of plates Plates area = /4 X 1.52 = 1.77 m2 Weight of a plate including liquid on it : 1.2kN/m2 X 1.77 m2 = 2.124 kN 50 plates = 50 X 2.124 = 106.2 kN 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 Total Wind loading Take dynamic wind pressure as 1280 N/m2, corresponding to 160 kph (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 =2.72 m Loading (per linear meter), W= 1280 N/m2 x 2.72 m = 3481.6 N/m Bending moment at bottom tangent line = Mx =
2

175.30 kN 106.20 kN 22.241 kN 303.741 kN

= (3481.6 (N/m)/2) x (37)2 m = 2,383,155.2 N.m Longitudinal and circumferential stress: At bottom tangent line, the pressure stresses are given by:

Longitudinal stress, L =
Circumferential stress, (N/mm2) =

= 30 N/mm2

h =

(N/mm2) =

= 60 N/mm2

Stress due to dead weight,

w =

(N/mm2) =

= 4.25 N/mm2

Do = Di + 2 x t = 1500 mm + 2 (15 mm) = 1530 mm = outer diameter of the column Bending Stresses, Iv = b = (
o 4

+Di4) =

(15304 + 15004) = 5.17 x 1011 mm ( )= 3.53 N/mm2

)=

Resultant longitudinal stress is given by,

z = L + w

w is compressive therefore it is negative.

z (upwind) = 30 + (- 4.25) + 3.53 = + 29.28 N/mm2 z (downwind) = 30 + (-4.25) 3.53 = + 22.22 N/mm2

29.28 N/mm2 (Upwind)

60 N/mm2

60 29.28 = 30.72 N/mm2

22.22 N/mm2 (Downwind)

60 N/mm2

60 22.22 = 37.78 N/mm2

Conclusion, Since the upwind stress (30.72 N/mm2) and downwind stress (37.78 N/mm2) are less than the allowable design stress (130 N/mm2), therefore the design metal thickness (tb = 15 mm) is satisfactory.

DESIGN OF SKIRT SUPPORT FOR THE VESSEL The resultant stresses in the skirt will be, s (tensile) = bs -ws s (compressive) = bs + ws bs = bending stress in the skirt bs = 4*Ms/ *(Ds + t)*t*Ds]