Mechanical Equipment Design

Dr. J.K.
Shrivastava,
H.O.D. Chemical Engineering
1
PRESSURE VESSELS

1. Internal pressure vessel (thin wall pressure vessels)
Shell design
For t/Di < 0.25 or Do/Di<1.5
(a) Cylindrical shell :
Internal pressure P = 2fJt/(Di+t) = 2fJ/(D0-t)
Thickness of the vessel t = PDi/(2fJ-P) = PD0/(2fJ+P)
Circumferential stress ou = PDi/2t
Longitudinal Stress ou = PD/4t
(b) Spherical shell :
Internal pressure P = 4ft/(Di+t) = 4fJt/ (Do-t)
Thickness of the vessel t = PDi/(4fJ-P) = PD0/(4fJ+P)
Circumferential stress s = PD/4t = longitudinal stress
Where,
P = internal design press. In N/m2
f = allowable stress value of material
J = Joint efficiency factor
t = thickness of wall w/o corrosion allowence
Di = inside dia
Do = outside dia of shell
D = average dia. = (Di + DO)/2
2. Internal pressure (thick wall pressure vessel)
When pressure exceeds 20 MN/m2 & the ratio of outer dia to inner
dia exceeds 1.5 then thick walled pressure vessel is used i.e. P>20 MN/m
2
&
Do/Di>1.5
Dr. J.K. Shrivastava,
2
Stresses in thick cylinder :
(a) Longitudinal stress oz = (PiDi
2
- PoDo
2
)/(Do
2
-Di
2
)
Where Pi-internal pressure
Po - external pressure
Do & Di - outer & inner dia of shell
(c) Radial stress o
z
= (PiDi
2
-PoDo
2
)/(Do
2
-Di
2
) ( Pi - Po) Di
2
Do
2
/[D
2
x
(Do
2
-Di
2
)]
Where D - Dia of shell where stress is to be calculated

(c) Hoop stress ou = (PiDi
2
-PoDo
2
)/(Do
2
-Di
2
) +( Pi - Po) Di
2
Do
2
/ [D
2
x
(Do
2
-Di
2
)]

Stresses at internal surface :
Considering Po = 0 ; D = Di : & Do/Di = K
Then ozi = Pi/(K
2
-1) ; ori= -Pi & ou = Pi x (K
2
+1)/(K
2
-1)
Stresses at the external surface.[
Considering Po = 0 : D = Di & Do/Di = K
Then ozi = Pi/(K
2
-1) oro = 0, & ou0 = 2Pi/(K
2
-1)
Theories of elastic failure :
1. Maximum principal stress theory :
ou (max) = oy = Pi x (K
2
+1)/ (K
2
-1) extra
where y o =Yields stress = factor of safety
2. Maximum strain theory :
ou (max) = oy = P1 [(1-) + (1+)K
2
]/(K
2
-1)
3. Maximum strain theory :
oy = Pi ( ) ( ) ) 1 ( 2 / 10 6
2 4
+ K K
3
4. Maximum shear theory :
Maximum shear stress t = ( - r)/2
Assume D = Di & Po = 0
t = (Pi-Po) Di
2
Do
2
/[Do
2
-Di
2
) D
2
] = (oy)
or oy = 2K
2
Pi/(K
2
-1) = 2t
this theory is not applicable for oy /1.5Pi < 2
Design stress = yield stress/ factor of safety (for double materials)
Design stress = ultimate tensile stress/ factor of safety (for brittle
materials)
Maximum stress theory :
oy = ) 1 K /( Pi K . 3
2 2

K =
Dia Inside
Dia Outside

t = thickness
2
Di Do
=

4
DESIGN OF PROCESS VESSELS UNDER
EXTERNAL PRESSURE
(Use of stiffeners and w/o stiffeners)

Any of the chemical process equipments are required to be operated under
such conditions when the inside pressure is lower than outside pressure, then
to provide towards failure of vessels due to elastic filure and platic
deformation, "STIFFENERS" are provided.

1. Critical length b/w stiffeners :
the expression for critical length is
Ic = 27 / ) t / d d )( ) 1 ( 4 ( 6 4
2
t
For steel vessel = 0.3
Ic = 1.11 Do/ ) t / Do (
Where Do = outer dia of shell & thickness of shell.

2. Out of the roundness of shell (U)
(a) For oval shape
U = [2(Dmax - Dmin)/(Dmax+Dmin)]100
(b) For dent or flat spots
U = 4a 100/Do
Where a is depth of dent or flat spots. (max value is to be taken)
For most of the numerical purpose U = 1.5 %

3. Determination of shell thickness w/o stiffening rings :
Design is to be checked for elastic instability and plastic deformation.
5
If the type of head & closure are not given then consider the vessel
has torrispherical head (standard dished head) is both end of shell (tower)
having Ri = Do and Vi = 0.1 Do, where Ri is inner crown radius and ri is
inner knuckle radius and Do is outer dia. of vessel.
The inside depth hi for torripherical head is calculated as :
hi = Ri - [Ri-Di/2)(Ri + Di/2-2ri)]
where Di = Do (approx.)
hi = inside height of head
Note : if heads and closures are given then hi = i/3 of each head and closure.

Effective length of tower w/o stiffener
L = tangent - to- tangent length + 1/3 (inside height of head) + 1/3
(inside height of closure)

Calculate Do/L ...
Now from table given below find value of K and m and calculate shell
thickness for elastic stability.
Do/L K m
0 0.733 3.00
0.1 0.185 2.60
0.2 0.224 2.54
0.3 0.229 2.47
0.4 0.246 2.43
0.6 0.516 2.49
0.8 0.660 2.48
1.0 0.879 2.49
1.5 4.572 2.52
2.0 2.364 2.54
3.0 5.144 2.61
4.0 9.037 2.62
5.0 10.359 2.58

6
P = K E /t/Do)m
Where
P = inside pressure (design pressure)
E = young's modulus = 1.67105 MN/m
2

Do = outer dia of shell.
t = shell thickness w/o corrosion allowance
Now checking for plastic deformation
This is done by using

It Do/L 5 then P = 2f (t/Do)
| |
(
+ (t/Do) 00 0.2Do/L)/1 - (1 5 . 1 1
1
U

Where f = allowable compressive stress. (from table a-1)
= 70 MN/m2
U = 1.5 (for new vessel)

if Do/L > 5 then P = 2f (t/Do)

If P is greater than internal (design) pressure then calculated thickness
from elastic stability is correct, otherwise the thickness is not safe & then
calculate thickness against plastic deformation.

4. Determination of thickness using stiffener ring :
It stiffeners are used, effective length of the tower will be the tray
spacing (if given) else, the critical length b/n stiffeners is to be considered, L
= tray spacing.
7
Calculate Do/L & find the value of K & m & calculate shell thickness
for elastic stability.
P = KE (t/Do) m
Where
P = inside pressure (design pressure)
E = young's modulus
Do = outer dia of shell
t = shell thickness w/o corrosion allowance
Now checking for plastic deformation.
This is done by using
If
(
|
.
|
\
|
+
|
.
|
\
|
=
Do
t
/100)
L
Do
0.2 - (1 1.5U 1
1

Do
t
2f P

Where f = allowance compressive stress.
U = 1.5 (for new vessel)
Do/L > 5 then P = (t/Do)
P is greater than internal (design) pressure then calculated thickness
from elastic stability is correct, otherwise the thickness not safe & then
calculate thickness against plastic deformation.

Designing of circumferential stiffening ring :
Sign of stiffening rings involves 1st to select a standard structure then
to check for required M.O.I. with the M.O.L of the structure.
I = [Do
2
L (t+As/L)f]/12E
There,
I = req. M.O.I>
Do = outer dia. Of shell
8
L = effective lenght of tower
t = shell thickness with stiffness
As = cross sectional area of a stiffening ring

Select a 18 cm. Channel of following specification
Weight (W) = 14.6 kg/m.
As = 1.8410
-3
m
2

I = 8.9 10
-6
m
4

= 7850 kg/m
3

Total wt. of rings = no. of stiffeners (t Dow)
saving in shell material using stiffening ring :
= Do x (t-ts) t in kg.
Where t = shell thickness w/o stiffeners
ts = shell thickness with stiffeners
I = tang. tang tang. Length.

9
DESIGN OF HEAD AND CLOSURES :

A. Flat head :
Thickness of flat head is t = C De (P/f)
Where P = design pressure
De = effective dia. = Di = Do - 2ts
F = allowable stress of material
ts = shell thickness + Corrosion allowance
Factor C depends on the method of attachments to the shell. Cases follow.
(i) Flanged flat head butt welded to shell De = Di, C = 0.45
(ii) Plates welded to the inside of the shell De = Di C 0.55
(iii) Plates welded to the end of the shell (no inside welding) De = Di
C = 0.7
(iv) Covers riveted or bolted with full-face gaskets to shell flanges or side
plates.
De = Bolt circle dia, C = 0.42
(v) Covers with a narrow boled flanged joint is placed within the bolts
holes.
De = Mean dia of gasket
C = [0.31 + 190 (Fb hg/Pde
3
) ]1/2
hg = (bolt circle dia - De)
P = Design press.
Fb = bolt load
This thickness is theoretically calculated, to this 2 mm thickness corr.
Allowance is to be added and another say 6% to be added to take care of the
10
reduction in thickness at the torus section. This gives a practically required
min. thickness.
The value of C is generally taken as 0.45

B. Torrispherical (standard dished) and ellipsoidal dished head :
Thickness of head is given by : t = PDoC./2fJ
Where, P = design press
Do = outer dia
C = stress conc. Factor
F = allowable stress
J = joint efficiency factor = 1
Assume Ri = Ro = Do.
C depends upon he/Do & t/Do for the compensated or reinforced opening.
C depends upon he/Do & d/ tDo for the uncompensated
Where he = effective external height of the head w/o straight flange & equal
to the at least (min. value) of ho or D0
2
/4R0 or (Doro/2)
where ho = outside height of head (excluding flange height) = he
hi = inside height of head (excluding flange height)
Sf = flange height
ri, ro = inside & outside knuckle radius of head
Ri, Ro = inside & outside radius of head
Di, Do = inside & outside Dia of shell
d = largest dia of uncompensated opening.

For C
2fJ
P

DoC
t
=
11
Now find value of C from he/Do and t/Do by trial and error method using
graph.

C for formed head w/o opening or fully compensated opening is given in
graph.
Ro = Do
Blank dia = Do + Do/42 + (2/3) ri + 2Sf for t < 25 mm
= Do + Do/42 + (2/3) ri + 2Sf + t for t > 25 mm
where r
i
= r
o
- t
External height of the excluding strainght flange
ho = Ro - [Ro-Do/2) (Ro + Do/2 - 2ro]
ho =
0 R 4
Do
2
, ho =
2 / 1
2
|
.
|
\
| Doro
extra
By calculating Blank dia = sf r
D
D
i
2
3
2
42
0
0
+ + + (for t < 25mm)
= t sf r
D
D
i
+ + + + 2
3
2
42
0
0
(for t > 25 m)
V = (excluding strainght flange) = 0.0847 Di
3
for ri = 0.06 Di
= 0.1313 Di3 for 2.1 ellipsoidal or deep
Dished head :
For compensated opening for [2:1 elep. head] hE = ho = 0.25 Do
For accuracy it is suggested to recalculate ho by putting Ro = Ri + t and
calculate t from new value for he/do. Another method would be assumed
some value of t and check the same from = PDoC/2f

Ellipsoidal :
Neglecting thinning effect
C = 2fJt/ PDo
12
J = 1
for 2.1 ellipsoidal, he = ho= 0.25 Do, hi = 0.25 Di
he/Do = 0.25
From graph obtain d/ (tDo)
volume of elliptical dished head
Vn = (ZDo
2
/4) Do/6 = Z Do
3
/24

HEMISPHERICAL HEAD
Neglecting thinning effect
C = 2fJt /PDo
J = 1
he/Do = 0.5

From graph obtain d/ ) tDo (
Volume of elliptical dished head
Vn = (Z Do
2
/4) Do/6 = ZDo
3
/24
Total volume contain is vessel where D is internal dia.
Vvessel = [ZD
2
/4)
2
+ (ZD
3
/12)]
Volume of torrispherical dished head to straight flange
V = 0.000049 di
3

where di = inside dia of vessel in inches.

Elliptical Head
Thickness of elliptical head : tn = DV/2fJ
13
r = internal pressure
D = major axis
V = stress intensification factor = (2+K
2
)
K = (major axis x minor axis) = 272.6

Conical Head
(i) Thickness of conical head
t = De Z/ 2fJ
where Z is the factor to be taken for joint
De is outer dia
is design pressure
J = 0.85

For a single cone Z depends upon apex angle and knuckle radius
o
0
20 30 45 60
Z 1.00 1.35 2.05 3.20

Surface area A = t D
Volumetric capacity V = 1/3 t D
2
h/4

(ii) Thickness away from the junction :
t = [ Dk/(2fJ-))] (1/coso)
= design pressure
Dk internal dia of cone at a distance L
L = (De t/coso)
t = thickness of shell plus corrosion allowance
14
From the junction Dk = Di - 2 L Sin o
f = 0.85

Dk = Do - 2t
Do, Di = external & internal dia of shell
Design of flanged head
Knuckle Radius Rk = 0.1 Di
Re = Do
Di = Do - 2t
3

Thickness of conical section having o more than 70
0
is,
t = 0.5 (D-ri) (pf) 1/2 o/900
Stress in hemispherical heads in other places than at junction
fi = p/4th
Thickness of head is Tk = (pD) /(4f)
Formed head, Rc= Do = Crown radius
Rk = Di = Knuckle radius
t = (P
t
R
c
C
0
) /(2fJ - 0.2 P)
stress intensification factor = 1/4 [3+(R
c
/R
k
)
1/2
]

Note :
Pressure head Head
0.1 - 1.5 MN/m2 Torispherical
0.7 MN/m2 Elliptical
above 1.5 MN/m
2
Hemispherical

15
not less than 3 times of metal thickness and also not less than 6% of inside
diameter. should not be greater than outside diameter (Do), knuckle radius
should not be less than 10% of Di.

SHELL HEAD DESIGN UNDER EXTERNAL PRESSURE
Corrolated shell thickness required for elastic stability. P = DE (Dn)
where K and m from table based on Do/L.
Check for plastic deformation p= 2f[(t/D
0
) 1/[1.5U(1-0.2(D
0
/L)]/100 (D
0
)]
Where U = out of roundness in % 1.5

External pressure effects on :
1. Conical heads :
If o < 45
0
conical head is designed as cylindrical head with same Di as large
end of cone and a length equal to axial length of cone.
If 45
0
< o < 120
0
conical head are designed as shell, except that diameter at
large end of cone is taken as length equivalent cylinder.
It o < 120
0
conical head is designed as flat plate having diameter equal to
largest diameter of cone.

2. Torispherical, Elliptical and hemispherical heads :
These are designed on basis of preventation of collapse due to
bucking Tn = 4.4 R
c
[3(1-
2
)]
1/4
[/2E]
where = design external pressure
R0 = Crown radius for torispherical and hemispherical heads
and equivalent crown radius for elliptical head.
E = modulus of elasticallyu
= possion's rati
16
DESIGN OF NON PRESSURE STORAGE TANKS

1. Design of bottom plats :
Bottom plates uniformly resting on the groung of supporting sub
structure shall confirm to the following :
A. All bottom plates shall have a min. normal thickness of 6 mm. It tank
Dai. Is greater than 12 Mt. Min thickness is 8 mm.
B. All rectangular plates shall have a min width of 1500 mm.
C. All sketch plates which have one end rectangular shall also preferbly
have a min. width of 1500 mm for the rectangular end.
D. Bottom plates shall be of sufficient size so that when welded at least a
25 mm. width will project beyond the outside edge of the weld
attaching the bottom to the shell plate. Bottom plates shall be built
according to either of the two methods of construction.

A. Lap welded plates shall be reasonably rectangular & square edged.
Three plate laps shall not be closer than 300 mm. from each others
and also from the tank shell.
Plates shall be welded on top side only with a continous fillet weld on
all seams joints shall be lapped to 5 times the thickness of the thinner plates
but not need not exceed 25 mm.
Bottom plate attachement with the shell let may be made by an
annular ring of segmental plates. Such annular rings, where used, shall have
their radial seams butt welded with a backing strip. Bottom sketch and
rectangular plates with the lap not less than 5 times the nominal thickness of
the thinner plates joined.
17
B. Bottom may be of but welded construction. If square grooves are
employed, the root opening shall be not less than 6 mm. The butt welds shall
be made by applying a backing strip 3 min thick of heavier by tank welding
to

18
DESIGN OF STORAGE TANKS
(NON PRESSURE STORAGE TANKS)

1. Design of Tank :
Head of liquid is calculated as
H = V/tR
2

Where H = Head of liquid ( in meter)
V = Volume of tank (capacity) in m3
R = D/2 = inner radius in (m) or can be calculated from table

IS CODE : 803 - 1976
Internal pressure is calculated as :
P = (H-0.3)
Where = Density of liquid in Kg/m
3

g = Acceleration due to gravity (10 m
2
/sec)
Number of layers of plates in shell = H/Width of plate = n
Width of plate = 1.8 m (standard)
Thickness of shell plate from bottom
t = PD/ (2fJ) + C, t =
fJ
Do 0.3)] - [(H g

Standard dimension of plate
6.31.8 (m) 1 m
G = Sp gravity of filled material
Length of the plate = (tD ) - (t2)
where t = thickness in (m)
f = allowable stress in N/mm
2

19
P = Design pressure in N/mm
2

D = inner Dai of shell in m
C = Corrosion allowance
J = Joint efficiency factor (Given in table at Back)

The thickness calculated above is for the bottom plate.
Similarly we calculated the thickness of plate for each layer of
the tank up to total weight of tank for that we will assume thickness
and then we will find upto which it is safe by formula.
t = p (H-0.3) D/(2fJ)
We will calculate the thickness of each plate
Minimum thickness of shell plate should be 6 mm.
We will calculate teh average thickness by
t = (t
1
+ t
2
+ t
3
+t
4
+ ................ t
n
)/n
Where n = number of layers of plates in shell.
Now, stability check H1 = 1500 (t
av
/P) (t
vg
/D)
3/2

Where P - Superimposed Load (wind load in kg/m2, Sum of all
external
pressure acting on the tank)
D - inner dia of tank in m.
t
avg
- average thickness in mm
No of plate =
plate of length
joint of No 10 12 D
3
t

H1> H. then our calculated thickness is correct
where H1 = vertical distance between intermediate gerder and
top angle of the shell or the wind gerder of an open tank (in m.)

20
4. Bottom Design :
Diameter of the bottom of tank extends beyond the shell by 65 mm
Bottom Diameter,
Db = inside dia of shell + [2thickness of shell]+[265/1000]
Circumference of bottom = t D
b

From IS Code : 803-1976
It is given where tank diameter is more than 12 m then minimum thickness
of annular plate should be 8 mm, while other plates should be 6th mm thick.
Now, minimum width of annular plate
= 65+65+300+thickness of shell + 80
where, 300 = welding joint allowance (in mm)
80 = Corrosion allowance (in mm)

3. Roof Design :
Roof curb angle for non pressure tank.
a. tank upto 10 mm dia 65656 mm
b. tank over 10 m and upto 18 m dia 65658 mm
c. tank over 18 m and upto 36 m dia 757510 mm
d. tank over 36 mm dia 10010010 mm

Now,
Assume self supporting conical roof.
Then,
Maximum angle should be 37
0

21
4. Design for self supporting conical roof :
Thickness of roof plate is calculated as
t = D/(5 sinu)
Where D = Dia of shell in m
u = angle between cone roof and horizontal
assume maximum u = 37
0

or minimum sin u = 0.165 (slope 1 in 6)
t - thickness of roof plate in mm (0.12 > t >5) in mm
Now Dead load is calculated as
Dead load = thickness density of material
where m is density of material in kg/m
3

Here dead load is in kg/m
3

Total load on the roof :
P = superimposed load + dead load (Kg/m
2
)
The sloop of roof :
Sin u = (D/t) (p/0.202 E)
1/2

Where D = dia of shell in m.
t = thickness of plate in m.
p = Total load on roof in kg/m
2

E = Modulus of elasticity in kg/m
2

From this we calculate u (actual u)
Case (1) if actual u is less or equal to 37
0
, then we calculate actual thickness
of the roof plate as given below.
t
act
= D/(5sinu)
Where f = stress in roof plate in kgf/cm of N/mm2
= total load on roof inkg/cm2 or N/mm2
22
= tacf m + superimposed load
tacf = t= thickness of roof plate in mm.
D = dia of shell in m
u = Actual angle between cone roof and horizontal
Critical compressive stress can cause failure is
fe (critical) = [E/ 2 1 ] (t/r)
Where
E = modulus of elasticity
= Poisson's ratio
r = radius of curvature of roof = D/2Sinu
Permissible compressive stress is taken with factor of safety of 12 and
with
Poisson's ratio of 33 for steel.

fe ( permissble) = 0.102 E(t/D)sinu
Sin u = (D/r) [r/(0.204 E)]
1/2

The slope of the cone is limited to 1/5 or 1/6 i.e. tanu < 1/5 or 1/6 from
which thickness can be determined.

Case II - If actual u > 37
0
, requires to design supported roof (i.e. girder,
rafter, column supported roof)

(II) Self supporting dome and umbrella roofs :
Such roofs shall confirm to the following requirements :
Min R = 0.8 D
Max. R = 1.2 D Where R - Radiums of dome mm.
Min t = R/ 2.5 Load not less than 5 mm
23
Max. t = 12 mm
These formulae for self supporting roof assume a uniform load of 125
kgf/m
2

Self supporting roofs have the roof plate stiffened by sections heeled to
plates need not confirm to the minimum thickness requirement, but should
not be less than 5 mm.
Check. The cross sectional area of the top angle in cm3 plus the C.S. area of
the shell and roof plates with in a distance of 16 times their thickness
measured from their most remote point of attachment to the top angle shall
equal or exceed (DP/20)
Where D = nominal dia of tank shell in m,
R = Radius of curvature of roof in m.
t = nominal thickness of roof plate in m.

5. Supported Roof Design :
No of rafter on outer perphery = circumfermer/rafter spacing
= tD/2 (assumed)
No of rafter per grider = No of rafer / No of girder
(or sides of polygon or n)
Real rafting = t D/actual no of rafter
For 20-25 m Dai no of girder = 5
Length of one side of polygon (a) = D/(cosec 180/n) D is not the dia.
No of inner rafter = periphery of polygon / inner rafter space
= n a/1.75 (assume) or 2 (assume)
Number of ionner rafter per girder = no. of inner rafter/no. of sides of
polygon (n)
24
Actual rafter opening in inner side = n a/actual number of inner
rafter
Total Load = Surface area of cone density of material thickness of
plate = t RL. t
Where t is taken 6 mm.
L =
2 2
) 2 / D ( h +
u = tan
-1
1/16
Where h is the height of cone roof
tan u = h/H
1

16 m radius required 1 m height
D/2 radius required 1/16 D/2 m hiehgt
h = 1/16 D/2
Total load = 1/4 na2 cot 180/n et5
Area of polygon = 1/4 na
2
cot 180/n
Load on polygon = area of polygon density thickness
Load on outer rafters = total load - load on polygon
Load per outer rafter = load on outer rafter/actual no. of outer rafter
Load on inner rafter = Area of polygon thickness of plate = 6
mm

Load per inner rafter = load on inner rafter/ no. of inner rafter
Load per girder = W= (no. of inner rater load per inner
rafter + no of outer rafter load per outer rafter)/2n (n=sides of polygon)
Bending moment (M) = WL
2
/8
Section of modulus (Z) = M/f = B.M./Stress
At Z and M : We fine the size of girder from steel table.
25
Optimum Tank Proportions :
(1) When tanks have shell thickness independent of dia.
D = 2. HC1/(C2+C3+C4+C5)
Check D (H-0.3) < 121
(2) Tanks have shell thickness dependent on D and H.
D = 4HCl/C2+C3+C4+C5) for very large tanks
Check D (H-0.3)> 121
Where D = vessels dia, m
H = vessel height m
C1= Annual cost of fabricated shell, Rs/m
2

C2 = Annual cost of fabricated bottom, Rs/m
2

C3 = Annual cost of fabricated roof, Rs/m2
C4 = Annual cost of fabricated installed foundation , Rs/m
2
tank bottom area
C5 = Annual cost of fabricated land in the tank area, Rs/m
2
of tank bottom
area From above expression we calculated the D/H ratio
Cases the top curb angle has to be increased in size. The cross sectional area
required in indicated later under self supporting roof design.

Self Supporting Roof Design :
In this type of roof, the entire roof load is supported by the tank
periphery the roof shape may have the following forms.
(a) Cone roof : Appropriate to the surface of right cone. The shape of the
cone is 1 in 5 or 1 in 6
(b) Dome roof : The radius of curvature is a spherical radius.
(c) Umbrella roof : A modified dome roof, so formed that any horizontal
section is a regular polygon with as many sides as there are plates.

26
Roof Loading :
(a) A superimposed load of not less than 125 kg/m2 measured on teh
horizontal plane in addition to dead load roof sheets and supporting
structure.
(b) An internal pressure equivalent to
1. 75 mm water gauge or 75 kg/m2 for non pressure tanks.
2. 200 mm water gauge or 200 kg/m2 for class A tanks.
3. 550 mm water gauge or 550 kg/m2 for class B tanks

27
DESIGN OF TALL VESSELS
(i) Determination of shell thickness :
c
P fJ 2
PDo
ts +
+
=
Where, ts = thickness of shell, J = Joint efficiency (0.85)
P = Design pressure, f = allowable stress (98.% mn/m
2
,
standard)
C= Corrosion allowance
(ii) Calculation of axial stress due to pressure ;

t t Di t
zp zp
4
P.D
D, Di if ,
) ( 4
P.D

2
= =
+
= o o
where, D = Di for anternal pressure
D= Do for vaccum, t = corroded shell thickness
(iii) Calculation of axial stress due to dead load :

D N
zs
+
=
Ws
o
Ws = Wt of shell for Xm. length = (tD t 4s)
Ys = (78509.81) from, table = e.g. (N/m
2
)
Values of specific weight and poisson's ratio of some metals
Material SP. weight
N/m2
Poisson's Ratio
1. Aluminium 2.6510
4
0.34
2. Brass 8.3510
4
0.35
3. Copper 8.7910
4
0.35
4.Iron 7.7410
4
0.28
5. Nickel 8.7410
4
0.36
6. Steel 7.7010
4
0.30

28
(iv) Calculation of axial stress due to insulation :

6
10
Dt
Wi
zi

t
= o
Wi = (tDins tino Yius) 10
-6
MN, if D~ Dius
(v) No of Trays

(
+
|
|
.
|
\
|
= 1
Spacing Tray
spacing Top - X
n
(vi) Wt. of Liquid on trays

6
L
10
Dt
W
zi

t
= o
(vii) Weight of ladders = 3.6510
-4
()
weight of trays =
2
D
4
t
(tray loading or spacing) (No. of trace 10
-3
)
(viii) Weight of attachment :
Wa = Wt of head + Wt of ladders + (Wt of plate form) + Wt of liquid
trays
N M
Dt
Wa
zi
t
= o
(ix) Dead load stress zw o acting along the axial direction of shell
za zl zi zs zw o + o + o = o = o
(x) Calculation of stress due to wind load :
Pw = 0.05 Vw
2

From table - 2 taking the value of pwactual
(xi) T = 6.35 10-5 (H/D)
3/2
(W/t)
1/2

W = W
s
+ W
i
+ W
L
+ W
a

X = (H-Skirt weight)
(xii) P
w
= K
1
K
2
P
w
(X) Do
(xiii) M
w
= Pw
2
X
, J
29
(xiv) (xiv)
6
2
10
t D
4Mw
zwm

t
= o
(xv) Determination of resultant langitudinal stresses :
UPwind Side :
zwm zw - zp (tensile) z o + o o = o
fJ. z = o
Down wind side :
(t/Do) E 0.125 z = o
(xvi) Check for safe design :
Equivalent stress =
1/2 2 2
) z z . - ( e o + o ou ou = o
(a) Hoop stress =
t 2
t) - P(Do
or
2t
t) P(Di

+
= ou
(b) zwm zw - zp (tensile) z o + o o = o
X = H - skirt height
(xvii) If e o (calculated) < e o (check design condition)
e o < f.J.
Then calculated thickness is correct
(xviii) Check for safe design
At design condition :
(1) e o < fJ.
(2)
z
o (tensile) < fJ
(3)
z
o (comp.) < 0.125 E 1+/Do)
At test condition
(1) e o < 1.3 faJ
(2)
z
o (tensile) < 1.3 fa. J.
(3)
z
o (comp.) < 0.125 Ea (ta/Do)

30
STORAGE TANK
1. Shell designs
(a) D =
LP R b
C C C
HCs 4
+ +
, V = H D
4
2
t

(b) thickness :
t = C
fJ 2
10 D 0.3) - (H
3
+

(c) Stability check :
H
1
=
2 / 3
D
tavg
tavg.
P
1500
|
.
|
\
|

(d) No. of Plates
n =
Lenth
joints) of No 10 (2 - D
-3
t

Length =
n
s jo of No D ) int . 10 2 (
3

t

2. Bottom Design :
D bottom = Internal dia + 2 (bottom thickness) + 2 65 1

Design of Roof :
Roof Curb Angle calculation :

D = Diameter of shell
tr = Roof thickness
= load of roof
E = Elasticity of modulus (210
10
)
= w + Dead load
= w + o thickness
E 0.202
P

tr
D
= u Sin
31
According to IS - 803
If Diameter < 10 M 65 65 6 mm
Diameter 10 to 18 m 65 65 8 mm
Diameter 18 to 36 m 75 75 10
Diameter over 36 m 100 100 10 mm

Case-1
If u < 37
0
self supported roof is considered
Thickness of roof plate is calculated as :
t
act
= D/5 Sin u
Now,
The stress in the cone roof plate is determined by
f = pD/2t sinq
p = t
act

m
superimposed load
critical compressive stress that can cause failure is
Fe = (E/
2
1 ) t/r
= poison ratio = 0.3
r = radius of curvature = d/2sin u
Fe (permissible) = 0.102 E (t/D) sin u
Sin u (D/r) [P/(0.204 E)]1/2

Case- II If u>37
0
C then supported roof is considered
According to Data book - 803
(1) For Dia 10 to 15 circular support
(2) For Dia 15 to 20 Ractangular support
(3) For Dia 20 to 25 Pantagonal Support
32
(4) For Dia 25 to 30 Hexagonal support

H1 = H + AB
tanu =
R
AB
u' = permissible slope of conical roof = 1 in 5
R = D/2
H
2
= H
1
-R
1
tan u where R
1
= R/2
Length of outer rafter
Cosu=
3
) (
1
R R

Length of inner rafter
Cos u = R
1
/l
2

For irregular pentagon angle may be taken as
u = 108
0

Cos u /2 =
1
1
2 /
R

l
i
= length of girder is =
Now,
Total No. of rafter of outer girder is
=
rafter
D

2
D t
=
t
spacing
No. of girder = No. of sides in polygon.
For diameter range 20-25. No. of girder = 5
Read Rafter spacing = tD/actual No. of Rafter
No. of Rafter per girder = No. of Rafter/No. of girder.
Now for inner girder :
Total No. of rafter on inner girder
33
= tD'/2
= No. of Rafter of each girder
= No of Rafter/No. of girder

(a) Avg. inner rafter spacing
[(Actual spacing of per girder)+(spacing of crown plate)/2]
According to data - 803 dia of crown plate
= 20 10
-3
m
Now Avg. inner rafter spacing =
2
. .
|
|
.
|
\
|
+ =
Raf ter of No
Dc
girder of No
girder of length t

Now outer rafter spacing
2
. .
|
|
.
|
\
|
+ =
Raf ter of No
Dc
girder of No
girder of length t

D = out side diameter of shell

Section of Modulus :
For inner rafter
stress
moment beinding Maximum

F
M
Z = =
8
Wl
M
2
2
= W = P Avg. inner rafter spacing.
& P = Pwt Dead loap
Pw = 150 Kg /m
2
(Superimposed load)
From here :
2 will be calculated in Cm2
For this value of Z we determine
34
Specification & weight per unit length (W/l)
For inner spacing from steel table.

Similar Formul's of section modulus is applied for outer spacing
where
8
Wl
M
2
3
=
Load calculation :
(A) load due to inner rafter
W
1
=
i
l
W
|
.
|
\
|
l
2
No. of inner rafter
(B) Load due to outer rafter
W
2
=
0
|
.
|
\
|
W
l
3
No. of outer rafter
(C) Load due to Roof sheet
W
3
= tRl thickness
where,
3 2
+ =
(D) Total load = W1+W2+W3
(E) Total load on per unit inner rafter =
rafter inner of . No
to inn. to due Load

(F) Total load on per unit outer rafter =
rafter outer of . No
outer to to due Load

So
Total load on girder =
girder .
outer) (
of No
L inner L +

35
(b) The stress induced in the shell due to a distance X meters from top
Dozi = Wi/tt (Di+t)
Where, Wi = (p Dx tins yins) {wt of insulation up to a distance of X meter
from the tc
Where, tins = insulation thickness
yins = Specific weight of insulation (from table 1.1 given below)
(c) The stresses induced by the wt. of liquid supported by the inner
arrangement like of distance X meter from top is
No. of tray, N= [(X-top spacing)/tray spacing]+1
o zl = Wt/tt (Di +t)
Wi = t/4D
2
(weir height) (sp. gravity of water) (no. of trays)
W1 = Wt. of liquid supported for a distance X meters from the top
(d) The axial stress due to the attachements like treys, overhead
condensers top head, lateforms, ladders etc for a distance X meter
from the top is :
o za = Wa/tt (Di+t)
where, Wa = Wt of head + wt. of ladders + wt of plateform + wt of
liquid trays
Wt of ladder = 37 10
-4
MN
Wt of plateform = t/4 (dia of plate)
2
(Plateform loading)
Wt of trays = p/4D2 (tray loading) (no. of trays)
the design calculation weight of steel ladders plateforms caged ladders, plain
ladder trays (including liquid hold up) may be taken as given in the
following data :
Steel ladder (caged) = 37 kgf per meter linear length
Steel ladder (plane) = 15 kgf per meter length
Steel plate form = 170 kgf per sq. meter area
36
Distillation tray wt. (inclusive of liquid hold up) = 122 kgf per sq. meter
area.
dead load stress w o acting along the axial direction of the shell at the point
is given
za zl zi zs zw o + o = o + o = o
essel which does not contain internal attachments like tray but consists only
of still cations, heads, miner attachment additional load.

Axial stress (tensil & comperessive) due to wind load on self supporting tall
Load on tall cylinder vertical vessel can be calculated from the following
formula (for a shape factor of ew = 0.7)
Pw = 0.05 Vw
2

pw = wind stress in N/m
2
or min. Wind pressure
Vw = wind velocity in Km/hour.
And pressure for the bottom part & the rest of the upper part can be directly
from the following table depending upon the zone of installation of the
vessel.
Table : 2
wind pressure (kN/m2)
Gion at H = 20 m at H = 100 m
Area 0.7-1.0 1.5-2.0
area with moderate wind 0.4 1.0

The total load due to wind acting on the bottom and upper parts of the vessel
are determined from the following equations.
Pbw = k1k2p1h1Do = k1k2PwDo
Puw = k1k2p2h2Do
37
Do = out Dia + Insulation Data diameter

Where Pbw = total force due to wind load acting on the bottom parts of the
vessel with height < or = to 20 meter
Pw = 1000 N/m
2

Puw = total force due to wind load acting on upper part above 20 mtr.
hl = height of the bottom part of the vessel equal to or less than 20 meter.
h2 = height of upper part above 10 meter.
And pressure for the bottom part of the vessel (from table 2, value given for
11=20
wind pressure for the bottom part of the vessel ( to be determined from the
table 2 mid point of upper part of vessel by interpolation of data given)
Outer dia + (including insulation as the case may be = Do
= coefficient depending upon shape factor = k1)
= 90 degree to the wind
= 0.7 for cylindered surface
= coefficient depding upon the period of one cycle of vibration of the
vessel=k2
= 1 (if period of vibration T is 0.5 second or less)
= 2 (if period exceeds 0.5 seconds)[

The period of vibration T is given as
T = 6.35 10
-5
(H/D)
3/2
(W/t)
1/2

where H = tangent to tangent height+ skirt height = 20
W = total weight of shell in (KN)
= Ws + Wi + Wl + Wa
38
Ws = weight of shell
Wi = weight of insulation
Wl = weight of liquid in tray
Wa = weight of attachments
Put X = (H-skirt height) = tangened to tangent height
vessel height is less than 20 meter. Then wind load Pw.
Pw = k1k2 pw Dox
pw = wind pressure
Do = Di+ (2X Iins)
The bending moment at the base of the vessel due to wind determined from
the following eqn :
1. For the vessel with H< 20 mtr
Mw = PbwX/2 in J
2. for the vessel with H> 20 mtr
Mw = Pbw 1/2 + Puw (h1+h2/2) in
The resulting bending stress in the axial direction is computed from the
following correlation.
zwm o = 4Mw/[pDi+Di+t)]
where, zwm o = longitudinal stress due to wind moment (compressive on
down wind side & tensile on up wind side)
Mw = bending moment due to wind load
Di = internal diameter of the shell
t = corroded shell thickness

39
Determination of resultant longitudinal stresses :
The resultant tensile stress (on upwind side) in the cross section of the
vessel at distance X mtr from top in absence of eccentric loads will be
For internal pressure,
zw zwm zp z o o + o = o
z o (tensile) (maximum) = fJ
For external pressure
zw zp zwm z o o o = o
The resultant compressor stress (on downwind side) is given by
for internal pressure
zp zw zwm z o o + o = o
) Do / t ( E 125 . 0 max) comp ( z = o
E = 2 105 MN/m
2

For external pressure
zp zw zwm z o + o + o = o
Check (safe design)
Equivalent stress = ( )
2 / 1
2 2
z z e o + ouo ou = o
Here = = o Hoopstress q P(Di+t)/2t or P(Di-t)/2t
zw zwm zp z o o + o = o
X = H - skrit Height
and substitute the value of oz & oq in equation of equivalent stress and then
check from oe = fj
If oe (calculated) < oe (check design cond)
Then our calculated thickness is correct
Here oz is calculated by putting X = height of tower-height of skirt
Or tangent -to- tangent height
40
check for safe design
At design conditions
1. oe < fJ
2. o (tensile) < fJ
3. oz (comp) < 0.125 E (t/Do)
At test condition
1. oe < 1.3 faJ
2. o z tensile < 1.3 faJ
3. oz compression < 0.125 Ea (ta/Do)

calculate the value of oZ from :
oz = ozp + ozwm - ozm
and substitute the value of oz and oq in equation of equivalent stress and
then check from oe = fJ.
If oe (calculated) is < ow (checked design condtion), then our
calculated thickness in safe.

Table 1.1 Specific Weight of Insulating Materials
S.N. Material Apparent sp.
Weight KN/m
conductivity
Thermal
1. Asbestos 5.64 0.496
2. Chalk 15.00 0.692
3. Plaster, artificial 20.70 0.742
4. Cotton wood 0.78 0.042
5. Cork board 1.57 0.043
6. Diatomaceous earth 2.70 0.069
41
7. Powder, fine
8. Felt, wool 3.26 0.52
9. Graphite, powdered 4.78 0.18
10. Magnesia, molded & dry 12.20 0.432
11. Mineral, wood, shell 7.84 0.605
12. Rubber, hard 11.70 0.150
13. Sawdust 1.88 0.052
14. Silk 0.99 0.045
15. Wool 1.08 0.036

D.Q. Kern " process Heat tranfer" Mc Graw-Hill book Co. Inc. New York

SECTION MODULUS OF WIND GIRDERS :
Section through
wind girder
menber size Section modulus in Cm for She
thickness

top Angle

65*65
65*65
75*75*10.
5 m.m
6.4
8.3
13.6
6 m.m
6.5
8.5
13.0
65*65*6.
65*65* 8.
75*75*6
75*75*10
100*100*6
100*100*10

27.2
33.2
36.3
50.0
63.8
73.7
28.4
34.9
37.8
54.1
66.8
92.2
Curbe Angle

Single Angle
65*65*6
65*65*8
100*75*8
125*75*8
150*115*10
28.3
34.8
67.5
90.1
157.5
29.4
36.4
70.6
94.5
190.1

42
Data in Design of Skirt Support for process vessels :
(i) Skirt-wall thickness :
Maximum tensile and compressive stresses in the skirt wall are given
by :
o z
max

(tensile) = o zwm
min
(or o zsm) - o zw (without eccentric load.
o z (comp) = o zwm (or o zam) + o zw (without eccentric load)
(max all)

where, o zw

= stress due to total dead weight supported by skirt (to be
evaluated at the base of the skirt

43
DESIGN OR SUPPORTS FOR PROCESS
VESSELS

1. Thickness of shell for internal pressure in given by

P 2fJ
C PDo
ta
+
+
=
Where P= design pressure
f= allowable stress
J = Joint efficiency factor
C = corrosion allowance

Supports
(1) Skirt support
(i) The tensile stress in the skirt will be maximum when the dead load
(weight) is minimum i.e. the
Shell of the vessel is just erected and the shell is empty without any
internal attachment.
(ii) The compressive stress is to be determined when the vessel is filled up
with water for hydraulic
Test Maximum load may be expected at any time and this factor is
always to be considered.
The maximum weight of the vessel with two heads and shell will be
W min = Ws + Wh
Where Ws = Wt of shell = (Do) ta (H-4) Ys
and Wh = Wt of Head = 2 (Wt of each head)
44
Do - outer dia of shell (Di +t)
ta = shell thickness, with corrosion allowance
= specific weight of shell material from (table A-8) in
H = total height (tangent to tangent ht + skirt height)
Wmax = Ws + Wi + Wa
The value of Ws, Wi, Wl, Wa can be taken from "Tall vessel"
Now period of vibration at minimum dead weight is
T min = 6.35 10-05 (H/D) 3/2 (W min/ta)
1/2

Where h = Total height of vessel
D = outer dia of vessel
Ta = shell thickness with corrosion allowance
If T min < 0.5 then K2 = 1
T min > 0.5 then K2 = 2

Period of vibration at maximum dead weight is given by :
Tmax = 6.3510
-05
(H/D)
3/2
(Wmax/ta)
1/2

Total height of vessel is 20 m or less than 20 m, the wind load is determined
as
Pw - K
1
K
2
pw HD
For maximum wind load
(Pw) max = K
1
K
2
pw HDo
Where pw =wind pressure = 0.05 Vw
2

(Vw = wind velocity)
Do = outer dia of shell + 2 (thickness of insulation)
K1 = 0.7 for cylindrical surface
= 1.4 for flat surface 90 to wind
For minimum wind load
45
(Pw) min = K
1
K
2
pw H Do

Minimum and maximum wind moments are given
(Mw) min = Pw min H/2
(Mw) max = (Pw) max H/2

If the total height of vessel is greater than 120 then
(Pbw) min = k1 k2 p1h1D
(Pbw) min = k1 k2 p2h2D

Where p1 = wind pressure at height h1= 20 m
p2= wind pressure at h2>20 m
D = outer dia of shell
Similarly,
(Pbw) max = k1k2p1h1d
(Puw) max = k1k2p2h2d
Where k1, k2, h2, h1, p1, p2 are as before
Do = outer dia of shell + 2x insulation thickness

Maximum & minimum wind movements is given by :
(Mw) max = (Pbw) max (h1/2) + (Puw) max (h1+h2/2)
(Mw) min = (Pbw) min (h1/2) + (Puw) min (h1+h2/2)

As the thickness of the skirt is expected to be small assume Di = Do
Now, minimum longitudinal stress due to minimum wind moment is :
ozwm (min) = 4Mw (min)/tD
2
ts
46
Where D = outer dia of skirt (outer dia of shell when skirt support is
cylindrical)
ts = thickness of skrit
Maximum longitudinal stress due to maximum wind moment is
ozwm (max) = 4 Mw (max) / tD
2
ts
Minimum & maximum dead load stresses on the skrit is given by
ozw (min) = Wmin/tDts
ozw (max) = Wmin/tDts
Where D = Do when skirt is cylindrical
Now maximum tensile stress w/o any eccentric load
oz (tensile) max = ozwm (min)- ozw (min)
for safe tensile stress oz (tensile) f J coso
where f = allowable stress.
J = joint efficiency factor (0.7 for double welded but joint for class III
cons)
(0.85 for double welded butt joint for class II cons)
To find thickness, Equate
oz (tensile) = oz (tensile) max (1)

Maximum compressive stress due to maximum load is computed as
oz (comp.) max = ozwm (max) + ozw (max)
for safe compressive stress oz (comp.) = 0.125 E (ts/Do) coso
where E = young's modulus at design tempt.
ts = skirt thickness
Do = dia. of skirt (outer dia of shell when skirt is cylindrical)
o = Half the top angle of conical skin (10
0
maximum)
(0
0
for cylilndrical skirt)
47
To find thickness equate
oz (comp.) max = oz (compression) (2)
The thickness which is maximum for (1) & (2) is considered as per IS 2825-
1969, minimum corroded thickness of skirt is 7 mm and taking 1 mm as
corrosion allowance.

Design of Skirt Bearing plate :
The maximum compressive stress b/w the bearing plate and the
concrete foundation is given by :
oc (max) = Wmax /A + Mw (max) /Z
Where A = area of contact b/w bearing plate and concrete foundation
is given by
A = t (Do - l) l
Do = outer dia of skirt
l = outer radius of bearing plate - outer radius of skirt

Z = t Rm
2
l
Rm = (Do-l)/2

The allowable compressive strength of concrete foundation varies
from 5.5 MN/m
2
to 9.5 MN/m
2

Substitute oe (max) = 5.5MN/m2 and calculate "l"
By substituting the value of l again in same equation and calculated oc
(max)
Thickness of bearing plate w/o gussets
tpb = l ) f / e 3 ( o
oc = oc (max)
48
M max = oc b1(1/2)
for b = 1
Mmax = oe (2/2)
If bearing plate thickness is equal to or less than 12 to 20 mm, gussets
are reqd. other wise gussets are reqd. to reinforce the plate from table 10.1,
l/b=1
Mmax = My = -0.119 oel
2

tbp = f max/ M 6

Anchor Bolt Design :
omin = Wmin/A -- Mw/Z
j = Wmin R/Mw(min)
if j < 1.5 then vessel is not steady by its own weight

Therefore anchor bolt are used.
Pbolt (n)= omin A
Where Pbolt = load on bolt
N = no. of bolt
A = area of contact /w bearing plate and foundation
= t (Do-l)l
(Ar.n.)f = (n) Pbolt
Where are is root area of bolt = 31.5 min
for "f" of bolt use table 7.5

49
BRACKET SUPPORT OR LUG SUPPORT
1. Maximum compressive load due to wind :
Pw = k p H Do
Where k = k1k2 = const.
Pw = wind pressure H - Hight of vessel

The main load on the bracket supports is the dead weight of the vessel
With its contents & the wind load.
The max total compressive load on the supports is given by
P = (4Pw (H-F)/nDb) + (

W/n)
Where P = total forces due to wind load acting on the vessel
H= height of the vessel above foundation
F = vessel clearance from foundation to vessel botton
Db = dia of the bolt circle

W = max wt. of vessel with attachments and its contents

Wmax = Ws + Wi + Wl + Wa
n = No. of brackets.

2. Bracket (thickness of base plate) :
From table 13.2
Vessel dia. (D) = (given) v/s A = ?
No. of brackets = (given) v/s B = ?
Where B = length of base plate.
Average press. On the base plate is given by
Pav. = P /aB
50
Where = total load
= (140 mm)
Maximum stress in a plate subjected to a pressure Pav fixed at the edge is
f = 0.5 Pav (B
2
/T
1
2
) (a
2
/B
2
+a
2
) (1)
Where f = bending stress (given)
In this case the load is only distributed on the surface of contact b/w the base
plate & the supporting beam the actual stress may be taken as 40 % more
f = 0.7 Pav (B
2
/T
1
2
) (a
2
/B
2
+a
2
) (2)
thickness of base plate T1 equation (2) is always used

Thickness of web plates gussets plates :
There are two web plates for each bracket. The bending moment for
each plate is
PC/2100 = B.M.
(A-dia of tank)/2
A = Anchor bolt diameter
stress x the edge of f = (3PC/T2h2) (1-cosu)
Where = H (in cm) from table 13.3
u = 45
0

f = bending stress (given)
3PC = bending moment calculated above
Calculate T
2
from equation (3)
T
2
may be taken as 4 to 6 mm

51
4. Column support for bracket :
It is proposed to use a channel section as column. The size chosen ios
ISMC 150 (from table c- bhatt)
Size = 150 75
Area of cross section (A) ? (From table c-3)
Modulus of section (Zyy) = 19.4 cm3.
Radius of gyration (ryy) = ? (From table c-3)
Weight (W) = 164 kg/m

Height from foundation (1) given in ques
Equivalent length for fixed ends (lc) = 1/2
Slenderness ratio = lc/ryy
f = (P/A) + (Px width of flange/modulus of section)
fe = (P/A) [(1+1/ ) (le/r)
2
]+

(Pwidth of flange/modulus of section)]
Where = density of material (steel)
5. Base plate for column :
Size of column = ......................... ....................
Assume the base plate extend in mm on either side of channel

Side B = 0.8 (width of flange) + 2 (extended length)
Side C = 0.95 (depth of section) + 2 (extended length)
Extended length is always taken as 20 mm.
Bearing pressure Pb = (P/no. of brackets) (I/C)
Pb should be less than the permissible bearing pressure for concrete
Stress in the plate f = [(side C/2)(extended length
2
/10
2
]/(t
2
/6)
f = bending stress given
Calculate "t" usually 4 to 6 mm thick
52
SADDLE SUPPORT FOR HORIZONTAL VESSEL

1. Longitudinal bending moment at the support is
M
1
= QA [1+{1-(A/L) + (R
2
-H
2
)/2AL} (1+4H/3L)]
Where A =distance b/w support and its nearest end of vessel
H = height of head
L = tangent -to- tangent height
R = radius of tank
Q = W/2, W= Wt. of vessel & contents)

the volume of A, H is taken from table 13.3
Q = (W/2) [L+4H/3]
W = uniformly distributed length
Similarly the bending moment at the center of the span
M
2
= (QL/4) [{1+2(R
2
-H
2
/L
2
}/(1+4H3L)-4A/L]

2. Stress in shell at saddle :
(a) if A < 0.5 R
then
(i) At the top most fiber of the cross section
f2 = M1/(k1tR2t), ts = shell thickness
t = t3 -tc tc = corrosion allowance
(ii) At the bottom most fiber of cross section
f2 = M1/k2tR
2
t), t = ts-tc
Where is thickness of shell.
k1 = k2 = 1 0
53
(b) if A > 0.5 R
f1 & f2 are same as above
k1 = 0.107 for q = 120
0

= 0.161 for q = 150
0

k2 = 0.192 for q = 120
0

= 0.272 for q = 150
0

3. Stress in the shell at the mild span
f
3
= M
2
/tR
2
t, t = ts-tc

the axial stress in the shell due to internal pressure
fp = pd/4t
where p = design pressure
d = tank diameter
t = thickness w/o corrosion allowance
the combined stresses (f
b
+f
1
), (f
b
-f
2
) & (f
p
+f
3
) should be within permissible
stress.

54
DESIGN OF FLANGES
1. Gasket Dimension :
do/di = [(y-pm)/(y-p(m+1)]
1/2

where di = B + 0.01
where B = shell outside dia = flange inner dia
di = flange inner dia
do = flange outer dia
y = min. design yeild stress
p = internal pressure (Design Pressure ) in MN/m
2
)
The value of 'y' and 'm' can be determined from table 7.1
For b
0
> 6.3 ; b = 2.5
0
b
For b
0
> 6.3 ; b = b
0

The minimum gasket width = (d0-d)/2 = N
Basic gasket seating width = N/2 = b
0

Diameter at location of gasket load reaction G = di+N
Maximum bolt spacing = 2d + (G/m+0.5)
d = bolt dia
t = flange thickness
m = gasket factor

The minimum bolt circle diameter will be calculated on the
requirement of satisfying the radial clearance
C = B + 2(g
1
+R) (1)
And so satisfy bolt spacing requirement
C = nB/t (2)
Where, C= Bolt circle diameter
55
B = inside diameter of flange = outside dia of shell
B1= Bolt spacing
gi = thickness of hub at back of flanges
R = radial clearance from bolt circle to point of
connection of hub or nozzle and back of flange
n = actual number of bolts

The larger valves from Eqn. (1) and (2) is to be considered
The value of B, R is taken from table 7.4

2. Estimation of bolt Loads :
Load due to design pressure H = t G
2
p/4
Load to keep joint tight under operation
Hp = tG(2b
0
)mp
Where
p = design pressure (MN/m2)
m = gasket factor
G = Diameter at location of gasket load reaction
b0 = effective gasket seating width

- Minimum bolt load required under operation condition is given
W
0
= H + H
p
in MN
- Determination of bolt load under bolting up condition is given by
W
g
= t Gby in MN
where y = minimum gasket seating stress
if W
0
> W
g
then controlling load = W
0

If W
0
< W
g
then controlling load = W
g

56
- Determination of minimum bolt area theoreticaly required Am is :
(A
m
= A
0
)
It "A" is the bolt area required under operating condition and "Ag" the
area required under bolting condition then
A
0
= W
o
/S
o

A
g
= W
g
/S
g

Where S0 = allowable stress of the bolting material at design
temperature
Sg = allowable stress for bolting material at atmosphere temperature.

Theoratically required minimum bolt area Am will be larger of A0
and Ad for ideal esign A0 and Ag should approximated equal

Table Flanges
Bolt
size
Root
area
Min
no. of
bolt
Actual
no of
bolts
(n)
R(m) B
s
(m) C =
nB/t
(m)
C =
D+2
xgl
(m)
M166 1.5410
-
4

50.8 0.52 0.025 0.075 1.24 1.0583
M182 1.5410
-
4

43.7 44 0.027 0.075 1.05 1.0623
M202 210
-4
33.7 36 0.030 0.075 0.86 1.0683
M302 4.910
-4
32 0.955

C = 1.07 = Bolt circle dia from the above table
57

1. Loose type flange B Gl
1. lap joint flange Outside dia gl = g0
2. Raised face with
hub
Outside dia g1 = 0.5 g0
II Integral
1. Ring only type
plane face
Outside dia g1 = g0
2. Lap weld hub
raised face
Outside dia g1=2
1/2
g0
III Optional type
1.Place face with
weld hub
Outside dia g1=2
1/2
g0
2. Ring only type
raised face
Outside dia g1 = g0

Table Flanges 1.2 A

Determination actual bolt area :
Actual bolt Ab will not be less than Am to satisfy the theoritical
experiment requirement next, a standard bolt dia is to be selected.
actual no of bolt should be such that it is a multiple of 4 from practical
consideration and also the bolt spacing should not be too large or too
small . After satisfying calculation of optimum bolt size all these
rquirement Ab becomes usually larger than Am. It will be economical
if the difference is small.
58
Calculation of flange outside diameter (A)
A = C + bolt dia + 0.02 meters
Check for gasket width :
To prevent damage to gasket during bolting up condition following
condition to be satified
Ab = Actual no. of bolt Root area (from table)
Flange Moment computaition
(a) For operating condition
W
0
= W
1
+W
2
+W
3

W
1
=

tB
2
/4 P
where w1 = hydrostatic end force on area inside of flange in MN
P = Internal Design Pressure (MN/m
2
)
B = Shell outside dia in (mm)
w2 = H-w1 = t/4(G
2
-B
2
)
W3 = gasket load = W
0
- H= H
p

Total flange moment is given by
M
0
= W
1
a
1
+ W2a2+W3a3 in MJ

a1, a2, a3 are locations or respective lads acting of flange and values
are calculated using table 3 a in m.
Types of
Flanges
a1 a2 a3
Integral type
flanges
R+(g1/2) (R+g1+a3)/2 (C-G/2)
Loose type
except lapjoint
flanges (optional)
(C-B)/2 (a1+a3)/2 (C-G)/2
Lap joint flanges (C-B)/2 (C-G)/2 (C-G)/2
59
(b) for bolting - up condition (no internal pressure)
M3 = Wa3

Where W = [(A
m
+ A
b
)/2]S
q

Controlling moment M = M
0
or M
2

(Greater value is to be taken)

Calculation of flange thickness

t2 = MC
F
Y/BS
t
= MC
f
Y/BS
F0

also Y is calculated
F
F
F
F
MC
S Bt
MC
S Bt
Y
0
2 2
= =
Where M- controlling moment
Cf - initially taken is taken as unity
K = A/B = Flange outside dia/shell outside dia.
K = 1.11
we find value of y

At K = 1.11 (from table)
calculate y
St = Allowable stress to flange material
S
T
= MC/Bt
2
xy - ZS
R

General S
r
= S
FO
= 100 is taken
On substituting the values of M, C
F
, Y, B, S
r
we calculate thick
Actual bolt spacing Bs = tC/n
Where n = no of actual bolts.
60
C = bolt circle diameter
Width the calculated thickness, we calculated
Bolt pitch correction factor C
F

CF = (B
s
/2d+t)
1/2

Where d = bolt Dia
The actual flange the thickness is calculated by
M
SFo Bt
y
2
=
K = 1.38

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W = max wt. of vessel with attachments and its contents

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