ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINNERING
COURSE TITLE: CHEMICAL ENGINEERING APPARATUS DESIGN
COURSE CODE: ChEg 4191
GROUP PROJECT: NETWORK - 2
PROJECT ON MECHANICAL DESIGN OF PRESSURE VESSEL
S. NO
1.
2.
3.
4.
5.

GROUP MEMBERS
BRHANE MEHARI
JEMAL SEID
KIBROM ABRAHA
MOKENEN G/WAHID
YEMANE MENGSTU

ID NUMBERS
RET 0336/06
RET 0834/06
RET 0893/06
RET 1064/06
RET 1636/06

SECTION
ONE
ONE
ONE
ONE
ONE

SUBMITTED TO: ZINABU HAILU (MSc)

th

SUBMISSION DATE: 12 DECEMBER 2016

Declaration
We declare that this written submission represents our ideas in our works and where other ideas
or words have been included,we have adquatly cited and referred the original sources.We also
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declare that we have adherd to all principls of academic honesty and integrat and have not misrepresented or falsified any idea(data)sources in our submission.

Acknowledgment
We are really grateful because we managed to complete our design apparatus project with in the
time given by our MscZinabu.This project can not be completed with out the effort and cooperation from our group memmbers ,Brhane,Kibrom,Jemal,Mokenen and yemane.We also
sincerely thank our MscZinabu for the guidance and encouragement in finishing this project and
also teaching.Last but not least,we would like to express our gratitude to our librarians and
respondents for the support and willingness.

Executive summary
High pressure rise is developed in the pressure vessel and pressure vessel
has to withstand severe forces. So the selection of pressure vessel is most
critical. Thats why we can say that pressure vessel is the heart for storage of
fluid. Pressure vessel
must pass series of Hydrostatic tests. These tests examine the ability of the
structure to withstand various pressures to see if protective zone around the
operator station remains intact in an overturn. The structure is to be
designed, fabricated, fitted
and checked as per ASME standard. Plant safety and integrity are
fundamental concern in pressure vessel design and these of course depend
on the adequacy of design codes. The performance of a pressure vessel
under pressure can be determined
by conducting a series of tests to the relevant ASME standard. Efforts are
made in this paper to design the pressure vessel using ASME codes &
standards to legalize the design.

List of figure
List of tables
material construction..table 3.1.1
typical standard flangetable 3.2.1
column spesfication.table 3.2.2
nozzle spesfication...table 3.2.3
other sive plate column spesficationtable 3.2.4

Acronyms
e=minimum thickness,m
2
pi=internal pressure,N/ mm

Di=internal diameter,m
2
F=design stress,N/ mm
J=joint factor
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Wv=total weight of vessel,N

CV=factor account to weight of nozzles
Dm=mean diameter,m
Hv=height or length of the vessel,m
t=wall thickness,m
2
g=gravitational acceleration,9.81m/ s
=density of vessel material,kg/ m3
Wp=weight of the plate,KN
Wi=weight of insulation,KN
3
V=volume, m
2
Pw=wind pressre,N/ m

Fw=wind load,N/m
Mx=bending moment,Nm
l =longitudinal stress,N/ mm2
h=circumsferential stress,N/ mm2
z= resultant longitudinal stress,N/ mm2
w= dead weight stress,N/ mm2
b= bending stress,N/ mm2
4

Iv=second moment area, mm

c=elastic stability(critical buckling stress),N/ mm2

Rc=crown radius,m
Rk=knuckle radius,m
Cs=stress concentration factor
Dn=diameter of the nozzle,m
tn=actual nozzle thickness,m
th=theoretical thickness of shell,m
C=corrosion allowance,mm
2
As=area of the shell, m
2
Av=area of compensation provide by nozzle, m

2
bending stress in the skirt, N /mm

bs=

2
=dead weight stress in the skirt, N / mm

ws

Ms=maximum bending moment

ts=skirt thickness,m
Ds=inside diameter of the skirt,m
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fs=maximum allowable design stress for the skirt,N/ mm

=base angle of conical skirt
s
2

Ab=area of bolt, mm
Nb=number of bolts

2
fb=maximum allowable bolt stress,N/ mm

Db=bolt diameter,m
Fb=load on the base ring,N/m
Lb=base ring width,mm
fc=maximum allowable pressure on the concret foundation pad,N/ mm

tb=base ring thickness,mm

Lr=distance between the skirt and the ring,mm
2
f c =actual pressure on the base,N/ mm
2
fr=allowable design stress in the ring material,N/ mm

CHAPTER ONE
1.Introduction
Sieve plate column is one of the distillation columns with cross-flow trays, which is widely
used in various mass transfer operations. Sieve plates offer high capacity and efficiency, low
pressure drop, ease of cleaning and , low capital cost When developing sieve plate column
design, It is crucial to develop and specify the basic design information for a particular vessel,
to ensure the pressure vessel work effectively. The design of such vessels requires application of
current design codes and standards to be practiced along with the stress analysis relatively. In all the
major industrialized countries, the design and fabrication of thin-walled pressure vessels is covered
by national standards and codes of practice. The primary purpose of the design codes is to establish
rules of safety relating to the pressure integrity of vessels and provide guidance on design, materials
of construction, fabrication, inspection, and testing. Improper vessel design and maintenance increase
the risk of vessel failure and may lead to serious safety hazard. Thus a chemical design of the column
is highly important in essence of keeping the safety hazard and maintenance cost at minimum.
Therefore, based on the design code drawn as well as specifications and requirements outlined, which
include column wall thickness, selection and sizing of vessel heads, reinforcement of any openings,
nozzles, flanges, column supporting skirt and base ring, the pressure vessel design is developed
accordingly. Column wall thickness , selection and sizing of vessel heads , reinforcement of openings,
nozzles and flanges , column supporting skirt and base ring as well as design loads such as internal
pressure, wind loading and dead weight of vessel and its contents are considered when developing the
intended design. Appropriate assumptions are drawn in, to execute certain conditions for the design.
To present the completed design, a dimensional sketch as well as column specifications sheet of the
design is issued at the end of the report.

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1.1 Background
A column should be designed with a specific wall thickness to ensure it has sufficient rigidity to be able to
cope with the maximum amount of pressure which it is expected to be susceptible to in operation. The
minimum column wall thickness needed to withstand the vessel weight itself as well as other incidental
loads such as internal pressure is calculated and shown in the following calculation section. The design
pressure for vessels under internal pressure is conventionally taken as the pressure where the relief device
is set. This is usually about 5-10 % above the regular working pressure. This is done to avoid spurious
operation during minor process upsets. (Sinott 2008).

1.2 Statement of the problem

The pressure vessel that not flow any standard codes can be very
dangerous.in fact many fatal accidents have occurred in the history of
their operation and development.In addition the formulas and concepts
applied in the systems are always unknown by the users.

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1.3 Objective
1.3.1 General objective
The objective of this project is to design pressure vessel, to justify the pressure design and
material selection as well as the cause of the failure was investigated and finished element
analysis.

1.3.2 Specific objective

A sieve plate column that satisfied the preliminary specifications summary given and dimensional sketch
of the design and column specification sheet is expecte d.

And this project is to justify the pressure vessel design and material selection as well as the cause
of the failure was investigated and finished element analysis was done by under various
simulated conditions to insure that the mechanical properties and material selection where not
the cause of the vessel failure.

1.4 significance of study

The project will bring a great significant not only for the fertilizer industry but also to the all
manufacturing sector that used a various pressure vessel for daily operation. By completing this
project, readers will get exposure to the aim of codes and standards.
CHAPTER TWO

2.0 Literature review

2.1 Design
Design is a creative activity and as such can be one of the most rewarding and satisfying
activities under taken by an engineer. When considering possible way of achieving the objective
of the designer will be constrained by many factors, which narrow down the number of designs.
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Constraints are factors that has influence on the design of a given solutions, they may arise from
physical law, government law, regulation and standards.

2.2 Pressure vessel

Pressure vessel design is a specialized subject; the chemical engineer will be responsible for
developing and specifying the basic design information for a particular design vessel.pressure
vessel is a container designed to hold gases or liquids at a pressure substantially different from
the ambient pressure.

2.3 Consideration parameters to design pressure vessel

2.3.1 Design pressure: A vessel must be designed to withstand the maximum pressure to
which it is likely to be subjected in operation. For vessels under internal pressure, the design
pressure is normally taken as the pressure at which relief the device is set. This will normally be
5 to 10
above the normal working pressure.

2.3.2 Design Temperature: The strength of metals decreases with increasing temperature.so,
the maximum allowable design stress will depend on the material temperature.

2.3.3 Materials: Pressure vessels are constructed from plain carbon steels, low and high alloy
steel, otheralloys, clad plate, and reinforced plastics.

2.3.4 Design stress (nominal design strength): For design purpose it is necessary to
decide a value for the maximum allowable stress that can be accepted in the material of
construction. For materials not subject to high temperatures the design stress is based on the
yield stress or tensile strength of the material at the design temperature.

2.3.5 Welded joint efficiency and construction categories: the strength of a

welded joint will depend on the type of joint and quality of the welding. The soundness of welds
is checked by visual inspection and non-destructive testing.
There are three construction categories:
Category one: the highest class required 100% non-destructive testing of the Weld, no restriction
of the plate thickness.
Category two: requires less nondestructive testing and maximum plate thickness.
Category three: the lowest class requiresvisual inspection of the weld.

2.3.6 Corrosion allowance:is the additional thickness of metal added to allow for material
lost by corrosion and erosion. The allowance should be based on experience will the material
construction under similar service conditions to those for the proposed design. Forcarbon steel
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and low alloy steel a minimum allowance of 2mm should be used, where more severe conditions
are anticipated this should be to 4mm.

2.3.7 Design loads: A structure must be designed to resist gross plastic deformation and
collapse under all the conditions of loading. Load can be classified as major load and subsidiary
loads.

2.3.8 Minimum practical wall thickness: there will be a minimum wall thickness required
to ensure that any vessel is sufficiently rigid to with stand its own weight and any incidental
loads. The wall thickness of any vessel should not be less than the given value.

Other related literatures:

Skirt supports: are used for tall, vertical columns and it consists of cylindrical or conical
shell welded to the base of the vessel .the flanges at the bottom of the skrit transmits the load to
the foundations.

Base ring and anchor bolt design: The loads carried by the skirt are transmitted to the
foundation slab by the skirt base ring(bearing plate).
CHAPTER THREE

3. Materials and Methods

3.1 Materials construction
Table 3.1.1
Vessel
Nozzle
Skirt support

Stainless
steel,unstablised(304)
Stainless
steel,unstablished(304)
Carbon steel,silcon killed

3.2 Methods
Minimum Column Wall Thickness for cylindrical
With the specifications and requirement provided previously, the column wall thickness is then
calculated using Equation

e=

PiDi
2 fJPi

Where,
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Pi=design pressure (N/ mm

Di=internal diameter (mm)

J= joint efficient factor
f=maximum allowable working or design stress (N/mm2)
e=minimum plate thickness (mm)

Minimum column wall thickness for torispherical head

PiRc Cs
e= 2 fJ+ Pi (Cs0.2)

( )

1
Rc
but,Cs= 4 3+ Rk
where,

e=minimum thickness for torispherical head(mm)

pi=design pressure(N/mm2)
Rc=crown radius
Rk=knuckle radius
Cs=stress concentration factor
j=joint efficient factor

Minimum thickness for ellipsoidal head

With most standard ellipsoidal heads are manufactured with major and minor axis ratio of 2:1.

PiDi
2 fJ0.2 Pi

where,e=minimum thickness of ellipsoidal head(mm)

Pi=design pressure(N/mm2)
Di=internal diameter(mm)

f maximum effective design allowable stress(N/mm2)

j=joint factor

Dead weight of vessel

Wv=240CvDm(Hv+0.8Dm)t
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Where, Wv=total weight of shell(N)

Cv=factor account to weight of nozzle,internal supports and man holed
Dm=mean diameter(Di+t) m;where,Di=internal diametr (m),t=wall thickness (m)
Hv=height or lengthof the vessel(m)
t=wall thickness(m)

Weight of the plate

2
Di
Plate area= 4
Weight of plate=1.7 plate area
weight of insulation
volume of insulation= DHv ( t)insulation
weight of insulation= Vg
Total weight=Wvessel + Wplate + Winsulation

Wind load
3
Dm=Di +2(t+ tin) 10

Wind load,Fw=PwDm

Bending moment at bottom tangent

Mx=

FwHv
2

Analysis stress
l=

PiDi
4t

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h=

PiDi
2t

Dead weight stress

w=

Wv
( Di+ t ) t

Bending stress
Do=Di +2 t

( Do4 Di 4 )
Iv= 64

b=

Mx Di
+t
Iv 2

Resultant longitudinal stress

z=l+ w b

Check elastic stability(critical buckling stress)

c=2 104

( Dotb )

Area of compensation
PiRcCs
et(torisphere)= 2 fJ+ Pi (Cs0.2) =th

( )

1
Rc
,Cs= 4 3+ Rk

PiDi
en(nozzle)= 2 fJPi = t n
Maximum horizontal distance=2 Dn
Maximum vertical distance=6 th

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Area of compensation provide by head:As=Dn(tn th c)

Area of compensation provide by nozzle:Av=2H2(tn-t n -c) but,H1=H2=2.5tn
Area of compensation required: A=A (A1 + AS + AV)
Area covered by a ring:dr=(1.5 to 2)Dn=Do
Ar=(DO-Di)tn,Dir=Din+tn

Typical standard flanges

Table 3.2.1

Design of skirt support

Approximate weight=

( 4 Di Hv ) wg
2

Total weight=weight of vessel + approximate weight

Bending moment of skirt base:
2

Fw (Hv + Hs)
Ms=
2

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4 Ms
bs= ( Ds+tbs ) tbsDs

ws ( test )=

App . wt
( Ds+ts ) ts

ws ( operating ) =

weight of vessel
( Ds+ts ) ts

^
Maximum s (compressive)= bs+ ws (test )

`
Maximum ^s ( tensile ) =bsws(operating )
^s (tensile) Fsjsin

ts
^s (compressive)
Ds
)sin
0.125 E

Sieve plate column design specification

Table 3.2.2:column specification
Properties
Length of cylinder section,L
Internal diameter,Di
Heads
Number of sieve plates,n
Design temperature,T

Specifications
37m
1.5m
Standard ellipsoidal
50
150

Design pressure,Pi

1200 kN / m

Corrossionallowance,Co
Table 3.2.3:Nozzlesspecification

2mm

Properties
Feed
Vapour out
Bottom product

At mid point
At 0.7m below top of
cylindrical section
At center of vessel

Specification
200mm inside diameter
250mm inside diameter
200mm inside diameter reflux
return
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At 1.0 m below top of

cylindrical section

200mm inside diameter

Table 3.2.4:other sieve plate column specification

Properties

Specification

Diameter of access
ports(manholes)

0.6m

Height of support skirt

Thickness of insulation
Ladded
Vessel
Nozzle
Skirt

2.5m
50mm
Access ladder with platforms
Stainless steel,unestabilised(304)
Stainless steel,unestabilised(304)
Carbon steel,silicon killed

-at 1.0m above the bottom

-at 1.5m below the top of the
column
Carbon steel, silicon killed
Mineral wool

Assumption
-no significant loading from piping and external equipment
-earthquake loading need not be considered
-plate and plate supports design is negligible
-assume flanges are standard flanges

CHAPTER FOUR
4. RESULT AND DISCUSSION
SOLUTION:
Step 1.determine the minimum plate thickness to resist the internal
pressure

t = PiDi/(2fj-Pi) = (1.2*1500)/(2*130*1-1.2) = 6.955 mm , round off to

7 mm and add corrosion allowance then
t=7 mm+2 mm =9 mm
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Step2.determine the minimum thickness of the two heads.

The minimum thickness of ellipsoidal is given
t= PiDi/(2fj-0.2 Pi)

Pi = Design pressure = 1.2 N/mm2

Di = inner diameter of the column = 1500 mm
f = the design stress of the material 11of construction = 130 N/mm2
j = the weld joint efficiency = 1.0
The weld joint is double welded butt or equivalent joint and 100 percent
degree of radiography.

t= ( 1.2 (1500))/(2(130)(1)-0.2(1.2))
t= 6.93 mm
roundoff to 7 mm

The minimum thickness of torispherical is given by :

t = PiRcCs/(2fj+Pi(Cs-0.2))
Rc = Di = 1.5 mm = 1500 mm
mm

, Rk = 0.06Rc = 0.06(15000 mm) = 90

Rc/Rk = 1500/90 = 16.67

Cs = 1/4(3+16.6) = 1.77
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= 1.2(1500)1.77/(2(130)(1)+1.2(1.77-0.2)) = 12 mm ,

But the minimum thickness is more preferable .

Step3. So that we select & size the ellipsodial head because it has
smallest thickness and less economical than torispherical.
Step4. 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.

7
9
11
13
15

For all other calculations, the average thickness is used. The average
thickness = ts =11 mm .

Step5. Dead weight of vessel :

Stress due to the dead weight of the vessel:
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For a steel vessel

Take Cv = 1.15, vessel with plates for distillation column
Dm = 1.5 + 11 x 10-3 = 1.511m
Hv = 37 m
t = 11 mm
Wv = 240 CvDm (Hv + 0.8 Dm) t
Wv = 240 X 1.15 X 1.511 (37 + 0.8 X 1.511) 11
Wv= 175,279 N
Wv= 175.3kN
Step6. Weight of plates :
Plates area = /4 X 1.52 = 1.77 m2
Weight of a plate including liquid on it : 1.7kN/m2 X 1.77 m2 = 3.009
kN
50 plates = 50 X 3.009 = 150.45 kN
Step7. Weight of insulation :
Mineral wool density = 130 kg/m3
Approximate volume of insulation

V = DiHvtin=
Weight = 8.72

37m

103

50

x 130 kg/

x 9.81 m/

1.5 m=8.6025
s

m3

=11,112 N

Double this to allow for fitting,Win = 22.224 kN

Step 8 .Total weight:
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WV = 175.3KN
WP=150.45kN
Win=22.224KN
W Total=347.96KN

Step 9.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, Dm = Di + 2( ts
+tins) x

10

= 1.5 + 2(11+50) x

103

=1.622 m
Wpressure = 1280N/

Fw =Loading (per linear meter)=Wp

Dm

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

Bending moment at bottom tangent line = Mx = Fw/2
Mx=(Fw

Hv 2

(Hv)^2)/2=(2076.16*(37)^2)/2=1421131.52Nm

Step 10 .Longitudinal and circumferential stress:

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At bottom tangent line, the pressure stresses are given by:

Longitudinal stress,
l=PiDi/4tb=(1.2*1500)/(4*15)=30N/

mm2

Circumferential stress,
h=PiDi/2tb=(1.2*1500)/(2*15)=60N/

mm2

step 11. Stress due to dead weight,

w=Wv/(Di+tb)tb=(175.3*

103

)/(1500+15)15=2.4566N/

mm2

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

the column
Step 12. Bending Stresses,
b=Mx/Iv(Di/2 + tb) , where Iv=/64(
1500

)=2.048*

10

10 mm

b=(1421131.52*

10

DO4

Di4

)=/64((

1530
4

-(

)/(2.048*

10

10

)(1500/2+15)=

53.08N/

mm

step 13 .Resultant longitudinal stress is given by,

z=l+wb ,where w(compressive)= negative
z(up-wind )=l-w+b=

30-2.4566+53.08=80.5N/

z(down-wind)=l-w-b=30-2.4566-53.08=-25.5N/

mm2

mm2

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Up-wind

Down-wind

Therefore greatest difference between the principal stresses will be on

the down-wind side.

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Since the upwind stress (80 N/mm2) and downwind stress (25.5N/mm2)
are less than the allowable design stress (130 N/mm2), therefore the
design metal thickness (tb = 15 mm) is satisfactory.
Step 14: Check elastic stability (buckling).
Critical buckling stress can be calculated as
c=2*

104

(tb/Do) = 2*

104

(15/1530)=196.07N/

mm2

The maximum resultant compressive stress will occur when the vessel is
not under pressure given by.

z=b+w = 53.08+2.4566=55.54N/

mm2

Since the maximum resultant compressive resultant stress

(55.54 N/mm2) less than that of critical buckling stress (196.07N/

).

So the design procedure of the vessel is correct.

Design 0f Skirt support and base ring calculation

Ms= (FW(

Hv 2

)/2

Hvs=Hs+Hv

Where Hvs=height the skirt vessel,

HVS=37+2.5=39.5 m

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Step 1: Determine the height of the vessel isncludingheight of each

ellipsoidalhead.

Height of the vessel, Hv

Given:
Length of cylindrical section = 37 m
Internal column diameter = 1.5 m
Height of each ellipsoidal head, h
Since the ellipsoidal heads used for this design are of a standard
measurement as shown below in Figure 1.1.1, it is safe to assume that
the heads are manufactured with a major and minor axis ratio of
2:1(Coulson and Richardsons chemical engineering Vol.6).

Figure 3.4.2: Standard ellipsoidal head

The height of each ellipsoidal head, h = D/(4 ) , 1.5/4=0.375 m
The height of vessel, Hv:
Hv = (Length of cylindrical section) + (Height of the two ellipsoidal
heads)
= 37+2(0.375) = 37.75m
Step 2: Determine the bending moment, in skirt.

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x=Hs+Hv
Where,
HS= Height of skirt=2.5m
H V =Height of the vessel=37+2(0.375)=37.75m
x=37.75+2.5=40.25 m
Ms=(Fw*x^2)/2,where Fw =load per unit length is from a bove
calculation =2076.16N/m
X = Hs+Hv
Ms=bending moment at the base of the skirt

Ms= (Fw*

)/2=(2076.16*

40.25

)/2=1681754.48Nm

Step 3: Determine the bending stress in the skirt.

The bending stress in the skirt is given by the following formula,
Assume as a first trial, take the skirt thickness as the same as that
of the bottom section ofthe vessel, 15 mm.

bs= 4Ms/(Ds+ts)Dsts
Where,
Ds =Internal column diameter, =1.5m
ts = Thickness of the skirt = Thickness of the bottom section, =15mm
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bs=Bending stress in the skirt

Thus,
bs=(4*1681754.48*1000)/(*(1500+15)*15*1500)=62.85N/

mm2

Step 4: Determine the dead weight stress for the test and operating
conditions.
For test condition,ws(test):
Formula given by,

ws(test)=Wwater/(Ds+ts)ts

Where,
ws(test)=Dead weight stress in the skirt for test condition
Wwater= dead weight of the vessel with contents (water) is
approximate weight
Wwater=(*D^2*Hv*w*g)/4=(*

1.52

*37.75*1000*9.81)/4=653424.

2N=653.4242KN
Thus,
ws(test)=Wwater/(Ds+ts)ts

ws(test)=653424.2/(*(1500+15)*15)= 9.2N/mm2
For operating condition, ws(operating):
The formula given by,
ws(operating)=Wvessel/(Ds+ts)ts
Where,
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ws(operating)=Dead weight stress in the skirt for operating condition

Wvessel= dead weight of vessel with heads.
Thus,
ws(operating)=(175.3*1000)/((1500+15)*15)=2.45668 N/mm2
Step 5: Determine the resultant bending stress in the skirt.
For maximum:
s(compresive)= bs + (test)
s(compresive)=62.85+8.975=71.825 N/mm2
For minimum:
ws(tensil)=bs+w(opersting)
ws(tensil)=62.85-2.45668= 60.4N/mm2
Step 6: Design criteria:
If given the worst combination of both wind and dead-weight loading,
the skirt thickness should not exceed that of its design criteria, as
shown below
From the specification table,
=90
fs= 115 N/mm2
E = Youngs modulus (Sinnott. and Tower., 7.3.7. Effect of
Temperature onthe Mechanical Properties 1999) =200,000 N/mm
For the maximum:
Given the formula,
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s(compresive)0.125E(ts/Ds)sins
71.825 N/

mm2

0.125200,000(15/1500)

71.825 N/

mm2

250 (Fulfilled)

sin 90

For minimum:
Given the formula,
s(tensil)fsJsins
60.41151sin90Type equation here.
65.3N/

mm

115 (Fulfilled)

Since all the calculations and comparison above shows that the all
design criteria were fulfilled,add 2 mm for corrosion, gives a design
thickness of new skirt thickness, ts:
New skirt thickness, ts:
ts= (Old thickness of the skirt) + (Corrosion allowance)
=15mm + 2mm= 17mm
Base ring/flange and anchor bolt design
For DS = 1.5 m
Step 1 .Determine the number of bolts required, N bolts
Since the measurements for the pitch diameter were not given, it
was assumed that the measurement of column diameter would be used to
make an assumption for the pitch diameter. An estimation of 10%
allowance was then added to the pitch circle diameter column.
Number of bolts required N bolts given by the formula:
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N bolts=Dp/600
Where;
Ds = Internal column diameter = 1.5 m
Dp = Pitch circle diameter
= Ds + (10% Ds)
= 1.5 + 0.1 x 1.5
= 1.65 m
= 1,650 mm
Thus, Nbolts=(1650*)/600=8.635mm
By taking the nearest multiple of 4, 12 is the nearest value to the number
of bolts required, Nbolts.
Step 2: Determine the required bolt area, Ab
The required bolt area, A given by the formula:
Ab=1/(Nbolt*fb)(4Ms/Dp-Wv)
Where,
N bolt=Number of bolts required = 12 Bolts.
fb = Bolt design stress = 125 N/mm2
Ms =Bending moment in skirt
Wvessel= dead weight of vessel with heads
Dp = Pitch circle diameter = 1.6 5m = 1,650 mm
Ab=1/(Nbolt*fb)((4Ms )/Dp - Wvessel)
ADIGRAT ETHIOPIA

= 1/(12*125)((4*1681754.48)/1650 175.3*1000)
=2601.12

mm2

Step 3: Determine the bolt root diameter, D bolt.

The bolt root diameter given by the formula:
D bolt =(4Ab/)=((4*2601.12)/)=57.56mm
With the addition of base rings, the bolt should be sufficient enough to
distribute the total compressive load to the foundation.
Step 4: Determine the total compressive load on each base ring per unit
length, Fbolt.
Given the formula:
Ds

Fbolt= 4Ms/(*

) + Wv/DS

Where,
Wvessel=dead weight of vessel with heads = 175.3 KN
Ms=Bending moment in skirt = 1681754.48Nm
Ds=Internal column diameter = 1.5m

Fbolt=(4*1681754.48*1000)/(*

15002

) + (175.3*1000)/

(*1500)=989.38N/mm
Step 5: Determine minimum width of base ring, Lb.
Given by the formula:
L b = Fb/(fc*

10

)
ADIGRAT ETHIOPIA

F bolt=Total compressive load on the base ring per unit length =

1,196.40N/mm
fc=Maximum allowable bearing pressure on the concrete foundation pad
bearing pressure 5 N/

Lb=989.38/(5*

103

)=0.1978mm

Due to the large base ring width, a flared skirt shall be used as an
alternative to the design. Therefore, the requirements and assumptions
for the new skirt are:
Flared skirt bottom diameter, Ds = 2.5 m = 2500 mm
Bolt circle diameter, Dolt= Ds+ (10% of Ds)
= 2.5 m + (1.5*0.1)= 2.5 m + 0.15 m
= 2.65 m (Assumed)
= 2,650 mm
Number of bolt, (Nbolt) =(*(Dp) )/600 = but , D'p=D's+(10%D
s)
D'p=2.5+(10%2.5) = 2.75 m
= 2,750mm
(Nbolt)

= (*2750)/600=14.4mm

For Ds = 2.5m
Step 1: Determine the skirt base angle, s.
ADIGRAT ETHIOPIA

Skirt base angle, s (With Ds =2.5 m) given by,

s=

tan 1

s=

tan

(Ds) /(0.5((D s-Ds)) ))

(2.5/(0.5(2.5-1.5)))= 78.7

Step 2: Determine bolt spacing.

Bolt spacing given the formula:
Bolt specing =(Dbolt*) /(Nbolt)
Where,
Dbolt'=Bolt circle diameter = 2650 mm
Nbolt'=Number of bolts =14.39
boltspecing=(*2650)/14.4=577.8 mm (satisfactory)ss
Step 3: Determine new required bolt area, Ab
Given by the formula:
Ab=1/(Nbolt*fb) (4Ms/(Dbolt) -Wvessel)
Wvessel=l dead weight of vessel with heads = 175.3 KN
Ms=Bending moment in skirt
Nbolt'=Number of bolts required = 14.4
Dbolt'=Bolt circle diameter = 2.650m = 2,650 mm
fb=Bolt design stress = 125 N/mm2
Ab=1/(14.4*125)((4*1681754.48*1000 )/2650 -(175.3*1000))= 255.2
mm2

ADIGRAT ETHIOPIA

Step 4: Determine the total compressive load on each base ring per unit
length, Fbolt.
Given the formula:
Ds2

Fbolt=4Ms/(*((

) ) +Wv/((*Ds) )

Where,
W vessel= dead weight of vessel with heads =175.3 KN
Ms= Bending moment in skirt = 1681754.48Nm
D's=Flared skirt bottom diameter=2.5m =2500mm
(Fbolt) =(4*1681754.48)/(*2500^2 ) + 175.3/(*2500)=365
N/mm
Step 5: Determine minimum width of base ring, Lb
Given the formula:
(Lb) =(Fbolt) /(fc*

103

fc=Maximum allowable bearing pressure on the concrete foundation pad

Bearing pressure = 5 N/mm2
(Lb) =365/(5*

10

)= 0.073mm

Step 6: Determine the actual bearing pressure on the concrete

foundation,
Given the formula:
f'c=Fbolt'/(Actual width)

ADIGRAT ETHIOPIA

Actual width =Lr + ts + ti

Where,
ts = Skirt thickness = 17mm
ti = Insulation thickness = 50mm
(Fbolt) = Total compressive load on the base ring per unit length
Lr =Distance from the edge of the skirt to the outer edge of the ring =
178 mm (Sinnott., Coulson & Richardson's Chemical Engineering 1999)
:Using Bolt size 70 (BS 4190:1967)
Actual width = 178 + 17 +50 = 245mm
(fc) =(Fbolt) /(Actual Width)=365/245=1.489 N/mm2
Step 7: Determine the base ring thickness, tb
The base ring thickness given by the formula:
tb = Lr((3*(fc) )/Fr)

tb=178((3*1.489)/140)=31.795mm

Reinforcement of Opening calculation

Required Area of Reinforcement:
All process vessels will have openings for connections, man ways, and
instrument fittings. The presence of opening has its own drawback
ADIGRAT ETHIOPIA

whereby it weakens the shell and gives rise to stress concentrations. The
stress at the edge of a hole will be higher than the average stress in
surrounding plate. Thus, in order to reduce this stress it is important that
the opening is compensated with increase of wall thickness in the region
adjacent to the opening. In other words, a reinforcement of opening will
be done towards the hole in order to cope with a sufficient stress that
countered the weakening effect of the opening without.
Reinforcement of opening is given by :
A=d*tr*F+2*tn*tr*F(1-fr1)
Preliminary calculation of thickness & distance
Such as tr,trn,t,ti,tn& h
Step1.determine the required thickness under circumferential stress ,tr
for seamless shell or head is given by : tr=PiR/(fj-0.6Pi)=PiK1D/(fj0.6Pi)
Where tr=required thickness for a seamless sphere with radius of K1D,
R=K1D
f=maximum stress allowance=130N/

mm2

Pi=1.2N/

j=joint factor=1

mm2

K1=0.9

D= 600mm=0.6m
tr=(1.2*0.9*600)/(130-0.6*1.2)=5.012mm
Step2.tn=50mm
Step3.determine the vessel wall thickness ,t is given by:
t=PiR/(fj-0.6Pi)+c where R=D/2 =1500/2=750mm
ADIGRAT ETHIOPIA

c=corrosion allowance=2mm
t=(1.2*750)/(130-0.6*1.2)+2=8.96mm 9mm
Step4.determine the nominal thickness of internal projection of the
nozzle wall ,ti ,is given by:
ti=tn-2c=50-2(2)=46mm
Step5.determine the distance nozzle projects beyond the inner surface of
the vesselwall ,h ,is given by:
h=(2.5t , 2.5ti)
h=(2.5*9,2.5*46)=(22.5,115)
Step6.determine diameter of finished opening,d, is given by :
d=D+c=600+2=602mm
Note: the opening is in a corroded condition.thus,a corrosion allowance
is added to the diameter of the opening.
Calculation of area required for reinforcement
Assuming correction factor,f=1 & d=D
A=d*tr*F+2*tn*tr*F(1-factor)
To determine whether additional reinforcement is necessary for the man
holes the actual area available for reinforcement must be calculated &
compare with the area required for reinforcement.
The following condition should be satisfied if no addition reinforcement
is required,
A<Ai,where Ai= A1+A2+A3+A41+A43
A1(largest):
ADIGRAT ETHIOPIA

(A1 ) =d(E1t-Ftr)-2tn(E1t-ftr)(1-fr1) ,where fr1=f/f=130/130=1

Since the nozzle & vessel are made-up of from the same material (i.e
from stainless steel).
Therefore the term 2tn(E1t-Ftr)(1-fr1) is equal to zero.

Then (A1 ) =d(E1t-Ftr) ,but E1=F=E=1

(A1 ) =d(t-tr)=602(9-5.012)=2400.77

mm2

(A1 ) =2(t+tn)(E1t-Ftr)-2tn(E1t-Ftr)(1-fr1) but f=1 , E1 =F=1,the

equation becomes
(A1 ) =2(t+tn)(E1t-Ftr)=2(9+50)(9-5.012)=470.584
Since (A1 ) >(A1 ) ,then A=(A1 ) =2400.77

mm2

mm2

A2(smallest)
(A2 ) : first of all assuming Fr2 =Fr1=1
Since the both have the same formula (Sn/Sv)
( A2 ) =5(tn-trn)fr2t ,

substituting the vessels

(A2 ) =5(50-4.173)(1*9)=2062.215

mm2

(A2 ) =5(tn-trn)Fr2 tn=5(50-4.173)50=11456.75

2

mm

Since (A2 ) <(A2 ) ,then A2=(A2 ) =2062.215

mm2

A3(smallest)
ADIGRAT ETHIOPIA

(A3 ) =5t(tiFr2)=5*9(46*1).where Fr2=1

(A3 ) =2070

mm2

(A1 ) =5ti (tiFr2)=5*46*46=10580

mm

(A3 ) =2h(tiFr2)=2*17.5(46*1)=1610

mm

Since (A3 ) <(A3 ) <(A2 ) Then A3=(A3 ) =1610

mm2

For areas A41 & A43 they are not consider since the welds vary
from fillet to bolt weld type.
Thus,A41=A43=0
Then we sum up from A1 to A3

Ai=A1+A2+A3= (2400.77+2062.215+1610)
=6072.985

mm2

mm2

By comparing both the required area for reinforcement and the area
available reinforcement area equals to 3007.38
A=3007.78

mm2

and Ai=6072.985

mm2

mm2

Therefore .the condition A<Ai is satisfactory, no additional

reinforcement will be required .
Table 4.1 Summerization of all final results
Minimum cylindrical
thickness,mm
Minimum ellipsoidal

e or t

9mm

e or t

7mm
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thickness,mm
Minimum torispherical
thickness,mm
Average thickness,mm
Dead weight of
vessel,KN
Weight of plate,Kn
Weight of
insulation,KN
Total weight,KN
Wind load,N/m
Bending moment,Nm
2
Stress analysis, N /mm
Longitudinal stress
Circumsferential stress
Dead weight stress

e or t

12mm

tave
Wv

11mm
175.37KN

Wp
Win

3.009kN
22.224KN

wtotal
Fw
Mx

347.90KN
2076.16N/m
1421131.52Nm

30N/

60N/mm2
2.45666N/mm2

mm2

CHAPTER FIFE
5.1 CONCLUSION
As the process of this project is completed,it can be concluded that the
objectives of this project is successfully done.This project has lead to
several conclusions;However,the major conlusions is:The design of
apressure vessel is more selection of procdure,selection its components
to be more precise rather than designing each and every compenent.
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5.2 RECOMMENDATION
In a nut shell in terms of design rules, there are many aspects to looking
from the important to have a complete and perfect pressure vessel.
The design code and standard must be appropriately revised to make
sure the safe enough.

ADIGRAT ETHIOPIA

ADIGRAT ETHIOPIA