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TABLE OF CONTENTS

CHAPTER NO CHAPTER TITLE PAGE

NO

CHAPTER-1 Literature review 07

CHAPTER-2 Introduction 10

2.2 Components of pressure vessels 12

2.21 Shell 12

2.22 Head 12

2.23 Nozzle 13

2.24 Support 13

2.3 Mount storage vessel 14

2.4 History of pressure vessel 15

2.4.1 Classification of boilers 17

2.4.2 High pressure vessel 18

2.4.4 Type of failures 19

2.4.5 Types 20

2.4.6 Thermal stress 22

2.5 Fatigue analysis 22

2.5.1 Stress 23

2.5.2 Type of stress 24

1
2.5.3 Primary general stress 25

2.5.4 Pressure stress 26

2.5.5 Secondary stress 26

2.6 Failure in pressure vessels 27

Chapter-3 Codes and standards 29

Materials of constructions 30

Materials of constructions 31

Material property summary 32

3.1 Material selection for pressure vessel 33

construction

3.2 General material selection process 34

3.3 Material used for pressure vessels 34

1 Q235-A 34

2 20g 35

3 16MnR 35

4 The material for low temperature vessel 36

3.4 Steel for high temperature vessel 36

Chapter-4 Design of multilayer high pressure vessel 37

4.1 Design objectives 38

4.2 Design consideration 39

2
4.3 Design data of vessel 40

4.4 Design criteria 41

4.4.1 Minimum shell/head thickness 42

Chapter-5 Factor considered for designing pressure 43

vessel

5.1 Vessel sizing 43

5.2 Vessel end closure 43

5.3 Pressure 44

5.3.1 Operating pressure 44

5.3.2 Design pressure 45

5.3.3 Test pressure 47

5.3.4 Corrosion allowance 48

5.5 Calculation 49

5.6 Design procedure and calculation 50

5.6.1 Circumferential or hoop stress 51

5.6.2 Longitudinal stress 52

5.7 Design of shell due to internal pressure 52

5.7.1 Rule 52

5.7.2 Design of elliptical head 52

5.8 Design calculation 53

3
5.8.1 Thickness of cylinder 53

5.8.2 Design of man hole 54

5.8.3 Design calculation summary 54

Advantages 55

Conclusion 56

Reference 57

4
Figure No Figure Name Page No

Codes and standards 29

Materials of constructions 30

Case-2 31

Material of constructions

Material property summary 32

Design data of vessel 40

Design calculation summary 54

5
DESIGN AND FABRICATION OF STEAM POWER PLANT

ABSTRACT

The main objective of this paper is to design and fabrication of steam

power plant. analysis of multilayer high pressure vessels features of

multilayered high pressure vessels, their advantages over mono block vessel

are discussed. Various parameters of Multilayer Pressure vessels are

designed and checked according to the principles specified in American

Society of Mechanical Engineers (A.S.M.E).

A boiler is a closed vessel in which water or other fluid is heated. The fluid

does not necessarily boil. ("furnace" is normally used if the purpose is not

actually to boil the fluid.) The heated or vaporized fluid exits the boiler for

use in various processes or heating applications, including water heating,

central heating, boiler-based power generation, cooking, and sanitation.

6
CHAPTER:1

LITERATURE REVIEW

High-pressure vessels, such as ammonia converters, urea reactors and

supercritical fluid extractors, etc., are widely used in chemical, oil refining,

energy industries, and so on. Such vessels are key equipments in various

processes industries and have potential hazards. Much attention has been

paid to using them safely and to lowering their costs, with great progress

being made in the last century. For example, Analysis of Pressure Vessel

junction by the Finite element Method written by Mahadeva

Sivaramakrishna Iyer not only tells the use of method to solve such high

tension zone problems but also gives a way to predict results for stresses and

optimize the design

[1], Finite element analysis of Pressure vessel by David Heckman also

tells the use of computer programs instead of hand calculations for analyzing

the high stress area’s and different end connections

[2].The different types of stresses and modeling of pressure vessel

joints are also depicted in ASME code in section “Design by analysis”

[3]. the use of hemispherical end in pressure vessels is the most

economical and common use which can be seen in India and other

developing countries. Although with the recent trends in Mechanical


7
engineering with the use of Finite element software’s the sheet thicknesses

are validated for different end connections and for cylinder shell itself. As

per the conventional theory of mechanics of materials stated by S

Timoshenko, the required thickness of hemispherical end is one-half the

thickness of the shell to result in equivalent stresses in the cylinder

[4] Adali et al. (1995) gave another method on the optimization of

multi-layered composite pressure vessels using an exact elasticity solution. A

three dimensional theory for anisotropic thick composite cylinders subjected

to axis symmetrical loading conditions was derived. The three dimensional

interactive Tsai-Wu failure criterion was employed to predict the maximum

burst pressure. The optimization of pressure vessels show that the stacking

sequence can be employed effectively to maximum burst pressure. However

Adali’s results were not compared with experimental testing and the stiffness

degradation was not considered during analysis.

[5] The effect of surface cracks on strength has been investigated

theoretically and experimentally for glass/epoxy filament wound pipes, by

Tarakçioglu et al. (2000). They were investigated theoretically and

experimentally the effect of surface cracks on strength in glass/epoxy

filament wound pipes which were exposed to open ended internal pressure.

8
[6] Mirza etal. (2001) investigated

the composite vessels under concentrated moments applied at discrete lug

positions by finite element method. Jacquemin andVautrin (2002) examined

the moisture concentration and the hydro thermal internal stress fields for

evaluating the durability of thick composite pipes submitted to cyclic

environmental condition. Sun et al. (1999) calculated the stresses and

bursting pressure of filament wound solid-rocket motor cases which are a

kind of composite pressure vessel; maximum stress failure criteria and

stiffness-degradation model

The present research focuses on:

a. Determination of first failure pressures of pressure vessels by

using a finite element method

b. Optimization of composite pressure vessels

c. Comparison of filament winding angles of composite pressure

vessels

d. Comparison of theoretical results with experimental

9
CHAPTER: 2

INTRODUCTION

2. INTRODUCTION

In Process Industries, like chemical and petroleum industries design

have recognized the limitations involved for confining large volumes of high

internal pressures in single wall cylindrical metallic vessels. In process

engineering as the pressure of the operating fluid increases, increment in the

thickness of the vessel intended to hold that fluid is an automatic choice. The

increment in the thickness beyond a certain value not only possesses

fabrication difficulties but also demands stronger material for the vessel

construction. The media which a pressure vessel contains produce critical

changes to the physical properties of the vessel material during service. One

of these that is often encountered is hydrogen, which under the action of high

pressure and / or high temperature produces two effects: (1) A diffusion into

the metal as atomic hydrogen and a process of recombining to its molecular

form within the metal, thereby creating extremely high pressures with

resulting surface bulging, and (2) a mechanical decarburizing, and reducing

10
effect on sulfides or oxides present in the steel creating a brittleness and

resultant cracking under high stress.

Multilayer Pressure Vessels have extended the art of pressure vessel

construction and presented the process designer with a reliable piece of

equipment useful in a wide range of operating conditions for the problems

generated by the storage of hydrogen and hydrogenation processes the term

pressure vessel referred to those reservoirs or containers, which are subjected

to internal or external pressures. The pressure vessels are used to store fluids

under pressure. The fluid being stored may undergo a change of state inside

the pressure vessels as in case of steam boilers or it may combine with other

reagents as in chemical plants. Pressure vessels find wide applications in

thermal and nuclear power plants, process and chemical industries, in space

and ocean depths, and in water, steam, gas and air supply system in

industries. The material of a pressure vessel may be brittle such as cast iron,

or ductile such as mild steel.

11
2.1 INTRODUCTION TO PRESSURE VESELS

Pressure vessel is a closed container containing fluid under pressure

(internal or external) more than the atmospheric pressure used for channeling

and storing fluids and for performing various unit operations.

2.2 COMPONENTS OF PRESSURE VESSELS

2.2.1 SHELL

The shell is the primary component that contains the pressure.

Pressure vessel shells are welded together to form a structure that has a

common rotational axis. Most pressure vessel shells are cylindrical, spherical

and conical in shape.

2.2.2 HEAD

All pressure vessel shells must be closed at the ends by heads (or

another shell section). Heads are typically curved rather than flat. Curved

configurations are stronger and allow the heads to be thinner, lighter, and

less expensive than flat heads. Heads can also be used inside a vessel.

12
2.2.3 NOZZLE

A nozzle is a cylindrical component that penetrates the shell or heads of a

pressure vessel. The nozzle ends are usually flanged to allow for the

necessary connections and to permit easy disassembly for maintenance or

access. Nozzles are used for the following applications

 Attach piping for flow into or out of the vessel.

 Attach instrument connections, (e.g., level gauges, thermo wells, or

pressure gauges).

 Provide access to the vessel interior at many ways.

2.2.4 SUPPORT

The type of support that is used depends primarily on the size and

orientation of the pressure vessel. In all cases, the pressure vessel support

must be adequate for the applied weight, wind, and earthquake loads.

Calculated base loads are used to design of anchorage and foundation for the

pressure vessels.

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2.3 MOUNDED STORAGE VESSEL

Comprises the storage of pressurized gases at ambient temperatures in

horizontal cylindrical vessels placed near ground level and covered with

suitable backfill. Several vessels may be located side by side in one mound.

The decision for the earth covered type of installation is mainly justified by

the safety advantages in respect to external influence on the vessel; such has

high temperature in case of fire and dynamic pressure from near by

explosion. The design procedure of the mounded storage vessel conforms to

ASME-Boiler and Pressure vessel code, section VIII pressure vessels –

Division II .The various stresses (due to pressure, seismic, mound and dead

loads) on mounded storage vessel are calculated. Stress analysis of mounded

storage vessel is done with the help of the FEA (Finite element analysis)

package ANSYS. Induced stresses obtained from manual calculations using

fundamental formulae and induced stresses obtained from FEA using

ANSYS were compared

14
2.4 HISTORY OF PRESSURE VESSELS:

Pressure vessels are a group of critical equipments of different types

of construction used in modern industries for various operations like storage,

process etc. of various fluids. These equipments can be

 Atmospheric Storage Tanks

 Pressurized Tanks

 Process columns and Vertical Pressure Vessels

 Horizontal Pressure Vessels

 Heat Exchangers

 Process Heaters

Boilers Throughout the world the use of process equipment has

expanded considerably. In petroleum industry, pressure vessels are used at

all stages of processing oil. At the beginning of cycle, they are used to store

15
crude oil. Much different types of these pressure vessels, process the crude

oil into oil and gasoline for the customer. The use of pressure vessels in

chemical industries is equally extensive.

Pressure vessels are made in all sizes and shapes. The smaller one may

be no longer than a fraction of an inch in diameter; whereas large pressure

vessels may be of dia 150ft. or more in India .Some are buried in ground or

deep in oceans, most are positioned on ground or supported on platform and

some are found as storage tanks and hydraulic units in aircrafts.

The internal pressure to which process equipment is designed is varied

as size and shape. The usual range of pressure for mono block construction is

about15 psi to 5000 psi. Although there are many vessels designed

for pressure below and above that range .The ASME boiler and pressure

vessel code section VIII Div.II, specify a range of internal pressure from 15

psi at bottom to no upper limit. However at an internal pressure above 3000

psi.

16
2.4.1 CLASSIFICATION OF BOILERS

Unfired Cylindrical Pressure Vessels (Classification Based on IS 2825-

1969)

a) Class 1: Vessels that are to contain lethal or toxic substances.

Vessels designed for the operation below -20 C and Vessels

intended for any other operation not stipulated in the code.

b) Class 2: Vessels which do not fall in the scope of clas1 and class 3

are to be termed as class2 vessels. The maximum thickness of shell

is limited to 38 mm.

c) Class 3: There are vessels for relatively light duties having plate

thickness not in

excess of 16 mm, and they are built for working pressures at

temperatures not

exceeding 250 c and unfired .class3 vessels are not recommended

for services at

temperature below 0c.

17
2.4.2 TYPES OF HIGH PRESSURE VESSELS

High Pressure vessels are used as reactors, separators and heat

exchangers. They are vessel with an integral bottom and a removable top

head, and are generally provided with an inlet, heating and cooling system

and also an agitator system. High Pressure vessels are used for a pressure

range of 15 N/mm2 to a maximum of 300 N/mm2. These are essentially

thick walled cylindrical vessels, ranging in size from small tubes to several

meters diameter. Both the size of the vessel and the pressure involved will

dictate the type of construction used.

A solid wall vessel consists of a single cylindrical shell, with closed

ends. Due to high internal pressure and large thickness the shell is considered

as a „thick‟ cylinder. In general, the physical criteria are governed by the

ratio of diameter to wall thickness and the shell is designed as thick cylinder,

if its wall thickness exceeds one-tenth of the inside diameter. A solid wall

vessel is also termed as Mono Block pressure vessel.

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2.4.3 TYPES OF FAILURES

 Elastic deformation—Elastic instability or elastic buckling, vessel

geometry, and stiffness as well as properties of materials are protecting

against buckling.

 Brittle fracture—can occur at low or intermediate temperature. 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 cyclic-dependent phenomenon

 Elastic 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 cyclic fatigue is strain-governed and occurs mainly

in lower strength/ high-ductile materials.

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 Stress corrosion—it is well know that chlorides cause stress corrosion

cracking in stainless steels; likewise caustic service can cause stress

corrosion cracking in carbon steel. Materials 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.

2.4.4 TYPES

 Thick Walled Pressure Vessels

 Mono-bloc- Solid vessel wall.

 Multilayer—Begins with a core about ½ in. thick and successive layers

are applied. Each layer is vented (except the core) and welded

individually with no overlapping welds.

 Multi-wall—Begins with a core about ½ in. to 2 in. thick. Outer layers

about the same thickness are successive “shrunk fit” over the core. This

20
creates compressive stress in the core, which is relaxed during

pressurization. The process of compressing layers is called auto-

frottage from the French word meaning self hooping.” Multilayer auto-

frettage Begins with a core about ½ in. thick. Bands or forged rings are

slipped outside and then the core is expanded hydraulically.

 The core is stressed into plastic range but below ultimate strength. The

outer rings are maintained at a margin below yield strength. The elastic

deformation residual in the outer bands induces compressive stress in

the core, which is relaxed during pressurization. Wire wrapped vessels:

Begin with inner core of thickness less than required for pressure. Core

is wrapped with steel cables in tension until the desired auto frottage is

achieved.

 Coil wrapped vessels: Begin with a core that is subsequently wrapped

or coiled with a thin steel sheet until the desired thickness is obtained.

Only two longitudinal welds are used, one attaching the sheet to the

core and the final closures weld. Vessels 5 to 6 ft in diameter for

pressure up to 5000psi have been made in this manner.

21
2.4.5 THERMAL STRESS

 Whenever the expansion or contraction that would occur normally as a

result of heating or cooling an object is prevented, thermal stresses are

developed. The stress is always caused by some form of mechanical

restrain.

 Thermal stresses are “secondary stresses” because they are self-

limiting. Thermal stresses will not cause failure by rupture. They can

however, cause failure due to excessive deformations.

2.4.6 DISCONTINUITY STRESSES

Vessel sections of different thickness, material, diameter and change in

directions would all have different displacements if allowed to expand

freely. However, since they are connected in a continuous structure,

they must deflect and rotate together. The stresses in the respective

parts at or near the juncture are called discontinuity stresses.

Discontinuity stresses are “secondary stresses” and are self-limiting.

Discontinuity stresses do become an important factor in fatigue design

where cyclic loading is a consideration.

22
2.5 FATIGUE ANALYSIS

When a vessel is subject to repeated loading that could cause failure

by the development of a progressive fracture, the vessel is in cyclic service.

Fatigue analysis can also be a result of thermal vibrations as well as other

loadings.

In fatigue service the localized stresses at abrupt changes in section, such as

at ahead junction or nozzle opening, misalignment, defects in construction,

and thermal gradients are the significant stresses.

2.5.1 STRESS

It is defined as the ratio of load into area is known as stress

23
2.5.2 TYPES OF STRESSES

1. Tensile 14. Compressive

2. Shear 15. Bending

3. Bearing 16. Axial

4. Discontinuity 17. Membrane

5. Tensile 18. Principal

6. Thermal 19. Tangential

7. Longitudinal 20. Load induced

8. Strain induced 21. Circumferential Longitudinal

Radial

9. Normal

10. Primary Stress

11. Primary general bending stress P b

12. Primary local stress, PL

13. Secondary stress:

24
2.5.3 PRIMARY GENERAL STRESS:

These stress act over a full cross section of the vessel. Primary stresses

are generally due to internal or external pressure or produced by sustained

external forces and moments. Primary general stress are divided into

membrane and bending stresses. Calculated value of a primary bending

stress may be allowed to go higher than that of a primary membrane stress.

1. Primary general membrane stress, Pm

2. Circumferential and longitudinal stress due to pressure.

3. Compressive and tensile axial stresses due to wind.

4. Longitudinal stress due to the bending of the horizontal vessel over

the saddles.

5. Membrane stress in the centre of the flat head.

6. Membrane stress in the nozzle wall within the area of reinforcement

due to pressure or external loads.

7. Axial compression due to weight.

8. Primary general bending stress, Pb Bending stress in the centre of a

flat head or crown of a dished head.

9. Bending stress in a shallow conical head.

10. Bending stress in the ligaments of closely spaced openings.

25
2.5.4 PRESSURE STRESS:

The pressure stress limits may be discussed by considering a vessel

that is constructed of a thin cylindrical shell of length L that is capped

by a hemisphere at either end. The mean radius of the cylinder (and

the caps) is denoted by R. The cylinder has a uniform thickness equal

to tc; each cap has a uniform thickness equal to vessel is subjected to

an internal pressure (p) and a zero external pressure. No other external

forces act. The vessel walls are at a uniform temperature and are

constructed of a single material.

2.5.5 SECONDARY STRESS:

 Secondary membrane stress Qm

 Axial stress at the juncture of a flange and the hub of the flange

 Thermal stresses.

 Membrane stress in the knuckle area of the head.

 Membrane stress due to local relenting loads

 Secondary bending stress, Qb

26
 Bending stress at the gross structural discontinuity: nozzle, lugs,

etc., (relenting loadings only).

 The non uniform portion of the stress distribution in a thick-walled

vessel due to internal pressure.

 The stress variation of the radial stress due to internal pressure in

thick-walled vessels.

 Thermal stress in a wall caused by a sudden change in the surface

temperature.

 Thermal stresses in cladding or weld overlay.

2.6 FAILURE IN PRESSURE VESSELS

Categories of Failures:

 Material--Improper Selection of materials; 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.

27
 Service—Change of service condition by the user;

inexperienced operations or maintenance personnel; upset

conditions. Some types of services which requires special

attention both for election of materials, design details, and

fabrication methods are as follows:

1. Lethal 6. Fatigue (cyclic)

2. Brittle (low temperature) 7. High

Temperature

3. High shock or vibration 8. Vessel contents

4. Hydrogen 9. Ammonia

5. Compressed air

28
CHAPTER: 3

CODES AND STANDARDS

The following codes and standards shall be followed unless otherwise

specified:

ASME SEC. VIII DIV. For Pressure vessels

IS: 2825

ASME SEC. VIII DIV.2 For Pressure vessels (Selectively for high

Pressure / high thickness / critical service)

ASME SEC. VIII DIV.2 for Storage Spheres

ASME SEC. VIII DIV.3 For Pressure vessels (Selectively for high

API 650 / IS: 803 pressure)

API 620 For Storage Tanks.

API 620 / BS 7777 For Low Pressure Storage Tanks,

ASME SEC. VIIIDIV.1 Cryogenic Storage Tanks (Double Wall)

For workmanship of Vessels not categorized

under any other code.

29
CASE 1: MATERIALS OF CONSTRUCTION

YP (Min)
UTS (Min)
Description Material Type of Steel N/mm2
N/mm2

SA 515 GR 267.6
Shell Liner Austenitic 492.9
70

-
Shell Layers SA 212 GR B Carbon Steel 490.0

SA 515 GR 267.6
Dished Ends Austenitic 492.9
70

30
MATERIAL PROPERTY SUMMERY

Material Tensile Tensile Density(g/cm3)

strength(Mpa) Modulus(Mpa)

Aluminum(6061 t6) 310 69 2.71

Steel(SAE4340) 1034 200 7.83

Boron Fiber 3516 300 2.57

Carbon Fiber(p-55) 1724 379 1.99

Gr 33 150 gsm/BT 250 1965 13100 1.55

31
3.1 MATERIAL SELECTION FOR PRESSURE VESSEL

CONSTRUCTION

Materials are generally selected by the user for whole of the plant and

specifically, by pressure vessel designer/ supplier according to the following

criteria.

 Corrosive or noncorrosive service

 Contents and its special chemical/physical effects

 Design condition (temperature)

 Design life and fatigue affected events during the plant life

 Referenced codes and standards

 Low temperature service

 Wear and abrasion resistance

 Welding and other fabrication processes

32
3.2 GENERAL MATERIAL SELECTION PROCESS

The objective is to select the material which will most economically

fulfill the process requirements. The best source of data is well-documented

experience in an identical process unit. In the absence of such data, other

data sources such as experience in pilot units, corrosion coupon tests in pilot

or bench-scale units, laboratory corrosion-coupon tests in actual process

fluids, or corrosion- coupon tests in synthetic solutions must be used.

Permissible corrosion rates are an important factor and differ with

equipment. Appreciable corrosion can be permitted for tanks and lines if

anticipated and allowed for in design thickness, but essentially no corrosion

can be permitted in fine-mesh wire screens, orifices, and other items in

which small changes in dimensions are critical.

In many instances use of nonmetallic materials will prove to be attractive

from an economic and performance standpoint. These should be considered

when their strength, temperature, and design limitations are satisfactory.

In the selection of materials of construction for a particular fluid system, it is

important first to take into consideration the characteristics of the system,

giving special attention to all factors that may influence corrosion. Since

33
these factors would be peculiar to a particular system, it is impractical to

attempt to offer a set of hard and fast rules that would cover all situations.

The materials from which the system is to be fabricated are the second

important consideration; there

3.3 MATERIALS USED FOR PRESSURE VESSELS

Most of pressure vessels used in the petrochemical equipment is made of

steel. The manufacturing materials are varied, and the commonly used

materials are as follows.

1. Q235-A

With more silicon content and complete deoxidization, Q235-A has

better quality. The limited range of application: the design pressure is less

than or equal to 1.0MPa, the design temperature is between 0 and 350℃,

and the thickness of steel plate cannot be more than 16mm when Q235-A

is used to manufacture the shell. Q235-A cannot be used to manufacture

the pressure vessel which is filled with liquefied petroleum gas and the

medium with its extreme toxicity degree and high harm, and is heated

directly by flame.

34
2. 20g

20g boiler steel plate is the same as the common 20 high-quality

steel. Compared with Q235-A, 20g boiler steel plate has lower sulfur

content and higher strength, and the range of its service temperature is

from -20 to 475℃. Therefore, 20g is often used to manufacture the

medium pressure vessels with higher temperature.

3. 16MnR

16MnR common low alloy vessel steel plate is used to manufacture

medium, low pressure vessels, which can reduce the weight of the vessel

with higher temperature. Besides, the range of its service temperature is

from -20 to 475℃.

35
4. THE MATERIAL FOR LOW TEMPERATURE VESSELS (LESS

THAN -20℃)

This kind of material is mainly required to have better toughness to

prevent the brittle rupture at low temperature. Generally the steel for low

temperature vessel mostly adopts manganese vanadium steel.

3.4 STEEL FOR HIGH TEMPERATURE VESSELS

When the temperature is less than 400℃, the common carbon steel

can be adopted; when the service temperature is between 400 to 500℃,

15MnVR and 14MnMoVg can be adopted; when the service temperature

is between 500 to 600℃, 15CrMo and 12Cr2Mol are adopted; when the

service temperature is from 600 to 700℃, such high alloy steels as

0Cr13Ni9 and 1Cr18ni9Ti should be adopted.

36
CHAPTER 4

DESIGN OF MULTILAYER HIGH PRESSURE VESSEL

Multi layer vessels are built up by wrapping a series of sheets over a

core tube. The construction involves the use of several layers of material,

usually for the purpose of quality control and optimum properties. Multi

layer construction is used for higher pressures. It provides inbuilt safety,

utilizes material economically, no stress relief is required. For corrosive

applications the inner liner is made of special material and is not considered

for strength criteria. The outer load bearing shells can be made of high

tensile low carbon alloys.

37
4.1 DESIGN OBJECTIVES

1. To show that multilayer pressure vessels are suitable for high

operating pressures than solid wall pressure vessels.

2. To show a significant saving in weight of material may be made by

use of a multilayer vessel in place of a solid wall vessel.

3. To show there may be a uniform stress distribution over the entire

shell, which is the indication for most effective use of the material in

the shell.

4. To check the suitability of using different materials for Liner shell

and remaining layers for reducing the cost of the construction of the

vessel.

5. To verify the theoretical stress distribution caused by internal pressure

at outside surface of the shell and to ascertain that the stresses do not

reach yield point value during testing.

6. Finally check the design parameters with FEM analysis by using

ANSYS package to ascertain that FEM analysis is suitable for

multilayer pressure vessel’s analysis.

38
4.2 DESIGN CONSIDERATIONS

1. A multilayer Vessel is designed to ASME Code Section VIII division

I.

2. A Safety Factor of “3” on Ultimate Tensile Strength is considered in

the design of the multi layer shell only. For other parts the Factor of

Safety is taken as “4” at room temperature.

3. A joint efficiency of 100% for longitudinal seam on liner shell is

taken.

4. 100% radiography for longitudinal seam of liner shell.

5. Fully ultrasonic test for dished end plates is considered.

6. Dished ends to be stress relieved after attachment of boss, nozzle etc.,

7. The longitudinal welds in a multilayered shell were staggered.

8. The number segments (longitudinal welds) in a layer are taken as “3”.

9. The coefficient of weld shrinkage is taken as 10%.(From Davis R.L,

“Circumferential welds in Multilayer Pressure Vessel” Paper .70-

WA/PVP-6.)

10. The thickness of the liner shell is taken as 12 mm.

11. The thickness of subsequent layers is 6 mm.

39
4.3 DESIGN DATA OF THE VESSEL:

Design Pressure P - 21 N/mm2, Hydrogen.

Design Temperature, T - 200C

Hydrostatic Pressure PH - 27.3 N/mm2

Drawing of Multilayer Pressure Vessel

40
4.4 DESIGN CRITERIA

4.4.1 MINIMUM SHELL/HEAD THICKNESS

Minimum thickness shall be as given below

a) For carbon and low alloy steel vessels- 6mm (Including corrosion

allowance not exceeding 3.0mm), but not less than that calculated as per

following:

FOR DIAMETERS LESS THAN 2400mm

Wall thickness = Dia/1000 +1.5 + Corrosion Allowance

FOR DIAMETERS 2400mm AND ABOVE

Wall thickness = Dia/1000 +2.5 + Corrosion Allowance

All dimensions are in mm.

b) For stainless steel vessel and high alloy vessels -3 mm, but not less than

that calculated as per following for diameter more than 1500mm.

Wall thickness (mm) = Dia/1000 + 2.5

Corrosion Allowance, if any shall be added to minimum thickness.

41
c) Tangent to Tangent height (H) to Diameter (D) ratio (H/D) greater than 5

shall be considered as column and designed accordingly.

d) For carbon and low alloy steel columns / towers -8mm (including

corrosion allowance not exceeding 3.0mm.

e) For stainless steel and high alloy columns / towers -5mm.

Corrosion allowance, if any, shall be added to minimum thickness.

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CHAPTER: 5

FACTORS CONSIDERED FOR DESIGNING PRESSURE VESSEL

5.1 VESSEL SIZING

 All Columns based on inside diameter

 All Clad/Lined Vessels Based on inside diameter

 Vessels (Thickness>50mm) Based on inside diameter

 All Other Vessels based on outside diameter

 Tanks & Spheres based on inside diameter

5.2 VESSEL END CLOSURES:

1. Unless otherwise specified Deep Torispherical Dished End or 2:1

Ellipsoidal Dished

2. End as per IS - 4049 shall be used for pressure vessels. Seamless

dished end shall be used for specific services whenever specified by

process licensor.

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3. Hemispherical Ends shall be considered when the thickness of shell

exceeds 70mm.

4. Flat Covers may be used for atmospheric vessels

5. Pipe Caps may be used for vessels diameter < 600mm having no

internals.

6. Flanged Covers shall be used for Vessels /Columns of Diameter <

900mm having Internals.

7. All columns below 900mm shall be provided with intermediate body

flanges. Numbers of Intermediate flanges shall be decided based on

column height and type of internals

5.3 PRESSURE

Pressure for each vessel shall be specified in the following manner:

5.3.1 OPERATING PRESSURE

Maximum pressure likely to occur any time during the lifetime of the

vessel

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5.3.2 DESIGN PRESSURE

When operating pressure is up to 70 Kg./cm2 g , Design pressure

shall be equal to operating pressure plus 10% ( minimum 1Kg./cm2 g ).r

all the three cases, Allowable Stress values: Shell Liner & Layers ; 164

N/mm2 Dished Ends : 123 N/mm2

5.3.3 TEST PRESSURE

a) Pressure Vessels shall be hydrostatically tested in the fabricators shop to

1.5 /1.3/ 1.25 (depending on design code) times the design pressure corrected

for temperature.

b) In addition, all vertical vessels / columns shall be designed so as to permit

site testing of the vessel at a pressure of 1.5/ 1.3 / 1.25 (depending on design

code) times the design pressure measured at the top with the vessel in the

45
vertical position and completely filled with water. The design shall be based

on fully corroded condition.

c) Vessels open to atmosphere shall be tested by filling with water to the top.

d) 1.Pressure Chambers of combination units that have been designed to

operate independently shall be hydrostatically tested to code test pressure as

separate vessels i.e. each chamber shall be tested without pressure in the

adjacent chamber.

2. When pressure chambers of combination units have their common

elements designed for maximum differential pressure the common elements

shall be subjected to 1.5/ 1.3 times the differential pressure.

3. Coils shall be tested separately to code test pressure.

e) Unless otherwise specified in applicable design code allowable stress

during hydro testing tension shall not exceed 90% of yield point.

f) Storage tanks shall be tested as per applicable code and specifications.

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5.3.4 CORROSION ALLOWANCE:

Unless otherwise specified by Process Licensor, minimum corrosion

allowance shall be considered as follows:

- Carbon Steel, low alloy steel column, Vessels, Spheres : 1.5 mm

- Clad / Lined vessel: Nil

- Storage Tank, shell and bottom: 1.5 mm

- Storage tank, fixed roof / Floating Roof: Nil

For alloy lined or clad vessels, no corrosion allowance is required on the

base metal. The cladding or lining material (in no case less than 1.5 mm

thickness) shall be considered for corrosion allowance.

Cladding or lining thickness shall not be included in strength calculations.

Corrosion allowance for flange faces of Girth / Body flanges shall be

considered equal to that specified for vessel.

47
5.5.5 CALCULATION

Dynamic analysis of each column shall be carried out for stability

under transverse wind induced vibrations as per standard design practice.

The recommended magnification amplitude shall be limited to tower

diameter divided by five.

5.6 DESIGN PROCEDURE AND CALUCULATION:

5.6.1 CIRCUMFERENTIAL OR HOOP STRESS:

Tensile stress acting in a direction tangential to the circumference is

called Circumferential or Hoop Stress.

In other words, it is on longitudinal section (or on the cylinder walls).

Let,

p = Intensity of internal pressure,

d = diameter of the cylinder shell

l = length of cylinder,

t = Thickness of the shell, and

σ t1= hoop stress for the material of the cylinder.

Now, we know that

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Total force on a longitudinal section of the shell = Intensity of pressure

× projected Area

= px d × l ………….….. (1)

and the total resisting force acting on the cylinder walls=σ t1× 2t ×

l...…(2)

From equation (1) and (2), we have

σ× 2t × l = p × d × l or

σ t1x2txl= p d l (or) σ t1 =pd/2t

5.6.2 LONGITUDINAL STRESS:

Tensile stress acting in a direction of the axis is called longitudinal stress. In

other words, it is tensile stress acting on the transverse or circumferential

section.

Let

σ t2= Longitudinal stress.

In this case,

total force acting on the transverse section= Intensity of pressure × Cross-

sectional Area

= p ×4π (d) ² ………(i) and

Total resisting force = σ t2×d.t ……ii

49
From equation (i) and (ii), we have

σ t2×πd.t = p ×4 π (d) ²

σ t2x4txl= p d l (or) σ t2 =pd/4t

5.7.1 DESIGN OF SHELL DUE TO INTERNAL PRESSURE:

As discussed in article on thin vessel are cylindrical pressure vessel is

subjected to tangential (σ t) and longitudinal (σ l) stresses.

σ t=Pi x Di/2t σ l=Pi xDi /4t

Where

D= mean diameter

D=Di + t

5.7.2 RULE:

The design pressure is taken as 5% to 10% more than internal pressure,

where as the test pressure is taken as 30% more than internal pressure.

Considering the joint efficiency,

The thickness of shell can be found by following procedure,

η ×σ =Pi×(Di+t)/2t

η ×σ x2t =Pi×(Di+t)

50
5.7.3 DESIGN OF ELLIPTICAL HEAD:

Elliptical heads are suitable for cylinders subjected to pressures over 1.5

MPa. The shallow forming reduces manufacturing cost. It’s thickness can be

calculated by the following equation:

t = pi di W/2σ J

Where,

di = Major axis of ellipse

W= Stress intensification factor

W= 1/6 (2+K2)

Where

k = Major Axis Diameter/Major Axis Diameter

51
5.8 DESIGN CALCULATION:

5.8.1 THICKNESS OF CYLINDER:

Given data

Internal pressure (P) = 0.588 MPa

Internal Diameter (Di) = 496mm

Corrosion Allowance (CA) = Nil.

Joint Efficiency for shell = 1.

t=(Pi xDi /2 xσ x η –Pi)x CA ( CA is NIL)

= 1.066

∴ t = 1.066mm

52
5.8.2 DESIGN OF MANHOLE:

GIVEN DATA:

Internal pressure (Pi) = 0.588 N/mm2

Internal diameter (Di) = 496 mm

Thickness (t) = 6 mm.

CA = NIL

Joint Efficiency (η) = 1

Internal diameter of nozzle (di) = 254.51 mm

d = d i + CA = 254.51 mm.

tr = require thickness = 1.066 mm.

tn = Actual thickness of nozzle = 9.27 mm.

trn = Required thickness as per calculation in mm.

A1= 0.588 x 254.51/ 2 137 x 1 0.588

tm=P i D i /2 σ η –Pi

ttm= 0.588 x254.51/ 2 137 x1 0.588

t m=1.66mm

53
5.8.3 DESIGN CALCULATION SUMMARY:

SHELL INTERNAL 496mm

DIAMETER

(DI)

THICKNESS 6mm

(T)

HEAD THICKNESS 6mm

(T)

HEIGHT (H) 173mm

THICKNESS 9.27mm

OF NOZZLE

(TN)

CYLINDER THICKNESS 1.6mm

54
ADVANTAGES

 Home application.

 Industrial application.

55
CONCLUSION

This project work has provided us an excellent opportunity and experience, to

use our limited knowledge. We gained a lot of practical knowledge regarding,

planning, purchasing, assembling and machining while doing this project work. We

feel that the project work is a good solution to bridge the gates between institution and

industries.

We are proud that we have completed the work with the limited time

successfully.

It is working with satisfactory conditions. We are able to understand the

difficulties in maintaining the tolerances and also quality. We have done to our ability

and skill making maximum use of available facilities.

In conclusion remarks of our project work, let us add a few more lines about our

impression project work.

By using more techniques, they can be modified and developed according to the

applications.

56
REFERENCES

1. Matthews, Clifford. Engineers’ Guide to Pressure Equipment. London:

Professional Engineering Publishing, 2001.

2. Chattopadhyay, Somnath. Pressure Vessel Design and Practice. s.l. : CRC

Press, 2005.

3. Carruci, Vincent A. Overview of Pressure Vessel Design. s.l. : ASME

International, 1999.

4. ASME, the American Society of Mechanical Engineers. Rules for

Construction of Pressure Vessels (Sec. VIII, Division 1). ASME Boiler and

Pressure Vessel Code. New York: ASME (The American Society of Mechanical

Engineers), 2007.

5. Ellenberger, J. Phillip, Chuse, Robert and Carson, Bryce E. Pressure

Vessels: The ASME Code Simplified. 8th Edition. s.l.: McGraw-Hill, 2004.

57
6. Bringas, John E. The Metals Black Book. Edmonton, Alberta: CASTI

Publishing Inc, 1995.

7. Moen, Richard A. Practical Guidebook Series™ ASME Section II 1997

Materials Index. Edmonton, Alberta: CASTI Publishing Inc., 1996.

8. Perry, R. H., and Chilton, C. H. Perry’s Chemical Engineer’s Handbook,

5th ed. New York: McGraw-Hill, 1973.

9. White, R. A. and Ehauke, E. F. Materials Selection for Refineries and

Associated Facilities. San Francisco, California:

10. Bednar, Henry H. Pressure Vessel Design Handbook. 2nd Edition. Malabar,

Florida: Krieger Publishing Company, 1986.

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