Chemical and petroleum Engineering Department

Chemical engineering design

Pressure vessel design

Submitted by:

Siraj Ibrahim Ahmed Al sharif

I.D:
3115204

supervised :
Dr. Mohammed Edali
1
 Fall (2019-2020)

Problem statement
It is required to design 30 m3 a storage tank to
store mixture ( i-Butane 30% , n-Butane 70%)
under 5.5 bar And 48.5 °C.

Information table:
Description Symbo Valu Uni
l e t
Volume V 30 m3
o
Temperature T 48.5 C

Pressure P 5.5 bar

iso-butane Xi-b 0.3 -

n-butane Xn-b 0.7 -

2
 Page
Chapters Contents
number

1.1. Introduction 7

1.2. Pressure vessel 7

Chapter
1.3. Classification of pressure vessels 8
one
1.4. Pressure vessel parts 9

1.5. Design of pressure vessel 10

2.1. Calculation of vessel dimensions 12

2.1.1. Calculation of vessel inside diameter 12

2.1.2. Calculation of vessel length 13

Chapter
2.1.3. Calculation of vessel thickness 13
two
2.1.4. Calculation of vessel outside diameter 15

2.1.5. Calculation of vessel mean diameter 15

2.1.6. Calculation of vessel weight 15

3.1. Physical properties of material 19

3.2. Physical properties of insulation 19

Chapter
three 3.3. Physical properties of air 20

3.4. Physical properties of mixture 20

4.1. Choice of closure and head thickness 22

4.1.1. For section Head thickness (Torispherical) 23

4.2. Thickness of Insulation 24

Chapter 4.2.1. Heat without Insulation 24

four
4.2.2. Heat with Insulation 30

3 4.3. Weight of loads

4.3.1. Weight of ladders

32

32

4.3.2. Weight of insulation 32

 4.3.3. Weight of head 33

4.3.4. Weight of vessel 34

4.3.5. Dead weight 34

4.3.6. Life weight 35

4.3.7. Total Weight 35

4.4. The calculation of wind 36

4.4.1. Wind of Loads 36

4.4.2. Bending Moment 37

4.5. Analysis of stress 37

4.5.1. Longitudinal stress 37

4.5.2. Circumferential stress 37

4.5.3. Dead weight stress 38

4.5.4. Bending stress 38

4.5.5. The Resultant of longitudinal stresses 39

4.5.6. The Maximum Operating stresses 39

4.5.7. Elastic Stability 40

4.6. Vessel Support (Skirt Support) 41

4.7. Shirt thickness 42

4.7.1. Bending Stress in the Skirt 42

4.7.2. Dead Weight Stress in the Skirt 43

4.7.3. The Resultant Stress on the Skirt 44

4.8. The Optimum Pipes Diameter and Flange
46
Design for Carbon steel
5.1. Storage Tank Cost Estimation 49
Chapter
5.2. Insulation Cost Estimation 50
five
5.3. Total Cost Estimation 50

4  
References 52
 Page
Chapters List of figures numbe
r

Figure 1.1. Pressure vessels classes 8

Figure 1.2. Pressure vessels classifications according to the 9

Chapter
one Figure 1.3. Vertical pressure vessel 9

Figure 1.4. Horizontal pressure vessel 10

Figure 4.1. Domed heads (a) Hemispherical (b) Ellipsoidal (c)
Torispherical 22

Figure 4.2. Horizontal cylindrical vessel on saddle supports 41

Figure 4.3. Typical skirt-support designs. (a) Straight skirt. (b)
Chapter 41
Conical skirt.
four
Figure 4.4. Bracket supports. (a) Supported on legs. (b) Supported
42
from steelwork
Figure 4.5. Flange types. (a) Welding-neck. (b) Slip-on. (c) Lap- joint.
46
(d) Screwed
Figure 4.6. Typical standard flange design (All dimensions mm). 47
Chapter
Figure 5.1. Horizontal pressure vessels. Time base mid-2004 (10) 49
five

Page
Chapters List of tables
number

Table 2.1. Typical design stresses for plate 14

Table 2.2. Maximum allowable joint efficiency 14

Chapter
two
Table 2.3. Calculation of vessel dimensions 16

Table 2.4.Minimum thickness of vessel 17

Table.3.1. Physical properties of carbon steel at T=30oC 19

Table.3.2. Physical properties of glass wool fibers 19

Chapter
three Table.3.3. Physical properties of air 20

Table.3.4. Physical proprieties of mixture at T=53.35oC 20

5 Chapter
five
Table 5.1. Inventory Index Factors for 2019. Index Code:
A , Average For All
51
 Chapter one:
Introduction

6
1.1. Introduction
Chemical engineering involves the application of sciences to the process
industries, which are primarily concerned, with the conversion of one material
into another by chemical or physical means. These processes require the
handling or storing of large quantities of materials in containers of varied
constructions, depending upon the existing state of the material, it's physical and
chemical properties and the required operations, which are to be performed. For
handling such liquids and gases, a container or vessel is used. It is called a
pressure vessel, when they are containers for fluids subjected to pressure. They
are leak proof containers. They may be of any shape ranging from types of
processing equipment. Most process equipment units may be considered as
vessels with various modifications necessary to enable the units to perform
certain required functions, e.g. an autoclave may be considered as high pressure
vessel equipped with agitation and heating sources.

1.2. Pressure vessel

A pressure vessel is considered as any closed vessel that is capable of storing a
pressurized fluid, either internal or external pressure, regardless of their shape
and dimensions

A pressure vessel is a device which has a pressure difference inside it by

atmospheric pressure. As high operating pressures are a danger, utmost care
should be taken while designing the pressure vessels. Any mechanical structure
fails if there are stresses induced in them. The pressure vessel life under cyclic
load is related to the number of cycles it is exposed to and to the intensity of the
stress . The pressure vessel is assumed to be a thin cylinder, and therefore the
analysis follows the thin cylinder formulae. The modeling was done on a modeling
software pro-e, and a finite element analysis was carried out to highlight the
various points of stress concentration. As anticipated the highest stress value
occurs at the junction of the nozzle attachment, to analyze the aspects of stress

7
concentration which may develop when the end closure of a high-pressure vessel
is attached to a conically shaped nozzle. The main reason for this occurrence is
that the conical nozzle must be connected separately. This process would result
in geometrical discontinuities between the pressure vessel and the nozzle at the
point of attachment . The solution for the value of stress at the connection of
cylindrical nozzle to an ellipsoidal shape pressure vessel. The stress calculations
were carried out using finite element method, and a parametric model was
developed . Tests were carried out for various positions of the cylindrical nozzle
on the pressure vessel along with multiple orientations of the connection instead
of a central radial hole . The tests carried out confirmed that the actual stress
value of the maximum allowable internal pressure is different for various
orientations of the attachment and states that further investigation is necessary
to determine the most efficient connection.

1.3. Classification of pressure vessels

Pressure vessels can be classified according to their intended service,
temperature and pressure, materials and geometry. Different types of pressure
vessels can be classified as follows:

Figure 1.1:Pressure vessels classes

According to the intended use of the pressure vessel, they can be divided into

8
storage containers and process vessels.

The first classes are only used for storing fluids under pressure, and in
accordance with the service are known as storage tanks. Process pressure vessels
have multiple and varied uses, among them we can mention heat exchangers,
reactors, fractionating towers, distillation towers, etc.

According to the shape, pressure vessel may be cylindrical or spherical. The

former may be horizontal or vertical, and in some cases may have coils to
increase or lower the temperature of the fluid.

Figure 1.2:Pressure vessels classifications according to the

shape

1.4. Pressure vessel parts

The following two sample vessels are presented: vertical and horizontal. In both
cases the main parts are shown

9
 Figure 1.3: Vertical pressure vessel

Figure 1.4: Horizontal pressure vessel

1.5. Design of vessel

The first step in designing a container is choosing the best type for the service for
which it is intended. The factors influencing the choice of type are the function of
10
the container, the location, the nature of the fluid that has to be stored, the
temperature and operating pressure and their ability to store the volume needed
by the process.
 Chapter two:
Chemical design

11
2.1. Calculation of vessel dimensions:-

2.1.1. Calculation of vessel inside diameter, Di

4∗V D
D i= 3

√ L
D
∗π
… … … … … … … … … … … … … … … … …(Eq .2 .1)

Where :

T : Temperature operating = 48.5 °C

P : Pressure operating = 5.5 bar ( 0.48 N/mm2 )

V : Volume operating = 30 m3

Di: inside diameter, m

D: Vessel diameter, m

L: Length of vessel, m

VD : Volume design, m3 = 1.1 * V

TD : Temperature design, °C = 1.1 * T

PD : Pressure design, N/mm2 = 1.1 * P

L/D = (2.5 – 5)

12
By substitution :

TD = 1.1 * 48.5 = 53.35 °C

 PD = 1.1 * 0.55 = 0.605 N/mm2

VD = 1.1 * 30 = 33 m3 or 8718.6 gal

The vessel will be horizontal (because : volume design, VD > 5000 gal)

For First L/D =2.5

4∗33
√
D i= 3
( 2.5 )∗(π)
= 2.5615 m or 2561.5 mm

2.1.2. Calculation of vessel long, L

L
L= ∗D i … … … … … … … … … … … … … … … … … … … … … … … ( Eq.2 .2)
D

By substitution :

L= 2.5*2.5615 = 6.4038 m or 6403.8 mm

2.1.3. Calculation of vessel thickness, tv

P D∗Di
t v= +C … … … … … … … … … … … … … … …(Eq .2 .3)
2∗J∗f −PD

Where :

13
f: Design stress, N/mm², from table 2.1

J: Welding joint efficiency from table 2.2 = 0.85

C: corrosion allowance = 2 mm

Table 2.1. Typical design stresses for plate

Table 2.2. Maximum allowable joint efficiency

By substitution :

P D=0.605 N /mm 2.
14 J=0.85

f =125 N /mm2 for carbon steel at TD = 53.35°C

 C= 2 mm

Di= 2561.9 mm

0.605∗2561.5
t v= +2=9.313568 mm
2∗125∗0.85−0.605

2.1.4. Calculation of vessel outside diameter, Do

D o =D i+ 2∗( t v ∗10−3 ) … … … … … … … … … … … … … … ( Eq .2 .3 )

By substitution :

Do = 2.5615+2 ( 9.313568∗10−3 ) = 2.58013 m or 2580.13 mm

2.1.5. Calculation of vessel mean diameter, Dm

Di + Do
Dm = … … … … … … … … … … … … … … … … … … … … … . ( Eq: 2.1.5 )
2

By substitution :

Dm = (2.5615+2.58013) /2 = 2.570815m or 2570.815mm

2.1.6. Calculation of vessel weight, Wv

W v =C w∗π∗ρ m ¿ D m∗g∗( H v +0.8∗D m )∗t v∗10−3)……….…( Eq :2.1.6 )

15
Where :

Hv = Di : For horizontal vessel, m

Wv: Total weight of the vessel, N

Cw: Factor to account for the nozzles = 1.08

ρm: Density of carbon steel= 7833 kg/m³

By substitution :

W v =1.08∗π∗7833∗2.570815∗9.81∗( 2.5615+0.8∗2.570815 )∗9.313568 *10-3

W v =¿11213. 9N

Table 2.3. Calculation of vessel dimensions

L/Di Di L tv Do Dm Wv
- m m mm m m N
2.5 2.5615 6.4038 9.313568762 2.58013 2.570815 11213.9
3 2.4105 7.2314 8.882331705 2.42823 2.419348 10064.3
3.5 2.2897 8.0141 8.53762497 2.30681 2.298273 9189.35
4 2.1901 8.7602 8.253013334 2.20656 2.198306 8496.45
4.5 2.1057 9.4758 8.012270529 2.12176 2.113748 7931.16
5 2.0331 10.165 7.804783373 2.04867 2.04087 7459.26

From the table , the less wight when the ratio L/D = 5

Then:

Diameter of vessel is 2.03306541 m

16
Length of vessel is 10.165327 m

Weight of vessel is 7459.26 N

 Table 2.4.Minimum thickness of vessel

The minimum thickness from calculations is less than the minimum thickness
from table, so that is acceptable

17
 Chapter three:
Physical properties

18
3.1. Physical properties of material :
The material that is used is a carbon steel, the physical properties of carbon steel are shown
that in table 3.1.

Table.3.1. physical properties of carbon steel at T=30oC

Property Unit Value

Density kg/m3 7833

Heat capacity kJ/kg . K 0.465

Thermal conductivity W/m . K 54
Thermal diffusivity m2/sec 1.474*10-5

3.2. Physical properties of insulation :

The insulation that is used is a glass wool fibers, the physical properties of glass wool fiber are
shown that in table 3.2.

Table.3.2. physical properties of glass wool fibers

Property Unit Value

Density kg/m3 24

Thermal conductivity W/m . K 0.038

19
3.3. Physical properties of air:-
Physical properties of air taken at Tfilm= 36°C (309K) . By interpolation between
temperature (300 K and 350 K). this properties shown in table 3.3.

Table.3.3. physical properties of air

Property Unit Value

Density kg/m3 1.14351

Heat capacity J/kg . oC 1014.67

Viscosity kg/m . s 1.9E-05

Kinetic viscosity m2/s 1.7E-05

Thermal conductivity W/m . oC 0.02747

Thermal diffusivity m2/s 2.4E-05

Prandtl   0.69652

3.4. Physical properties of Mixture:-

The mixture is consists of n-butane and i-butane, the physical properties of this mixture are
taken at design temperature (TD), and shown in table 3.4.

Table.3.4. physical proprieties of mixture at T=53.35 oC

Property Unit Value

Density kg/m3 530.137

Viscosity kg/m . s 0.00013

Thermal conductivity W/m . K 0.09243
Heat capacity J/kgmol . K 2638.15
Kinetic viscosity m2/s 2.4E-07

Thermal diffusivity m2/s 6.6E-08

20 Prandtl 3.67856
 Chapter four:
Mechanical design

21
4.1. Choice of closure and head thickness
Flat plates are used as covers for manways, and as the channel covers of heat
exchangers. Formed flat ends, known as “flange-only” ends, are manufactured by
turning over a flange with a small radius on a flat plate, Figure 4.1.a. The corner
radius reduces the abrupt

Figure .4.1. Domed heads (a) Hemispherical (b) Ellipsoidal (c) Torispherical

change of shape, at the junction with the cylindrical section; which reduces the
local stresses to some extent: “Flange-only” heads are the cheapest type of formed
head to manufacture, but their use is limited to low-pressure and small-diameter
vessels. Standard torispherical heads (dished ends) are the most commonly used
end closure for vessels up to operating pressures of 15 bar. They can be used for
higher pressures, but above 10 bar their cost should be compared with that of an
equivalent ellipsoidal head. Above 15 bar an ellipsoidal head will usually prove to
be the most economical closure to use. A hemispherical head is the strongest

22
shape; capable of resisting about twice the pressure of a torispherical head of the
same thickness. The cost of forming a hemispherical head will, however, be
higher than that for a shallow torispherical head. Hemispherical heads are used
for high pressures.
4.1.1. For section Head thickness (Torispherical) :
Because the Design pressure is less then 15 bar. The thickness of the upper and
lower head is given :

PD∗Rc∗103∗Cs
t h= +C …………………………………………(Eq.4.1)
2∗f∗J + PD (Cs−0.2)

Where:

Cs: stress concentration factor for torispherical

1 R
4 √
C s= * (3+ 2 c )………………………………………...(Eq.4.2)
Rk

Rc :Crow radius=D i , m.

Rk : Knuckle radius=0.06∗Rc ,m .

By substitution:

Rc = 2.0330654 m

Rk = 0.06 * 2.0330654 = 0.121983925 m

23 1
C s= * (3+ 2 2.0330654 )
4 √0.121983925

Cs = 1.770621
 0.605∗2.0330654∗103∗1.770621
t h= +2
2∗0.85∗125+0.605∗( 1.770621−0.2 )

th = 12.20318 mm

4.2. Thickness of Insulation :

4.2.1. Heat without Insulation .

We use (glass wool) for the following reasons:

. Low cost.

. Low density.

. Low thermal conductivity.

In general the heat flow is given by:

∆T
q= …………………………………(Eq.4.3)
∑R

Where:

q: Amount of heat transfer, W.

∑ R :Total resistance of heat transfer, K/W.

∆ T : Temperatuer difference between the fluid and surrounding, K.

The total thermal resistance is:

∑ R=Rm + R¿ + Rf + ¿ R a ¿………………………..(Eq.4.4)
24
Where:

Rm : Thermal resistance of the vessel material, K/W.

R f : Thermal resistance of the fluid ( mixture), K/W.

Ri : Thermal resistance of the insulation, K/W.

Ra : Thermal resistance of the air, K/W.

T f −T w
q without Insulation=
r2
ln ⁡( ) ……………………………..
1 r1
+
hiAi 2 π∗km∗L
(Eq.4.5)

Where:

Tf: Temperature of the mixture ( temperature design) = 53.35°C

Tw: Temperature of wall = 41.7°C

km: Thermal conductivity of the carbon steel from table 3.1.

hi: Heat transfer coefficient of mixture, W/m2 . K

ho: Heat transfer coefficient of air, W/m2 . K

Calculate of h0 heat transfer coefficient of Air :

Assume:-

T max : above stage temperature 55°C .

T min: below stage temperature 5°C .

25 T max +T min 55+5
T air = = =30°C
2 2
 T D−T air
boundary layer= … … … … … … … … … … … … … … ..( Eq .4 .6)
2

53.35−30
boundary layer ¿ = 11.7 °C
2

T w =T D + Boundary layer …………………………………………( Eq .4 .7)

T w =53.35+11.7=41.7 ° C

T w + T air
T film= ………………………………………………(Eq.4.8)
2

41.7+30
T film ¿ = 36°C or 309 K at properties of air from table.3.3.
2

Nu∗k a
h0 = … … … … … … … … … … … … … … … … … … … … … … … … … … .(Eq .4 .9)
l

1 1
0.62 R e 2 p r 3 pr > 0.2 ………( Eq .4 .10)
Nu=0.3+

26
¿¿

V Do
ℜ= ……………………………………………….(Eq.4.11)
v
 (Table:6-8: J.P. Holman)

Where:

k a :is the thermal conductivity of the Air from table 3.3.

l :effctive of length =Do of horizontal vessel=2.048674976 m.

Re: Reynold’s number.

Pr: Prandtl’s number from table 3.3.

v : kinematic viscosity of air from table 3.3.

V : Velocity of air = 37 km/h = 10.2778 m/sec (assumed).

By substitution :

10.2778∗2.048674976
ℜ= −5
=1.276927∗106 Ra<10 7
1.6603∗10

1 1
0.62 ( 1.276927∗106 ) 2 0.6965183 3
Nu=0.3+ ¿¿

Nu=1507.712882

1507.712882∗0.0274687 W
h0 =
27 2.048674976
=20.2155 2
m .K
Calculate of hi heat transfer coefficient of mixture :

Nu∗k
hi = … … … … … … … … … … … … … … … … … … … …(Eq .4 .12)
Di

Nu=c Ram … … … … … … … … … … … … … … … … … … … …. ( Eq .4 .13 )

Ra=Gr∗Pr … … … … … … … … … … … … … … … … … … … … … … ( Eq.4 .14 )

g∗β∗( T D−T W )∗Di3

Gr= … … … … … … … … … … … … … … … …( Eq .4 .15)
ν2

1
β= … … … … … … … … … … … … … … … … … … … … …(Eq .4 .16)
T film

T w+ T D
T film= … … … … … … … … … … … … … … … … … … … .( Eq .4 .17)
2

Where: Nu: Nusselt number

k: Thermal conductivity of the mixture from table 3.4.

Di: Diameter of vessel = 2.0330654 m

Gr: Grashof number

Pr: Prandtl number, from table 3.4.

Ra: Rayleigh number

c, m: Constants, which is depended on Ra from

g: Acceleration of gravity = 9.81 m/s²

28
β: Thermal expansion coefficient for mixture

Tfilm: Temperature of film for mixture

TW: Temperature of wall = 41.7 °C

TD: Temperature design = 53.35 °C

v : kinematic viscosity of the mixture from table 3.4.

By substitution :

( 41.7+273.15)+(53.35+273.15)
T flim= =320.6625 K
2

1
β= =¿0.003118544 K-1
320.6625

9.81∗0.003118544∗( 53.25−41.7 )∗2.033065413

Gr= 2
( 2.43103∗10−7 )

Gr=¿ 5.079*1013

Ra=Gr * Pr = 1.868*1014

c=0.13 ,m=0.33 For 109 < Ra

(Table:7-5: J.P. Holman)

29 Nu=0.13 ( 1.868∗1014 )
0.33
 Nu =7431.676

7431.676∗0.092427172
hi =
2.0330654

W
hi=337.8587
m2 . K

D o 2.048675
r2 = = =1.02434 m , Ao =
2 2
π*Do*l

Ao = 3.14*2.048675*10.16533 =65.3919 m2

Di 2.0330654
r1 = = =1.01653 m , Ai = π *Di*l
2 2

Ai = 3.14*2.0330654*10.16533 = 64.9266 m2

T f −T w
q without Insulation=
r2
ln ⁡( )
1 r1
+
h i Ai 2 π∗k m∗L

30
By substitution :

35.35−41.7
q with out Insu .=
1.02434
ln ⁡( )
1 1.01653
+
337.8587∗64.9266 2 π∗54∗10.16532705

q with out Insu .=¿ 244222.7 W

4.2.2. Heat with Insulation :

T f −T air
q with Insu .= … … … … … … … … … … … .(Eq .4 .18)
r2 r3
ln ⁡( ) ln ⁡( )
1 r1 r2 1
+ + +
hi A i 2 π∗k m∗L 2 π∗k ¿∗L ho A o

Where:

Tf: Temperature of the mixture ( temperature design)= 53.35°C

Tair: Temperature of air = 30°C

kin: Thermal conductivity of the insulation from table 3.2.

By substitution :

31
The maximum heat loss should be not exceed 10% then :
 q with Insu .=qwith out Insu .∗0.1

q with Insu .=¿ 244222.7*0.1

q with Insu .=¿ 24422.27 W

53.35−30
24422.27=
1.02434 r
ln ⁡(
) ln ⁡( 3 )
1 1.01653 r2 1
+ + +
337.8587∗64.9266 2 π∗54∗10.16533 2 π∗0.038∗10.16533 20.2155∗2 π∗r 3∗10

By solved

r3 = 1.02472 m

Thickness insulation = r3 – r2

Thickness insulation = 1.02472 - 1.02434

Thickness insulation = 0.00038 m or 0.38 mm

32
4.3. Weight of loads :
4.3.1. Weight of ladders (Wl):

W l =150∗L … … … … … … … … … … … … … … … … (Eq.4 .19)

L=( 0.25∗contour ) + H … … … … … … … … … … …(Eq .4 .20)

contour=2∗3.14∗ ( Do2 ) … … … … … … … … … … .( Eq .4 .21)

H=Hight support of vessel=1.28 m

¿ ( Figure :13.26 Vol .6 Chemical Engineering Design 4 th Edition )

By substitution :

contour=2∗3.14∗ ( 2.048675
2 )=6.4361m
L=( 0.25∗6.4361 ) +1.28=2.88903m

W l =150∗2.88903=433.354 N

4.3.2. Weight of insulation (Win):

W ins =V ins ρins g … … … … … … … … … … … … … … … … … … … …(Eq . 4.22)

Where:

33
V ins : surface area of insulation of length m³

ρins : density of insulation from table 3.2.

By substitution :

V ins = π (r32 – r22)L

= π (1.024722 − 1.024342) * 10.16533

= 0.02481 m3

Wins = (0.02481*24*9.81) =5.84163 N

4.3.3. Weight of head ( WH ) :

W H =ρm ¿ ………………………………………..( Eq .4 .23)

Where:

ρm :density of metal (488.037 Ib/ft3) .

D0=¿ 80.612 in

t h : head thickness (0.2917 in ).

34
a=2

weight of upper∧lower =2∗W H

By substitution :

W H =488.037 ¿

W H = 1290.62 N

4.3.4. Weight of vessel ( Wv ) :

W v =W less = 7459.26 N¿ table 2.5

4.3.5. Dead weight ( WD ):

𝑊𝐷 = 𝑊𝑣 + 2 ∗ 𝑊𝐻 + 𝑊𝑙 + 𝑊𝑖𝑛 …………………. ( Eq .4 .24)

By substitution :

WD = 7459.26 + 2 *1290.62 + 433.354 + 5.84163

WD = 10479.7N

35
4.3.6. Life weight ( Wf ) :

W f = ρf ∗V f ∗g … … … … … … … … … … … … … … … … … … … … …(Eq .4 .25)

Where:

ρ f : density of mixture ( 530.16 kg/m3 ) .

π π
V f : ∗Di2∗l = ∗( 2.0334 )2∗10.1670=33 m3
4 4

By substitution :

W f =530.16∗33∗9.81=171621 N

4.3.7. Total Weight ( WT ) :

W T =W f +W D ……………………………………….. ( Eq .4 .26)

36
By substitution :

W T =171621+10479.7

W T =182101 N
4.4. The calculation of wind :

4.4.1. Wind of Loads :

F w =Pw∗D m …………………………………… ( Eq .4 .27)

Pw =0.05∗u w 2…………………………………...( Eq .4 .28 )

Where:

F w: Pressure loading per length (N/m).

Pw : Wind pressure (N/m²).

Dm: Mean diameter ( 2.04087 m )

m
uw :Velocity of wind (10.2778 )
sec

By substitution :

37 Pw =0.05∗10.27782= 5.28164 N/m2

F w =5.28164∗2.04087 = 10.7791 N/m

4.4.2. Bending Moment (Mx) :

F w∗X 2
M x= ………………………………………………( Eq .4 .29 )
2

Where:

X : Distance measured from the free end.(x=L= 10.1653 m)

By substitution :

10.7791∗10.1653 2
M x= = 556.925 N.m
2

4.5. Analysis of stress:

4.5.1. Longitudinal stress (σ h , N /mm2):-

P D Di
σ h= ……………………………………………… ( Eq .4 .30 )
2t v

By substitution :

0.605∗2.0330654
σ h= = 78.7981 N/mm2
2∗7.8047833/1000

38
4.5.2. Circumferential stress (σ l , N /mm2):-
P D∗Di
σl= …………………………………………
4tv
( Eq .4 .31 )
By substitution :

0.605∗2.0330654
σl= = 39.3991 N/mm2
4∗7.8047833/1000

4.5.3. Dead weight stress (σ w , N /mm2):-

W
σ w = ¿ ¿D …………………………………………………( Eq .4 .32 )

By substitution :

10479.7 0.20942 N /mm ²

σ w=
¿¿

4.5.4. Bending stress (σ b , N /mm2 ):-

M x Di
σ b=± ( +t ) ………………………………………………( Eq .4 .33 )
Iv 2 v

39 I v=
π
( D4 + Di4 )…………………………………………………( Eq .4 .34 )
64 0

Where:
I v :Second moment of area of the vessel about plant of bending.

By substitution :

π
I v= ( 2048.6754 +2033.0654 4 ) =1.7033*1012mm4
64

556.925∗1000 2033.0654
σ b=± ( +7.8047834)
1.7033∗1012 2

σ b=± 3.35∗10−4 N/mm2

4.5.5. The Resultant of longitudinal stresses (

σ z , N /mm2):-

σ z=σ l−σ w ± σ b ……………………………………………..( Eq .4 .35 )

By substitution :

At the up wind ( + σ b ) .

σ z=39.3991−0.20942+3.35∗10−4 =39.1893 N /mm ²

At the down wind (−σ b ) .

40
σ z=39.3991−0.20942−3,35∗10− 4=39.1893 N /mm ²
4.5.6. The Maximum Operating stresses (σ max , N /mm2):-
The greatest difference between the principle stresses will be down wind side so:

σ max=σ h−σ z ……………………………………………….( Eq .4 .36 )

By substitution :

σ max=78.7981−(39.189)=39.6088 N /mm ²

Check :

The ( σ max < f ) , (39.6088<125 ¿ .

The thickness of vessel is satisfactory where f is the stress.

4.5.7. Elastic Stability (σ c , N /mm2) :

2∗104∗t v
σ c= ………………………………………………………( Eq .4 .37 )

41 Do

For check must be ( σ b +σ w < σ c ) .

By substitution :

2∗104∗7.8047833 2
σ c= =76.1934759 N / mm
2048.675

Check :

( 3.35∗10−4 + 0.20942< 76193.4759 ) ,Then that isit acceptable . .

4.6. Vessel Support (Skirt Support) :

42
 Figure 4.2. Horizontal cylindrical vessel on saddle supports

Figure 4.3 : Typical skirt-support designs. (a) Straight skirt. (b) Conical skirt.

Figure
4.4:

43
Bracket
supports. (a) Supported on legs. (b) Supported from steelwork.
4.7. Shirt thickness :

4.7.1. Bending Stress in the Skirt (σbs) :

4∗Mxs
σ bs = … … … … … … … … … … … … … … … … … … … … ( Eq.4 .38 )
π∗(Ds+ts)∗ts∗Ds

Fw
Mxs= ∗( L+ Ls )2 … … … … … … … … … … … … … … … … … … … … … … … ( Eq .4 .39 )
2

Where :

Ls : Skirt Lenght (2.8873 m)

Assume: t s =t v (¿ 7.805mm)

Assume: D s=D i (¿ 2033.0654 mm)

By substitution :

44 M xs =
10.77913
∗( 10.1653270+ 2.8873 )2= 918.2262N.m or 918226.2 N.mm
2
 4∗918226.2
σ bs = =0.036102 N/mm2
π∗(2033.0654+ 7.805)∗7.805∗2033.0654

4.7.2. Dead Weight Stress in the Skirt (σws) :

WD
σ ws ( test )= … … … … … … … … … … … … … … … … … … ( Eq .4 .40 )
π∗( D s +t s )∗t s

By substitution :

10479.7059
σ ws (test )= =¿ 209422.3 N/m2
π∗(2.0330654+.007805)∗.007805

Wf
σ ws ( operation )= … … … … … … … … … … … … … … … … … ( Eq .4 .41 )
π∗( D s +t s )∗t s

By substitution :

45 σ ws (operation)=
171621.237
π∗(2.0330654+ 0.007805)∗0.007805
=¿ 3429611 N/m2
4.7.3. The Resultant Stress on the Skirt:

σ s ( tensile )=σ bs −σ ws ( operationg ) … … … … … … … … … … … … … … ( Eq.4 .42 )

For tensile must be 𝜎𝑠(𝑡𝑒𝑛𝑠𝑖𝑙𝑒) ≤ 𝐽 ∗ 𝑓 ∗ 𝑠𝑖𝑛𝜃

By substitution :

σ s ( tensile )=36102.08−3429611=¿-3393509 N/m2

𝐽 ∗ 𝑓 ∗ 𝑠𝑖𝑛𝜃 = 0.85 ∗ 125 ∗ 𝑠𝑖𝑛90 = 94.9871 𝑁/𝑚𝑚²

Check :

-3. 393509 < 94.9871 , Then that is it acceptable

𝜎𝑠(𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) = 𝜎𝑏𝑠 − 𝜎𝑤𝑠 (𝑡𝑒𝑠𝑡) …………………………………………….( Eq .4 .43 )

For Compressive must be :

𝜎𝑠 (𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) ≤ 0.125 ∗𝐸 ∗ (𝑡𝑠/ 𝐷𝑖) ∗ 𝑠𝑖𝑛𝜃

46
Where:

E : Young's Modulus of Elasticity for Carbon steel at 30°C

From the Young Modulus of Elasticity for Metals and Alloys from ( Engineering
ToolBox.com)=201956.4N/mm²

By substitution :

𝜎𝑠(𝐶𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑖𝑣𝑒) = 36102.08 – 209422.3 =-173320 𝑁/𝑚²

=0.125 ∗ 𝐸 ∗ (𝑡𝑠/ 𝐷𝑖) ∗ 𝑠𝑖𝑛𝜃

= 0.125 ∗ 201956.4∗ ( 7.805 /2033.0654 ) ∗ 𝑠𝑖𝑛90

= 96911.9 N/mm2

Check :

0.112961 < 96911.9, Then that is it acceptable.

4.8. The Optimum Pipes Diameter and Flange Design for

Carbon steel:-

𝑑𝑜𝑝𝑡 = 293 ∗ 𝐺0.53 ∗ 𝜌𝑚−0.37………………………………………..( Eq .4 .44 )

47
Where:
Assume : 𝐺 = 0.5 kg/sec
𝜌𝑚 : density of mixture from table 3.4 = 530.137 kg/m3
By substitution :

𝑑𝑜𝑝𝑡 = 293 ∗ 0.50.53 ∗ 530.137 −0.37 = 19.92 mm

Figure 4.5. Flange types. (a) Welding-neck. (b) Slip-on. (c) Lap- joint. (d) Screwed.

STEEL SLIP-ON BOSS FLANGE FOR WELDING

Nominal pressure 6 bar

48
 Figure 4.6 Typical standard flange design (All dimensions mm).

49
 Chapter five:
Cost estimation

50
5.1. Storage Tank Cost Estimation :-

51 Figure 5.1 Horizontal pressure vessels. Time base mid-2004

 lenght of vessel=10.16533 m

Diameter of vessel=2.0330654 m

Pressure Design=6.05 ¯¿
Presser factor=1.1 ¿( Figure 5.1)
Material factor for Carbon steel=1.0

Bare cost ¿( Figure 5.1)=22060.75 $

" Time based 2004 "

Purchase cost = (base cost from figure) * Material factor *Pressure factor……………( Eq .5.1 )

Purchase cost = 22060.75*1*1.1 =24266.83 $

" Time based 2004 "

5.2. Insulation Cost Estimation:-

Assume the cost of insulation is 10% of the cost vessel.

Cost of insulation= Cost of vessel * 0.1……………………………………………( Eq .5.2 )

Cost of insulation = 24266.83*0.1=2426.683 $

" Time based 2004 "

52
5.3. Total Cost Estimation:-
The total cost of design is the summation of vessel cost and insulation cost
 Total cost= cost of vessel +cost of insulation………………………………………………..

( Eq .5.3 )

Total cost = 24266.83+2426.683 =26693.51 $

" Time based 2004 "

IndexValue(2019)
Total cost (2019) = Total cost (2004) * ……………………………………………….
Index Value(2004)
( Eq .5.4 )

Table 5.1. Inventory Index Factors for 2019. Index Code: A , Average For All

53
Index Value ( 2019 ) =1716.2

Index Value ( 2004 )=1133.2

 1716.2
Total cost ( 2019 ) = 26693.51 *
1133.2

Total cost ( 2019 ) = 40426.58 $

54
References
1) “Design of pressure vessel project report” Submitted by MIJO JOSEPH.

2) “PRESSURE VESSELS, Part I: Pressure Vessel Design, Shell, Head, Nozzle

and Basic Flange” by Javier Tirenti , www.arvengconsulting.com.

3) Kirtikumar Tamboli1, ―Fatigue Analysis of Pressure Vessel by FEA

Techniques,” International Journal of Engineering Trends and Technology
(IJETT) – Volume 13 Number 1 – Jul 2014.

4) Pravin B.Sonawane1, P.G.Damle2, “Design And Analysis of Top Conical End

Closure Nozzle Junction And Pressure Vessel,” International Journal of
Engineering Sciences & ResearchTechnology, Value: 3.00, August 2016.

5) B.S.Thakkar1, S.A.Thakkar2, “Design of Pressure Vessel Using ASME Code,

Section VIII,Division 1”, International Journal of Advanced Engineering
Research and Studies, IJAERS/Vol. I/Issue II/January-March, 2012/228-
234.

6) Shyam R Gupta1, Ashish Desai2, “Optimize Nozzle Location for Minimization

of Stress In Pressure Vessel,” Innovative Research in Science & Technology|
Vol. 1, Issue 1, June 2014| ISSN(online): 2349-6010

7) V.N. Skopinsky1, A.B. Smetankin2, “Modeling And Stress Analysis Of Nozzle

Connections In Ellipsoidal Heads Of Pressure Vessels Under External
Loading,” Int. J. of Applied Mechanics and Engineering, 2006, vol.11, No.4,
pp.965-979.

8) A. Al-dubbouss, F.Saleem,”Pressure Vessels of Chemical Engineering Design”,2019

9) Coulson Richardson's Chemical Engineering Vol.6 Chemical Engineering

Design 4th Edition

10) J. P. Holman ,“Heat Transfer”, Tenth Edition, 2010

11) Material Engineering Department/ College of Engineering/Al-Mustansiriya

55 University/Baghdad , Aseel Kais Rasheed Ministry of science and

technology / Renewable Energy Directorate - Mechanical and Physical
Properties of Glass Wool-Rigid Polyurethane Foam Composites

12) Index values as published by Marshall & Swift Valuation Service 01/201