Design of Pressure Vessels Under ASME Section VIII

ACKNOWLEGEMENT:
First of all thanks to Allah Almighty who has guided us and

made difficult thing easier for us throughout our project and
secondly to our respected teachers and dear parents for their help
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MAIN CONTENTS
CHAPTER NO 1: introduction to pressure vessels
1.1 INTRODUCTION.
1.2 TYPES OF VESSELS.
1.3 STRESSES IN PRESSURE VESSELS.
1.4 PRESSURE VESSEL SAFETY
1.5 VESSELS IN REFRIGRATION SYSTEM
1.6 FACTOR OF SAFETY
1.7 STRESS ANALYSIS.
1.8 STRESS/FAILURE THEORIES.
1.9 FAILURES IN PRESSURE VESSELS.
1.10 LOADINGS.
1.11 ASME SECTION VIII DIVISION 1
1.12 TYPES AND CLASSES OF STRESS.
1.13 DEFINITIONS.
1.14 WEIGHTS OF PRESSURE VESSEL COMPONENTS
1.15 DESIGN PRINCIPLES.
CHAPTER NO 2: stresses and their effects
2.1 STRESS
2.2 TYPES OF STRESSES
2.3 TENSOR
2.3 (a) DUAL SPACE
2.3 (b) STRESS ENERGY TENSOR
2.3 (c ) CAUCHY STRESS TENSOR
2.4 FORMS OF DEFORMATION DUE TO APPLIED LOAD
2.5 MECHANICAL FAILURE MODES
2.6 TYPES OF STRUCTURAL ELEMENTS
2.7 TYPES OF CROSS-SECTIONS USED
2.8 TYPES OF SUPPORTS USED
2.9 STATICAL DETERMINANCY
2.10 STRESS STRAIN DIGRAM
ULTIMATE TENSILE STRENGTH
YIELD STRENGTH
FRACTURE STRESS
NECKING
2.11 STRESS CONCENTRATION
2.12 VON MISSES CRITERION
2.13 PLANE STRESS
2.14 PLANE STRAIN
2.15 MOHR STRESS CIRCLE
2.16 PRESSURE VESSEL DESIGN MODEL FOR CYLINDERS

CHAPTER NO 3: materials for pressure vessels
ASME pressure vessel codes
ASME section viii division 1
CHAPTER NO 4: design of pressure vessel
Summary
Diagram
Material Properties
Shell & Plate design
Head design
N-1 4`` sch-160
N-2 4`` sch-160 on head
N-1&N-2 Flanges
N-3 1``NPT6000# H.cplg
N-4&N-5 4`` process conn
M-1 12``x16`` MWY on shell
M-2 12``x16`` MWY on Head
Vessel Weight & Volume
Lifting Lugs
CHAPTER NO 1
INTRODUCTION TO PRESSURE VESSELS
CONTENTS:1.1 INTRODUCTION.
1.2 TYPES OF VESSELS.
1.3 STRESSES IN PRESSURE VESSELS.
1.5 VESSELS IN REFRIGRATION SYSTEM
1.6 FACTOR OF SAFETY
1.7 STRESS ANALYSIS.
1.8 STRESS/FAILURE THEORIES.
1.9 FAILURES IN PRESSURE VESSELS.
1.10 LOADINGS.
1.11 ASME SECTION VIII DIVISION 1
1.12 TYPES AND CLASSES OF STRESS.
1.13 DEFINITIONS.
1.14 WEIGHTS OF PRESSURE VESSEL COMPONENTS
1.15 DESIGN PRINCIPLES.
1.1 INTRODUCTION:What is a pressure vessel?

Definition:
A pressure vessel is any container that has pressure that is
different than atmospheric pressure. Also, any container...vessel that
has the potential to pressurize should be considered a pressure
vessel.
figure1.1 horizontal pressure vessel
figure 1.2 horizontal pressure vessel
1.2 How many types of pressure vessels are there?

There are many types Thinned wall
Thick walled
Storage tanks
Transportable Containers
Propane bottles
Gas cylinders
A pressure vessel is a container that holds a liquid, vapor, or gas at a
different pressure other than atmospheric pressure at the same
elevation.
You could even say that a carbonated soda bottle is a pressure
vessel. In fact, there is over 15-psi of pressure in a high carbonated
soda bottle. We must be practical too.
Pressure vessel types?

Thinned wall These pressure vessels are the most categorized. A thinned walled
pressure vessel is any cylinder [shell] ratio that is 10% or less the ratio
of the thickness to the diameter. Another way of saying this is a
pressure vessel is thinned walled if the diameter is 10-times or more
the thickness.
t < 0.1
d
figure1.3 stress distribution in thin walled pressure vessel
Thick walled These pressure vessels are the least common. A thick walled
pressure vessel is any cylinder [shell] ratio that is 10% or more the
ratio of the thickness to the inside diameter.
t > 0.1
d
figure 1.4 thick walled pressure vessel
Storage tanks Storage tanks are a category of thin walled pressure vessels except
that are typically under 15-psi and are super thin when compared to
the ratio above.
figure 1.5 hot water storage tank
Transportable Containers These are the most common pressure vessel and potentially the most
ignored. These are mass produced and require testing every 10-years
for propane and gas.
Propane bottles - Fork trucks, barbecues,
Gas cylinders - CO2, O2,...
Other - Containers, gas cans, bubblers,...
1.3 STRESSES
A pressure vessel has to retain to pressure. In doing this the pressure
applies two types of stresses in a pressure vessel. They are
circumferential and longitudinal.
figure 1.6
What is important to remember is longitudinal stresses are half as
much as the circumferential stresses. Therefore, we can say that
longitudinal strength is twice as strong as circumferential strength.
This is only true for illustration purposes.
FACTOR OF SAFETY:Factors of Safety are used because no manufacture can guarantee

100% quality. Every pressure vessel has a factor of safety. A factor of
safety accounts for uncertainties in materials, design,,and

fabrication.
Factory of Safety [FS] = Actual Breaking Strength
Load
To believe in that a F.S. makes a PV [Pressure Vessel] safe is
DANGEROUS and unwise. Putting this in another way, a factor of
safety compensate for imperfections in the pressure vessel; therefore,
every pressure vessel should be treated the same regardless of the
factor of safety.

There are four types of over pressurization devices:
Rupture Disks.
Relief Valves.
Safety Relief Valves.
Safety Valves.
What should you expect on an over-pressurization device?

Every device must have a name tag. The name tag must have one of
the following ASME symbols UV [spring loaded over pressurization
device] UD [rupture disk]. The name tag will have the set pressure
and capacity. The set pressure should never be greater than the
pressure vessels MAWP [maximum allowable working pressure].
Here are some special rules to the set pressure Relief Valves, Safety Relief Valves, and Safety Valves should be
set at or below pressure vessel ASME nameplate MAWP.
Rupture Disks should be set not higher than the PV [pressure

vessel] nameplate. Under special circumstances the rupture disk
can be set up to 110% of the MAWP. In addition to this special
condition, whenever there is a possibility of internal fire in the
pressure vessel the rupture disk can be set not higher than
160%, but a pressure vessel engineer will need to be consulted.
Remember There should never be a shut off valve between the PV
and over pressurization device.
How should the over-pressurization device be installed?

Always in an Upright installation.
Installed the over pressurization device a few pipe diameters
away from the PV, but consult the code and manufacture for
maximum distance.
Make sure the exhaust discharges safely away, so no one could
be injured.
TYPES OF OVER PRESSURIZATION DEVICES:Safety Valves Safety valves are strictly for vapor or gas service. The vapor or gas
should be relatively clean to ensure continued and successful
operation. A typical vapor is steam, an example for gas would be
compressed air. These are not meant for liquids. These valves pop
open at a set pressure and reset at a lower pressure called blow down.
Safety Relief Valves -
These valves differ from safety valves in that they are meant to handle
fluid streams that have liquids and vapor. These valves pop open at a
set pressure and reset [blow down] at a lower pressure [very much like
a safety valve].
Relief Valves Relief valves open at a set pressure and re-close at the same
pressure. These devices are suitable for liquid service.
Rupture Disks Rupture disks are probably the most versatile over- pressurization
device. These can only be used once. They are the only device that
can be used in conjunction with other over-pressurization devices.
1.5 VESSELS IN INDUSTRIAL REFRIGERATION SYSTEMS
HIGH PRESSURE RECIEVERS:-
Figure High pressure receiver
LOW PRESSURE RECEIVERS:-
figure liquid level maintained in a low pressure receiver
OIL POTS:-
figure OIL POTS WITH THEIR TYPICAL

CONNECTIONS.
SEPARATION ENHANCERS:-
The fig (a) shows drawing inlet flows downward and drawing vapor from the
top.
(b) installation of a metal mesh for mist elimination.
THERMOSYPHON RECEIVERS:-
figure combination of a thermosyphon receiver with a system receiver [1]
1.6 STRESSES IN PRESSURE VESSELS:-
Structural elements must be considered).
1.7 STRESS ANALYSIS

STRESS ANALYSIS IS THE DETERMINATION OF THE
RELATIONSHIP BETWEEN EXTERNAL FORCES
APPLIED TO A VESSEL AND THE CORRESPONDING
STRESS. [2]
1.8 STRESS/FAILURE THEORIES
They are
1. MAXIMUM STRESS THEORY.
2. MAXIMUM SHEAR STRESS THEORY.
MAXIMUM STRESS THEORY:-
MAXIMUM SHEAR STRESS THEORY:-
GRAPH OF MAXIMUM STRESS THEORY

QUADRANT 1: BIAXIAL TENSION.
QUADRANT 2: TENSION.
QUADRANT 3: BIAXIAL COMPRESSION.
QUADRANT 4: COMPRESSION.
GRAPH OF SHEAR STRESS THEORY.

COMPARISON OF TWO THEORIES:-
1.9 FAILURES IN PRESSURE VESSELS
CATEGORIES OF FAILURES:-
TYPES OF FAILURES:-
1.10 LOADINGS
1.11 STRESS
ASME CODE , SECTION VIII, DIVISION1
VERSES DIVISION 2:-
1.12 TYPES AND CLASSES OF STRESS
Simultaneously are called stress categories.
TYPES OF STRESS:-
CLASSES OF STRESS:-
1.13 DEFINITIONS
mum design temperature would be the MDMT.
1.14 WEIGHTS OF VESSELS AND ITS COMPONENTS
1.15 DESIGN PRINCIPLES
DESIGN LOADS:-
the design.
[3]
CHAPTER NO 2
STRESSES AND THEIR EFFECTS
CONTENTS:
2.1 STRESS
2.2 TYPES OF STRESSES
2.3 TENSOR
2.3 (a) DUAL SPACE
2.3 (b) STRESS ENERGY TENSOR
2.3 (c ) CAUCHY STRESS TENSOR
2.6 TYPES OF STRUCTURAL ELEMENTS
TYPES OF CROSS-SECTIONS USED
2.7 TYPES OF SUPPORTS USED
2.8 STATICAL DETERMINANCY
2.9 STRESS STRAIN DIGRAM
ULTIMATE TENSILE STRENGTH
YIELD STRENGTH
FRACTURE STRESS
NECKING
2.10 STRESS CONCENTRATION
2.11 VON MISSES CRITERION
2.12 PLANE STRESS
2.13 PLANE STRAIN
2.14 MOHR STRESS CIRCLE
2.15 PRESSURE VESSEL DESIGN MODEL FOR CYLINDERS
2.1 STRESS:
The concept of stress was introduced by Cauchy around 1822 as;
Stress is a measure of the average amount of force exerted per unit area of the
surface on which internal forces act within a deformable body. In other words,
it is a measure of the intensity, or internal distribution of the total internal
forces acting within a deformable body across imaginary surfaces. These
internal forces are produced between the particles in the body as a reaction to
external forces applied on the body. External forces are either surface forces
or body forces. Because the loaded deformable body is assumed as a
continuum, these internal forces are distributed continuously within the
volume of the material body, i.e. the stress distribution in the body is
expressed as a piecewise continuous function of space coordinates and time.
UNITS:
The SI unit for stress is the pascal (symbol Pa), which is equivalent to one
newton (force) per square meter (unit area). The unit for stress is the same as
that of pressure, which is also a measure of force per unit area. Engineering
quantities are usually measured in Megapascals (MPa) or gigapascals (GPa).
In imperial units, stress is expressed in pounds-force per square inch (psi) or
kilopounds-force per square inch (ksi). [4]
figure 2.1 Stress in a loaded deformable material body assumed as a

continuum.
40
41
The most general definition of stress is;

force per unit area
mathematically;
=F/A
A = UNIT AREA
F = FORCE
Structural and solid body mechanics are concerned with analyzing the effects
of applied loads. These are external to the material of the structure body and
result is internal reacting forces. These internal reacting forces are termed
as stresses, together with the deformations are displacements, conforming to
the principles of Newtonian mechanics.
Both the analysis and design of a given structure involves the determination
of stresses and deformations. [5]
DESCRIPTION:
Equilibrium:
A particle is in the state of equilibrium if the resultant force and moment
acting on it is zero.
Hence according to Newtons law of motion it will have no acceleration and
will be at rest. This hypothesis can be extended to the clusters of particles
42
that interact with each other with equal and opposite forces but have no
overall resultant. Thus it is evident that solid bodies, structures, or any
subdivided part, will be in equilibrium if the resultant of all external forces
and moments is zero.
A material body can be acted upon by external forces, which are of two kind:
surface forces and body forces. Surface forces or contact forces act on the
bounding surface as a result of mechanical contact between bodies, and their
intensity is proportional to the area of contact. Body forces, such as
gravitational and magnetic forces, are forces distributed over the volume of a
body, and their intensity is proportional to the mass of the body. Surface
forces can also occur within internal surfaces of a body.
These acting external forces are then transmitted from point to point within
the material body, leading to the generation of internal forces. The
transmission of such forces is governed by the conservation laws of linear and
angular momenta Newton's Second Law of motion. For bodies in static
equilibrium, these laws are related to the principles of equilibrium of forces
and moments, respectively.
The measure of the intensity of this internal forces acting within the material
body across imaginary surfaces is called stress. In other words, stress is a
measure of the average quantity of force exerted per unit area of the surface
on which these internal forces act. For example, if we compare a force applied
to a small area and a distributed load of the same resulting magnitude applied
to a larger area, we find that the effects or intensities of these two forces are
locally different because the stresses are not the same.
2.2 TYPES OF STRESSES:

Following are the basic types of stresses;
(i). normal stresses
(ii). shearing stresses
(iii). bearing stresses
(i) Normal Stresses:
this types of stresses occurs in the member under axial loading
normally denoted by
figure 2.2
Normal stress is the intensity of forces acting perpendicular to infinitely
small area dA with and object per unit area. If the normal stress acting on dA
pulls on it then it is called as tensile stress whereas if it pushes on the area
then it is called as compressive stress.
The plane of a tensile or compressive stress lies perpendicular to the axis of
operation of the force from which it originates.
figure2.3 tensile stress

Compressive stress:
Compressive stress is the stress applied to materials resulting in their
compaction (decrease of volume).
When a material is subjected to compressive stress, then this material is under
compression. Usually, compressive stress applied to bars, columns, etc. leads
to shortening.
Loading a structural element or a specimen will increase the compressive

stress until the reach of compressive strength. According to the properties of
the material, failure will occur as yield for materials with ductile behaviour
(most metals, some soils and plastics) or as rupture for brittle behaviour
(geomaterials, cast iron, glass, etc).
In long, slender structural elements -- such as columns or truss bars -- an
increase of compressive force F leads to structural failure due to buckling at
lower stress than the compressive strength.
Compressive stress has stress units (force per unit area), usually with negative
values to indicate the compaction.
figure2.4 compressive stress

(ii)
Shearing Stresses:
shearing stresses are caused by the application of equal and opposite

transverse forces
normally denoted by
figure 2.5
shear stress is applied parallel or tangential to the face of the material as

opposed to the normal stress which is applied perpendicularly
The plane of a shear stress lies in the plane of the force system from which
it originates.
figure 2.6 description of planes in tensile compressive and shear stresses
figure 2.7 description of tensile and shear stress

(iii)
Bearing Stresses:
bearing stresses are created by bolts and pins in the members they connect
normally denoted by
= P / td
where;
P = load
t = thickness of member
d = diameter of pin of bolt
figure 2.7 bearing stress

The applied load divided by the bearing area. Maximum bearing stress is the
maximum load in pounds, sustained by the specimen during the test, divided
by the original bearing area.
For the two force member under axial loading; stress analysis is done by
estimating the normal and shearing stresses in an oblique plane. Secondly
ultimate strength of the material is determined and finally by using the factor
of safety of any component the allowable load for the structural component is
determined.
DISCONTIUITY STRESSES:
Discontinuity stresses occurs in case of compound cylinderscompound
cylinders are used to increase the range of pressure that can be used inside a
cylinder.
Membrane stresses:
Membrane stress in mechanics means the average stress across the cross
section involved
Thermal stresses:
Thermal stresses arises in the material when they are heated and cooled
Principal stresses:
Normal stresses along principal directions are called as principal stresses
Tangential stresses:
tangential stresses occurs in the direction perpendicular to the
circumference
Radial stresses:
radial stress is a stress towards or away from the central axis of the curved
member
Circumferential stresses:
Longitudinal stresses:
Longitudinal stresses occurs along the longitudinal axis
it usually occurs in case of pipe shaped objects [6]
2.3 TENSOR
An element as a result of tensor product of vector spaces is called as tensor
Given a finite set { V1, ... , Vn } of vector spaces over a common field F. One
may form their tensor product V1 ... Vn. An element of this tensor product
is referred to as a tensor.
figure 2.8 stress tensor
2.3( a) Dual Space:

In mathematics, any vector space, V, has a corresponding dual vector space
(or just dual space for short) consisting of all linear functionals on V.
Dual vector spaces defined on finite-dimensional vector spaces can be used
for defining tensors which are studied in tensor algebra.
2.3 (b) STRESS ENERGY TENSOR:
The stress-energy tensor (sometimes stress-energy-momentum tensor) is a
tensor quantity in physics that describes the density and flux of energy and
momentum in spacetime
figure 2.9 stress energy tensor
2.3 ( c) CAUCHY STRESS TENSOR:

In general, however, the stress is not uniformly distributed over a cross
section of a material body, and consequently the stress at a point on a given
area is different than the average stress over the entire area. Therefore, it is
necessary to define the stress not at a given area but at a specific point in the
body .
figure 2.10 a point in an object under stress

According to Cauchy, the stress at any point in an object, assumed to be a
continuum, is completely defined by the nine components of a second order
tensor known as the Cauchy stress tensor
9 components of a second order tensor
The Cauchy stress tensor obeys the tensor transformation law under a change
in the system of coordinates. A graphical representation of this transformation
law is the Mohr's circle for stress.
According to the principle of conservation of linear momentum, if the
continuum body is in static equilibrium it can be demonstrated that the
components of the Cauchy stress tensor in every material point in the body
satisfy the equilibrium equations (Cauchy's equations of motion for zero
acceleration). At the same time, according to the principle of conservation of
angular momentum, equilibrium requires that the summation of moments with
respect to an arbitrary point is zero, which leads to the conclusion that the
stress tensor is symmetric, thus having only six independent stress
components, instead of the original nine.
By continuum body we mean anybody which undergoes gradual transition
from one state to another state without abrupt changes example ductile
materials..
Forces results into four basic forms of deformations or displacement of

structures or solid bodies
1.
2.
3.
4.
TENSION
COMPRESSION
BENDING
TWISTING OR TORSION
TENSION:
is the magnitude of the pulling force exerted by a string, cable, chain, or
similar object on another object.
It is the opposite of compression. As tension is a force, it is measured in
newtons (or sometimes pounds-force) and is always measured parallel to the
string on which it applies.
COMPRESSION:
Due to applied load there is a decrease in length or volume of the material
It is opposite to tension. It is subjected force applied by one object on another

object
Since compression is also expressed in terms of force so it is measured in
Newton and pound.
BENDING:
In the force analysis of frame works the members were only subjected to the
axial force, namely tension or compression then due to the effect transverse
loads acting on the structure, the resulting deformation is called as bending.
Bending is very common in structures and machines i.e, floor joists, railway
axles, aeroplane wings, leaf springs etc.
The external applied loads which cause bending give rise to internal reacting
forces.
In engineering mechanics, bending (also known as flexure) characterizes the
behavior of a slender structural element subjected to an external load applied
perpendicularly to an axis of the element. The structural element is assumed
to be such that at least one of its dimensions is a small fraction, typically 1/10
or less, of the other two. When the length is considerably larger than the
width and the thickness, the element is called a beam.
TORSION:
In torsion a solid or tubular member is subjected to torque about its
longitudinal axis resulting in twisting deformation.
The engineering examples of the above are obtained in shafts transmitting
power in machinery and transport, structural members in aeroplanes, springs.
figure 2.11 torsion

Following are the failure modes that commonly exists in mechanical
applications.
BUCKLING
CORROSION
CREEP
FATIQUE
FRACTURE
IMPACT
MECHANICAL OVERLOAD
RUPTURE
THERMAL SHOCK
BUCKLING:
In engineering,
buckling is a failure mode characterized by a sudden failure of a structural
member subjected to high compressive stresses, where the actual compressive
stress at the point of failure is less than the ultimate compressive stresses that
the material is capable of withstanding
This mode of failure is also described as failure due to elastic instability.
Mathematical analysis of buckling makes use of an axial load eccentricity that
introduces a moment, which does not form part of the primary forces to which
the member is subjected.
figure 2. 12 buckling of a column

CORROSION:
Corrosion can be defined as the disintegration of a material into its
constituent atoms due to chemical reactions with its surroundings
. In the most common use of the word, this means a loss of electrons of metals
reacting with water and oxygen. Weakening of iron due to oxidation of the
iron atoms is a well-known example of electrochemical corrosion. This is
commonly known as rusting. This type of damage typically produces oxide
and/or salt of the original metal. Corrosion can also refer to other materials
than metals, such as ceramics or polymers. Although in this context, the term
degradation is more common.
Most structural alloys corrode merely from exposure to moisture in the air but
the process can be strongly affected by exposure to certain substances .
Corrosion can be concentrated locally to form a pit or crack, or it can extend
across a wide area to produce general deterioration. While some efforts to
reduce corrosion merely redirect the damage into less visible, less predictable
forms, controlled corrosion treatments such as passivation and chromateconversion will increase a material's corrosion resistance.
fig 2.13 effect of oxygen concentration on the corrosion of a material in mm
CREEP:
Creep is the tendency of a solid material to slowly move or deform
permanently under the influence of stresses. It occurs as a result of long term
exposure to levels of stress that are below the yield strength of the material
Creep is more severe in materials that are subjected to heat for long periods,
and near the melting point.
Creep always increases with temperature.
FACTORS:
The rate of this deformation is a function of the material properties, exposure
time, exposure temperature and the applied structural load. Depending on the
magnitude of the applied stress and its duration, the deformation may become
so large that a component can no longer perform its function
example creep of a turbine blade will cause the blade to contact the casing,
resulting in the failure of the blade.
Creep is usually of concern to engineers and metallurgists when evaluating
components that operate under high stresses or high temperatures. Creep is a
deformation mechanism that may or may not constitute a failure mode.
Moderate creep in concrete is sometimes welcomed because it relieves tensile
stresses that might otherwise lead to cracking.
Difference from brittle fracture:
Unlike brittle fracture, creep deformation does not occur suddenly upon the
application of stress. Instead, strain accumulates as a result of long-term
stress.
Creep deformation is "time-dependent" deformation.
Creep deformation is important not only in systems where high temperatures
are endured such as nuclear power plants, jet engines and heat exchangers, but
also in the design of many everyday objects.
FATIGUE:
In materials science,
fatigue is the progressive and localized structural damage that occurs when
a material is subjected to cyclic loading
The maximum stress values are less than the ultimate tensile stress limit, and
may be below the yield stress limit of the material.
MECHANICAL OVERLOAD:
failure or fracture of a product or component in a single event is known as
mechanical overload
It is a common failure mode, and may be contrasted with fatigue, creep,
rupture, or stress relaxation. In structural engineering this term is used when
analysing product failure. Failure may occur because either the product is
weaker than expected owing to a stress concentration, or the applied load is
greater than expected and exceeds the normal tensile strength, shear strength
or compressive strengthof the product.
Examples include the many components which fail in car crashes, train
crashes, and airplane crashes as a result of impact loading. The problem for
the investigator is to determine which failures have been caused by the crash,
and which may have caused the crash. It usually involves examining the
broken parts for signs of fatigue crack growth or other damage to the part
which cannot be attributed to the crash itself. For very large structural failures
such as the collapse of bridges, it is necessarily a long and tedious process of
sifting the broken parts.
THERMAL SHOCK:
Thermal shock is the name given to cracking as a result of rapid
temperature change.
Glass and ceramic objects are commonly exposed to this form of failure, due
to their low toughness, low thermal conductivity, and high thermal expansion
coefficients. However, they are used in many high temperature applications
due to their high melting point.
Thermal shock occurs when a thermal gradient causes different parts of an
object to expand by different amounts. This differential expansion can be
understood in terms of stress or of strain, equivalently. At some point, this
stress overcomes the strength of the material, causing a crack to form. If
nothing stops this crack from propagating through the material, it will cause
the object's structure to fail.
Prevention from thermal shock:
Thermal shock can be prevented by:
1. Reducing the thermal gradient seen by the object, by:
a) changing its temperature more slowly
b) increasing the material's thermal conductivity
2. Reducing the material's coefficient of thermal expansion
3. Increasing its strength
4. Decreasing its Young's modulus
5. Increasing its toughness, by
a) crack tip blunting, i.e., plasticity
b) crack deflection [7]
2.6 TYPES OF STRUCTURAL AND SOLID BODY COMPONENTS
1. TIE:
A member that prevents two parts of a structure from moving apart is
subjected to a pull at each end, or tensile force, and is termed as tie
figure 2.14 tie

2. STRUT:
A slender member which prevents parts of a structure moving toward each
other is under compressive force and is termed as strut
figure 2.15 strut

3. COLUMN:
A vertical member which is perhaps not too slender and supports some of the
mass of the structure is called as column
Column is capable of supporting axial loads
4. CABLE:
A cable is generally recognized term for a flexible string under tension which
connects two bodies
It cannot supply resistance to the bending action.
5. BEAM:
It is supported horizontally and carries transverse loading or vertical
loading
6. CANTILEVER BEAM:
A common special case of beam is cantilever beam where one end is fixed
and provides all the necessary support
figure 2.16 cantilever beam geometry

7. BEAM COLUMN:
As the name implies it combines the functions of beam and a column.
figure 2.17 beam column
ARCH:
The arch has the same function as the beam or beam-column, but is curved
in shape
the filling and carrying of load over an area or space are achieved by flat
slabs or plates by panels and also by shells, which are the curved versions of
the former.
8. SHAFT:
The transmission of torque and twist is achieved through a member which is
frequently termed as shaft
figure 2.18 shaft [8]
\
DIFFERENT TYPES OF CROSS- SECTIONS USED:
The members described above can have variety of cross-sectional shapes
depending upon the particular type of loading to be carried. Some typical
cross sections are;
1. angle
figure 2.19 angle
2. channel
figure 2.20 channel

3.
I-section
figure 2.21 I-Section

4. T-section
figure 2.22 T-Section
6. Z-section
figure 2.23
7. Tubes:
figure 2.24 [9]
2.7 TYPES OF SUPPORTS USED FOR STRUCTURAL MEMBERS

1. built-in or fixed support
one horizontal and one vertical reaction and in case of welded joint 2reactions plus one moment in addition
fig 2.25 built on or fixed support

2. pin connection:
one horizontal and one vertical reaction
figure 2.26 pin connection

3. roller support
one vertical reaction
fig 2.27 roller support
4. sliding support
fig 2.28
one horizontal reaction
the applied loading on the structural component is transmitted to the

supports which provide the required reacting forces to maintain the overall
equilibrium. [10]
The separate members of the structure are joined together by bolting, riveting
or welding. If the joints are stiff when the members of the framework were
deformed under load, the angles between the members at the joint would not
change. This would also imply that the joint is capable of transmitting a
couple.
It is found in practice that there is some degree of rotation between members
at a joint to the elasticity of the system. For the purposes of calculations, it is
assumed that these joints may be represented by a simple ball and socket or
pin in a hole. Even with this arrangement, which is of course cannot transmit
a couple or bending moment (other than by friction which is ignored),
deformation of the members are relatively small. Consequently, changes in
angle at the joints are also small. [11]
2.8 STATICAL DETERMINANCY:

If the number of unknown reactions or internal forces in the structure or
component is greater than the number of equilibrium equations available,
then the problem is said to be statically indeterminate.
Additional equations have to be found by considering the displacement or
deformation of the body.
Conditions:
There are three conditions;

Under-stiff: if there are more equilibrium equations than unknown forces
or reactions the system is unstable and is not a structure but a mechanism
Just-stiff: this is the statically determinate case for which there are the
same number of equilibrium equations as unknown forces. If any member
is removed then a part of the whole of the frame will collapse
Over-stiff: this is the statically indeterminate case in which there are more
unknown forces than available equilibrium equations. There is at least one
member more than is required for the frame to be just stiff
2.9 STRESS STRAIN DIAGRAM:
During testing of a material sample, the stressstrain curve is a graphical

representation of the relationship between stress, derived from measuring
the load applied on the sample, and strain derived from measuring the
deformation of the sample, i.e. elongation, compression, or distortion.
The nature of the curve varies from material to material.
The following diagrams illustrate the stressstrain behaviour of typical
materials in terms of the engineering stress and engineering strain where the
stress and strain are calculated based on the original dimensions of the sample
and not the instantaneous values.
fig 2.29 Stress-strain diagram of ductile material:
Steel generally exhibits a very linear stressstrain relationship up to a well

defined yield point . The linear portion of the curve is the elastic region and
the slope is the modulus of elasticity or Young's Modulus. After the yield
point, the curve typically decreases slightly because of dislocations. As
deformation continues, the stress increases on account of strain hardening
until it reaches the ultimate strength. Until this point, the cross-sectional area
decreases uniformly because of Poisson contractions. The actual rupture
point is in the same vertical line as the visual rupture point.
However, beyond this point a neck forms where the local cross-sectional area
decreases more quickly than the rest of the sample resulting in an increase in
the true stress. On an engineering stressstrain curve this is seen as a decrease
in the stress. Conversely, if the curve is plotted in terms of true stress and true
strain the stress will continue to rise until failure. Eventually the neck
becomes unstable and the specimen ruptures.
2.9 (a) Offset method:
Less ductile materials such as aluminum and medium to high carbon steels
do not have a well-defined yield point.
For these materials the yield strength is typically determined by the "offset
yield method", by which a line is drawn parallel to the linear elastic portion of
the curve and intersecting the abscissa at some arbitrary value (most
commonly 0.2%). The intersection of this line and the stressstrain curve is
reported as the yield point. Also the yield point is how much pressure and
weight a piece of metal can hold before it gets to the elasticity point.
figure 2.30 stress strain diagram for a ductile material

2.9 (b) stress-diagram for brittle material:
Brittle materials such as concrete and carbon fiber do not have a yield point,
and do not strain-harden which means that the ultimate strength and breaking
strength are the same.. Typical brittle materials like glass do not show any
plastic deformation but fail while the deformation is elastic. One of the
characteristics of a brittle failure is that the two broken parts can be
reassembled to produce the same shape as the original component as there
will not be a neck formation like in the case of ductile materials. A typical
stress strain curve for a brittle material will be linear.
Testing of several identical specimen, cast iron, or soil, tensile strength is
negligible compared to the compressive strength and it is assumed zero for
many engineering applications. Glass fibers have a tensile strength stronger
than steel, but bulk glass usually does not. This is because of the Stress
Intensity Factor associated with defects in the material. As the size of the
sample gets larger, the size of defects also grows. In general, the tensile
strength of a rope is always less than the tensile strength of its individual
fibers.
figure 2.31 stress strain diagram for a brittle material
2.9 ( c ) LINEAR ELASTICITY:

Linear elasticity is the mathematical study of how solid objects deform and
become internally stressed due to prescribed loading conditions..
The fundamental "linearizing" assumptions of linear elasticity are:
infinitesimal strains or "small" deformations (or strains) and linear
relationships between the components of stress and strain. In addition linear
elasticity is only valid for stress states that do not produce yielding . These
assumptions are reasonable for many engineering materials and engineering
design scenarios. Linear elasticity is therefore used extensively in structural
analysis and engineering design, often through the aid of finite element
analysis.
2.9 (d) YIELDING:

The yield strength or yield point of a material is defined in engineering and
materials science as the stress at which a material begins to deform
plastically.
Prior to the yield point the material will deform elastically and will return to
its original shape when the applied stress is removed. Once the yield point is
passed some fraction of the deformation will be permanent and nonreversible.

In the three-dimensional space of the principal stresses (1,2,3), an infinite
number of yield points form together a yield surface.
Knowledge of the yield point is vital when designing a component since it

generally represents an upper limit to the load that can be applied. It is also
important for the control of many materials production techniques such as
forging, rolling, or pressing. In structural engineering, this is a soft failure
mode which does not normally cause catastrophic failure or ultimate failure
unless it accelerates buckling.
fig 2.32
fig 2.33
(e) RESIDUAL STRESSES :
Residual stresses are stresses that remain after the original cause of the
stresses (external forces, heat gradient) has been removed.
They remain along a cross section of the component, even without the
external cause. Residual stresses occur for a variety of reasons, including
inelastic deformations and heat treatment.
Example:
Heat from welding may cause localized expansion, which is taken up during
welding by either the molten metal or the placement of parts being welded.
When the finished weldment cools, some areas cool and contract more than
others, leaving residual stresses.
2.9 (f) STRESS CONCENTRATION:
A stress concentration (often called stress raisers or stress risers) is a

location in an object where stress is concentrated
. An object is strongest when force is evenly distributed over its area, so a
reduction in area, e.g. caused by a crack, results in a localized increase in
stress. A material can fail, via a propagating crack, when a concentrated stress
exceeds the material's theoretical cohesive strength. The real fracture strength
of a material is always lower than the theoretical value because most materials
contain small cracks that concentrate stress. Fatigue cracks always start at
stress raisers, so removing such defects increases the fatigue strength.
figure 2.34 stress concenctration
2.9 (g) fatigue strength:
In materials science, fatigue is the progressive and localized structural

damage that occurs when a material is subjected to cyclic loading. The
maximum stress values are less than the ultimate tensile stress limit, and may
be below the yield stress limit of the material.
2.9 (h)ultimate tensile strength:
Tensile strength (UTS or SU ) is indicated by the maxima of a stress-strain
curve and, in general, indicates when necking will occur. As it is an intensive
property, its value does not depend on the size of the test specimen. It is,
however, dependent on the preparation of the specimen and the temperature of
the test environment and material.
Tensile strength, along with elastic modulus and corrosion resistance, is an
important parameter of engineering materials used in structures and
mechanical devices. It is specified for materials such as alloy, composite
materials, ceramics, plastics and wood.
figure 2.35 figure showing ultimate tensile strength of a ductile material

2.9 (i) frature stress:
The true normal stress on the minimum cross-sectional area at the
beginning of fracture. In a tensile test, it is the load at fracture divided by the
cross-sectional area of the specimen.
figure 2.36
2.9(j) necking:
Necking, in engineering or materials science, is a mode of tensile deformation
where relatively large amounts of strain localize disproportionately in a small
region of the material
The resulting prominent decrease in local cross-sectional area provides the
basis for the name "neck". Because the local strains in the neck are large,
necking is often closely associated with yielding, a form of plastic

deformation associated with ductile materials, often metals or polymers
figure 2.37 necking
figure 2.38 stress analysis of ductile material showing necking

phenomenon
2.10 OCTAHEDRAL STRESSES:

Considering the principal directions as the coordinate axes, a plane whose
normal vector makes equal angles with each of the principal axes is called an
octahedral plane. There are a total of eight octahedral planes . The normal
and shear components of the stress tensor on these planes are called
octahedral normal stress and octahedral shear stress , respectively
Figure 2.39 octahedral stresses
2.11 VON MISSES CRITERION:
The von Mises yield criterion suggests that the yielding of materials begins
when the second deviatoric stress invariant reaches a critical value . For
this reason, it is sometimes called the -plasticity or flow theory. It is part of a
plasticity theory that applies best to ductile materials, such as metals. Prior to
yield, material response is assumed to be elastic.
In material science and engineering the von Mises yield criterion can be also
formulated in terms of the von Mises stress or equivalent tensile stress, , a
scalar stress value that can be computed from the stress tensor. In this case, a
material is said to start yielding when its von Mises stress reaches a critical
value known as the yield strength, . The von Mises stress is used to predict
yielding of materials under any loading condition from results of simple
uniaxial tensile tests. The von Mises stress satisfies the property that two
stress states with equal distortion energy have equal von Mises stress.
Figure 2.40 von-misses criterion yield envelope
2.12 PLANE STRESS:

A state of plane stress exist when one of the three principal , stresses is zero.
This usually occurs in structural elements where one dimension is very small
compared to the other two, i.e. the element is flat or thin. In this case, the
stresses are negligible with respect to the smaller dimension as they are not
able to develop within the material and are small compared to the in-plane
stresses. Therefore, the face of the element is not acted by loads and the
structural element can be analyzed as two-dimensional, e.g. thin-walled

structures such as plates subject to in-plane loading or thin cylinders subject
to pressure loading.
Figure 2.41
2.13 PLANE STRAIN:

If one dimension is very large compared to the others, the princpal strain
in the direction of the longest dimension is constrained and can be assumed
as zero, yielding a plane strain condition.
In this case, though all principal stresses are non-zero, the principal stress in
the direction of the longest dimension can be disregarded for calculations.
Thus, allowing a two dimensional analysis of stresses, e.g. a dam analyzed at
a cross section loaded by the reservoir.
figure 2.42 plane stress and plane strain

2.14 MOHR STRESS CIRCLE:
The Mohr's circle, named after Otto mohr
is a two-dimensional graphical representation of the state of stress at a
point.
The abscissa , , and ordinate , , of each point on the circle are the normal
stress and shear stress components, respectively, acting on a particular cut
plane with a unit vector with components . In other words, the circumference
of the circle is the locus of points that represent state of stress on individual
planes at all their orientations.
Mohr stress circle for plane stress and plane strain:
The circle represents all possible states of normal and shear stress on any
plane through a stressed point in a material.
n ( x + y ) = 1/ 2 ( x - y ) cos 2 + xy sin 2
- s = ( x - y ) sin 2 - xy cos 2
squaring both sides and adding the equations;
[ n ( x + y ) ] ^2 + s ^ 2 = ( x - y ) ^ 2 + xy ^ 2
this the equation of circle of radius

[ 1 /4( x - y ) ^ 2 + xy ^ 2] ^1/2
Figure 2.43
SIGN CONVENTIONS:
The sign conventions used on the circle will be, for normal stress, positive to
right and negative to the left of the origin. Shear stresses which might be
described as trying to cause a clockwise rotation of an element are plotted
above the abscissa axis i.e, positive and shear stresses appearing as
antclockwise rotation are plotted above the axis i.e, negative.
Maximum shear stress:
smax = [1 /4( x - y )^2 + xy ^ 2 ] ^ 1/2 xy
plane on which maximum shear stress acts is calculated by the formula

tan 2 = - ( x - y / 2 xy)
principle stresses and planes:

1=( x + y)/2 + [ x - y )^2 +4 xy ^ 2] ^1/2
2 =( x + y)/2 1/2[ x - y )^2 +4 xy ^ 2] ^1/2
planes:
= tan -1 ( 2xy/ x-y)
maximum shear stress in terms of principal stresses:
smax = (1 - 2)
2.14 (b) mohr stress circle in three dimensional state of stress:
figure 2.44
to obtain the true maximum shear stress for use in design calculations it is
necessary to consider all three principal planes. The three dimensional
element subjected to the principal stresses is considered. The principal stress
3 is zero in this principal case because only plane stress condition is
considered. Considering each of the three principal stresses to be labeled as 1,
2 and 3 it is possible to construct the Mohrs diagram for each. Then the
composite Mohrs diagram is constructed by superimposing these diagrams
then enables the maximum shear stress in the material to be determined.
figure 2.45 [12]
2.15
CYLINDER UNDER PRESSURE:
equation A;
CASE STUDY : STRESS ANALYSIS OF THICK WALLED

CYLINDER:
Figure 7. Mohr's circle for a three-dimensional state of stress
CASE STUDY: THIN WALLED THEROY APPLIED TO

CYLINDRICAL ANALYSIS
COMBINED STRESSES IN PRESSURE VESSELS:
THIN-WALLED PRESSURE VESSEL:
thin-walled pressure vessel
Cylindrical thin-walled pressure vessel showing co-ordinate axes

And cutting planes ( a, b and c)
free body diagram of segment of cylindrical pressure vessel

showing pressure and internal hoop stresses
free body diagram of end section of cylindrical thin-walled

pressure vessel
showing pressure and internal axial stress
SPHERICAL PRESSURE VESSEL:

Spherical pressure vessel can be analyzed in the similar way as the
cylindrical pressure vessel. The axial stresses results from the pressure acting
on the projected area of the sphere such that;
free body diagram of end section of spherical thin-walled pressure

vessel showing pressure and internal hoop and axial stresses
Analysis of equation A and C shows that element either cylindrical or

spherical is subjected to biaxial stresses ( a normal stress acting in two
direction)
THICK WALLED PRESSURE VESSEL:
stress distribution of radial and hoop stresses
elasticity method is used for thick walled pressure vessel it is very difficult
only results are displayed
[13]
CHAPTER # 4
DESIGN OF PRESSURE VESSEL
CONTENTS:
Summary
Diagram
Material Properties
Shell & Plate design
Head design
N-1 4`` sch-160
N-2 4`` sch-160 on head
N-1&N-2 Flanges
N-3 1``NPT6000# H.cplg
N-4&N-5 4`` process conn
M-1 12``x16`` MWY on shell
M-2 12``x16`` MWY on Head
Vessel Weight & Volume
Lifting Lugs
Pressure Vessel Design Summary:

PVE Sample Vessels
Sample Vertical Vessel
Sample 4
Sample 4
Sample 4
60"
120"
213
Non-lethal
6000
19000
19000
Outside Diameter [inch]

straight Shell (not including straight flange on heads)
Volume [cuft]
Fluid (value from Material Properties)
Weight Empty [lbs.]
Weight Full
Weight Under Test
Maximum Internal pressure, psi Maximum External Pressure, psi At Temperature, F
150
Maximum Temperature, F
0
Minimum Temperature, F
120
Test Pressure, psi
195
0.75
0.3
SA-516 Gr.70
20,000
0.09375
No
No
None
0.125
ASME VIII-1
2007
IID
None
Customer
Vessel
Part Number
Drawing
Job
-20
120
At Pressure, psi
150
At a Minimum Temperature of: F For a Minimum Duration of:
Ambient
1/2 hr
Maximum Allowed Working Pressure

Maximum Design Metal Temperature
Hydrostatic Test
Seismic Zone
Foundation Factor
Primary Material of Construction
Allowable Stress
Minimum allowed thickness per UG-16(b)
Material Normalized
Material Impact Tested (not required per UG-20(f))
Radiography required
Corrosion Allowance
Code
Edition
Addenda
Materials
UG-22 Loadings Considered

(a) Internal pressure
Yes
No
(a) External pressure
Yes
(b) Vessel weight full, empty and at hydro
test (c) Weight of attached equipment and
No
piping (d)(1) Attachment of internals
No
(d)(2) Attachment of vessel supports
Yes
(d) Cyclic or dynamic reactions
No
(f) Wind
No
(f) Snow
No
(f) Seismic
Yes
(g) Fluid impact shock reactions
No
(h) Temperature gradients
No
(h) Differential thermal expansion
No
(i) Abnormal pressures like deflagration
No
Code Cases Required
1
2
Material Properties
2.01
Sample Vertical Vessel <- Vessel
3
4
5
Design Pressure
22(a)
7
8
9
10
11
12
13
14
15
16
17
ver
150.0
0.0
Water. fresh
12.000
1.000
Design Pressure =
UG-
<- P, internal operating pressure at top of vessel (psig)

<- mPa, external operation pressure
<- Operating Fluid
<- h, fluid height (ft)
<- rho, fluid density (1.0 for water)
P + 0.4331*rho*h
= 150 + 0.4331 * 1 * 12
Hydro Test
(UG-99(b))
Test Press = P * 1.3 * MR
Material
Properties
pressure measured at top of vessel, rounded up
= 150 * 1.3 * 1
(ASME IID)
120 <- mTemp, design temp F
Material
Where Used
18
19
20
21
22
23
24
SA-516 70 Plate
SA-106 B Seamless Pipe
SA-240 316 Plate
SA-105 Forging
SA/CSA-G40.21 44W (38W Stresses used)
SA-193 B7 Bolts <= 2.5"
mDp = 155.2
Shell, Heads
Nozzles, Manway
Flange Pads
Flanges, Couplings
Legs
mTp = 195
Test at ambient temp
Ambient Design
Strength Max F
Strength Strength Ratio
20000
20000
1.000
1000
17100
17100
1.000
1000
20000
20000
1.000
1500
20000
17100
25000
20000
17100
25000
1.000
1.000
1.000
Min Ratio (MR) =
1.000
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
1000
650
1000
Ext
Graph
CS-2
CS-2
HA-2
CS-2
CS-2
Pipe and Shell :

Rolled Plate Shell Description
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Interior
No Exterior
Rolled Plate
Non-Threaded
No
ip? - Calculate interior pressure

ep? - Calculate exterior pressure
pr? - Pipe or rolled plate
pt? - Type of pipe
relief? - Stress Relief Calculations Required
Dimensions:
60.000
0.5000
0.094
120.000
0.125
Do [in] - outside diameter

t [in] - nominal wall thickness
tminUG16b [in] - minimum wall per UG-16(b)
L [in] - length for volume and weight
Corr [in] - corrosion allowance
Stress Classification:
NOTE: Both validity checks need to be "Acceptable" in order to use this sheet
If not, refer to sheet "Thick Cylindrical Shell"
ckValidity1 =
ckValidity2 =
28
Variables:
29
30
31
32
33
Td =
UT [in] =
nt [in] =
Ri [in] =
Volume [cuft] =
Weight [lb] =
tmin < 0.5*(Do/2)

P< 0.385*S*El
0.000
t*UTP+UTI
t-Corr-UT-Td
Do/2-nt
((Do/2-t)^2)* *L/1728
(Do-t)* *L*t*40.84/144
34
35
36
37
38
39
40
41
42
43
44
Material and Conditions:

SA-516 70 Material
20,000 S [psi] - allowable stress level
0.70 El - longitudinal efficiency (circ. stress)
0.70 Ec - circ. connecting efficiency (longitudinal stress)
0.000% UTP [%] - undertolerance allowance
0.000 UTI [in] - undertolerance allowance
155.20 P [psi] - interior pressure
27
26
Do
Options:
Length
Long Seam
0.331 < 0.5*(60/2) = Acceptable

155.2< 0.385*20000*0.7 = Acceptable
0=
0.5*0+0 =
0.5-0.125-0-0 =
60/2-0.375 =
((60/2-0.5)^2)*3.1416*120/1728 =
0.000
0.000
0.375
29.625
189.859
(60-0.5)*3.1416*120*0.5*40.84/144 = 3180.84
Interior Pressure: VIII-1 UG-27(c)(1,2)

ta [in] = P*Ri/(S*El-0.6*P)
tb [in] = P*Ri/(2*S*Ec+0.4*P)
tmin [in] = MAX(ta,tb,tminUG16b)
tr1 [in] = P*Ri/(S*1-0.6*P)
Checkt = tmin <= nt
155.2*29.625/(20000*0.7-0.6*155.2) =
155.2*29.625/(2*20000*0.7+0.4*155.2) =
MAX(0.331,0.164,0.094) =
155.2*29.625/(20000*1-0.6*155.2) =
0.331 <= 0.375 =
0.331
0.164
0.331
0.231
Acceptable
PMaxA [psi] = (S*El*nt)/(Ri+0.6*nt)

PMaxB [psi] = (2*S*Ec*nt)/(Ri-0.4*nt)
PMax [psi] = Min(PMaxA,PMaxB)
CheckP = PMax >= P
(20000*0.7*0.375)/(29.625+0.6*0.375) =
(2*20000*0.7*0.375)/(29.625-0.4*0.375) =
MIN(176,356) =
176 >= 155.2 =
176
356
176
Acceptable
39
Heads :
Torispherical
40

F & D Heads <- Desc
22
42
43
44
45
48
49
51
53
54
55
56
57
58
59
60
61
65
66
69
70
74
75
Dimensions:
60.000
60.000
3.600
0.750
0.675
0.094
0.125
1.500
<- Do, outside diameter

<- L, inside crown radius
<- IKR, inside knuckle radius
<- tb, thickness before forming
<- tf, thickness after forming
<- tminUG16(b) - Min.t. Per UG-16(b)
<- Corr, corrosion allowance
<- Skirt, straight skirt length
Material and Conditions:

SA-516 70 <- material
20,000 <- S, allowable stress level (psi)
0.85 <- E, efficiency
155.2 <- P, interior pressure
0.0 <- Pa, exterior pressure
Calculated Properties:
68.7 <- Approx. blank dia (inch)
789.5 <- Approx. weight (lbs, steel)
76
78
115
116
123
125
126
128
131
134
137
138
141
142
146
149
150
153
157
158
159
165
166
167
177
180
181
184
185
186
187
188
189
190
191
11.66 <- Volume (cuft, includes skirt)

54.574 <- Spherical Limit
9.770153 <- Depth of Head
Variables:
D=
t=
L /r =
M=
Ro =
Do-2*t
tf-corr
L/IKR
0.25*(3+sqrt(L/ikr))
L + tb
Interior Pressure App 1-4(a), App 1-4(d):

App. 1-4(a) check:
0.0005 =< tf/L < 0.002
= 60-2*0.55
= 0.675-0.125
= 60/3.6
= 0.25*(3+sqrt(60/3.6))
= 60 + 0.75
= 0.0005=<0.675/60<0.002
IF(tf/L<0.002,IF(tf/L>=0.0005,"Calculation required","Error"),"Calculation not required")
TMinI =
=
TMin =
PMax =
=
D=
t=
L /r =
M=
Ro =
58.90
0.55
16.667
1.771
60.750
tf/L = 0.0113
App. 1-4(f) calculation not required
(P*L*M)/(2*S*E - 0.2*P) <= t

(155.197*60*1.771)/(2*20000*0.85 - 0.2*155.197) <= 0.55
Max(Tminl,tminUG16(b))<=tf-corr
Acceptable
(2*S*E*t)/(L*M + 0.2*t) >= P (2*20000*0.85*0.55)/
Acceptable
(60*1.771 + 0.2*0.55) >= 155.197
TminI = 0.485
TMin = 0.485
PMax = 175.8
Interior Pressure for Nozzles App 1-4(a), App 1-4(d), UG-37(a)(1):

TMinE1 = (P*L*M)/(2*S*1 - 0.2*P) <= t
(Nozzle in Knuckle) TMinE1 = 0.413
= (155.197*60*1.771)/(2*20000*1 - 0.2*155.197) <= 0.55
(Nozzle in Crown) Tsp = 0.233
TSp = (P*L*1)/(2*S*1 - 0.2*P) (155.197*60*1)/
= (2*20000*1 - 0.2*155.197)
Head stress relief UCS-79(d), UNF-79(d), UHA-44(d)
Rf = IKR+tb/2
= 3.6+0.75/2
% elong = ((75*tb)/Rf)*(1-Rf/Ro) = ((75*0.75)/3.975)*(1)
5.0% <- Max Elongation
14.2% <- Elongation
Yes <- Cold Formed
no <- Vessel carries lethal substances(Yes/no)
no <- Impact testing is required (Yes/no)
no <- Formed between 250 and 900 Degrees F
no <- Greater than 10% reduction in thickness
Yes <- Head is greater than 5/8" thick before forming
Rf = 3.975
% elongation = 14.2
Required
no
no
no
no
Yes ?
Stress Relieve ?
Yes ?
no
no
no
no
YES
YES
30
Nozzle Reinforcement
UW16(c) <- SavedDesign

Automatic dh - not hillside
Automatic Limit Diameter
Curved Shell or Head Section
31

N1 - 4" SCH 160 Pipe <- Description
22
33
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
54
55
57
58
61
71
74
87
88
90
95
101
102
108
111
127
133
141
142
143
145
146
148
149
180
181
182
183
207
208
209
212
215
216
219
220
225
226
230
231
240
249
250
Shell:
SA-516 70 <- Shell Material
Do
20,000 <- Sv, shell allowable stress level, PSI
1.00 <- E1, efficiency of shell at nozzle
Nt
59.00 <- Ds, Shell ID
0.500 <- Vt, shell wall thick, uncorroded, UT removed
0.231 <- tr, required shell wall thickness int. press.(E=1)
t
0.000 <- trE, required shell wall thickness ext. press.
Leg41
0.125 (E=1)
0.094 <- sca, shell corrosion allowance
Leg41
Shell
<- tmin16b, Min allowed wall per UG-16(b)
Nozzle:
SA-106B <- Nozzle Material
17,100 <- Sn, allowable stress level (Sn)
Vt
17,600 <- B, from A =
0.09590
1.00 <- E, nozzle efficiency
155.20 <- P, internal design pressure
UW-16.1 (c)
0.0 <- Pa, external design pressure
4.500 <- Do, outside diameter
0.531 <- Nt, wall thick, uncorroded
12.5% <- UTp, undertolerance (%)
0.125 <- nca, nozzle corrosion
6.000 allowance
<- L, exterior Projection
Reinforcing:
0.375 <- Leg41, size of weld fillet
1.000 <- F
Variables:
UT = Nt*UTp
= 0.531 * 0.125
Undertolerance
UT = 0.066
Rn = Do/2 - (Nt-nca) + UT
Effective Radius
Rn = 1.910
= 4.5/2 - (0.531-0.125) + 0.066
t = Vt-sca
t = 0.375
Effective Shell Thickness
= 0.5 - 0.125
tn = Nt-nca Dotn = 0.406
Avail. Nozzle Thick. No UT
= 0.531-0.125
d = 2*tn
d = 3.688
Opening Dia.
= 4.5 - 2*0.406
fr1 = MIN(Sn/Sv,1)
fr1 = 0.855
= MIN(17100/20000, 1)
fr2 = MIN(Sn/Sv,1)
fr2 = 0.855
= MIN(17100/20000, 1)
tcLeg41 = Min(0.25,0.7*Min(0.75,tn,t))
tc41 = 0.250
= Min(0.25,0.7*Min(0.75,0.406,0.375))
F = Min(Fenterered, 1)
F = 1.000
Pipe Required Wall Thickness - trn from internal, trnE from external
pressure LDo = L/Do
LDo = 1.333
Dot = Do/trnE
Dot = 0.000
trn = 0.017
trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT
= (155.2*1.91)/(17100*1 - 0.6*155.2)
Acceptable
trnR = 0.017
trnR = (P*Rn)/(Sn*1 - 0.6*P)
= (155.2*1.91)/(17100*1 - 0.6*155.2)
E=1
trnE = 0.000
trnE = (3*Do*Pa)/(4*B) <= tn-ut
Acceptable
= (3*4.5*0)/(4*17600)
Geometry Constraints:
0.7*Leg41 >= tc41
0.7*0.375 >= 0.25
0.263
>=
0.250
Acceptable
Appendix 1-7 Necessary
CheckDs>60,if(2*Rn<=Ds/3,if(2*Rn<=40, "App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations
when
required")
when Ds<=60,if(2*Rn<Ds/2,if(2*Rn<20,"App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
App. 1-7
calculations
required External
Area Replacement: Fig UG-37.1
Pressure
From:not Internal
A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1)
A Required (internal) = 0.879
= 1.0*3.688*0.231*1 + 2*0.406*0.231*1*(1Ae = 0.855)
0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1))
= 0.5*(3.688*0*1 + 2*0.406*0*1*(1-0.855))
A Required (external) = 0.000
A1 = max(d, 2*(t+tn)) * (E1*t-F*tr)-2*tn*(E1*t-F*tr)*(1-fr1)
A1 = 0.514
= max(3.688,2*(0.375+0.406))* (1*0.375-1*0.231)-2*0.406*(1*0.375-1*0.231)*(1A1e = 0.855)
A1e =
1.339
= max(d, 2*(t+tn)) * (E1*t-F*trE)-2*tn*(E1*t-F*trE)*(1-fr1)
A2 = max(3.688,2*(0.375+0.406))* (1*0.375-1*0)-2*0.406*(1*0.375-1*0)*(1A2 = 0.623
= 0.855) min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L))
A2e = min((0.406-0.017)*0.855*Min(5*0.375,2*6) , (0.406-0.017)*0.855*Min(5*0.406,2*6))
A2e =
0.651
= min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L))
A41 = Leg41^2*fr2
min((0.406-0)*0.855*Min(5*0.375,2*6)
, (0.406-0)*0.855*Min(5*0.406,2*6))
= 0.375^2*0.855
A41 = 0.120
0.120
Actual Area = 1.257
2.110
Actual-Required = 0.378
Acceptable
2.110
Nozzle
34
Tstd =
Swre =
Nact =
Tt =
331
332
333
334
335
336
337
338
339
340
341
342
Standard pipe wall thickness from

chart
tr
* Pa / P
= 0.231 * 0 / 155.197
Nt * (1-UTp)
= 0.531 * (1-0.125)
0.8/Nth
= 0.8/0
Req. Exterior pressure
UG-45
UG45 =
UG45a =
UG45b =
UG45b1 =
UG45b2 =
UG45b3 =
UG45b4 =
Max(UG45a, UG45b) <=

Nact Max(trn,trnE) + Nca + Tt
Min(UG45b3,UG45b4)
Max(tr + Sca, tmin16b + Sca)
Max(Swre + Sca,tmin16b +
Sca) Max(UG45b1,UG45b2)
Tstd*0.875 + Nca
= Max(0.142, 0.332) <= 0.465

= Max(0.017,0) + 0.125 + 0
= Min(0.356, 0.332)
= Max(0.231 + 0.125, 0.094 + 0.125)
= Max(0 + 0.125,0.094 + 0.125)
= Max(0.356,)
= 0.237*0.875 + 0.125
Actual Wall Thick.

Ug-31(c)(2) threads
Tstd =
Swre =
Nact =
Tt =
0.237
0.000
0.465
0.000
Acceptable
UG45 = 0.332
UG45a = 0.142
UG45b = 0.332
UG45b1 = 0.356
UG45b2 =
UG45b3 = 0.356
UG45b4 = 0.332
30
31

N2 - 4" SCH 160 Pipe on Bot. Head <- Description
22
33
35
36
37
39
40
41
42
43
44
45
46
47
48
49
50
51
54
55
57
58
61
71
74
87
88
90
95
101
102
108
111
127
133
141
142
143
145
146
148
149
207
208
209
212
215
216
219
220
225
226
230
231
240
249
250
Shell:
Do
Nt
0.000 <- trE, required shell wall thickness ext. press.(E=1)
t
Leg41
0.094 <- tmin16b, Min allowed wall per UG-16(b)
Nozzle:
Leg41
Shell
17,600 <- B, from A =
0.09590
Vt
UW-16.1 (c)
0.125 <- nca, nozzle corrosion allowance
6.000 <- L, exterior Projection
Reinforcing:
1.000 <- F
Variables:
UT = Nt*UTp
= 0.531 * 0.125
Undertolerance
UT =
Effective Radius
= 4.5/2 - (0.531-0.125) + 0.066
Rn =
t = Vt-sca
= 0.5 - 0.125
t=
tn = Nt-nca Do= 0.531-0.125
tn =
Opening Dia.
d = 2*tn
= 4.5 - 2*0.406
d=
fr1 = MIN(Sn/Sv,1)
= MIN(17100/20000, 1)
fr1 =
fr2 = MIN(Sn/Sv,1)
= MIN(17100/20000, 1)
fr2 =
tcLeg41 = Min(0.25,0.7*Min(0.75,tn,t))
= Min(0.25,0.7*Min(0.75,0.406,0.375))
tc41 =
F=
Pipe Required Wall Thickness - trn from internal, trnE from external pressure
LDo = L/Do
LDo = 1.333
Dot = Do/trnE
Dot = 0.000
trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT
= (155.2*1.91)/(17100*1 - 0.6*155.2)
trn = 0.017
trnR = (P*Rn)/(Sn*1 - 0.6*P)
= (155.2*1.91)/(17100*1 - 0.6*155.2)
E=1
trnR = 0.017
= (3*4.5*0)/(4*17600)
trnE = 0.000
0.7*0.375 >= 0.25
0.263
>=
0.250
0.7*Leg41 >= tc41
Pressure From: Internal
A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1)
= 1.0*3.688*0.233*1 + 2*0.406*0.233*1*(1-0.855)
Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1))
= 0.5*(3.688*0*1 + 2*0.406*0*1*(1-0.855))
A Requi red (external) =
A1 = 0.507
= max(3.688,2*(0.375+0.406))* (1*0.375-1*0.233)-2*0.406*(1*0.375-1*0.233)*(1-0.855)
A1e =
A1e = max(d, 2*(t+tn)) * (E1*t-F*trE)-2*tn*(E1*t-F*trE)*(1-fr1)
= max(3.688,2*(0.375+0.406))* (1*0.375-1*0)-2*0.406*(1*0.375-1*0)*(1-0.855)
A2 = 0.623
A2 = min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L))
= min((0.406-0.017)*0.855*Min(5*0.375,2*6) , (0.406-0.017)*0.855*Min(5*0.406,2*6))
A2e =
A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L))
= min((0.406-0)*0.855*Min(5*0.375,2*6) , (0.406-0)*0.855*Min(5*0.406,2*6))
= 0.375^2*0.855
A41 = 0.120
A41 = Leg41^2*fr2
Actual Area = 1.250
Acceptable
Nozzle
34
Tstd =
Swre =
Nact =
Tt =
331
332
333
334
335
336
337
338
339
340
341
342
Standard pipe wall thickness from chart

tr * Pa / P
= 0.233 * 0 / 155.197
Nt * (1-UTp)
= 0.531 * (1-0.125)
0.8/Nth
= 0.8/0

Actual Wall Thick.
Ug-31(c)(2) threads
UG-45
UG45 =
UG45a =
UG45b =
UG45b1 =
UG45b2 =
UG45b3 =
UG45b4 =
Max(UG45a, UG45b) <= Nact

Max(trn,trnE) + Nca + Tt
Min(UG45b3,UG45b4)
Max(Swre + Sca,tmin16b + Sca)
Max(UG45b1,UG45b2)
Tstd*0.875 + Nca
= Max(0.142, 0.332) <= 0.465

= Max(0.017,0) + 0.125 + 0
= Min(0.358, 0.332)
= Max(0.233 + 0.125, 0.094 + 0.125)
= Max(0 + 0.125,0.094 + 0.125)
= Max(0.358,)
= 0.237*0.875 + 0.125
0.237
0.000
0.465
0.000
Acceptable
UG45 = 0.332
UG45a = 0.142
UG45b = 0.332
UG45b1 = 0.358
UG45b2 =
UG45b3 = 0.358
UG45b4 = 0.332
Tstd =
Swre =
Nact =
Tt =
0.066
1.910
0.375
0.406
3.688
0.855
0.855
0.250
1.000
Acceptable
Acceptable
Acceptable
External
0.000
1.339
0.651
0.120
2.110
2.110
18
B16.5/16.47 Flange
SlipOn
19
20
21
22

N1 & N2 - 4" Class 150 RFSO <- Description
23
24
Select Flange
SA
Forged
SA 105
150
4.00
25
26
27
28
29
<- Category
<- Material Type
<- Material
<- Pressure Class
<- Nominal Size
31
Nominal Table Max Temp F Pod, pipe OD -
32
33
34
35
36
C-Si
2-1.1
1000
4.500
Nozzle
0.531 <- tn, Nozzle Wall Thickness (inch)
0.017 <- tnr, Required Nozzle Wall Thickness (inch)
37
38
39
40
41
42
43
Operating Conditions
120 <- T, temperature F
155.2 <- P, pressure, psig
0.125 <- Corr, corrosion allowance
Acceptable
Max press @100F [p1] 285
Max press @120F [p2] 280
44
45
47
48
49
50
Flange Welds:
0.531
0.531
17100
20000
<- F1, pipe fillet size

<- F2, flange fillet size F2
<- Sp, allowable stress, pipe
<- Sf, allowable stress, flange
53
54
61
63
64
67
68
69
70
72
74
75
78
79
81
82
83
Geometry constraint: VIII UW-21 (b)

wtmin = 0.7*tn
wt = 0.7*MIN(F1,F2)
= 0.7*MIN(0.531,0.531)
Weld Strength:
Min Sa =
Max Weld Stress =
Weld Load =
Weld Area =
=
Weld Stress =
= 0.7*0.531
Req. weld throat

Actual weld throat
MIN(Sp,Sf)
= MIN(17100,20000)
Sa * 0.49
= 17100 * 0.49
POD^2*pi*P/4
= 4.5^2*pi*155.197/4
Pod*pi*(F1-corr + F2)
4.5*pi*(0.531-0.125 + 0.531)
Load/Area
= 2468.305/13.247
wtmin = 0.372
wt = 0.372
Acceptable
Min Sa =
Max S =
Load =
Area =
17,100
8,379
2,468
13.247
Stress = 186
Acceptable
15
Coupling
UW16.1Z1M
16

N3 - 1" Class 6000 NPT Half Coupling <- Description
22
18
20
0.675
0.233
1.875
155.2
23
24
26
28
29
30
31
32
33
35
37
38
COD
Shell:
Coupling:
1 inch 6000#
SA-105
20,000
0.3750
0.094
0.125
39
40
42
44
46
<<<<-
t, Shell Wall Thick (inch)

tMin, Min Required Wall at E=1 (inch)
D, Shell Opening Diameter (inch)
P,design Pressure (psi)
POD
t
F1
Outsid
e
FUL
L
PEN.
t1
<<<<<<-
Coupling
Coupling Material
D
Sn, Allowable Stress Level (Sn)
F1, Weld Size
UW-16.1 (Z-1)
tmin16b, Min allowed wall per UG-16(b)
(Modified)
Corrc, Coupling Corrosion Allowance (inch)
2.250 <- COD - Coupling OD
1.315 <- POD - Pipe OD
11.500 <- n, Threads Per Inch
0.358 <- pt, Corresponding sch XXS Wall Thickness (inch)
12.5% <- UT, Under Tolerence (%)
Inside
Vessel
47
49
50
51
53
56
64
Geometry Restrictions Fig. UW-16.1

tcp = (COD-POD)/2-CORRC
Tmin = Min(0.75,tcp,t)
tcmin = Min(0.25,0.7*Tmin)
t1 = 0.7*F1
t1 > = tcMin
=
=
=
=
=
(2.25-1.315)/2-0.125
Min(0.75,0.343,0.675)
Min(0.25,0.7*0.343)
0.7*0.375
0.263 >= 0.24
Tcp
Tmin
tcmin
t1
=
=
=
=
0.343
0.343
0.240
0.263
Acceptable
74
75
76
77
78
Required Coupling Wall Thickness UG-44(c), B16.11 - 2.1.1 and UG-31(c)(2)

Ro = POD/2-0.8/n
= 1.315/2-0.8/11.5
tp = (1-UT)*pt-Corrc-0.8/n
= (1-0.125)*0.358-0.125-0.8/11.5
Min Thick = P*Ro/(Sn*1+0.4*P)
= 155*0.588/(20000*1+0.4*155. Acceptable
Ro = 0.588
tp = 0.119
trn = 0.005
79
80
81
82
83
88
89
Pressure Weld Stress UW-18(d) - Pressure Load only

UW-16(f)(3)(a)(3)(b)
Load = COD^2*(PI()/4)*P
= 2.25^2*(PI()/4)*155.197
Load
Weld Area = pi()*((COD+F1)^2-COD^2)/4
Weld Area
= pi()*((2.25+0.375)^2-2.25^2)/4
= Min(20000,0) * 0.55
Max Stress
Max Stress = Min(Sn,Sv) * 0.55
Weld Stress = Load / Area
= 617 / 1.436
Weld Stress
90
95
96
97
98
99
100
101
104
105
106
107
108
109
= 11000
= 430
Acceptable
UG-45
Tstd
Nact
Tt
UG45
=
=
=
=
=
UG45a =
102
103
= 617
= 1.436
UB45b =
=
UG45b1 =
=
UG45b4 =

Tstd =
Pt * (1-UT)
Actual Wall Thick.
Nact =
Tt =
0.8/n
Ug-31(c)(2) threads
UG45 =
Max(0.199, 0.241) <= 0.313
trn + corrc + Tt
UG45a =
0.005 + 0.125 + 0.07
Min(UG45b1, UG45b4)
UB45b =
Min(0.358, 0.241)
Max(tmin+ CORRC, Tmin16b + CORRC)
UG45b1 =
Max(0.233 + 0.125, 0.094 + 0.125)
Tstd*0.875 + corrc
= 0.133*0.875 + 0.125
UG45b4 =
0.133
0.313
0.070
0.241
Acceptable
0.199
0.241
0.358
0.241
30
UG40(a-2) <- SavedDesign

31
22
33
34
35
36
37
39
40
41
42
49
57
62
64
65
66
67
70
72
74
77
78
79
80
81
82
83
84
85
86
87
91
95
98
104
112
115
119
120
121
122
123
124
130
133
148
156
185
199
200
201
202
203
204
205
206
207
210
213
217
221
237
245
249
250

N4 & N5 - 4" Double Sided Flange Pad <- Description
Shell:
tp
di
Flange Pad:
SA-240 316 <- Flange Pad Material
20,000 <- Sp, allowable stress level
9.000 <- Dp, outside diameter
4.500 <- di, inside (uncorroded)
1.500 <- tp, pad thick
1.000 <- F
5.500 <- GOD - gasket OD
4.500 <- GID - gasket ID
3.000 <- m - gasket factor
1,800 <- gy - gasket factor y
7.500 <- varC - bolt circle dia
0.625 <- BoltOD, bolt size
8 <- Nbolt, number of bolts
1.000 <- DepthT, depth of bolt holes
25,000 <- Sb - allowable bolt stress at DESIGN temp
25,000 <- Sba - allowable bolt stress at ASSEMBLY temp
Variables:
Dp = Min(2*d,DpEntered)
= Min(2*4.75,9)
t = Vt-sca
= 0.5 - 0.125
te = tp-Vt
= 1.5-0.5
d = di+2*nca
= 4.5 - 2 * 0.125
fr2 = MIN(Sp/Sv,1)
= MIN(20000/20000, 1)
fr4 = MIN(Sp/Sv,1)
= MIN(20000/20000,1)
varN = (GOD-GID)/2
= (5.5-4.5)/2
b0 = varN / 2
= 0.5 / 2
varb = min(Sqrt(b0)/2,b0)
= min(Sqrt(0.25)/2,0.25)
varG = max(GOD-2*varb,(GOD-GID)/2 + GID)
= max(5.5-2*0.25,(5.5-4.5)/2 + 4.5)
= 9/2
Ro = Dp/2
= Min(0.25,0.7*MIN(0.75,1,0.375))
tcLeg42 = Min(0.25,0.7*MIN(0.75,te,t))
0.7*Leg42 >= tc42
0.7*0.5 >= 0.25
Bolt Loads:
H = 0.785*varG^2*P
= 0.785*5^2*155.197
= 2*0.25*3.14*5*3*155.197
HP = 2*varb*3.14*varG*m*P
HD = pi/4 * di^2 * P
= pi/4 * 4.5^2 * 155.197
= 3046 - 2468
HT = H - HD
Wm1 = H + HP pi*varb*varG*gy
= 3046 + 3655
= pi*0.25*5*1800
Wm2 = max(Wm1/Sb, Wm2/Sa)
Am = Root*Nbolt >= Am
= max(6701/25000, 7069/25000)
= 0.207*8
Ab =
A = 1.0*d*tr*F
= 1.0*4.75*0.231*1
Ae = 0.5*d*trE*1
= 0.5*4.75*0*1
A1 = (d)* (E1*t-F*tr)
= (4.75) * (1*0.38-1*0.23)
A1e = (d) * (Eone*t-F*trE)
= (4.75) * (1*0.375-1*0)
A5 = ((Dp - d)te-BoltOD*DepthT*2)*fr4
= ((9-4.75)*1-0.625*1*2)*1
= 0.5^2*1
A42 = Leg42^2*fr2
Full
F
Penn.
t
Leg42
Dp
Leg42
Shell
Vt
UG-40 (a-2)
Effective Reinforcing
Effective Reinf. Thick.
Finished Opening Dia.
Gasket Width in Contact

gasket seating width
eff seating width
gasket load reaction diameter
Dp =
t=
te =
d=
fr2 =
fr4 =
varN =
b0 =
varb =
varG =
9.000
0.375
1.000
4.750
1.000
1.000
0.500
0.250
0.250
5.000
Ro = 4.500
tc42 = 0.250
F = 1.000
0.350
>=
0.250
H=
HP =
end load
HD =
face load
HT =
bolt load
Wm1 =
seating load
Wm2 =
req bolt area
Am =
Acceptable
Ab =
A Required (external) =
A1 = 0.684
A1e =
A5 = 3.000
A42 = 0.250
Actual Area = 3.934
Acceptable
end load
contact load
Acceptable
3046
3655
2468
577
6701
7069
0.283
1.656
External
0.000
1.781
3.000
0.250
5.031
5.031
Flange
ASME VIII Div I Appendix 2
N4 & N5 - 4" Process Connections Description
3
4
5
9.000
4.500
1.500
0.500
7
8
9
12
13
14
17
18
19
20
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
HG
t
tn
hT
Shell
HD
5.500
4.500
3.00
1,800
GOD [in] - gasket OD

GID [in] - gasket ID
m - gasket factor
gy - gasket factor y
7.500
0.625
8.0
1.000
0.500
varC [in] - bolt circle dia

BoltOD [in] - bolt size
Nbolt - number of bolts
DepthT [in] - thread depth
Leg1 [in]
HT
C
A
Fig 2-13.2 Modified
Operating Conditions:
0.125 Corr [in] - corrosion allowance
155.2 P [psi] - internal operating pressure
Material Properties:
NonCast CastMaterial? - Cast Or NonCast
20,000 Sf [psi] - allowable flange stress at DESIGN temp.
20,000 Sfa [psi] - Allowable Flange Stress at ASSEMBLY temp.
27,900,000 Efo [psi] -Operating Flange Modulus
27,900,000 Efs [psi] - Seating Flange Modulus
20,000 Sb [psi] - allowable bolt stress at DESIGN temp
20,000 Sba [psi] - allowable bolt stress at ASSEMBLY temp
tmin = min(0.75,tn,t)
tc = max(0.25,0.7*tmin)
ThroatLeg1 = 0.7*Leg1
ChTL1 = ThroatLeg1 >= tc
MIN(0.75,0.5,1.5) =
MAX(0.25,0.7*0.5) =
0.7*0.5 =
0.35 >= 0.35 =
47
48
Bolt Loads:
38
39
40
41
42
43
44
45
46
49
50
51
52
hD
Calculated Dimensions:
B = Bn+2*Corr
4.5+2*0.125 =
varN = (GOD-GID)/2
Gasket width in contact
(5.5-4.5)/2 =
b0 = varN / 2
Gasket seating width
0.5 / 2 =
varb = IF(b0>0.25,Sqrt(b0)/2,b0)
Effective seating width
IF(0.25>0.25,SQRT(0.25)/2,0.25) =
varG = IF(b0>0.25,GOD-2*varb,(GOD-GID)/2 + GID)
IF(0.25>0.25,5.5-2*0.25,(5.5-4.5)/2 + 4.5) =
ThreadMin = 0.75*Sf/Sb
UG-43(g)
0.75*20000/20000 =
CheckTrdMin = ThreadMin <= DepthT
0.75 <= 1 =
37
Bolting:
16
21
A [in] - flange OD
Bn [in] - ID, uncorroded
t [in] - flange thickness
tn [in] - nozzle wall thickness
Gasket:
11
15
Fig2-13.2modified fd? - Select a flange design
10
hG
Dimensions:
0.500
0.350
0.350
Acceptable
4.750
0.500
0.250
0.250
5.000
0.750
Acceptable
(VIII App 2-5)
H=
HP =
HD =
HT =
0.785*varG^2*P
end load
2*varb*3.14*varG*m*P
contact load
pi()/4 * A^2 * P
end load
H - HD
face load
0.785*5^2*155.2 =
2*0.25*3.14*5*3*155.2 =
PI()/4 * 9^2 * 155.2 =
3046 - 9873 =
3,046
3,655
9,873
-6,827
Flange :
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
bolt load
Wm1 = H + HP
3046 + 3655 =
Wm2 = pi()*varb*varG*gy
seating load
PI()*0.25*5*1800 =
Am = Max(Wm1/Sb, Wm2/Sba)
Bolt area required
MAX(6701/20000, 7069/20000) =
RootArea [sq. in] = PVELookup("BoltSizing","Lookup","Root Area",BoltOD)
Ab = RootArea*Nbolt
0.208*8 =
CheckExcess = Ab>=Am
1.664>=0.353 =
Flange Loads: (App 2-5)

W [lb] = (Am + Ab)*Sba/2
seating conditions
HG [lb] = Wm1 - H
operating conditions
TBoltLoad [lb] = (W+Wm1)/Nbolt
Flange Moment Arms: (Table App 2-6 - loose flanges)
mhD [in] = (varC-A)/2
mhT [in] = (varC-(A+varG)/2)/2
mhG [in] = (varC-varG)/2
21
Flange Moments: (App 2-6)

MD [in-lb] = HD * mhD
end pressure
face pressure
MT [in-lb] = HT * mhT
gasket load
MG [in-lb] = HG * mhG
Mo1 [in-lb] = MD+MT+MG
total operating
total seating
Mo2 [in-lb] = W*(varC-varG)/2
22
Graph:
16
17
18
19
20
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
6,701
7,069
0.353
0.208
1.664
Acceptable
(0.353 + 1.664)*20000/2 = 20,174

6701 - 3046 = 3,655
(20174+6701)/8 = 3,359
(7.5-9)/2 = -0.750
(7.5-(9+5)/2)/2 = 0.250
(7.5-5)/2 = 1.250
9873 * -0.75 =
-6827 * 0.25 =
3655 * 1.25 =
-7405+-1707+4569 =
20174*(7.5-5)/2 =
-7,405
-1,707
4,569
-4,543
25,218
App 2-7.1 Value of Y
K = A/B
Y = PVELookup("Y","FlangeFactorK",K)
9/4.75 = 1.895
3.205
Flange Seating Stress: (App 2-7,8)

STs = Y*ABS(Mo2) / (t^2*B)
CheckSTs = ABS(STs) <= Sfa
3.205*ABS(25218) / (1.5^2*4.75) = 7,563

ABS(7563) <= 20000 = Acceptable
Flange Operating Stress: (App 2-7,8)

STo = Y*ABS(Mo1) / (t^2*B)
CheckSTo = STo <= Sf
3.205*ABS(-4543) / (1.5^2*4.75) = 1,362

1362 <= 20000 = Acceptable
Flange Flexibility: (App 2-14)

Jseating = (109.4*Mo2) / (Efs*t^3*ln(K)*0.2)
(109.4*25218) / (27900000*1.5^3*LN(1.895)*0.2) =
CheckJSt = ABS(Jseating) <= 1
ABS(0.229) <= 1 =
Joperating = (109.4*Mo1) / (Efo*t^3*ln(K)*0.2)
(109.4*-4543) / (27900000*1.5^3*LN(1.895)*0.2) =
CheckJOp = ABS(Joperating) <= 1
ABS(-0.041) <= 1 =
0.229
Acceptable
-0.041
Acceptable
31
22
33
34
35
36
37
39
40
41
42
43
44
45
46
47
48
49
50
51
54
55
57
58
59
61
63
65
66
69
71
72
73
75
87
88
90
91
95
96
97
101
102
108
111
114
115
126
131
132
141
143
145
146
148
151
155
158
171
Nozzle Reinforcement :
UW16(h) <- SavedDesign

M1 - 12" x 16" Manway on Head c/w 3" x 3/4" Ring <- Description
Shell:
Do
Nt
Leg41
Leg42
te
Ring
Nozzle:
g
Vt
Shell
17,600 <- B, from A =
0.09590
Proj
Dp
Weld to connect
t
to reinforcing pad
Leg43
UW-16.1 (h)
0.750 <- Ip, interior projection
Reinforcing:
SA-516 70 <- Reinforcing plate material
At least one telltale hole (max. size NPS 1/4 tap) in repad required
20,000 <- Sp, allowable stress level
21.500 <- Dp, outside diameter
0.500 <- te, reinforcement thick
0.675 <- LegG, depth of groove
Variables:
UT = Nt*UTp
= 0.75 * 0
Undertolerance
UT = 0.000
Effective Radius
= 17.5/2 - (0.75-0) + 0
Rn = 8.000
Effective Reinforcing
Dp = Min(2*d,DpEntered)
= Min(2*16,21.5)
Dp = 21.500
t = Vt-sca
= 0.675 - 0.125
t = 0.550
Nom Thick of Int. Proj.
ti = Nt-2*nca
= 0.75 - 2 * 0
ti = 0.750
Effective Reinf. Thick.
te = teEntered
te = 0.500
tn = Nt-nca
= 0.75-0
tn = 0.750
Opening Dia.
= 17.5 - 2*0.75
d = Do-2*tn
d = 16.000
fr1 = MIN(Sn/Sv,1)
= MIN(17100/20000, 1)
fr1 = 0.855
= MIN(17100/20000, 1)
fr2 = MIN(Sn/Sv,1)
fr2 = 0.855
fr3 = MIN(Sn/Sv,Sp/Sv,1)
= MIN(17100/20000, 20000/20000,1)
fr3 = 0.855
= MIN(20000/20000,1)
fr4 = MIN(Sp/Sv,1)
fr4 = 1.000
h = MIN(Ip-sca,2.5*t,2.5*ti)
= MIN(0.75-0.125,2.5*0.55,2.5*0.75)
h = 0.625
= Min(0.25,0.7*Min(0.75,0.55,0.75))
tcLeg43 = Min(0.25,0.7*Min(0.75,t,tn))
tc43 = 0.250
F = 1.000
F = 1.000
trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT
= (155.2*8)/(17100*1 - 0.6*155.2)
trn = 0.073
Acceptable
trnR = (P*Rn)/(Sn*1 - 0.6*P)
= (155.2*8)/(17100*1 - 0.6*155.2)
E=1
trnR = 0.073
Acceptable
= (3*17.5*0)/(4*17600)
trnE = 0.000
0.7*Leg41 >= 0.7*min(0.75,te,tn)
0.7*0.5 >= 0.7*Min(0.75,0.5,0.75)
0.350
>=
0.350
Acceptable
0.7*Leg42 >= 0.5*Min(0.75,te,t)
0.7*0.375 >= 0.5*Min(0.75,0.5,0.55)
0.263
>=
0.250
Acceptable
0.7*Leg43-nca >= tc43
0.7*0.375-0 >= 0.25
0.263
>=
0.250
Acceptable
Nozzle
30
175
207
208
209
212
215
216
219
220
223
224
228
229
233
234
236
241
244
247
249
250
256
257
260
261
262
266
267
271
272
273
276
277
278
279
283
284
288
294
295
296
297
301
308
309
312
313
320
321
326
327
331
332
333
334
335
336
337
338
339
340
341
342
M1 - 12" x 16" Manway on Head c/w 3" x 3/4" Ring
Pressure From:
Internal
A Required (internal) =
A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1)
6.690
= 1.0*16*0.413*1 + 2*0.75*0.413*1*(1-0.855)
A Requi red (external) =
Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1))
= 0.5*(16*0*1 + 2*0.75*0*1*(1-0.855))
A1 = 2.170
= max(16,2*(0.55+0.75))* (1*0.55-1*0.413)-2*0.75*(1*0.55-1*0.413)*(1-0.855)
A1e =
= max(16,2*(0.55+0.75))* (1*0.55-1*0)-2*0.75*(1*0.55-1*0)*(1-0.855)
A2 = min((tn-trnR)*fr2*min(5*t,2*L) , (tn-trnR)*(Min(2.5*tn+te,L)*fr2*2)
A2 = 1.592
= min((0.75-0.073)*0.855*min(5*0.55,2*1.5) , (0.75-0.073)*(Min(2.5*0.75+0.5,2*1.5)*0.855*2)
A2e =
A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , 2*(tn-trnE)*Min(2.5*tn+te,L)*fr2)
= min((0.75-0)*0.855*Min(5*0.55,2*1.5) , 2*(0.75-0)*Min(2.5*0.75+0.5,1.5)*0.855)
A3 = 0.802
A3 = Min(5*t*ti*fr2, 5*ti*ti*fr2, 2*h*ti*fr2)
= Min(5*0.55*0.75*0.855, 5*0.75*0.75*0.855, 2*0.625*0.75*0.855)
=(21.5 - 16 - 2*0.75)*0.5*1
A5 = 2.000
A5 = (Dp - d - 2tn)te*fr4
A41 = 0.5^2*0.855
A41 = 0.214
A41 = Leg41^2*fr3
A42 = 0.375^2*1
A42 = 0.141
A42 = Leg42^2*fr4
= (0.375-0)^2*0.855
A43 = 0.120
A43 = (Leg43-nca)^2*fr2
Actual Area = 7.038
Acceptable
Internal Weld Load: (UG-41)
WmaxI = (A - A1 + 2*Tn*Fr1*(E1*t-F*tr))*Sv, min0
= (6.69 - 2.17 + 2*0.75*0.855*(1*0.55-1*0.413))*20000
WmaxI =
W 1-1 = MIN((A2 + A5 + A41 + A42)*Sv,WmaxI)
= MIN((1.592 + 2 + 0.214 + 0.141)*20000,93927)
W 2-2 = Min((A2 + A3 + A41 + A43 + 2*Tn*t*frone)*Sv,WmaxI)
= Min((1.592 + 0.802 + 0.214 + 0.12 + 2*0
W 3-3 = Min((A2 + A3 + A5 + A41 + A42 + A43 + 2*Tn*t*fr1)*Sv,WmaxI)
Weld load
= Min((1.592 + 0.802 + 2 + 0.214 + 0.141 + 0.12 + 2*0.75*0.55*0.855)*20000,93927)
External Weld Load: (UG-41)
WmaxE = (Ae - A1e + 2*Tn*Fr1*(E1*t-F*tr))*Sv, min0
W1-1 =
=
W 2-2 =
W 3-3 =
=
Min((A2e + A3 + A41 + A43 + 2*Tn*t*frone)*Sv,WmaxE)
Weld load
= Min((1.763 + 0.802 + 0.214 + 0.12 + 2*0
Min((A2e + A3 + A5 + A41 + A42 + A43 + 2*Tn*t*fr1)*Sv,WmaxE)

Min((1.763 + 0.802 + 2 + 0.214 + 0.141 + 0.12 + 2*0.75*0.55*0.855)*20000,0)
Component Strength (UG-45(c), UW-15(c))

A2 shear = PI()/2*(Do-tn)*tn*Sn*0.7
g tension = PI()/2*Do*LegG*Min(Sv,Sn)*0.74
A41 shear = PI()/2*Do*Leg41*Min(Sn,Sp)*0.49
A42 shear = PI()/2*DP*Leg42*Min(Sv,Sp)*0.49
Weld load
= PI()/2*(17.5-0.75)*0.75*17100*0.7
= PI()/2*17.5*0.675*Min(20000,17100)*0.74
= PI()/2*17.5*0.5*Min(17100,20000)*0.49
= PI()/2*21.5*0.375*Min(20000,20000)*0.49
Failure mode along strength path (Greater than Weld Load, see App L-7)
S1-1 = A42s + A2s >= W1-1
= 124113 + 236206 >= 78923
S2-2 = A41s + gt >= W2-2
= 115165 + 234795 >= 68654
S3-3 = gt + A42s >= W3-3
= 234795 + 124113 >= 93927
Tstd = Standard pipe wall thickness from chart
Swre = tr * Pa / P
= 0.413 * 0 / 155.197
Actual Wall Thick.
Nact = Nt * (1-UTp)
= 0.75 * (1-0)
Ug-31(c)(2) threads
Tt = 0.8/Nth
= 0.8/0
UG-45
UG45 = Max(UG45a, UG45b) <= Nact
= Max(0.073, 0.328) <= 0.75
UG45a = Max(trn,trnE) + Nca + Tt
= Max(0.073,0) + 0 + 0
UG45b = Min(UG45b3,UG45b4)
= Min(0.538, 0.328)
UG45b1 = Max(tr + Sca, tmin16b + Sca)
= Max(0.413 + 0.125, 0.094 + 0.125)
UG45b2 = Max(Swre + Sca,tmin16b + Sca)
= Max(0 + 0.125,0.094 + 0.125)
UG45b3 = Max(UG45b1,UG45b2)
= Max(0.538,)
UG45b4 = Tstd*0.875 + Nca
= 0.375*0.875 + 0
0.000
8.680
1.763
0.802
2.000
0.214
0.141
0.120
13.720
13.720
93,927
W 1-1 = 78,923
W 2-2 = 68,654
W 3-3 = 93,927
WmaxE = 0
= (0 - 8.68 + 2*0.75*0.855*(1*0.55-1*0.413))*20000
MIN((A2e + A5 + A41 + A42)*Sv,WmaxE)

MIN((1.763 + 2 + 0.214 + 0.141)*20000,0)
External
W 1-1e = 0
W 2-2e = 0
W 3-3e = 0
A2s
gt
A41s
A42s
=
=
=
=
236,206
234,795
115,165
124,113
Acceptable
S1-1 = 360,318
Acceptable
S2-2 = 349,960
Acceptable
S3-3 = 358,908
Tstd =
Swre =
Nact =
Tt =
0.375
0.000
0.750
0.000
Acceptable
UG45 = 0.328
UG45a = 0.073
UG45b = 0.328
UG45b1 = 0.538
UG45b2 =
UG45b3 = 0.538
UG45b4 = 0.328
30
UW16(c)mod <- SavedDesign
31
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
54
55
57
58
59
61
71
73
74
87
88
90
95
96
101
102
108
111
126
127
131
133
141
142
143
145
146
148
150
158
171
180
181
182
183
207
208
209
212
215
216
219
220
225
226
230
231
233
234
240
247
249
250

M2 - 12" x 16" Manway c/w 4 x 3/4" Ring on Shell <- Description
Shell:
OD Nozzle
Nt
Leg43
59.00 <- Ds, Shell ID
Full
Penn.
t
Leg41
Leg41
Shell
Nozzle:
Vt
17,600 <- B, from A =
0.09590
Leg43
Proj
UW-16.1 (c) modified
0.875 <- Ip, interior projection
Reinforcing:
1.000 <- F
Variables:
UT = Nt*UTp
= 0.75 * 0
Undertolerance
= 17.5/2 - (0.75-0.125) + 0
Effective Radius
t = Vt-sca
= 0.5 - 0.125
ti = Nt-2*nca
= 0.75 - 2 * 0.125
Nom Thick of Int. Proj.
tn = Nt-nca
= 0.75-0.125
Avail. Nozzle Thick. No
d = Do-2*tn
= 17.5 - 2*0.625
UT Opening Dia.
fr1 = MIN(Sn/Sv,1)
= MIN(17100/20000, 1)
fr2 = MIN(Sn/Sv,1)
= MIN(17100/20000, 1)
h = MIN(Ip-sca,2.5*t,2.5*ti)
= MIN(0.875-0.125,2.5*0.375,2.5*0.5)
tcLeg41 = Min(0.25,0.7*Min(0.75,tn,t))
= Min(0.25,0.7*Min(0.75,0.625,0.375))
tcLeg43 = Min(0.25,0.7*Min(0.75,t,tn))
= Min(0.25,0.7*Min(0.75,0.375,0.625))
LDo = L/Do
LDo = 0.150
Dot = Do/trnE
Dot =
trn = (P*Rn)/(Sn*E - 0.6*P) <= tn-UT
= (155.2*8.125)/(17100*1 - 0.6*155.2)
trn =
trnR = (P*Rn)/(Sn*1 - 0.6*P)
= (155.2*8.125)/(17100*1 - 0.6*155.2)
E=1
trnR =
= (3*17.5*0)/(4*17600)
trnE =
0.7*Leg41 >= tc41
0.7*0.375 >= 0.25
0.263
>=
0.7*Leg43-nca >= tc43
0.7*0.625-0.125 >= 0.25
0.313
>=
Nozzle
22
Tstd =
Swre =
Nact =
Tt =
332
333
334
336
337
338
339
340
341
342
UT =
Rn =
t=
ti =
tn =
d=
fr1 =
fr2 =
h=
tc41 =
tc43 =
F=
0.000
0.074
0.074
0.000
0.250
0.250
0.000
8.125
0.375
0.500
0.625
16.250
0.855
0.855
0.750
0.250
0.250
1.000
Acceptable
Acceptable
Acceptable
Acceptable
Appendix 1-7 Necessary Check

when Ds>60,if(2*Rn<=Ds/3,if(2*Rn<=40, "App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
when Ds<=60,if(2*Rn<Ds/2,if(2*Rn<20,"App. 1-7 calculations not required","App. 1-7 calculations required"),"App. 1-7 calculations required")
App. 1-7 calculations not required
External
A = 1.0*d*tr*F + 2*tn*tr*F*(1-fr1)
= 1.0*16.25*0.231*1 + 2*0.625*0.231*1*(1-0.855)
Ae = 0.5*(d*trE*1 + 2*tn*trE*1*(1-fr1))
= 0.5*(16.25*0*1 + 2*0.625*0*1*(1-0.855))
A Required (external) = 0.000
A1 = 2.315
= max(16.25,2*(0.375+0.625))* (1*0.375-1*0.231)-2*0.625*(1*0.375-1*0.231)*(1-0.855)
A1e =
6.026
= max(16.25,2*(0.375+0.625))* (1*0.375-1*0)-2*0.625*(1*0.375-1*0)*(1-0.855)
A2 = min((tn-trnR)*fr2*Min(5*t,2*L) , (tn-trnR)*fr2*Min(5*tn,2*L))
A2 = 0.883
= min((0.625-0.074)*0.855*Min(5*0.375,2*2.625) , (0.625-0.074)*0.855*Min(5*0.625,2*2.625))
A2e = min((tn-trnE)*fr2*Min(5*t,2*L) , (tn-trnE)*fr2*Min(5*tn,2*L))
A2e =
1.002
= min((0.625-0)*0.855*Min(5*0.375,2*2.625) , (0.625-0)*0.855*Min(5*0.625,2*2.625))
A3 = Min(5*t*ti*fr2, 5*ti*ti*fr2, 2*h*ti*fr2)
A3 = 0.641
0.641
= Min(5*0.375*0.5*0.855, 5*0.5*0.5*0.855, 2*0.75*0.5*0.855)
A41 = Leg41^2*fr2
= 0.375^2*0.855
A41 = 0.120
0.120
A43 = (Leg43-nca)^2*fr2
= (0.625-0.125)^2*0.855
A43 = 0.214
0.214
Actual Area = 4.173
8.003
Acceptable
8.003
331
335
Page 16 of 22

tr * Pa / P
= 0.231 * 0 / 155.197
Nt * (1-UTp)
= 0.75 * (1-0)
0.8/Nth
= 0.8/0
UG-45
UG45
UG45a
UG45b
UG45b1
UG45b2
UG45b3
UG45b4
=
=
=
=
=
=
=

Max(trn,trnE) + Nca + Tt
Min(UG45b3,UG45b4)
Max(Swre + Sca,tmin16b + Sca)
Max(UG45b1,UG45b2)
Tstd*0.875 + Nca
= Max(0.199, 0.356) <= 0.75

= Max(0.074,0) + 0.125 + 0
= Min(0.356, 0.453)
= Max(0.231 + 0.125, 0.094 + 0.125)
= Max(0 + 0.125,0.094 + 0.125)
= Max(0.356,)
= 0.375*0.875 + 0.125
Actual Wall Thick.

Ug-31(c)(2) threads
Tstd =
Swre =
Nact =
Tt =
0.375
0.000
0.750
0.000
Acceptable
UG45 = 0.356
UG45a = 0.199
UG45b = 0.356
UG45b1 = 0.356
UG45b2 =
UG45b3 = 0.356
UG45b4 = 0.453
Vessel Weight and Volume

Sample Vertical Vessel Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Volume:
2
1.00
12.00
190.00
nhead - Number of heads?

SG - Fluid Specific Gravity
VE [ft3] - Volume of Each Head
VS [ft3] - Volume of Shell
Construction:
789 Wh [lb] - Weight of Each Head
3181 Ws [lb] - Weight of Shell
650 Wm [lb] - Misc Weight
Calculations:
V [ft3] =
V2 [Imp. Gallons] =
V3 [US Gallons] =
Wf [lb] =
WC [lb] =
WT [lb] =
VE*nhead + VS
V*6.229
V*7.4805
62.37*SG*V
Wh*nhead + Ws + Wm
WC + Wf
total volume
fluid weight
construction weight
total weight
12*2 + 190 =
214*6.229 =
214*7.4805 =
62.37*1*214 =
789*2 + 3181 + 650 =
5409.83 + 13347.18 =
214.00
1,333.01
1,600.83
13,347.18
5,409.83
18,757.01
Lifting Lugs
Sample Vessel 4 Liftng Lugs Description
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Dimensions:
6,000
8.000
0.500
2.500
1.500
2.500
0.250
Load [lb] - vessel weight empty

W [in] - width
Thick [in] - lug thickness
H [in] - hole height
Dia [in] - hole diameter
OR [in] - outside radius
Weld [in] - leg size
Load Case
1
OR
Dia
Load C
Case
Load
2
H
SA-516 70 Material
20,000 SA [psi] - allowed stress in tension
All of load assumed carried by one lug
Weld
All load cases analyzed independently
W
Never load lug perpendicular to face
Contour lug to fit vessel
Do not move or support vessel with this lug when full or pressurized
SB = UG-34(b) Max Bending Stress, SS = IID Tbl 1A(d) Max Shear Stress, SSw = UW-15(c) UW-15 Max Weld Shear
SB [psi] = SA * 1.5
SS [psi] = SA * 0.8
SSw [psi] = SA * 0.49
Tensile Stress (case 1):
A1 [in ] = Thick*(OR-Dia/2)
A [in ] = A1 * 2
Stress [psi] = Load / A
CheckTenStr = Stress <= SA
2
Pin Bearing Stress (case 1 and 2):

Area [in ] = Dia * Thick PinStress
[psi] = Load / Area CheckPinStr =
PinStress <= (1.6 * SA)
2
Bending Stress (case 2):

Moment [in-lb] = Load * H
I [in ] = Thick * W^3 / 12
c [in] = W/2
BendStress [psi] = Moment*c/I
CheckBendStr = BendStress <= SB
4
Shear Stress (case 2):

ShrArea [in ] = W*Thick
ShrStress [psi] = Load/ShrArea
CheckShStr = ShrStress <= SS
2
Weld Stress (case 1):

Circ [in] = W*2+Thick*2+Weld*4
WeldArea [in ] = Circ * Weld
WeldStress [psi] = Load / WeldArea
CheckWldStr = WeldStress <= SSw
2
20000 * 1.5 = 30,000

20000 * 0.8 = 16,000
20000 * 0.49 = 9,800
0.5*(2.5-1.5/2) =
0.875 * 2 =
6000 / 1.75 =
3429 <= 20000 =
0.875
1.750
3,429
Acceptable
1.5 * 0.5 = 0.750

6000 / 0.75 = 8,000
8000 <= (1.6 * 20000) = Acceptable
6000 * 2.5 =
0.5 * 8^3 / 12 =
8/2 =
15000*4/21.333 =
2813 <= 30000 =
15,000
21.333
4.000
2,813
Acceptable
8*0.5 = 4.000
6000/4 = 1,500
1500 <= 16000 = Acceptable
8*2+0.5*2+0.25*4 =
18 * 0.25 =
6000 / 4.5 =
1333 <= 9800 =
Weld Stress (case 2):

Moment2 [in-lb] = Load * H
6000 * 2.5 =
I2 [in ] = (Thick +2*Weld)* (W+2*Weld)^3 / 12 - I
(0.5 +2*0.25)* (8+2*0.25)^3 / 12 - 21.333 =
c2 [in] = W/2 + Weld
8/2 + 0.25 =
WldStress2 [psi] = Moment2*c2/I2
15000*4.25/29.844 =
CheckWldStr2 = WldStress2 <= SSw
2136 <= 9800 =
18.000
4.500
1,333
Acceptable
15,000
48
49
50
51
29.844
4.250
2,136
Acceptable
15
Vessel On Beams Ver 2.24
19
20
21
22
23
24
25
26
27
28
29
30
31
32
35
38
39
40
41
42
43
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
71
72
73
74
75
76
77
78
79
80
84
94
95
96
97
98
99
100
101
102
112
7-Jan-09
IBC-2000
17
18
Vessel Dimensions (Inch and Lbs):

162.500 <- H, height
90.000 <- L, center of gravity
27.000 <- ls, leg free length
60.000 <- Do, shell outside diameter
60.500 <- ds, leg pitch diameter
0.500 <- t, shell corroded thickness
0.250 <- ws - leg weld size
18.000 <- lw - length of leg to shell weld
35.000 <- lwf - length of weld on foot
19,000 <- W, Weight lbs
155.2 <- Pr, Pressure
Site Specific Seismic Information per IBC-2000:
1.000 <- I, occupation importance factor
E <- Site Class
0.750 <- Ss, Acc
Acceleration at Short Periods
0.300 <- S1, Accele ration at a period of one second
1.200 <- Fa, Site Coefficient
2.800 <- Fv, Site Coefficient
3.000 <- R, Res
Response Modification Factor
Leg Supports:
W6x15
4
29.100
9.320
1.460
4.430
6.000
6.000
0.800
<<<<<<<<<-
Structural Description
n, number of legs
Ix, for one leg
Iy, for one leg
fFactor, Least radius of Gyration
A, Leg Cross Sectional Area
2cx, Beam Depth
2cy, Beam Width
K1, Leg Anchor Factor
Material Properties:
17,100 <- maximum leg bending stress (Sb)
20,000 <- maximum shell stress (Sa)
Attachment Dimensions:
6.000 <- 2C1, Width of rectangular loading
6.000 <- 2C2, Length of rectangular loading
Static Deflection
E = 30,000,000
bc = 12.0
leg boundary condition based on fixed or loose leg
y = (2*W*ls^3)/(bc*n*E*(Ix + Iy))
= (2*19000*27^3)/(12*4*30000000*(29.1 + 9.32))
Period of Vibration
g = 386
T = 2*pi*sqrt(y/g)
Base Shear
Sms =
Sm1 =
Sds =
Sd1 =
Cs =
CsMAX =
CsMIN =
Csfinal =
V=
=2 * 3.14 * sqrt(0.01/386)
Fa*Ss
= 1.2*0.75
Fv*S1
= 2.8*0.3
2/3*Sms
= 2/3*0.9
2/3*Sm1
= 2/3*0.84
Sds/(R/I)
= 0.6/(3/1)
Sd1/(T*R/I)
= 0.56/(0.037*3/1)
0.044*Sds*I
= 0.044*0.6*1
if(cs<=csmax, if(cs>csmin, cs, csmin), csmax)
Csfinal*W
= 0.2*19000
y = 0.014
T = 0.037
Sms =
Sm1 =
Sds =
Sd1 =
Cs =
CsMAX =
CsMIN =
Csfinal =
V=
0.9
0.84
0.600
0.560
0.200
5.020
0.026
0.200
3800
115
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
Sample Vertical Vessel Vessel On Beams

Horizontal Seismic Force at Top of Vessel
Ftmax = 0.25*V
= 0.25 * 3800
Ftp = 0.07 * T * V
= 0.07 * 0.037 * 3800
Ft = if (T < 0.7, 0, min(0.07*T*V, Ftmax))
Horizontal Seismic Force at cg
Fh = V - Ft
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
Ftmax = 950
Ftp = 9.89
Ft = 0
= 3800 - 0
Fh = 3,800
Vertical force at cg
Fv = W
Overturning Moment at Base
Mb = L*Fh + H*Ft
Fv = 19,000
= 90 * 3800 + 162.5 * 0
Mb = 342,000
Overturning Moment at Bottom Tangent Line

Mt = (L-ls)*Fh + (H-ls)*Ft
= (90 - 27) * 3800 + (162.5 - 27) * 0
Maximum eccentric load
f1 = Fv/n + 4*Mto/(n*Do)
Mt = 239,400
= 19000/4 + 4*239400/(4 * 60)
f1 = 8,740
= 19000/4 + 4*342000/(4 * 60.5)
f2 = 10,403
Axial Load
f2 = Fv/n + 4*Mb/(n*ds)
138
139
140
7-Jan-09
Leg Loads
f3x = 0.5*V*Ix/(Ix+Iy)
f3y = 0.5*V*Iy/(Ix+Iy)
Leg Bending Moments
e = (ds-Do)/2
Mx = f1*e + f3x*ls
My = f1*e + f3y*ls
Leg Bending Stress
Sbmax = Sb * 1.25
fx = Mx*cx/Ix
fy = My*cy/Iy
=0.5* 3800*29.1 /( 29.1+9.32)

=0.5* 3800*9.32 /( 29.1+9.32)
f3x = 1,439
f3y = 461
=(60.5-60)/2
=8740*0.25 + 1439*27
=8740*0.25 + 461*27
e = 0.25
Mx = 41,041
My = 14,629
=17100 * 1.25
=41041 * 3 / 29.1
=14629 * 3 / 9.32
Leg axial stress

K1*ls/fFactor =
=0.8 * 27 / 1.46
Fa max = AISC code lookup based on K1*ls/r
fa = f2/A
=10403 / 4.43
Acceptable
Acceptable
K1*ls/fFactor = 14.795
Fa max = 25,675
fa = 2,348
Acceptable
Maximum Euler Stress

Fe = 12*pi^2*E/(23*(K1*L/r)^2)
= 12*pi^2*30000000/(23*14.795^2)
Combined Stress
Fc1 = fa/Famax + 0.85*fx/((1-fa/Fe)*Sbmax)
= 2348/25675 + 0.85*4231/((1-2348/705785)*21375)
Fc2 = fa/Famax + 0.85*fy/((1-fa/Fe)*Sbmax)
= 2348/25675 + 0.85*4709/((1-2348/705785)*21375)
Sbmax = 21,375
fx = 4,231
fy = 4,709
Fe = 705,785
Acceptable
Fc1 = 0.26
Acceptable
Fc2 = 0.28
171
172
173
174
175
176
177
Sample Vertical Vessel Vessel On Bea
7-Jan-09
Beam to Shell Attachment Stresses

Beam Dimensions
cx = 2cx/2
cy = 2cy/2
cx = 3.000
cy = 3.000
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
C dimensions for weld stress

weld area = ws*lw
wa = 4.500
wcx = lw/2
wcx = 9.000
wcz = cy + ws
wcz = 3.250
wcy = sqrt(wcx^2 + wcy^2)
Shear Force Distribution
Vx = (V*Ix)/((n/2)*(Ix+Iy))
Vy = (V*Iy)/((n/2)*(Ix+Iy))
Vg = W/n
= sqrt(9^2 + 9.569^2)
gravity
= (3800*9.32)/
((4/2)*(29.1+9.32))
= (0.25*18^3/12)*2
Iwx = 243.0
Iwz = 87.9
= 243 + 88
Iwy = 330.9
Weld Moments
Mx =
=
My1 =
Mz =
Vx*(ls+lw/2) + Vg*(ds-Do)/2
1439*(27+18/2) + 4750*(60.5-60)/2
Vy*(ls+lw/2)
Vy*(ds-Do)/2
= 461*(27+18/2)
= 461*(60.5-60)/2
Weld Stresses
Sx =
Sy =
Sz =
Sg =
Mx*wcx/Iwx
My1*wcy/Iwy
Mz*wcz/Iwz
Vg/(wa*2)
=
=
=
=
Stress Limits and Ratios

Slim = min(Sb,Sa)*0.49
SxR
SyR
SzR
SgR
=
=
=
=
Sx/Slim
Sy/Slim
Sz/Slim
Sg/Slim
Bending
Twisting
Torision
Gravity
Mx = 52,995
219
220
221
222
223
224
225
226
227
My1 = 16,593
Mz = 115
41041*9/243
16593*9.569/330.9
115*3.25/87.9
4750/(4.5*2)
= min(17100,20000)*0.49
=
=
=
=
1520/8379
480/8379
4/8379
528/8379
Acceptable
217
218
Vx = 1,439
Vy = 461
Vg = 4,750
= (3800*29.1)/
((4/2)*(29.1+9.32))
Weld Moments of Inertias

Iwx = (ws*lw^3/12)*2
Iwz = (lw*ws^3/12 + wa*(cy+ws/2)^2)*2
= (18*0.25^3/12 + 4.5*(3+0.25/2)^2)*2
Iwy = Iwx + Iwz
Foot Plate Attachment Stresses

waf = ws*lwf
Vv = V/n
Sv = Vv/waf
Sgf = Vg/waf
SvRf = Sv/Slim
SgRf = Sgf/Slim
wcy = 9.569
weld area in foot = 0.25*35

= 3800/4
Sx =
Sy =
Sz =
Sg =
1,520
480
4
528
Slim = 8,379
SxR =
SyR =
SzR =
SgR =
total (<1)
0.181
0.057
0.001
0.063
0.302
waf = 8.750
Vv = 950
= 950/8.75
= 4750/8.75
Sv = 109
Sgf = 543
= 109/8379
= 542.857/8379
Acceptable
SvRf = 0.013
SgRf = 0.065
total (<1) 0.078
7-Jan-09
231
232
WRC 107 - shell local stress at support
233
234
Loads (psi and lb)

1,439.1
10,402.9
0.0
14,629.5
0.0
0.0
235
236
237
238
239
240
<<<<<<-
P, Axial Load (=vx)

VL, Longitudinal load(=f2)
Vc, Circumferential load
ML, Moment (=My)
Mc, Moment
MT, Torisional
241
242
243
244
245
246
247
248
249
250
280
281
282
283
284
285
286
287
288
289
290
291
Parameters
MaxSPm = Sa
for Pm stresses
MaxSPmb = 1.5*Sa
for Pm + Pb stresses
MaxSPmbQ = 1.5*Sa
for Pm + Pb + Q
Ri = (Do-2*T)/2 stresses
Rm = (Do-T)/2
r = Rm/T
Beta1 = 2C1/2/Rm
Beta2 = 2C2/2/Rm
SL = (Ri-0.4*T)*Pr/(2*T)
Sc = (Ri+0.6*T)*Pr/T
Stress concentration factors
Shell Combined Stresses:
Lookup A
Curve
A Value
A Value
Pressure Stress
VIII-1 Code
4C
3C
No/(P/Rm)
3C or 4C
9.80981
7.99937
Mo/P
1C or 2C-1 0.10736
0.07214
No/(Mc/
3A
2.00349
(Rm^2*beta))
Mo/(Mc/(Rm*beta))
1A
0.08976
No/(ML/(Rm^2*beta))
3B
6.62238
Mo/(ML/(Rm*beta)) 1B or 1B-1
0.04054
292
293
294
295
296
297
298
299
300
301
VIII-1 Code
3C or 4C
1C-1 or 2C
Nx/(Mc/
4A
(Rm^2*beta))
Mx/(Mc/(Rm*beta))
2A
Nx/(ML/
4B
(Rm^2*beta))
Mx/(ML/(Rm*beta)) 2B or 2B-1
Pressure Stress
Nx/(P/Rm)
Mx/P
302
303
304
307
Shear VL
Shear VC
Total Shear
308
S1m
305
306
310
S2m
S12
311
S23
309
313
S31
Sm<= MaxSPmb
314
S1m+b
315
S2m+b
312
316
317
S12
S23
319
S31
Smb<= MaxSPmb
320
S1m+b+Q
321
S2m+b+Q
318
322
323
324
325
S12
S23
S31
Smb<= MaxSPmbQ
9.80981
0.07151
7.99937
0.10957
3.02513
0.04374
1.96743
0.05817
Pm - primary membrance stress

Pb - primary bending stress
Q - secondary stress
=
=
=
=
=
MaxSPm =
MaxSPmb =
MaxSPmbQ =
Ri =
Rm =
r=
Beta1 =
Beta2 =
SL =
Sc =
Kn =
29.75/0.5
6/2/29.75
6/2/29.75
(29.5-0.4*0.5)*155.197/(2*0.5)
(29.5+0.6*0.5)*155.197/0.5
Kb = 1
Equation
SC
Kn*A*P/(Rm*T)
Kb*A*6*P/T^2
Kn*A*Mc/(Rm^2*beta*T)
Kb*A*6*Mc/(Rm*beta*T^2)
Kn*A*ML/(Rm^2*beta*T)
Kb*A*6*ML/(Rm*beta*T^2)
Pm
Pm+Pb
Pm+Pb+Q
SL
Kn*A*P/(Rm*T)
Kb*A*6*P/T^2
Kn*A*Mc/(Rm^2*beta*T)
Kb*A*6*Mc/(Rm*beta*T^2)
Kn*A*ML/(Rm^2*beta*T)
Kb*A*6*ML/(Rm*beta*T^2)
Pm
Pm+Pb
Pm+Pb+Q
VL/(Pi*sqrt(c1*c2)*T)
VC/(Pi*sqrt(c1*c2)*T)
Sum of shears
((Sx+So)/2)+SQRT(((Sx-So)/2)^2+Txo^2)
((Sx+So)/2)-SQRT(((Sx-So)/2)^2+Txo^2)
abs(S1m - S2m)
abs(S2m-0)
abs(0-S1m)
max(S12,S23,S31)<=30000
abs(S1m - S2m)
abs(S2m-0)
abs(0-S1m)
max(S12,S23,S31)<=30000
abs(S1m - S2m)
abs(S2m-0)
abs(0-S1m)
max(S12,S23,S31)<=60000
Cat
Pm
Pm
Pb
Pm
Q
Pm
Q
So
So
So
Pm
Pm
Pb
Pm
Q
Pm
Q
Sx
Sx
Sx
Txo
Acceptable
Acceptable
Acceptable
20,000
30,000
30,000
29.5
29.75
59.50
0.101
0.101
4,547
9,250
1
Au
9250
-949
-2492
AL
9250
-949
2492
Bu
9250
-949
-2492
BL
9250
-949
2492
-2171
-4661
6130
3638
-1023
4547
-774
-3784
-2171
4661
6130
8621
13282
4547
-774
3784
2171
4661
10472
7980
12641
4547
-774
-3784
2171
-4661
10472
12963
8302
4547
-774
3784
-645
-6486
3128
-656
-7142
-645
6486
3128
6913
13399
645
6486
4418
634
7120
645
-6486
4418
8203
1717
0
0
6,130
3,128
3,001
3,128
6,130
6,130
3,638
-656
4,294
656
3,638
4,294
-1,023
-7,142
6,119
7,142
1,023
7,142
0
0
6,130
3,128
3,001
3,128
6,130
6,130
8,621
6,913
1,709
6,913
8,621
8,621
13,399
13,282
116
13,282
13,399
13,399
0
0
10,472
4,418
6,053
4,418
10,472
10,472
7,980
634
7,346
634
7,980
7,980
12,641
7,120
5,521
7,120
12,641
12,641
0
0
10,472
4,418
6,053
4,418
10,472
10,472
12,963
8,203
4,761
8,203
12,963
12,963
8,302
1,717
6,585
1,717
8,302
8,302
Cu
9250
-774
-3708
0
0
CL
9250
-774
3708
0
0
Du
9250
-774
-3708
0
0
DL
9250
-774
3708
0
0
8476
4768
4768
4547
-949
-2470
0
0
8476
12184
12184
4547
-949
2470
0
0
8476
4768
4768
4547
-949
-2470
0
0
8476
12184
12184
4547
-949
2470
0
0
3598
1128
1128
-2208
3598
6068
6068
-2208
3598
1128
1128
2208
3598
6068
6068
2208
-2208
9,327
2,747
6,579
2,747
9,327
9,327
5,809
87
5,722
87
5,809
5,809
5,809
87
5,722
87
5,809
5,809
-2208
9,327
2,747
6,579
2,747
9,327
9,327
12,897
5,354
7,543
5,354
12,897
12,897
12,897
5,354
7,543
5,354
12,897
12,897
2208
9,327
2,747
6,579
2,747
9,327
9,327
5,809
87
5,722
87
5,809
5,809
5,809
87
5,722
87
5,809
5,809
2208
9,327
2,747
6,579
2,747
9,327
9,327
12,897
5,354
7,543
5,354
12,897
12,897
12,897
5,354
7,543
5,354
12,897
12,897
123
124

Design of Pressure Vessels Under ASME Section VIII

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Design of Pressure Vessels Under ASME Section VIII

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ACKNOWLEGEMENT:

First of all thanks to Allah Almighty who has guided us and

2.16 PRESSURE VESSEL DESIGN MODEL FOR CYLINDERS

INTRODUCTION TO PRESSURE VESSELS

1.1 INTRODUCTION:What is a pressure vessel?

figure1.1 horizontal pressure vessel

figure 1.2 horizontal pressure vessel

1.2 How many types of pressure vessels are there?

Pressure vessel types?

figure1.3 stress distribution in thin walled pressure vessel

figure 1.4 thick walled pressure vessel

figure 1.5 hot water storage tank

FACTOR OF SAFETY:Factors of Safety are used because no manufacture can guarantee

safety accounts for uncertainties in materials, design,,and

1.4 PRESSURE VESSEL SAFETY

What should you expect on an over-pressurization device?

Rupture Disks should be set not higher than the PV [pressure

How should the over-pressurization device be installed?

Safety Relief Valves -

1.5 VESSELS IN INDUSTRIAL REFRIGERATION SYSTEMS

HIGH PRESSURE RECIEVERS:-

Figure High pressure receiver

LOW PRESSURE RECEIVERS:-

figure liquid level maintained in a low pressure receiver

figure OIL POTS WITH THEIR TYPICAL

figure combination of a thermosyphon receiver with a system receiver [1]

1.6 STRESSES IN PRESSURE VESSELS:-

Structural elements must be considered).

1.7 STRESS ANALYSIS

1.8 STRESS/FAILURE THEORIES

MAXIMUM SHEAR STRESS THEORY:-

GRAPH OF MAXIMUM STRESS THEORY

GRAPH OF SHEAR STRESS THEORY.

1.9 FAILURES IN PRESSURE VESSELS

1.12 TYPES AND CLASSES OF STRESS

Simultaneously are called stress categories.

mum design temperature would be the MDMT.

1.14 WEIGHTS OF VESSELS AND ITS COMPONENTS

1.15 DESIGN PRINCIPLES

figure 2.1 Stress in a loaded deformable material body assumed as a

The most general definition of stress is;

2.2 TYPES OF STRESSES:

figure2.3 tensile stress

Loading a structural element or a specimen will increase the compressive

figure2.4 compressive stress

shearing stresses are caused by the application of equal and opposite

shear stress is applied parallel or tangential to the face of the material as

figure 2.6 description of planes in tensile compressive and shear stresses

figure 2.7 description of tensile and shear stress

figure 2.7 bearing stress

figure 2.8 stress tensor

2.3( a) Dual Space:

figure 2.9 stress energy tensor

2.3 ( c) CAUCHY STRESS TENSOR:

figure 2.10 a point in an object under stress

9 components of a second order tensor

Forces results into four basic forms of deformations or displacement of

It is opposite to tension. It is subjected force applied by one object on another

figure 2.11 torsion

2.5 MECHANICAL FAILURE MODES

figure 2. 12 buckling of a column

fig 2.13 effect of oxygen concentration on the corrosion of a material in mm

2.6 TYPES OF STRUCTURAL AND SOLID BODY COMPONENTS