Class Notes On Pressure Vessel PDF

Class Notes on Pressure Vessel
The main focus of equipment design in chemical plant is the design of vessel. But while
designing the pressure vessel, chemical engineer alone will not usually be called on to undertake
the detailed design of a pressure vessel. The mechanical engineer who is familiar with the current
design codes, standard methods & various stresses theory. However the chemical engineer will
be liable for developing and specifying the basic design information for a particular vessel and
needs to have a general appreciation of pressure vessel design to work efficiently with the
specialist designer.
Chemical engineering involves the application of the sciences to the process industries
and converting raw material into finished products by using physical & chemical processes.
While performing this, handling and storing of large quantities of materials in containers of
varied construction, depending upon the nature of materials, physical and chemical properties
and the required operations which are to be performed. And for handling & storing of such a
large container is called as “vessel”. When the vessel which operates at under pressure or in
which pressure is more than atmospheric pressure is called as pressure vessel. If we take a simple
example in case of pressure cooker which was invented by Denis Papin, a French physicist, in
1679. An early pressure cooker, called a steam digester. It is also acts as a pressure vessel.
Several types of such equipment are used in chemical industry and are categorized into
two groups i.e. Fired & Unfired pressure vessel. The fired pressure vessel includes boiler. While
unfired pressure vessel includes heat exchanger, digesters, storage vessels, kettles, distillation
column, evaporators, autoclaves etc.
When the pressure is to be maintained inside the vessel then it is called as vessel
subjected to internal pressure while when the pressure is lower than the atmospheric pressure and
is to be maintained inside the vessel it is termed as vessel subjected to external pressure or vessel
operating under vacuum. Most of the process equipment’s may be considered to be vessels with
various modifications to perform certain required functions. For example, heat exchanger may be
considered to be a pressure vessel as it has suitable provision of transferring heat through
appropriate tubes operated at a certain temperature and pressure.
Apart from of the nature of the application of the vessel, a number of factors usually must
be considered in designing the units. The basic data needed by the specialist engineer will be
1. Vessel function
2. Type of fluid being handled & processed
3. Operating parameters i.e. temperature & pressure
4. Availability of different materials of construction and their cost data
5. Geometry & type of the vessel required
6. Type of service required (whether continuous, intermittent, fluctuating)
7. Influence of environment, including corrosion from chemical attack of fluid contained
and of the atmosphere. Also effects of erosion caused by high velocity of fluid flow
8. External loadings such as wind, snow etc. Also piping system attached to vessel for
subjected to internal pressure.
9. Specification of heating and cooling jackets or coils.
10. Specification of internal fittings
Classification of Pressure Vessel
The most important consideration while designing any equipment the first step is the
selection of the type of vessel that performs the requisite service to satisfy the given
condition. Thus the most common type of vessel may be classified as follows
i) According to their geometry-: it is classified as open tanks, closed tanks. A simple

cylinder with piston such as a cylinder of a press is an example of open tank vessel
whereas a tank is an example of closed vessel. It may be also either vertical or
horizontal cylinder and spherical vessel.
ii) According to their dimensions-: It is classified into either thin or thick pressure
vessel. If the ration of D/t is more than 10, then it is called as thin shell and if this
ratio is less than 10, then it is said to be thick shells which are used for a high pressure
vessel.
If the ratio of ft/P is more than 6 then it is called as thin shells and if this
ratio is less than 6 then it is called as thick shell.
If the ratio of Do/ Di is more than 1.5 then it is called as thick shells and if
this ratio is less than 5 then it is called as think shell.
In past decades, the non hazardous liquids such as brine and other aqueous solutions,
may be stored in ponds if it’s having very low value. Or they may use open steel,
wooden or concrete tanks if it’s have greater value. If the fluid is toxic, combustible
or gaseous in the storage condition and if the pressure is more than atmospheric then
it is necessary to use closed vessel. For storage of fluids at atmospheric pressure,
cylindrical tanks with flat bottoms and conical roofs are commonly used.
Pressure Vessel Code

A number of national codes which specify requirements of design, fabrication,
inspection and testing of unfired pressure vessels are available. The Indian Standards
Institute has prepared a similar code IS-2825. These codes are (add some data of law)
Material specification for temperature services
i) High temperature services-: when operating a pressure vessel at high

temperatures it may be failure because of thermal stress. For that purpose the
most important material properties that need to be considered while designing
an equipment is namely strength, short-time tensile properties at high
temperatures. It has been observed that because of rise in temperature almost
all carbon steel vessels reduced their strength, therefore it is generally
operated at a 5000C.
To increase the strength of such material, then addition of Cr, Mo, V
improves the strength at elevated temperature as well as it acts as a
resistance to scaling and oxidation. The higher the Cr content the greater is
the limiting temperature without excessive scaling. Approximate limiting
temperatures for various steels are shown as below:
C- steel : 400 0C
1 : 500 0C
C- Mo steel
2
1 1 : 540 0C
1 Cr- Mo steel
2 2
1 1 : 560 0C
2 Cr- Mo steel
2 2
1 : 620 0C
5 Cr- Mo steel
2
12 Cr : 700 0C
18 Cr-8 Ni : 900 0C
27 Cr : 1100 0C
25 Cr -12 Ni : 1040 0C
15 Cr- 20 Ni : 1100 0C
It has been important while operating steel at high temperature services, the presence
of some particular bases like H2 in the environment can cause the hydrogen
embrittlement at high temperature and pressure. For such hydrogen services,
austenitic stainless steel is used.
Similarly if in the gaseous environment containing Sulphur & Sulphur containing
compounds are also affected to austenitic stainless steels at high temperature. In such
1
environment specially has been seen in refineries processesing sour crude, 5Cr- Mo
2
steel provides good corrosion resistance in addition to high temperature strength. For
more severe conditions, 9Cr-1Mo steel provides better protection.
ii) Low temperature services-: Many chemical processes are operated at sub-zero
temperatures (below 0 0C),
Vessels subjected to internal Pressure
Failure of Cylindrical Shell-:
If a cylinder of constant wall thickness t, having length L, diameter of cylinder D, is subjected to

an internal pressure P, it is likely to be failure in the following two ways
i) The cylinder may be failure along the longitudinal direction i.e. circumferential stress
breaking the cylinder into two troughs, as shown in fig a
ii) The cylinder may be failure along the transverse i.e. longitudinal stress breaking the
cylinder into two cylindrical shells, as shown in fig b
Fig a) failure of cylinder in longitudinal direction
Fig b) Failure of cylinder in axial direction
Stress induced in cylindrical shells
Consider a thin cylindrical shells subjected to internal pressure as shown in fig. a & b. A
tensile stress acting in a direction tangential to the circumference is called circumferential or
hoop stress.
The total force acting on a longitudinal section of the shell
= Intensity of pressure × Projected area
=P×D×L
Where D = diameter of shell
L = length of shell
Area of total resisting force acting on the cylindrical shell
= 2× t × L (i.e of two section)

Where t = thickness of shell
Force
Therefore Circumferential/ Hoop stress =
Area
pDL
=
2tL
pD
ft1 =
2t
pD
or t =
2f t1 ……………(1)
While constructing a pressure vessel like steam boiler, reaction vessel, heat exchanger etc are
joined either by riveted joint or welded joint which are used in joining together the ends of steel
plates, then the wall thickness of the cylinder along with the corrosion allowance is
pD
t C
2f t1 J …………….. (2)
Where D = Mean diameter of shell i.e. mean diameter of ID & OD.
In case of internal diameter (Di) & outer diameter (Do) of shell is given by
Therefore
Di  Do
D
2
Di  Di  2t
D
2
2 D  2 D i 2t
D  D i t
Put these value in eq.2
p  ( Di  t )
t
2 fJ
2 fJt  p  Di  p  t
(2 fJ  p)  t  p  Di
p  Di
t
(2 fJ  p)
pDi
t C
2 fJ  p …………..… (3)
And for outside diameter
Therefore
Di  Do
D
2
Do  2t  Do
D
2
2 D  2 D o 2t
D  D o t
Put these value in eq.2
p  ( Do  t )
t
2 fJ
2 fJt  p  Do  p  t
(2 fJ  p )  t  p  Do
p  Do
t
(2 fJ  p)
pDo
t C
2 fJ  p …………..… (3)
And
pDo
t C
2 fJ  p ……………….. (4)
Longitudinal Stress-: Consider a closed thin cylindrical shell subjected to internal pressure as
shown in fig. c & d. Tensile stress acting in the direction of axis is called as longitudinal stress.
The total force acting on a longitudinal section of the shell
= Intensity of pressure × Projected area
D 2
=P×
4
Where D = diameter of shell
Area of total resisting force acting on the cylindrical shell
=  ×D×t
Force
Therefore Longitudinal stress =
Area
p D2
=
4Dt
pD
ft2 = ……………….(5)
4t
Or
pD
t=
4f t2 ……………… (6)
While constructing a pressure vessel like steam boiler, reaction vessel, heat exchanger etc are
joined either by riveted joint or welded joint which are used in joining together the ends of steel
plates, then the wall thickness of the cylinder along with the corrosion allowance is
pD
t = 4f t2 J + C ……………. (7)
In case of internal diameter (Di) & outer diameter (Do) of shell is given by
pDi
t C
4 fJ  p ……….…… (7)
And
pDo
t C
4 fJ  p …………….. (8)
And Radial Deflection for thin cylindrical vessel is given by
p r 2i
w
Et …………………….(9)
Design of Spherical Vessel
Vessel subjected to internal pressure:- In this case both stresses are equal to longitudinal stress
are as follows
pDo
t C
4 fJ  p ……………(4)
And
pDi
t C
, 4 fJ  p ………………(9)
Problems 1: A thin cylindrical pressure vessel of 500 mm diameter is subjected to an internal

pressure of 2 N/mm2. If the thickness of the vessel is 20 mm. find the hoop stress, longitudinal
stress and the maximum shear stress.
Given: D = 500 mm
P = 2 N/mm2 = 2 × 1.1 = 2.2
t = 20 mm
To find-: i) ft1 =……… N/mm2
ii) ft2 =............. N/mm2

iii) fs(max) = ………… N/mm2
Solution- : We know that
i) Hoop Stress
The hoop stress is given by
pD
ft1 =
2t
2.2 × 500
ft1 =
2 × 20
ft1 = 27.5 N/mm2 …………..Ans
ii) Longitudinal Stress
The longitudinal stress is given by
pD
ft2 =
4t
2 .2 × 500
ft2 =
4 × 20
ft2 = 13.75 N/mm2…………Ans
iii) We know that according to maximum shear stress theory, the maximum shear
stress theory is half of the algebraic difference of the maximum & minimum
principal stress i.e. circumferential & longitudinal stress resp.
f t1  f t 2
 fs 
2
27.5  13.75
fs 
2
f s = 6.875 N/mm2 ……………..Ans

Problem 2(D-1)(4063-308):- A pressure vessel having outer diameter 1.3 m and height 3.8 m is
subjected to an internal pressure of 12 kg/cm2. If the vessel is fabricated as class B vessel joint
efficiency is 85%. If the vessel is fabricated as class C vessel, with welded joint efficiency is
70% and 50%. If the vessel is provided with a metal strip all along the longitudinal joint, joint
efficiency is 100%. Calculate the vessel thickness under these different conditions and find out
how much is the percent of material is saving by welding a strip along the longitudinal joint.
Allowable stress of the material = 1020 kg/cm2, Corrosion allowance = 1 mm
Given: Do = 1.3 m 1.3 × 100 = 130 cm
H = 3.8 m
P = 12 kg/cm2
f = 1020 kg/cm2
C = 1 mm 1× 10-1 = 0.1 cm
To find-: i) t = …… cm for class B for 85 %
ii) t = ……cm for class C for 70 % & 50 %
iii) Percentage of metal saving by welding a strip along the longitudinal joint
Design pressure = 12 × 1.1 = 13.2 Kg/cm2
i) Thickness of vessel for class B (J = 85 %)
pDo
t C
2 fJ  p
13.2  130
t  0.1
2  1020  0.85  13.2
t = 1.082cm …………..Ans
ii) Thickness of vessel for class C (J = 70 %)

pDo
t C
2 fJ  p
13.2  130
t  0.1
2  1020  0.70  13.2
t = 1.2906cm …………..Ans
iii) Thickness of vessel for class C (J = 50 %)

pDo
t C
2 fJ  p
13.2  130
t  0.1
2  1020  0.50  13.2
t = 1.7608cm …………..Ans
iv) Thickness of vessel for class C (J = 100 %)

pDo
t C
2 fJ  p
13.2  130
t  0.1
2  1020  1  13.2
t = 0.9357cm …………..Ans
v) Percentage of metal saving by welding a strip
1.082  0.9357
J = 0.85  100 = 13.52% …………Ans
1.082
1.2906  0.9357
J = 0.70  100 = 27.49%................Ans
1.2906
1.7608  0.9357
J = 0.50  100 = 46.85% …………Ans
1.7608
Problem 3(D-3): A cylindrical pressure vessel 1.8 m in diameter and 5 m in height is subjected
to an internal pressure of 8 kg/cm2. Corrosion allowance is 2 mm.
If the vessel is fabricated as:
Class B vessel with J = 0.85
Class C vessel with J = 0.5 & 0.7
What will be the minimum thickness of the vessel?
If a strip of suitable size is welded all along the longitudinal joint, (joint efficiency = 1.0), what
will be the thickness of the vessel and how much percentage saving in the material can be
achieved?
Allowable stress of the material = 1400 kg/cm2,
Given: let Do = 1.8 m 1.8 × 100 = 180 cm
H=5m
P = 8 kg/cm2
f = 1400 kg/cm2
C = 2mm 2× 10-1 = 0.2 cm
To find-: i) t = …… cm for class B for 85 %
ii) t = ……cm for class C for 70 % & 50 %
iii) Percentage of metal saving by welding a strip along the longitudinal joint
i) Thickness of vessel for class B (J = 85 %)
pDo
t C
2 fJ  p
8.8  180
t  0.2
2  1400  0.85  8.8
t = 0.8630cm …………..Ans
ii) Thickness of vessel for class C (J = 70 %)

pDo
t C
2 fJ  p
8.8  180
t  0.2
2  1400  0.70  8.8
t = 1.004cm …………..Ans
iii) Thickness of vessel for class C (J = 50 %)

pDo
t C
2 fJ  p
8.8  180
t  0.2
2  1400  0.50  8.8
t = 1.3243cm …………..Ans
iv) Thickness of vessel for class C (J = 100 %)

pDo
t C
2 fJ  p
8.8  180
t  0.2
2  1400  1  8.8
t = 0.7639cm …………..Ans
v) Percentage of metal saving by welding a strip
0.8630  0.7639
J = 0.85  100 = 11.48%.............Ans
0.8630
1.004  0.7639
J = 0.70  100 = 23.91%...............Ans
1.004
1.3243  0.7639
J = 0.50  100 = 42.31%..............Ans
1.3243
Problem 4(unsolved D-7): A cylindrical shell has an inside diameter of 25 cm and an outside
diameter of 37.5 cm. The maximum allowable tensile stress is 1400 kg/cm2. Calculate the
maximum internal pressure that can be exerted in the vessel.
Given: Di = 25 cm
Do = 37.5 cm
f = 1400 kg/cm2
To find-: i) P =………..kg/cm2
Do = Di + 2t
DO  D I
t
2
37.5  25
t
2
t = 6.25 cm
pD
ft1 = where D = Diameter of vessel = outside diameter of vessel=Do
2t
2tf t1
p
D0
2  6.25 1400
p
37.5
p = 466.66 kg/cm2 …………………Ans

Problem 5(unsolved D-9): Find the thickness of a cylindrical shell of diameter 5000 mm to
resist an internal pressure of 200 kg/cm2. The shell is constructed of steel whose allowable stress
is 1600kg/cm2 and the welded joint efficiency is 100%
Given: let Do = 5000 mm 5000 × 10-1 = 500 cm
P = 200 kg/cm2
f = 1600 kg/cm2
J = 1.0
To find-: i) t = …… cm
Design pressure = 200 × 1.1 = 220 Kg/cm2
i) Thickness of vessel
pDo
t
2 fJ  p
220  500
t
2  1600  1.0  220
t = 32.16 cm …………..Ans
Problem (D-2)-: A cylindrical shell of a vessel has an inside diameter 2 m and is subjected to an
internal pressure 5 kg/cm2. Calculate the required thickness and corresponding deflection.
Allowable tensile stress of the material is 1020 kg/cm2.
Poissons ration µ = 0.3; Youngs modulus of elasticity E = 2.09×106 kg/cm2
Given: Di = 2 m 2 × 100 = 200 cm
P = 5 kg/cm2
f = 1020 kg/cm2
µ = 0.3
E = 2.09×106 kg/cm2
To find-: i) W = …… cm
i) Thickness of vessel is given by
pDi
t
2 fJ  p
5.5  200
t
2  1020  1.0  5.5
t = 0.5407cm …………..Ans
Now to calculate the radial deflection & is given by
p r 2i
w
Et
5.5  100 2
w
2.09  10 6  0.5407
w = 0.0487 cm ………………….Ans
Problem (D-4)- : A vessel having 1.6 m outside diameter is to operate at a pressure of 5 kg/cm2. The
permissible stress of the material used for fabrication is 1020 kg/cm2. Welded joint efficiency is 85%.
Calculate the thickness required for a cylindrical vessel and a spherical vessel ? Which vessel should be
selected for operation.
Given: Do = 1.6 m 1.6 × 100 = 160 cm
P = 5 kg/cm2
f = 1020 kg/cm2
J = 0.85
To find-: i) t for cylindrical vessel = …… cm

ii) t for spherical vessel =………cm
i) Thickness of cylindrical vessel is given by
pDo
t
2 fJ  p
5.5  160
t
2  1020  0.85  5.5 (5.5 must be added)
t = 0.5091cm …………..Ans
i) Thickness of Spherical vessel is given by
pDo
t
4 fJ  p
5.5  160
t
4  1020  0.85  5.5 (5.5 must be added)
t = 0.2542cm …………..Ans
It can be seen that the thickness required for spherical vessel is 50% of the thickness required for
cylindrical vessel. Spherical vessel offers uniform stress distribution but the cost of fabrication is
too high. Therefore for economic reasons, cylindrical pressure vessel with 0.6 cm approximate
thickness has to be used.
Problem (3663-174) -: A cylindrical pressure vessel with 2 m ID is to be operated at a pressure

of 4kgf/cm2. The permissible stress of the material is 960 kgf/cm2. Welded joint efficiency is
85%. Calculate the thickness required.
If the vessel is fabricated in the spherical form, what maximum pressure will it be able to
withstand? (10 marks)
Given: Di = 2 m 2 × 100 = 200 cm
P = 4 kgf/cm2
f = 960 kgf/cm2
J = 0.85
ii) t for spherical vessel =………cm
Design pressure = 4 × 1.1 = 4.4Kgf/cm2
pDo
t (Di is taken into consideration)
2 fJ  p
4.4  200
t
2  960  0.85  4.4
t = .5407 cm …………..Ans
i) Thickness of Spherical vessel is given by
pDi
t
4 fJ  p
4 fJt  pt  pDi
p( Di  t )  4 fJt
4 fJt
p
( Di  t )
4  960  0.85  0.5407

p
(200  0.5407)
p = 8.80 kgf/cm2………………………..Ans
Problem (D-5)-: A cylindrical pressure vessel 2 m internal diameter is to be operates at a
pressure of 4 kg/cm2. The permissible stress of the material is 960 kg/cm2. Welded joint
efficiency is 85%. Calculate the thickness required for the vessel. If this vessel is fabricated in
spherical vessel what maximum pressure will it be able to withstand?
Given: Do = 2 m 2 × 100 = 200 cm (Di is given)
P = 4 kg/cm2
f = 960 kg/cm2
J = 0.85
ii) p for spherical vessel =………cm
ii) Thickness of cylindrical vessel is given by
pDi
t
2 fJ  p
4.4  200
t
2  960  0.85  4.4
t = 0.5407cm …………..Ans
ii) Thickness of Spherical vessel is given by
pDi
t
4 fJ  p
4 fJt  pt  pDi
p( Di  t )  4 fJt
4 fJt
p
( Di  t )
4  960  0.85  0.5407

p
(200  0.5407
p = 8.80 kg/cm2………………………..Ans
Problem (D-11)- : The inside diameter of cylinder is 25 cm and is subjected to an internal pressure of 600
kg/cm2. Allowable tensile stress of the material is 1400 kg/cm2. What should be the maximum thickness
of the vessel?
Given: Di = 25 cm
P = 600 kg/cm2
f = 1400 kg/cm2
J = 1.0 (Consider)
pDi
t
2 fJ  p
660  25
t
2  1400  1.0  660
t = 7.7103 cm……………….Ans
Problem (D-17) : A cylindrical shell of a vessel has an inside diameter 2.5 m and is subjected to
an internal pressure of 5 kg/cm2. Calculate the required thickness and corresponding deflection.
If the permissible stress is 1060 kg/cm2.
Poisson’s ration µ = 0.33; Youngs modulus of elasticity E = 2×106 kg/cm2
Given: Di = 2.5 m 2.5 × 100 = 250 cm
P = 5 kg/cm2
f = 1060 kg/cm2
µ = 0.33
E = 2×106 kg/cm2
ii) W = ………cm
i) Thickness of vessel is given by
pDi
t
2 fJ  p
5.5  250
t
2  1060  1.0  5.5
t = 0.6503 cm …………..Ans
Now to calculate the radial deflection & is given by
p r 2i
w
Et
5.5  1252
w
2  10 6  0.6503
w = 0.0661 cm ………………….Ans
Stresses induced in vessel or design of vessel subjected to combined loadings
Vessels are the part of process equipments which are arranged in either series or parallel.
They are connected to each other by pipelines for entering & excluding feed. If the vessels are
located in an open, wind load acts over the vessel. Therefore, while designing the vessel, the
thickness is estimated by taking into consideration with d ifferent stresses induced in vessel.
These stresses are as follows:
i) Pressure
ii) Weight of the vessel & its content
iii) Wind
iv) Pipelines are attached to the vessel
v) Earthquake
Due to internal pressure & external pressure, the circumferential stresses & longitudinal stresses
are induced & is given by
p ( Di  t)
f t1  …………..Circumferential stress ……….. (9)
2t
p ( Di  t )
ft 2  ……………Longitudinal stress ………….. (10)
4t
Weight of the empty vessel and weight of its content in the vessel induce direct stresses. These
stresses either tensile (positive) for points below the plane of the vessel supports, or compressive
(negative) for points above the supports, see Figure (fig no.) as shown in below.
The major sources of dead weight loads are:

1. Vessel shell.
2. Vessel fittings: manholes, nozzles.
3. Internal fittings: plates (plus the fluid on the plates);heating and cooling coils.
4. External fittings: ladders, platforms, piping.
5. Auxiliary equipment which is not self-supported; condensers, agitators.
6. Insulation.
7. The weight of liquid to fill the vessel.
Weight of the vessel contents depend upon the process requirement and the weight per unit
volume (kg/m3) of the content. Weight of the empty vessel depends upon the dimensions of the
vessel and its thickness is dependent upon the internal pressure exerted in the vessel.
W
fw  …………………… (11)
t ( Di  t )
Where W is the total weight of the vessel.
Bending stresses resulting from the bending moment because of wind forces acting over the
vessel. Wind loading will only be important on tall columns installed in the open. Columns and
chimney-stacks are usually free standing, mounted on skirt supports, and not attached to
structural steel work.
M
f bm   ……………………… (12)
Z
M = bending moment due to loads normal to the vessel axis

Z = modulus of section of the cylindrical vessel = π (Di) 2 t
Total stresses induces in the vessel along in the longitudinal direction is given by
f t = f t 2 + fw + f bm ............................. (13)
Any horizontal force acting on the vessel by additional equipment will produce a torque on the
vessel. Such loads can arise through wind pressure on piping attached to the vessel for inlet and
outlet of heat ing, cooling medium, drain pipes, vent pipes etc.
2T
fs  ………………….. (14)
Di t ( Di  t )
On the basis of shear strain energy theory the equivalent resultant stress induced in the vessel
subjected due to all the stresses can be calculated as follow
1
f R [ f 2
t1  f t1 f t  f t  3 f ] …………….. (16)
2
s
2 2
The equivalent resultant stress should be less than the permissible stress of the material.
Compressive stress induced in the vessel should be below the safe compressive stress value of
the material.
Permissible compressive stress can be calculated as:
1 E t
fc  …………………. (17)
12 3(1   ) ( Do / 2)
2
Where E = Young’s modulus of elasticity, kg/cm2
µ = Poisson’s ration of the material
Do = outside diameter of the vessel
For satisfactory design, the following conditions must be satisfied
f R (Tensile) ≤ f t1 (permissible)
f t (Tensile) ≤ f t1 (permissible)
f t (Compressive) ≤ f c (permissible)
If these conditions are not satisfied, the thickness t will have to be increased by employing the
trial & error method. The final thickness should be determined by addition of corrosion
allowance.
Problem 6: A pressure vessel 1.25 m in internal diameter is subjected to combined loading

operates to an internal pressure of 10 kg/cm2. Material used for fabrication has an allowable
stress of 980 kg/cm2. Welded joint efficiency is 85%. Weight of vessel with its contents is 6500
kg. torque exerted over the vessel is 55 kg-cm. Bending moment induced can be neglected.
Corrosion allowance is 1.5 mm. calculate the various stresses induced in the vessel and verify
that the equivalent stress is less than the permissible stress of the material. (Unsolved prob 33)
Given: Di = 1.25 m 1.25 × 100 = 125 cm
P = 10 kg/cm2
f = 980 kg/cm2
C = 1.5 mm 1.5× 10-1 = 0.15 cm
J = 0.85
T = 55 kg-cm
W = 6500 kg
To find-: i) longitudinal stress
ii) Circumferential stress
iii) Total longitudinal stress
iv) Equivalent stress
First we have to calculate the thickness of shell
pDi
t 
2 fJ  p (why C is not taken)
11  125
t
2  980  0.85  11
t = 0.831 cm……………(i)
i) We know that, For longitudinal stress
p ( Di  t )
ft 2 
4t
11 ( 125  0.831)
ft 2 
4  0.831
f t 2 = 416.408 kg/cm2……………………….Ans
ii) We know that, For Circumferential stress
p ( Di  t)
f t1 
2t
11 ( 125  0.831)
f t1 
2  0.831
f t1 = 832.816 kg/cm2
Stress due to weight of the vessel and its contents
W
fw 
t ( Di  t )
6500
fw 
  0.831(125  0.831)
f w = 19.79 kg/cm2…………………(2)
Stresses induced due to bending moment are zero, as bending moment is negligible in
this case.
f bm  0
...................................... (3)
iii) Total stresses induces in the vessel along in the longitudinal direction is given
by
f t = f t 2 + fw + f bm
ft
= 416.408 + 19.79 + 0
ft
= 436.198 kg/cm2……………………Ans
Stresses induced in the vessel due to piping is given by
2T
fs 
Di t ( Di  t )
2  55
fs 
  125  0.831(125  0.831)
f s = 0.00268 kg/cm2………………………(4)
IV) On the basis of all these induced stresses, the equivalent stress can be estimated as
1
f R [ f 2
t1  f t1 f t  f t  3 f ]
2
s
2 2
1
f R [(832.816) 2  (832.816  436.198)  (436.198) 2  3(0.00268) 2 ] 2
f R = 721.511 kg/cm2……………………………..Ans
For satisfactory design, the following conditions are satisfied
Problem (3763-174): A stainless steel pressure vessel with elliptical head is to be designed for an
internal design pressure of 0.5 N/mm2. The vessel has an internal diameter of 1500 mm. If the
weight of the vessel and its contents is 3000 kg and torque due to offset piping is 200 Nm. Find
the stresses due to combined loading and explain whether the design is safe or unsafe.
Permissible stress of stainless steel is 100 N/mm2, J = 1 (Wind loading and corrosion allowance
are not required to be considered) (8 marks)
Given: Di = 1500 mm 1500 ÷ 1000 = 1.5m
P = 0.5 N/mm2
f = 100 N/mm2
J = 1.0
T = 200 Nm
W = 3000 kg

pDi
t 
2 fJ  p
0.5  1500
t
2  1200  1.0  0.5
t = 0.3126 mm…………… (i) 0.3126 ÷ 1000 = 0.0003126 m
p ( Di  t )
ft 2 
4t
0.5 ( 1500  0.3126)

ft2 
4  0.3126
f t 2 = 599.933 N/mm2……………………….Ans
p ( Di  t)
f t1 
2t
0.5 ( 1500  0.3126)

f t1 
2  0.3126
f t1 = 1199.866 N/mm2
W
fw 
t ( Di  t )
3000
fw 
  0.0003126(1.5  0.0003126)
f w = 2036107.257 kg/m2 19.967 N/mm2… (2)
( 2036107.257 *9.81*10^-6 N/mm2)
this case.
f bm  0
...................................... (3)
by
f t = f t 2 + fw + f bm
ft
= 599.933 + 19.967+ 0
ft
= 619.9 N/mm2 ……..Ans
2T
fs 
Di t ( Di  t )
2  200
fs 
  1.5  0.0003126(1.5  0.0003126)
f s = 180987.3117 N/m2 or 0.1816 N/mm2………………… (4)
1
f R [ f 2 t1  f t1 f t  f t 2  3 f s2 ] 2
1
f R [(1199.866)  (1199.866  619.9)  (619.9)  3(0.1816) ]
2 2 2 2
f R = 1039.306 N/mm2……………………………..Ans
Problem (3363-174): A pressure vessel is to be designed for an internal diameter of 0.3 N/mm2.
The vessel has nominal diameter of 1.2 m. The vessel is made up of stainless steel with
permissible stress of 130 N/mm2. No corrosion allowance is necessary. If the weight of the
vessel and contents is 3200 kg and torque due to offset piping is 500 Nm. Find the stresses due to
combined loading. Calculate the thickness for various heads and suggest suitable head. (12
marks)
Given: Do = 1.2m 1.2 × 1000 = 1200 mm
P = 0.3 N/mm2
f = 130 N/mm2
T = 500 Nm
W = 3200 kg

pDi
t 
2 fJ  p
0.3  1200
t
2  130  0.85  0.3
t = 1.6312 mm…………… (i) 0.0016312 m
p ( Di  t )
ft 2 
4t
0.3 ( 1200  1.6312)

ft2 
4  1.6312
f t 2 = 55.2491 N/mm2……………………….Ans
p ( Di  t)
f t1 
2t
0.3 ( 1200  1.6312)

f t1 
2  1.6312
f t1 = 110.4982 N/mm2
W
fw 
t ( Di  t )
3200
fw 
  0.0016312(1.2  0.0016312)
f w = 519662.881 kg/m2 5.0961528 N/mm2… (2)
( 519662.881 *9.81*10^-6 N/mm2)
this case.
f bm  0
...................................... (3)
by
f t = f t 2 + fw + f bm
ft
= 55.2491 + 5.0961528+ 0
ft
= 60.3453 N/mm2 ……..Ans
2T
fs 
Di t ( Di  t )
2  500
fs 
  1.2  0.0016312(1.2  0.0016312)
f s = 135328.8753 N/m2 or 0.1353 N/mm2………………… (4)

1
f R [ f 2
t1  f t1 f t  f t  3 f ]
2
s
2 2
1
f R [(110.4982) 2  (110.4982  60.3453)  (60.3453) 2  3(0.1353) 2 ] 2
f R = 95.830 N/mm2……………………………..Ans (5)
Now to calculate the thickness of various head
Consider For torispherical (100-6) head it means that
Crown radius R = 100 % of diameter of vessel D = 1.2 m
Knuckle radius r = 6% of diameter of vessel D (1.2× 0.06) = 0.07 m
For ellipsoidal (2:1) head it means that
Major to minor axis ratio is 2:1
Also
D = 1.2 m 1.2  1000 =1200 mm
P = 0.3 N/mm2
f = 130 N/mm2
J = 0.85
To find-: i) t s (Torispherical (100-6) head) = …… cm
ii) t s (Torispherical (80-6) head) = …… cm
iii) t e (Ellipsoidal (2:1) head) = …… cm
iv) t h (Hemispherical head) = …… cm
Solution- :
i) We know that
The thickness of torispherical (100-6) head is given by
pDC
ts 
2 fj
Where C = stress intensification factor
1 R
C 3  
4  r 
1 1.2 
C  3  

4 0.07 
C = 1.78
pDC
ts 
2 fj
0.3  1200  1.78

ts 
2  130  0.85
t s = 2.8995 mm………………………….Ans
ii) We know that

The thickness of ellipsoidal head is given by
pDV
te 
2 fj
Where V = stress intensification factor
V 
1
6
2 k2  k 
2
1
2
V 
1
6
2  22 
V = 1.0
0.3  1200  1.0

 te 
2  130  0.85
t e = 1.6289 mm………………………….. Ans
iii) We know that
The thickness of hemispherical head is given by
pD
th 
4 fj
0.3  1200
th 
4  130  0.85
t h = 0.8145 mm ………………………..Ans
It can be seen that the maximum thickness is required for (100-6) torishperical head and minimum
thickness is required for hemispherical head.
Percentage reduction in thickness achieved by using:
2.8995  1.6289
i) (2:1) Elliptical head =  100
2.8995
2.8995  0.8145
ii) Hemispherical head =  100
2.8995
= 71.90%
Optimum proportion of the vessel
Pressure vessels can be either of cylindrical or spherical in shape. The cylindrical pressure
vessel is easy to fabricate as compared to spherical pressure vessels. But for uniform pressure, it
required a minimum surface area and minimum thickness per unit volume for storing or
processing a fluid is most economical method. In such condition, spherical vessels are used.
The cost of a fabricated vessel depends upon the weight of the vessel and the material
selected for construction. Before design pressure vessel, the proportion of height to diameter
must be established. There is no general rule for selection of the height to diameter ratio because
this ratio is often a function of the processing requirements and phisico-chemical properties of
the fluid being processed, available land area, and height limitations. In normal operation liquid
height to diameter ration is around unity. In processes where there is evolution of gas/ vapours,
more space has to be provided over the liquid surface. In processes where the gas is bubbling or
sparging is necessary, liquid height is maintained more than the column diameter and some space
above the liquid surface for the separation of bubbling gas and entrained liquid droplets. In case
of distillation column, L/D ratio is dependent upon the purity of the product, system
characteristics and the plate spacing.
So it is difficult to determine the actual optimum proportion of the vessel. Here is general
outline for the determination of the optimum proportions of a vessel operating under pressure
vessel and are influenced by the cost of foundations and cost of the land in the tank area that is
chargeable to the tank as well as by the cost of bottom , shell and roof.
Let D = diameter of vessel
H = height of the vessel

V= volume of the vessel
D 2
= H
4
4V
H 
D 2
Let A1= area of the shell = π DH
D 2
A2 = area of the bottom & roof of the vessel =
4
C1 = annual cost of fabricated shell
C2 = annual cost of fabricated bottom
C3 = annual cost of fabricated roof
C4 = annual cost of installed foundations under the vessel
C5 = annual cost of the land for the tank area
C = total annual cost of the vessel
 C = A1 C1 + A2 (C2 + C3 +C4+C5)
D 2
C = π DH C1 + (C2 + C3 +C4+C5)
4
Substitute the value of H in above equation
4V D 2
 C=πD + (C2 + C3 +C4+C5)
D 2 4
4V D 2
C= C 1+ (C2 + C3 +C4+C5)……………………………. (18)
D 4
For reasons of elastic instability, the minimum shell thickness is limited to 3/16” for smaller
tanks and 1/4” for larger diameters. Therefore tanks having shell thickness of 1/4” or less may be
considered as shell thickness is independent of D & H.
If D (H-1) = 1720 for butt-welded shells
D (H-1) = 1515 for lap-welded shells
Thus if D (H-1) equal to or less than 1720 or 1515 for either butt or lap welded shells, then the
shell thickness is independent of D & H.
Tanks having Shell thickness is independent of D & H
The stress in the shell is function of both diameter and height of the tank. Considering the
cost of the vessel depends upon the diameter of shell.
 Differentiating the total cost C w.r.t. diameter of the vessel (eq.18)
4V D 2
C= C 1+ (C2 + C3 +C4+C5)…
D 4
dC 4VC D
   21  (C 2 + C 3 + C 4 + C 5 )
dD D 2
dC
Assume  zero
dD
4VC1 D
 2
= (C 2 + C 3 + C 4 + C 5 )
D 2
8V C1
D3 
 C 2  C3  C 4  C5
D 2
Substitute the value of V = H
4
8 D 2  C1 
D3 = H  
 4  C 2  C3  C 4  C5 
 C1 
D = 2 H  
 C 2  C3  C 4  C5  ………………………………….(19)
Tanks having shell thickness is dependent upon D & H
The tanks having height and diameter such that the quantity of D (H-1) exceeds 1720 for butt-
welded shells are considered as shell thickness is dependent upon D & H. The cost of shell per
unit area C1 is function of D and H and for purposes of propotinating may be assumed to be
directly proportional to the shell thickness as follows.
C1 = C6 (H-1) D
C1
C6 
( H  1) D
Put the value of C1 in eq. 18
4V D 2
C= C1 + (C2 + C3 +C4+C5)
D 4
4VC 6 (H - 1) D D 2
C= + (C2 + C3 +C4+C5)
D 4
 4V  D 2
C = 4VC6  2 
 4VC6  (C2 + C3 + C4 + C5)
 D  4
 Differentiating the total cost C w.r.t. diameter of the vessel
dC 32C 6V 2 2D
  0 (C 2 + C 3 + C 4 +C 5 )
dD D 3
4
D 32C6V 2
(C 2 + C 3 + C 4 + C 5 ) =
2 D 3
Put the value of V & C6 in above equation

D 32C1  2D4H 2
(C 2 + C 3 + C 4 + C 5 ) =
2  ( H  1) D 4 16
Consider (H-1) = H
 D (C 2 + C 3 + C 4 + C 5 ) = 4C1πH
 C1 
D = 4 H  
 C 2  C3  C 4  C5  ……………………………. (20)
Optimum vessel size
Let the volume of a pressure vessel is V m3.
Length of pressure vessel is L m.
Diameter of pressure vessel is D m.
Thickness of shell is t m
Then total area of the vessel is given by
V = volume of bottom & roof + volume of shell
D 2 D
V 2 t  2 Lt
4 2
D 2
V t  DLt
2
 D2 
V    DL   t
 2 
But thickness of shell can be calculated as
pD
t C
2 fJ
 D2   pD 
V    DL    C
 2   2 fJ 
D 2
If V  L
4
4V
L 
D 2
 D2 4V   pD 
V    D 2 
  C
 2 D   2 fJ 
 D 2 4V   pD 
V      C
 2 D   2 fJ 
 Differentiating the total volume V w.r.t. diameter of the vessel D is given by (Ist ×Der. IInd +
IInd×Der. Ist)
dV  D 2 4V   p   pD   4V 
           C    D  2 
dD  2 D   2 fJ   2 fJ   D 
dV
Consider  Zero
dD
 pD 2 4Vp pD 2 4VpD 4VC 

    2
 CD  2   0
 4fJ 2 fJD 2 fJ 2 fJD D 
 pD 2 2Vp pD 2 2Vp 4VC 

     CD  2   0
 4fJ fJD 2 fJ fJD D 
 pD 2 pD 2   4VC 

    CD  2   0
 4 fJ 2 fJ   D 
 3 pD 2   4C D 2  D 2
   CD  2  L  0 V  L
 4 fJ   D 4  4
 3 pD 2 
   CD  CL  0
 4 fJ 
 3 pD 2 
   C D  L  0
 4 fJ 
3  pD 2 
   C ( L  D)
4  fJ 
3  pD 2 
   ( L  D)
4  CfJ 
3  pD 2 
 DL
4  CfJ 
3  pD 2 
LD  
4  CfJ 
 3  pD 
L  D 1   
 4  CfJ 
 3 
L  D 1  Dx  ………………………………….. (21)
 4 
 p 
Where x =  
 CfJ 
Now
D 2
V  L
4
Substitute value of L in above equation
D 2  3 
V  D 1  Dx 
4  4 
D 3  
1  Dx  ……………….. (22)
3
V 
4  4 
Problem D-31: A pressure vessel is required to have a capacity of 20 m3. The vessel has an
operating pressure 6 kg/cm2 and the material used for fabrication have an allowable stress of
1090 kg/cm2.
Welded joint efficiency is 85% ; Corrosion allowance is 2 mm.
Estimate the optimum diameter and length of the pressure vessel.
Given: V = 20 m3 20 × (102)3 = 20 × 106 cm3
P = 6 kg/cm2
f = 1090 kg/cm2
C = 2 mm 2× 10-1 = 0.2 cm
J = 0.85
To find-: i) D = …… cm
ii) L = ……cm
i) We know that
D 3  
1  Dx 
3
V 
4  4 
But
 p 
x =  
 CfJ 
x =  
6.6

 0.2  1090  0.85 
x = 0.03562 cm …………..Ans
D 3  
1  D0.03562
3
 20  10  6
4  4 
 20  10 6  0.7854 D 3 1  0.02672 D 
 20  10 6  0.7854 D 3  0.02098 D 4
Solve for D in calculator, we get
D = 167.1 cm …………………… Ans
ii) For length, We know that

D 2
V  L
4
4V
L 
D 2
4  20  10 6
L 
  167.12
L = 911.984 cm …………..Ans
Problem D-40: A pressure vessel is to be designed for some chemical process. The total volume
of the vessel required is 7.5 m3. The vessel operates at a pressure of 2.5 kg/cm2. Materials used
for fabrication have an allowable stress of 1060 kg/cm2. Welded joint efficiency is 85%.
Corrosion allowance is 2 mm. Weight of vessel with its contents is 6000 kg. The torque exerted
over the vessel is 75 kg-cm. Bending moment induced is negligible. The vessel is closed by two
elliptical heads of major to minor axis ratio is 2.0.
Estimate : i) Optimum proportion of the vessel
ii) Minimum thickness required for the vessel
Given: V = 7.5 m3 7.5 × (102)3 = 7.5 × 106 cm3
P = 2.5 kg/cm2
f = 1060 kg/cm2
C = 2 mm 2× 10-1 = 0.2 cm
J = 0.85
T = 75 kg-cm
K = 2.0
ii) L =……..cm
iii) t = ……….cm
Design pressure = 2.5 × 1.1 = 2.75 Kg/cm2
i) We know that
D 3  
1  Dx 
3
V 
4  4 
But
 p 
x =  
 CfJ 
x =  
2.75

 0.2  1060  0.85 
x = 0.01526 cm …………..Ans
D 3  
1  D0.01526
3
 7.5  10  6
4  4 
 7.5  10 6  0.7854 D 3 1  0.01145 D 
 7.5  10 6  0.7854 D 3  0.00899 D 4
D = 151.7 cm …………………… Ans

D 2
V  L
4
4V
L 
D 2
4  7.5  10 6
L 
  151.7 2
L = 414.95 cm …………..Ans
We know that

pD
t  C
2 fj
2.75  151.7
t  0.2
2  1060  0.85
t = 0.43 cm
t = 0.5 cm…………… (i)
We know that,
D  D i t
151.7 = Di + 0.5
Di = 151.2 cm
And Do = 152.2 cm
p ( Di  t )
ft 2 
4t
2.75 ( 151.2  0.5)

ft2 
4  0.5
f t 2 = 208.59 kg/cm2……………………….Ans
p ( Di  t)
f t1 
2t
2.75 ( 1060  0.5)

f t1 
2  0.5
f t1 = 417.18 Kg/cm2
W
fw 
t ( Di  t )
6000
fw 
  0.5(151.2  0.5)
f w = 25.18 kg/cm2
this case.
f bm  0
...................................... (3)
by
f t = f t 2 + fw + f bm
ft
= 208.59+25.18+ 0
ft
= 233.77 Kg/cm2 ……..Ans

2T
fs 
Di t ( Di  t )
2  75
fs 
  151.2  0.5(151.2  0.5)
f s = 0.00416 Kg/cm2………………… (4)
1
f R [ f 2 t1  f t1 f t  f t 2  3 f s2 ] 2
f R [(417.18)  (417.18  233.77)  (233.77)  3(0.00416) ]

2 2 2 2
f R = 362.16 Kg/cm2
f t (Tensile) ≤ f t1 (permissible)…………….Ans (i)
ii) We know that
pDV
te 
2 fj
V 
1
6
2 k2  k 
2
0
2
V 
1
6
2  22 
V = 1.0
2.75  151.7  1.0
t e 
2  1060  0.85
t e = 0.23 + 0.2
t e = 0.50 cm………………………….. Ans (ii)
Problem : Determine the optimum proportions of a pressure vessel required to handle 10000 kg
of liquid having density 1200 kg/m3 at 10 kg/cm2. Welded joint efficiency is 85%. Permissible
stress of the material used for fabrication = 1020 kg/cm2. Corrosion allowance is 1.5 mm.
(unsolved D-25)
Given: M = 10000 kg
D = 1200 kg/m3
D = M/V=
 V = M/D = 1200/1000 = 1.2 m3 1.2 × (102)3 = 1.2 × 106 cm3
P = 10 kg/cm2
f = 1020 kg/cm2
C = 1.5 mm 1.5× 10-1 = 0.15 cm
J = 0.85
ii) L =……..cm
i) We know that
D 3  
1  Dx 
3
V 
4  4 
But
 p 
x =  
 CfJ 
x =  
11

 0.15  1020  0.85 
x = 0.08458 cm …………..Ans
D3  
1  D0.08458
3
1.2  10 6
4  4 
1.2  10 6  0.7854 D3 1  0.06344 D 
1.2  10 6  0.7854 D 3  0.04982 D 4
D = 66.45 cm …………………… Ans

D 2
V  L
4
4V
L 
D 2
4  1.2  106
L 
  66.452
 L = 346.0201 cm……………….Ans
HEADS
"Nature gave men two ends... one to sit on and one to think with. Ever since then man's
success or failure has been dependent on the one he used most." - George R. Kilpatrick
The same thing is with case of pressure vessel, the ends of cylindrical shell are to
be important before putting into operation. This is done by means of heads or closure. The ends
of cylindrical shell are attached to the head either by welded, riveted or bolted construction. The
selection for a particular type depend on the factors like process temperature and pressure, nature
of feed and product material being handled, position of vessel either horizontal or vertical, nature
of support and above all the economy. Thus the vessels are usually provided with different types
of heads
a) Flat head-: The simplest cover for a cylindrical shell is a flat head which having same
diameter as the shell. These plates can be firmly secured to the shell by a suitable method
and must be capable of withstanding the working pressure. Form fabrication point of
view, this is the simplest type of head to construct just cutting the circular piece from flat
plate. As a result, for a particular diameter and operating conditions, material cost for flat
head is maximum, though the fabrication cost is very low. The flat head are generally
used for manholes in low pressure vessels and small bore openings. For high pressure
vessels or larger vessels, flat heads cannot be used due to localized stress concentration.
The stresses induced in a flat plate, due to internal pressure. The maximum stress is at the
circ umference and is given by
2 2
3 R 3 D
f  p  f  p 
4 t  Or 16 t 
Thus, the thickness of the plate can be calculated as
p
t f  CD
f
Where C = Edge fixity constant
D = diameter of the plate
P = working pressure
f = design stress at operating temperature
According to the method of attachment of the flat head to the shell the edge fixity
changes which varies from 0.4 to 0.7. (fig form mahajani 5.4)
The flange only head is also a type of vessel in which gradual changes in the
shape at the corner results in reduced local stresses. This is also economical to fabricate
and used for closing the ends of horizontal storage vessels at atmospheric pressure to
store liquids having low vapour pressure, such as fuel oil, kerosene etc. it is also used as
bottom head of vertical cylindrical vessels that rest on concrete slab.
b) Flange shallow dished head and flanged standard dished head or torispherical head-:
while pressing into dished shape, such head consist of two radii, namely,’ crown’ radius
and ‘knuckle’ radius as shown in fig. if the crown radius (R) is greater than the shell
outside diameter than the head is known as ‘flanged and shallow dished head’. On the
other hand, if the crown radius (R) is equal to less than the outside diameter, then such
head is known as ‘flanged standard dished head or torispherical head’. Due to small
inside knuckle –corner radius, localized stresses are very high. Thus such type of heads is
generally used for if vertical vessel then operates it at a low pressure while for horizontal
cylindrical vessel it operate generally for volatile fluids such as naphtha, gasoline and
kerosene.
If the pressure increased in flanged and dished heads, the local stresses at the
inside corner of the head must be reduced. This can be achieved by forming the head with
inside corner i.e. knuckle radius not less than three times the metal thickness and also not
less than 6 – 10 % of the inside diameter and also inside crown radius (Ri) should not be
greater than the outside diameter (Do).
The thickness of torispherical head is given by
pDC
ts 
2 fj
1 R
C 3  
4  r 
Where R = crown radius

r = knuckle radius
c) Ellipsoidal head-: These type of heads are generally used when the pressure in the range
of 100 to 200 psi. It is also called as semi-ellipsoidal head. According to IS specification
the major to minor axis ratio should not be greater than 2.6:1.

pDV
te 
2 fj
V 
1
6
2 k2 
Where k = ration of major to minor axis.
d) Hemispherical head-: This is the strongest type of head among the formed head. These
heads can be operated at pressure which is twice than the ellipsoidal head of cylindrical
shell having same thickness and diameter. The advantage of such type of head is that it
provides maximum volume and minimum discontinuity stresses. The disadvantage of this
type of head is too difficult to form; cost of fabrication is very high hence it is generally
used for heavy duty high pressure vessels.
pD
th 
4 fj
e) Conical head-: Conical heads are generally used as bottom head in evaporator, cyclone
separator, spray drier, crystallizers, settling tanks etc. The particular advantage lies in the
accumulation and removal of solids from such equipment. Another common application
of conical head is as reducer, providing a smooth transition between two parts of different
diameter in cylindrical process vessels. Conical heads with a sharp cylinder-cone junction
is easiest to manufacture, but this simplicity is partly lost, when a knuckle radius is
specified, to reduce the stress-concentration at the junction. Cones having apex angle 600
are commonly used for the removal of solids.
The thickness of conical head is given by
pD
tc 
2 fj cos
(Dia. from Dawande)
Problem D-8: Calculate the thickness of torispherical (100-6) head, torispherical (80-10) head
and ellipsoidal head (2:1) for a vessel having 1.0 m diameter and having a design pressure of 3.5
kg/cm2. Welded joint is fully tested so welded joint efficiency can be considered as 100%.
Permissible stress for the material of construction = 1250 kg/cm2. (Problem 08) (3463-171,3363-
374,2963-371)(10 marks)
Given: For torispherical (100-6) head it means that
Knuckle radius r = 6% of diameter of vessel D (1× 0.06) = 0.06 m
For torispherical (80-10) head it means that
Crown radius R = 80 % of diameter of vessel D (1× 0.80) = 0.8 m
Knuckle radius r = 10% of diameter of vessel D (1× 0.10) = 0.1m
Also
D = 1.0 m 1.0  100 =100 cm
P =3.5 kg/cm2
f = 1250 kg/cm2
J = 1.00

i) We know that
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1 
C  3  
4  0.06 
C = 1.77
pDC
ts 
2 fj
3.5  100  1.77

ts 
2  1250  1.0
t s = 0.2478 cm………………………….Ans
ii) We know that
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 0.8 
C  3  
4  0.1 
C = 1.46
pDC
ts 
2 fj
3.5  100  1.46

ts 
2  1250  1.0
t s = 0.2044 cm………………………….Ans
iii) We know that
pDV
te 
2 fj
V 
1
6

2 k2  k 
2
1
2
V 
1
6

2  22 
V = 1.0
3.5  100  1.0

 te 
2  1250  1.0
t e = 0.14 cm………………………….. Ans

It can be seen that the maximum thickness is required for (100-6), (80-6) torispherical head and minimum
0.2478  0.2044
i) (80-10) torispherical head =  100
0.2478
= 17.51%
0.2478  0.14
ii) (2:1) Elliptical head =  100
0.2478
= 43.50%
Problem D-9: Calculate the thickness of torispherical (100-6) head and (80-6) ellipsoidal head
(2:1) and hemispherical head for a pressure vessel haivng design pressure 7 kg/cm2.Diameter of
vessel is 1.5 m and the permissible stress is 1250 kg/cm2. Welded joint is 85%. (3263-374) (8
marks)
Crown radius R = 80 % of diameter of vessel D (1.5× 0.80) = 1.2 m
Also
D = 1.5 m 1.5  100 =150 cm
P = 7 kg/cm2
f = 1250 kg/cm2
J = 0.85
Solution- :
iv) We know that
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1.5 
C  3  

4 0.09 
C = 1.77
pDC
ts 
2 fj
7  150  1.77
ts 
2  1250  0.85
t s = 0.8746 cm………………………….Ans
v) We know that
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1.2 
C  3  

4 0.09 
C = 1.66
pDC
ts 
2 fj
7  150  1.66
ts 
2  1250  0.85
t s = 0.8202 cm………………………….Ans
vi) We know that
pDV
te 
2 fj

V 
1
6
2 k2  k 
2
1
2
V 
1
6
2  22 
V = 1.0
7  150  1.0
 te 
2  1250  0.85
t e = 0.4941 cm………………………….. Ans
vii) We know that
pD
th 
4 fj
7  150
th 
4  1250  0.85
t h = 0.2470 cm ………………………..Ans
0.8746  0.8202
0.8746
= 6.21%
0.8746  0.4941
0.8746
= 43.50%
0.8746  0.2470
iii) Hemispherical head =  100
0.8746
= 71.76%
Problem (Unsolved 1)- : Estimate the thickness of a (100-6) ;(80-10) torispherical heads,(2 :1) elliptical
head and hemispherical head to be provided to a vessel having design pressure 10 kg/cm2. Permissible
stress of the material is 1020 kg/cm2 and welded joint efficiency is 90%. Corrosion allowance is 1 mm.
Which head will you select for the vessel when diameter of vessel is 1.5 m.
Also
D = 1.5 m 1.5  100 =150 cm
P = 10 kg/cm2
f = 1020 kg/cm2
J = 0.90

i) We know that
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1.5 
C  3  
4  0.09 
C = 1.77
pDC
ts 
2 fj
10  150  1.77
ts 
2  1020  0.90
t s = 1.4465 cm………………………….Ans
ii) We know that

pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1.2 
C  3  
4  0.15 
C = 1.46
pDC
ts 
2 fj
10  150  1.46
ts 
2  1020  0.90
t s = 1.1904 cm………………………….Ans
iii) We know that
pDV
te 
2 fj
V 
1
6

2 k2  k 
2
1
2
V 
1
6

2  22 
V = 1.0
10  150  1.0
 te 
2  1020  0.90
t e = 0.8169 cm………………………….. Ans
iv) We know that
pD
th 
4 fj
10  150
th 
4  1020  0.90
t h = 0.4085 cm ………………………..Ans
1.4465  1.1904
1.4465
= 17.70%
1.4465  0.8169
1.4465
= 43.52%
1.4465  0.4084
iii) Hemispherical head =  100
1.4465
= 71.76%
Problem (Unsolved2)-: Estimate the thickness of a conical head having half apex angle 38 0. The
diameter of the vessel is 1.5 m. Permissible stress of the material is 1200 kg/cm 2. Welded joint efficiency
is 85%. (P = 10 kg/cm2)
Given: D = 1.5 m 1.5  100 = 150 cm
P = 10 kg/cm2 = 10  1.1=11 kg/cm2
f = 1200 kg/cm2
J = 0.85
To find-: i) t c = …… cm
pD
tc 
2 fj cos
11  150
tc 
2  1200  0.85  cos 38
t c = 0.8469 cm…………………………………Ans
Problem unsolved 5-: A flanged torispherical head having thickness 20 mm is to be used for a vessel
having internal diameter 3.0 m. The crown radius of the head is 3.0 m and the knuckle radius is 21 cm.
The permissible stress of the material is 1020 kg/cm2, welded joint efficiency is 85%. If the vessel is to be
operated at 5 kg/cm2, will this thickness be sufficient?
Given: D=3m 3  100 = 300 cm
P = 5 kg/cm2
f = 1020 kg/cm2
J = 0.85
R = 3.0 m 3  100 = 300 cm
r = 21 cm
To find-: i) t s = …… cm
The thickness of torispherical head is given by
pDC
ts 
2 fj
1 R
C 3  
4  r 
1 300 
C  3  
4  21 
C = 1.69
pDC
ts 
2 fj
5  300  1.69
ts 
2  1020  0.85
t s = 1.4619 cm………………………….Ans
Problem (unsolved 6)-: A hemispherical head with 750 mm diameter is subjected to an internal pressure
of 250 kg/cm2. If the permissible stress of the material is 1540 kg/cm2. Calculate the required thickness
of the head. Welded joint efficiency is 100%.
Given: D = 750 mm 750  10 = 75 cm
P = 250 kg/cm2 = 250  1.1= 275 kg/cm2

f = 1540 kg/cm2
J = 1.0
To find-: i) t h = …… cm
pD
th 
4 fj
275  75
th 
4  1540  1.0
t h = 3.3482 cm ………………………..Ans
Problem Unsloved 10- : Find the minimum thickness of seamless elliptical head of diameter 250 mm to
resist an internal pressure of 100 kg/cm2. The allowable stress of steel is 1200 kg/cm2.
(Major to minor axis ratio 2:1)
Given: D = 250 mm 250  10 = 25 cm
P = 100 kg/cm2 = 100  1.1= 110 kg/cm2
f = 1200 kg/cm2
J = 0.85
To find-: i) t e = …… cm

pDV
te 
2 fj
V 
1
6

2 k2  k 
2
1
2
V 
1
6

2  22 
V = 1.0
110  25  1.0
 te 
2  1200  0.85
t e = 1.3480 cm………………………….. Ans
Problem (Unsolved 3)-: A vessel having 1.5 m inner diameter and 8 mm thickness is provided with (80-
10) torispherical head. The permissible stress of the material is 1240 kg/cm 2 and welded joint efficiency
is 85%. No corrosion allowance is necessary. What maximum pressure the head will be able to
withstand?
Given: D = 1.5 m 1.5  100 =150 cm
f = 1240 kg/cm2
J = 0.85
t s = 8 mm 8  10 = 0.8 cm
To find-: i) P = …… kg/cm2

pDC
ts 
2 fj
1 R
C 3  
4  r 
1 1.2 
C  3  

4 0.15 
C = 1.46
pDC
ts 
2 fj
2 fJts
p
DC
2  1240  0.85  0.8

p
150  1.46
p = 7.7 kg/cm2……………………….Ans
Problem (Unsolved 4)-: A high pressure vessel is provided with a hemispherical head having thickness 35
mm. The inner diameter of the vessel is 500 mm. If the permissible stress of the material is 1400 kg/cm2,
what maximum pressure the head will be able to withstand? If this head is replaced with an elliptical
head having major axis to minor axis 2.0:1.0, what will be the required thickness? Welded joint
efficiency is 100%.
Given: D = 500 mm 500  10 = 50 cm
f = 1400 kg/cm2
J = 1.0
t h = 35 mm 35  10 = 3.5 cm
To find-: i) P = …… kg/cm2
ii) t e = ……..cm
pD
th 
4 fj
4 fjth
p
D
4  1400  1.0  3.5

p
50
p = 392kg/cm2 ………………………..Ans
Now to calculate the thickness for elliptical head (2:1)
pDV
te 
2 fj
V 
1
6
2 k2  k 
2
1
2
V 
1
6

2  22 
V = 1.0
392  50  1.0
 te 
2  1400  1.0
t e = 7 cm………………………….. Ans
Problem (Unsolved 32)-: Estimate the thickness of a (100-6) flanged torispherical head for a vessel
having 5 m internal diameter. Design pressure of the vessel is 5 kg/cm2. Permissible stress of the material
is 1200 kg/cm2. Welded joint efficiency is 100%.
Given: D=5m 5  100 =500 cm
f = 1200 kg/cm2
J = 1.0
P = 5 kg/cm2
Crown radius R = 100 % of diameter of vessel D = 5 m
Knuckle radius r = 6% of diameter of vessel D (5× 0.06) = 0.3 m
To find-: i) t s = …… cm
pDC
ts 
2 fj

1 R
C 3  
4  r 
1 5 
C  3  

4 0.3 
C = 1.77
pDC
ts 
2 fj
5  500  1.77
ts 
2  1200  1.0
t s = 1.84375
Problem (Unsolved 39)-: A pressure vessel is required to have a capacity of 30 m3. The vessel operates
at a pressure of 3.5 kg/cm2, the material used for fabrication of vessel has permissible stress of
1020kg/cm2. Welded joint efficiency is 85%. Corrosion allowance is 2 mm. Estimated the optimum
dimensions of the vessel.
Given: V = 30 m3 30 × (102)3 = 30 × 106 cm3
P = 3.5 kg/cm2
f = 1020 kg/cm2
C = 2 mm 2× 10-1 = 0.2 cm
J = 0.85
ii) L =……..cm

Design pressure = 3.5 × 1.1 = 3.85 Kg/cm2
i) We know that
D 3  
1  Dx 
3
V 
4  4 
But
 p 
x =  
 CfJ 
x =  
3.85

 0.2  1020  0.85 
x = 0.0222 cm …………..Ans
D 3  
1  Dx 
3
V 
4  4 
D 3  
1  D0.0222
3
 30  10 6 
4  4 
 7.5  10 6  0.7854 D 3 1  0.01665 D 
 30  10 6  0.7854 D 3  0.0131 D 4
D = 205.2 cm …………………… Ans

D 2
V  L
4
4V
L 
D 2
4  30  10 6
L 
  205.2 2
L = 907.145 cm …………..Ans
Problem (Unsolved-43)- : A pressure vessel of two elliptical heads have total volume 5.6 m3. It
operates at 15 kg/cm2. Weight of vessel with all its contents is 5000kg. The torque exerted over
the vessel is 100 kg.cm. Bending moment induced is negligible. Corrosion allowance is 1.5 mm.
Welded joint efficiency is 85%. Allowable stress of material is 1200 kg/cm2.
Estimate i) The optimum proportions of the vessel.
ii) Minimum standard plate thickness required for the vessel
Given: V = 5.6 m3 5.6 × (102)3 = 5.6 × 106 cm3
P = 15 kg/cm2
f = 1200 kg/cm2
C = 1.5 mm 1.5× 10-1 = 0.15 cm
J = 0.85
ii) L =……..cm
i) We know that
D 3  
1  Dx 
3
V 
4  4 
But
 p 
x =  
 CfJ 
x =  
16.5

 0.2  1200  0.85  (given C is 1.5)
x = 0.0809 cm …………..Ans
D 3  
1  Dx 
3
V 
4  4 
D 3  
1  D0.0809
3
 5.6  10 6 
4  4 
 5.6  10 6  0.7854 D 3 1  0.0607 D 
 5.6  10 6  0.7854 D 3  0.0476 D 4
D = 181.29 cm OR (1.81 m) …………………… Ans
(It is coming about 100cm)

D 2
V  L
4
4V
L 
D 2
4  5.6  10 6
L 
  181.29 2
L = 216.945 cm OR (2.13 m) …………..Ans
iii) Where volume of vessel with elliptical heads
 D 2 L D 3 
v  
 4 12 
   1.812  2.17   1.813 

v  
 4 12 
v = 5.583 + 1.552
v = 7.135 m3……………………………Ans
iv) First we have to calculate the thickness of shell

(L and D change, so bellow calculation will also change)
pDi
t 
2 fJ  p
16.5  181.29
t
2  1200  0.85  16.5
t = 1.4783 cm……………(i)
p ( Di  t )
ft 2 
4t
16.5 ( 181.29  1.4783)

ft2 
4  1.4783
f t 2 = 509.991 kg/cm2……………………….Ans
p ( Di  t)
f t1 
2t
16.5 ( 181.29  1.4783)

f t1 
2  1.4783
f t1 = 1019.981 kg/cm2
W
fw 
t ( Di  t )
5000
fw 
  1.4783(181.29  1.4783)
f w = 5.891 kg/cm2…………………(2)
this case.
f bm  0
...................................... (3)
by
f t = f t 2 + fw + f bm
ft
= 509.991 + 5.891 + 0
ft
= 515.882 kg/cm2……………………Ans
2T
fs 
Di t ( Di  t )
2  100
fs 
  181.29  1.4783(181.29  1.4783)
f s = 0.00130 kg/cm2………………………(4)
1
f R [ f 2 t1  f t1 f t  f t 2  3 f s2 ] 2
1
f R [(1019.981)  (1019.981 515.882)  (515.882)  3(0.00130) ]
2 2 2 2
f R = 883.349 kg/cm2……………………………..Ans
The equivalent resultant stress and longitudinal stress is less than permissible stress of 1060 kg/cm2.
v) Therefore, by adding corrosion allowance, 5 mm plate thickness can be safely specified for fabrication
of pressure vessel.
pDV
te 
2 fj
V 
1
6
2 k2  k 
2
1
2
V 
1
6
2  22 
V = 1.0
16.5  181.29  1.0

 te 
2  1200  0.85
t e = 1.46 cm or (14.6 mm)………………………….. Ans
Add corrosion allowance as 2 mm
So, standard plate thickness of 18 mm can be specified for the pressure vessel.
Problem (Unsolved-45)-: A pressure vessel of internal diameter 3 m is to be operate at an

internal pressure of 10 kg/cm2. The vessel has elliptical head at top with major to minor axis ratio
2.0 and conical head at bottom with an apex angle of 60 0. Material used for fabrication has an
allowable stress of 1020 kg/cm2. Welded joint efficiency is 85%. Corrosion allowance is 2 mm.
Density of material used for fabrication is 7800 kg/m3. Estimate the minimum standard plate
thickness required for fabrication of shell, elliptical head and conical head. Also estimate the
total dead weight of the vessel.
Given: P = 10 kg/cm2
f = 1020 kg/cm2
C = 2 mm 2× 10-1 = 0.2 cm
J = 0.85
Ρ = 7800 kg/m3
ii) t e =……..cm
iii) t c = ……….cm
i) First we have to calculate the thickness of shell
pDi
t C
2 fJ  p
11  300
t  0.2
2  1020  0.85  11
t = 2.1153 cm……………(i)
ii) The thickness of ellipsoidal head is given by
pDV
te  C
2 fj
V 
1
6

2 k2  k 
2
1
2
V 
1
6

2  22 
V = 1.0
11  300  1.0
 te   0.2
2  1020  0.85
t e = 2.1031 cm …………………….Ans
iii) We know that
pD
tc 
2 fj cos
11  300
tc 
2  1020  0.85  cos 60
t c = -tive ( t=3.806, it is +ve)
Thus it has been found that the half apex angle is in between 300.
 t c = 12.3374 + 0.2
t c = 12.5374 cm…………………………Ans
Now to calculate dead weight of vessel, first we have to calculate the volume of cylindrical vessel
 We know that,
D 3  
1  Dx 
3
V 
4  4 
 p 
But x =  
 CfJ 
D 3 3  pD  
V  1   
4  4  CfJ  

  33  3 11  300 
V  1    
4  4  0.2  1020  0.85  
V = 32  10^6 cm3
V = 32  10^7 cm3
V = 32 m3 (volume is coming 323.7 m3)
Now for calculating length
D 2
V  L
4
  32
 32  L
4
L = 0.22 m (it is 45m)
D 2
Total volume of cylindrical vessel = V  L
4
  32
V  0.22
4
V = 1.56 m3
Weight of cylindrical vessel = volume  density
 ( Do 2  Di 2 )
=  L   ( Do  Di  2t  3  2  0.0211  3.042 m )
4
 (3.042 2  3 2 )
=  0.22  7800
4
=342 kg
 ( Do 3  Di 3 )
Volume of elliptical head =
12
 (3.042 3  33 )
V
12
V =0.30 m3
Weight of cylindrical vessel = volume  density
= 0.30  7800
= 2340kg

Class Notes On Pressure Vessel PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Class Notes On Pressure Vessel PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Class Notes on Pressure Vessel

Classification of Pressure Vessel

i) According to their geometry-: it is classified as open tanks, closed tanks. A simple

Pressure Vessel Code

Material specification for temperature services

i) High temperature services-: when operating a pressure vessel at high

Failure of Cylindrical Shell-:

If a cylinder of constant wall thickness t, having length L, diameter of cylinder D, is subjected to

Fig a) failure of cylinder in longitudinal direction

Fig b) Failure of cylinder in axial direction

Stress induced in cylindrical shells

The total force acting on a longitudinal section of the shell

= Intensity of pressure × Projected area

Where D = diameter of shell

Area of total resisting force acting on the cylindrical shell

= 2× t × L (i.e of two section)

Where D = Mean diameter of shell i.e. mean diameter of ID & OD.

Put these value in eq.2

And for outside diameter

Put these value in eq.2

The total force acting on a longitudinal section of the shell

= Intensity of pressure × Projected area

Where D = diameter of shell

Area of total resisting force acting on the cylindrical shell

And Radial Deflection for thin cylindrical vessel is given by

Design of Spherical Vessel

Problems 1: A thin cylindrical pressure vessel of 500 mm diameter is subjected to an internal

P = 2 N/mm2 = 2 × 1.1 = 2.2

To find-: i) ft1 =……… N/mm2

ii) ft2 =............. N/mm2

Solution- : We know that

The hoop stress is given by

ft1 = 27.5 N/mm2 …………..Ans

ii) Longitudinal Stress

The longitudinal stress is given by

ft2 = 13.75 N/mm2…………Ans

f s = 6.875 N/mm2 ……………..Ans

Allowable stress of the material = 1020 kg/cm2, Corrosion allowance = 1 mm

Given: Do = 1.3 m 1.3 × 100 = 130 cm

To find-: i) t = …… cm for class B for 85 %

ii) t = ……cm for class C for 70 % & 50 %

Solution- : We know that

Design pressure = 12 × 1.1 = 13.2 Kg/cm2

i) Thickness of vessel for class B (J = 85 %)

ii) Thickness of vessel for class C (J = 70 %)

iii) Thickness of vessel for class C (J = 50 %)

iv) Thickness of vessel for class C (J = 100 %)

v) Percentage of metal saving by welding a strip

If the vessel is fabricated as:

Class B vessel with J = 0.85

Class C vessel with J = 0.5 & 0.7

What will be the minimum thickness of the vessel?

Allowable stress of the material = 1400 kg/cm2,

Given: let Do = 1.8 m 1.8 × 100 = 180 cm

C = 2mm 2× 10-1 = 0.2 cm

To find-: i) t = …… cm for class B for 85 %

ii) t = ……cm for class C for 70 % & 50 %

Solution- : We know that

Design pressure = 8 × 1.1 = 8.8 Kg/cm2

i) Thickness of vessel for class B (J = 85 %)

ii) Thickness of vessel for class C (J = 70 %)

iii) Thickness of vessel for class C (J = 50 %)

iv) Thickness of vessel for class C (J = 100 %)