1.

A cylindrical shell is subjected to internal pressure such that Hoop’s and axial stresses in the
wall reach 150 and 75 MPa respectively. Two small circular holes are punctured into the shell
wall such that the line joining the centres of the two circles is parallel to the axis of the
cylinder. The centres of the two circles are separated by distance 8x. One circular hole is of
diameter 2x and the other of 4x. Estimate the Hoope’s stress value in the wall at the midpoint
of the line joining the centres of the two holes.

2. A 1200 mm (48 inch) NB XS pipe has the following dimensional standards.

Nominal Bore Schedule Average wall thickness

48” XS 0.500”

For this pipe, recommend the maximum internal working pressure that can be used safely. If
such a pressure is applied, what would be the values of Hoop’s stress and axial stress in the
pipe and what would be their nature?

If the pipe is to withstand net external pressure with same magnitude as the above design
pressure without provision of stiffening rings, what would be the maximum length of the pipe
that you would allow? What would be the values of Hoop’s and axial stresses and their nature
in this case?

The design temperature is 500 C and the allowable stress of material at design temperature is
140 MPa. For external pressure service, use applicable material chart for SA-l06-B supplied
to you. Recommended corrosion allowance is nil and 12.5% negative mill tolerance is
recommended.

3. An ellipsoidal head with a = 1.2 m and b = 0.6 m and with thickness of 6 mm is subjected to
an internal pressure. Determine the MAWP if the MoC allowable is 100 MPa.

4. Find:
a. The largest size of a self compensating, non-protruding 40 SCH nozzle that can be
provided on a 24” SCH 40 pipe of the same material. Design pressure is 7.5 bar.
b. The lightest 16” NB pipe that can withstand internal vacuum over its 10 m
unstiffened run without the possibility of buckling failure. Design temperature is 400
C. Assume the MoC to be SA-106-B.
Take the allowable stress for the MoC as 120 MPa. Corrosion allowance as 1.5 mm, all
welds fully radiographed, zero mill tolerance.

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5. A vessel with the following design specifications is available. Recommend a safe operating
pressure for the same.

Cylindrical body : OD - 3 m, Wall Thickness - 12 mm, Tangent to Tangent length - 10 m

Top Closure: 2:1 ellipsoidal, 12 mm wall thickness, flanged connection with shell
Bottom Closure: Conical with 30 degrees half cone angle, 12 mm wall thickness,
welded to shell
Nozzles:
1. Nozzle on cylindrical body with its axis at 30 cm above bottom tangent, 4” NB,
40 SCH, seamless, protruding 3 cm inside the vessel, not reinforced
2. Nozzle on top closure at its crown, 6” NB, 40 SCH, non-protruding, seamless, not
reinforced
3. Nozzle on conical bottom, at half depth of the cone, oriented normal to cone wall,
4” OD, 40 SCH, non-protruding, seamless, not reinforced

6. Find the adequacy of the pressure vessel with design as in Question 5 for vacuum service.
Assume that the nozzles and the conical closure are unlikely to fail because of buckling. If
you find the cylindrical body to be inadequate, suggest suitable number of stiffeners. If top
closure is inadequate to withstand vacuum, suggest a suitable wall thickness for it.

7. A 150mm (6”) NB pipe needs to be designed for an external design pressure of 400 psi and a
design temperature of 400 C. The MoC of the seamless pipe is austenitic stainless to ASTM A
312 TP 304 L. The corrosion allowance is nil. Negative mill tolerance of 12.5 % should be
used on nominal thickness. Select a proper pipe schedule for a pipe segment of 7.5 m with
flanged connections at both the ends.

Recommend maximum operating pressure if the pipe designed by you is also to be used for
internal pressure service occasionally. Allowable stress of the MoC at design temperature is
40000 psi.

8. Design a spherical vessel for storage of a chemical for the following data.
Design Pressure (Internal) : 100 psig
Design Temperature : 300 C
Yield Stress at room temperature : 60000 psi
Weld Joint Efficiency : 0.85
Outer Diameter :2m
Corrosion Allowance : 3 mm

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 Negative mill tolerance on nominal thickness of 5% is acceptable.

Two nozzles (one protruding, another non-protruding) are to be provided on this vessel. Both
nozzles are made out of 6” NB 40 SCH welded pipe with weld joint efficiency of 0.85. Check
the nozzles for reinforcement requirement and suggest reinforcement pad thickness if the pad
is required. For suitable support design, the Civil department needs to be provided with the
weight of the tank if filled with water. Calculate the same.

9. A pressure vessel has a diameter of 1500 mm. It is to be provided with a flanged closure at its
top. The design pressure in the vessel is 35 bar (internal). Allowable stress for the MoC is 100
MPa. Determine the wall thickness of:
1. Formed hemispherical cover
2. 2:1 ellipsoidal closure with weld joint efficiency of 0.85
3. Formed Dished closure with crown radius same as vessel OD and knuckle radius 10% of
the crown radius.
4. Conical head with cone angle of 45 degrees, fully radiographed.

10. Design the lightest cylinder with welded hemispherical closures to store 15 kg air at 100 bar
pressure. Take allowable stress of MoC as 40000 psi, weld joint efficiency as 1 for all welds.
Make suitable assumptions if necessary. Corrosion allowance and negative mill tolerance are
zero. Fabrication is done using sheet material. Consider two cases: (A) When all parts must be
fabricated using sheet of same thickness. (B) When different parts could be fabricated using
sheets of different thicknesses.

11. Design a slip-on type plain face flange for a cylindrical shell with following specifications.
Design Pressure : 10 bar
Shell OD : 800 mm
Shell Thickness : 10 mm
Allowable Stress at Design Temperature : 120 MPa
Gasket Thickness : 3.2 mm
Gasket Factor : 11.0
Gasket Yield Stress : 20 MPa

You need not calculate the flange thickness. Assume that the bolts come in nominal diameters
in multiples of 3 mm and that the bolt root area is 5% less than the cross-sectional area

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 calculated using these nominal diameters. Recommended clearance from the BC to edge of
the flange is twice the diameter of the bolts.
Make suitable assumptions wherever necessary.

12. Design bolts for the following conditions:

Vessel ID : 480 mm
Hub Thickness : 30 mm
Allowable Bolt Stress : 140 MPa
Maximum Bolt Load : 2.1 MN
Minimum Bolt Span : 75 mm (up to a bolt size of 30 mm)
Minimum radial clearance of bolt centre from hub : 30 mm
Maximum bolt spacing : 118 mm

13. A tall distillation column of 1 m diameter and 50 mm wall thickness supports a vertical heat
exchanger whose axis is 3 m away from the axis of the column. The distance of the CG of the
exchanger from the base of the column is 15 m. Diameter of the exchanger is 0.3 m and its
length is 4 m. The exchanger weighs 900 kg. If the wind pressure of 1.2 bar is assumed to
bear on the exchanger, determine the stresses produced due to the presence of the exchanger
at the base of the column. Calculate all normal and shear stresses as well as maximum
principal and shear stresses (E = 280 GPa.)

14. A packed distillation column is 10 m tall and has a diameter of 1.5 m and uniform wall
thickness of 40 mm. The wind velocity to which it is expected to withstand is 80 kmph.
Determine the location and magnitude of highest shear and normal stresses produced in the
shell of the column due to wind load. The column is clamped at its base to a rigid foundation.
Find the maximum deflection of the column (E = 280GPa) .
The wind pressure is related to velocity by Pw = 10 Vw 2 . Fs where velocity (V) is in kmph, Pw
is in Pa, Fs is the form factor (= 2/π for circular cross-section).

15. Find the tallest square cross-section (1 m side) stack made out of 0.5” thick plate that can be
safe under a wind velocity of 140 kmph. Ignore seismic and other loads. Pressure inside the
stack is atmospheric and the stack is not insulated. Take allowable stress of the MoC at design
temperature as 120 MPa, corrosion allowance as 1.5 mm, all welds fully radiographed, zero
mill tolerance.

16. Find the maximum width of a sheet gasket placed over a 2 m diameter circle that can be used
for leak-proof performance under 5 bar internal design pressure service. Gasket yield stress is

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 25 MPa, gasket factor is 5.0, mating flange surfaces are grooved, 28 bolts of 20 mm nominal
diameter are provided over a 2.1 m diameter bolt circle.

17. A metallic, circular cross-section, un-insulated stack is to be designed for venting off flue
gases to atmosphere from a cement factory. The internal pressure in the stack is near-ambient.
Recommend a suitable design of a multiple thickness stack which weighs the least and does
not use more than 3 plates of different thicknesses including the plate used for the skirt.
Location of the factory is in Seismic Zone 2 and the maximum wind pressure reported by
IMD is 2000 Pa (for flat plate). The stack is supported on a skirt of 1.2 m height. Stack outer
diameter is 15 m, stack height is 40 m above the skirt, erosion allowance is 3 mm. Apart from
wind load and seismic load, you are expected to give due consideration to vibrations and
deflection of the stack.)

18. Two serrated (corrugated) mating flanges have a provision of 28 bolts which together can
bear a tensile load of at most 0.45 MN. The flanges allow for a 12 mm wide flat gasket with
mean gasket diameter of 732 mm, Design pressure is 8.5 bar internal. For this service, choose
the most appropriate gasket material from the following options. Explain your
rejection/selection criteria clearly.
Gasket material Yield Stress, MPa Gasket factor
Vegetable Fibre 7.50 1.75
Asbestos Filled Material 31.0 2.00
Solid Flat material (Aluminum) 60.0 4.00
Solid Flat Metal (Iron) 125.00 5.50
Solid Flat Metal (SS) 180.00 6.50

19. A slip-on type plain-faced flange has been designed for a cylindrical shell with following
specifications.
Design Pressure : 12 bar internal
Shell OD : 1000 mm
Shell Thickness : 15 mm
Allowable Stress at design temperature (bolt) : 120 MPa
Gasket Thickness : 3.2 mm
Gasket factor : 11.0
Gasket Yield Stress : 20 MPa
Mean Gasket Diameter : 1050 mm
Gasket Width : 12.5 mm

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 Bolt Circle diameter : 1090 mm
Bolt Nominal diameter : 25 mm
Number of bolts : 32

Assume that the bolt root area is 5% less than the cross-sectional area calculated using
nominal bolt diameter. Make other suitable assumptions wherever necessary.

Various bolt materials are available with allowable stress values of 80, 100, 120, 150 and 200
MPa. Bolting cost increases as the allowable stress of the bolt material increases. Select the
most economic bolt material for above design from among the available materials. If none of
these materials is suitable, suggest minimum allowable stress value of bolt material that you
would go for.

20. Three identical pipe sections are used for different services. The pipes are of different MoCs
(say Pipe A: MoC X, Pipe B: MoC Y, Pipe C: MoC Z). During operation, each of these pipes
develops the following stresses induced due to various external loads. Hoop’s stress : 60 MPa,
Axial Stress : 50 MPa, Shear Stress: 15 MPa. Following information is available.
I. Pipe A fails as per one failure theory but is seen safe as per remaining two theories.
II. Pipe B is safe as per only one of the theories but fails as per the remaining two
theories.
III. Pipe C fails as per all the three theories.
Find the lower and upper limits on possible values of yield stresses for the three MoCs from
this information.

21. Using membrane theory, develop expressions for compressive stresses generated in a closed
pressure vessel (a shape of revolution) subjected to a net external pressure P. The expressions
should allow calculation of stresses along a suitable set of orthogonal directions at any
location on the wall of the vessel individually. List all assumptions that you make in deriving
your results. Demonstrate that your general expressions reduce to expected results for the
Hoop’s, axial and radial stresses in a cylindrical shape.

22. A distillation column is to be designed as per given dimensional and other specifications.
Wind and eccentric loads are specified. Select an appropriate plate thickness if the shell and
skirt are all to be of same material and same plate thickness. Do not design the condenser or
closures.
Skirt height : 1.5m
Tangent-to-tangent height of the vessel : 30 m

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 Column diameter :2m
Insulation thickness : 35 cm
Internal design pressure : 20 bar
Maximum wind velocity : 200 kmph
Condenser attached to the column : (insulated diameter 0.5 m, height : 4 m,
distance between centre of mass of
condenser to column axis : 1.5 m, distance
between centre of mass of the condenser to
the skirt bottom: 17.5 m, weight of
condenser : 2000 kg)
Allowable stress of the MoC at Design
Temperature : 130 MPa
Girth welding efficiency : 1.0
Seam welding efficiency : 0.85

Also estimate the axial and Hoop’s stresses expected at the lower tangent of the column under
hydrostatic test conditions along with wind and eccentric loads.

23. Carry out a flange design for the following specification.

Type of flange : Welded neck
Hub Thickness : 20 cm
Mating Flange surface : Plain
Flange thickness : 5 cm
Vessel OD : 0.75 m, Thickness: 12 mm
Gasket yield stress : 50 MPa
Gasket factor : 6.0
Bolt and flange material allowable stress : 175 MPa, Young’s modulus: 160 GPa
Minimum Wrench clearance : Two bolt diameters between consecutive
bolt centres
Design Pressure : 10 bar

Summarize the following values in a table: Gasket Circle Diameter, gasket width, Bolt Circle
Diameter, Number of bolts, diameter of bolts, flange OD.

24. A jacketed piping system (pipe within pipe) is required to be designed as per the following
specifications. The core (inner pipe) and the jacket (outer pipe) carry same chemical
composition fluid, but at different temperatures and pressures as given. Decide a suitable pipe

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 schedule for each pipe. The core pipe is assembled by flanged connections of 6 m pipe
lengths. The jacket pipe run is designed similarly. Ignore thermal expansion of the jacketed
assembly.
Corrosion allowance : 1 .5 mm.
Material yield stress at room temperature : 75000 psi,
Material Young’s modulus at design temperature : 160 GPa
Core pipe fluid specifications : pressure 10 bar, temperature 200 C
Jacket fluid specifications: pressure 15 bar, temperature : 300 C
Core pipe : 200 mm NB
Jacket : 400 mm NB
Mill tolerance for core and jacket pipes : ± 12.5%
Core pipe is fully radiographed. Jacket pipe’s weld joint efficiency is 085.

25. Design a welded neck type serrated-faced flange for connecting two adjoining lengths of 1500
mm OD pipe of MoC with allowable stress of 120 MPa. The pipe thickness is 25 mm, design
pressure is 5 bar. Gasket material of 3 mm thickness has a yield stress of 80 MPa and gasket
factor of 5.0. Bolt material has an allowable stress of 140 MPa.

26. A tall column for vacuum distillation is to be designed. The tangent-to-tangent height of the
column above a skirt of 1.5 m height is expected to be 35 m. If only wind load is to be
considered (expected worst wind velocities arc 180 kmph), find the safe minimum thickness
of the column. Hydrostatic test on the erected column is proposed to be carried out at 10 bar
internal pressure. The column diameter (OD) is 1500 mm, girth and seam welding efficiencies
are 0.85 and 1.0 respectively, corrosion allowance is 1.5 mm, mill tolerance is zero, insulation
thickness is 20 cm. Allowable stress at design temperature is 120 MPa. The closures are
welded to the cylindrical body. The top closure is standard torispherical and the bottom
closure is conical with half apex angle of 30 degrees.
Find suitable number of stiffeners, if required, for the column. Assume other properties as for
material for which you have a chart (Factor A, Factor B). Design temperature is 150 C.

27. A 1 m outer diameter spherical shell made out of 8 mm thick plate is subjected to internal
pressure P. Find the maximum principal stress, maximum shear stress and octahedral shear
stress values in the pipe wall in terms of P.
If the above sphere had a non-protruding nozzle of 100 mm NB, schedule 40 pipe of the same
material, estimate the above three stresses at the worst affected portion of the junction of shell
wall and nozzle. Explain your logic.

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 Up to what maximum internal pressure, the above spherical shell with nozzle can be
considered safe without reinforcement if 140 MPa is the allowable stress for the MoC. Use
area compensation method for this calculation.
The sphere is fully radiographed and the pipe for nozzle is seamless. No corrosion allowance
need to be provided and mill tolerance is zero for plate as well as pipe.

28. A tall column is to be designed for 15 bar internal pressure. The tangent-to-tangent height of
the column above a skirt of 1.5 m height is expected to be 30 m. If only wind load is to be
considered (expected worst wind velocities are 160 kmph), find the safe minimum thickness
of the column Hydrostatic test on the erected column is proposed to be carried out at 20 bar
internal pressure. The column diameter (OD) is 2000 mm, girth and seam welding efficiencies
are 0.85 each, corrosion allowance is 3.0 mm, mill tolerance is 10%, insulation thickness is 35
cm. Allowable stress of MoC at design temperature is 110 MPa. The closures are welded to
the cylindrical body. The top closure is standard torispherical and the bottom closure is
conical with half apex angle of 30 degrees. Arrive at the thickness of the closures. Assume
other properties as for material for which you have a chart (Factor A, Factor B). Design
temperature is 250 C. Design slip-on type serrated-faced flanges for connecting the closures
to the body. Gasket material of 3 mm thickness has a yield stress of 80 MPa and gasket factor
of 10.0. Bolt material has an allowable stress of 140 MPa.

29. Find the largest self-compensating, non-protruding nozzle size that can be supported on a
standard dished end closure for a cylindrical shell of 4 m outer diameter. Design pressure is
30 bar, all joints have a weld joint efficiency of 0.85, corrosion allowance is 1.5 mm, mill
tolerance is 10%, allowable stress for the MoC is 120 MPa. Use area compensation method.
Closure is fabricated using plates.

30. Develop three design formulae for a cylinder subjected to internal design pressure of P, inner
diameter D, seam weld joint efficiency E, Girth weld joint efficiency e, suitable Y factor,
material yield stress ‘y’ and safety factor S that complies with each of the three theories of
failure. Each formula should give regulation thickness in terms of P, D, E or e, Y, S and y.
State the three theories of failure and their implications.

31. A square hoarding (side 3 m) is to be supported by a vertical 8” NB SCH 40 pipe of MoC-A

(Qu. 53). If wind velocity is 80 kmph, to what height can the hoarding be raised safely. Make
suitable simplifying assumptions.

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32. A jacketed reactor needs to be designed to carry out catalytic hydrogenation. The reaction
pressure is 45 bar a and the reaction temperature is 200 C. Steam at 260 C and 60 bar g
pressure is used in the jacket to maintain the temperature. Material of construction has an
allowable stress of 80 MPa at 200 C and 68 MPa at 300 C. The same material is used for the
reactor and its jacket. The reactor has a diameter of 3m, shell height of 3 m, standard dished
closure at top and an ellipsoidal closure (2:1) at the bottom. The jacket covers only the
cylindrical portion and the lower closure. There is an opening for 200 mm NB nozzle on the
top closure for agitator shaft. The nozzle is of thickest available 200 mm nominal diameter
pipe. Top closure is flanged to the shell while bottom closure is welded. 100% radiography is
recommended for all weld joints. Corrosion/erosion allowance is 1.5 mm for all surfaces
touched by process fluid or heating medium. Mill tolerance on plate material is ± 5%.
Carry out the design and indicate all major dimensional details on a neat sketch.

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