A process vessel is to be operated at maximum operating pressure of 2

MN/m 2 {g). The vessel has diameter of 3 m and length of 5 m. This vessel is
made of steel having allowable design stress value of 120 MN/m 2 at design
temperature. The corrosion allowance is suggested to be 3 mm for life span
expected for the vessel which is to be fabricated with a weld joint efficiency
factor of~
{a) Determine the thickness of the shell to nearest integer. I_/"
{b) Determine the thickness of the flat head having plates welded to the
.. _ end of the shell {no inside welding).
-
Solution Pgauge(Maximum operating) = 2 MN/ m12
P= Design Pressure=2.1 MN/m 2 --

f=120 MN/~ D0 = 3 m --
J=1 _. C.A= 3mm
(a) tmin= 2;::p=26.022 mm --
trrna1=29.022 mm \./
Tstandard=30 mm v' Flat head having plates welded to the end of
the shell (no inside welding) C HOT LESS rttAN 1•2st,

(b) t=CDe v(;)~ D =D·

e I
C=0.7 .
---

De=3-0@*2 = 2.94 m
T min = 272.248 mm
No addition of
Tfinal = 272.248 If tmin > 30 mm corrosion
Tstandard = 273 mm allowance
Solution 120° apex angle (with sharp edges i.e. no knuckle part) both at and away
f rom junction .

(C) (i) At the junction 2a is apex angle

t= pDeC \./"" De = Do a=4J=6QO C = 3.2
2fj -
tmin = 84 mm
tstandard =t final =84 mm

~ 0-01 0·02 0·03 0·04 0·06 0·08 0·10 0·15 0·20 0·30 0·iO 0·50

10• 0·70 0·65 0·60 0·60 o·ss 0·55 0·SS 0·55 0·SS 0·55 0·55 0-55
20• 1·00 0·90 0·85 0·80 0·70 0-65 0·60 0·55 0·55 0·55 0·55 0·55
so· 1·35 1·2 l'l l ·0 0 ·90 o·as 0·80 0·70 0 ·55 o-,, 0·55 0·55
45• 2·05 1·85 1·65 1·5 1·3 1·2 J• l 0·95 0·90 0·70 0·55 O·S!
60• S·2 2·85 2·55 2·35 2·0 1•75 1·6 1·4 1·25 1·00 0·70 0-55
411\ ( NPIEL ONLINE 75• 6·8 S·8S !i·SS 4·75 S·85 S·S S· IS 2·7 2·4 l •65 l•OO 0·55
• IIT ROORKEE """ CERTIFICATIO
Solution 120° apex angle {with sharp edges i.e. no knuckle part) both at and away
from junction .
Actual thickness (at the junction)
Away from the junction
L=0.5 ~ -
✓~
L = 0.354965 m
Dk = D0 -2t S-2L sina
= 3 - 2 * 0.03 - 2 * 0.354965 sin 60 = 2.325183 m
O 1
t . =
min
P * - - = 41 .049
/i
2/J- P cosa
mm
= 41 .049 mm
t final

tstand = 45 mm
Solution 100° apex angle with ri=0.05 De and 4)=25°.

2 a =100° (apex angle)

a=50°
r 1=0.05 De 4'=25°

At the junction
ri/ De =0.05 4'=25° Now,
r;/ De =0.04 4'=200 C=0.8 r;/ De =0.06 4'=20° C=0.7
r;/ De=0 ..04 4):300 C=1 r;/ De=0.06 4'=30° C=0.9
ri/ De=0 . 04 4'=25° C=0.9 ri/ De=0.06 4'=25° C=0.8

D = 0 . 05
!J.. 4' = 25° C = 0.85
e
tmin=
( DC) = 22.3125mm
p2fj tfina1=25.3125 mm
 ;a06
-

0-01 0·02 0·03 - 0-08 0·10 O·l5 0·20 0•3() 0·40 0·SO

0·70 0·65 0·60 0·60 0·55 0·55 0·55 0·55 0·55 0·55 0·55 0-55
100° ape>
Solution ~
20•) 1·00 0·90 0·85 0·70 v 0-65 0·60 0-55 0•55 0-55 0·55 0·5.S
90• 1-, :; 1·2 I·I 1·0
~
0•90 ✓ 0·8$ 0·80 0·70 O·!,j o-,, O·,_, 0·3'

2 a =100° (apex angle) 45• 2·05 1·85 1·65 1·5 1·3 1·2 I· I 0-95 0·90 0·70 0·55 0·s.'
60• 5·2 2·85 2·55 2·35 2·0 1·75 1·6 1·4 1'25 1·00 0·70 0-55
a=5O°
75• 6·8 5·85 5•9.S 4·75 9·8S 3 ·S 9·15 2·7 2·♦ 1·5!i 1·00 O·.SS
r 1=O.O5 D0 '+'=25°

At the junction
r;/ De =0.05 '+'=25° Now,
v
✓r;/ De =0.04 4J=2Oo C=O.~ r;/De =0.06 4J=2O0 C=0 .7 v
v r;/ De=0.04 4):300 C=1 r;/ De=0.06 4):300 C=O.9 v
r;/De=0.04 '+'=25° C=O.9 V r;/ De=0.06 '+'=25° C=O.8 ~

!:.l.. = 0.05 4J = 25° C = 0.85 t' =26.83 mm

De
tmin=(p2i1c) = 22.3125mm tfina1=25.3125 mm
-
tstand-28 mm
. \._....,/
Solution

Away from the junction v

L= 0.5 ~ =0.15222 m V
✓~
Dk = D0 -2tS -2Lsina
= 3-2*0.03-2*0.15222 sin50
= 2.706785 m v
tmin = 37.1715 mm . \..,/

t stand = 40 mm
 Determine the thickness of the plate required to fabricate a dished head for
Solution
the vessel. Specification for the head are Ri= l.1D 0 ; ri=0.07D 0 ; St= 70 mm.

(d) Ri = 1.1D0
ri = 0.07D 0
St = 70 mm
;.= (:i)
=Ri =3.3 m
Take R0 rO = ri = 0.21 m

ho=Ro-j( R (~•)) •(Ro+C•)- Zro)

0 -
J¥ = 0.5612486m

= 0.4921538 m
D5/4Ro = 0.681818 m
hi =minimum of the above 3 =h 0
= 0.492 1538 mm
•I .ll2.
 Dete rmine the thickness of the plate requi red to fabricat e a dished head
Solution
for t he vessel. Speci fication for t he head are Ri=l.1D 0 ; ri=0.07D 0 ; Sr= 70mm .

Assuming opening is compensated:

h E =0.164
Do

..!....
Do
= (!!..£)
2[}
= 8.75*10·3 C
C = 1.85 (by interpolation)
t = 0.04856 mm
tmin= 48.56 mm
tfinal = 1.06*tmin=51 .4 76 mm
tstand = 56 mm
 .00875
Determ ine the th ickness of the plate requ ired or
Solution .005
to fabricate a dished head for the vesse l. .3912
3.92 0.002 Specification for the head are Ri=l.1D0 ; .002091
2.3912 0.005 ri=0.07D 0 ; Sr= 70mm . or
1.954 0.01
1.7876 0.02 .005118
; =0.164
1.6296 0.04 () .02
1.7876
.011188
Without Opening or With Fully Compcosalcd Opcoings 6 .015
t!Do 1.8708
0.005 0.01 0.02
.008018
It.J D. 0.002
4. 55
--
2.66 2.15 1.95
-01.75
04
.016
0. 15
0.20 2.30 1.70 1.45 1.37 1.32 1.85416
0.25 1.38 1.14 1.00 1.00 1.00 .008629
0.30 0.92 0.77 0.77 0.77 0.77 .0162
0.40 0.59 0.59 0.59 0.59 0.59
0.55 0.55 0.55 0.55
1.850832
0.50 0.55
.008753
 Det ermine the t hickness of the plat e requ ired t o fabricate a dished head
Solution
for the vessel. Specificat ion for the head are Ri=l.1 D0 ; ri=0.07D 0 ; Sf= 70mm .

Assuming opening is compensated:

~ E =0.164 v
0
✓

_t
Do
= (E.£)
2tJ
= 8.75*10· 3 C

C = 1.85 (by interpol ation ) ✓

t = 0.04856 mm
tmin= 48.56 mm
tfina,= 1.06*tmin ,51.476 mm
tstand = 56 mm
 Determine the th ickness of the plate requ ired to fabricate a dished head
Solution
for the vessel. Specification for the head are Ri= l.1D 0 ; ri=0.07D 0 ; Sr= 70mm .

Now since flt > 10 mm

R0 = Ri+t5 = 3.356 m 1
ro= ri +ts = 0.266 m )
✓ h 0 =0 . 523096 m
tmin=44.625 mm
DJ =Q.670441 m V /oJo =0.631664
✓z
tfina1=1 .06*tmin=47.3025 mm
/4Ro tstand=50 mm
hE=h 0 =0. 523096
;E=0.174 ; = 8.75*10·3 C ~t<10 mm hence no need of
0 o
extra calculation
C = 1.7
 Determine the blank diameter of the plate for form ing the dished head.
Solution

(e) Since t>25 mm

Blank diamet~r = D0 + (:;) + (~) r 1 + 2S1 + t
=3.4014286 m
Example-2
A vessel is being operated at maximum pressure of 2 MN/m 2 (g). It has outer
diameter of 2.Sm and length of Gm. The allowable stress of shell and corrosion
allowance is 150 MN/m 2 and 3mm, respectively. The vessel is of Class 2 where
double welded butt joint with full penetration is used for all joints. Compute the
followings:
(a) Thickness of plate used to fabricate a _lorjspherical head for: this vessel. In this
two fullv compensated openings are provided with diameters of 0.lm and 0.2m.
Consider Ri = 1.2 D0 , ri = 0.063D0 , St= 60mm. Carry out only one iteration.
(b} What is the maximum diameter of uncompensated opening can be made if 2:1
ellipsoidal head (hE=0.25D 0 ) of same thickness as computed in Part (a) is used.
(c) Thickness of flat formed head when flanged heads are butt welded to the shell.
 Design pressure = p = 2.1 MN/m 2
Solution Thickness of shell = t = 0.02042 m
t with corrosion allowance = 23.42 mm
t standard = 25 mm
Assumption Ri = Ro ri=ro
(a) Thickness of plate used
Calculation of hE Ri=l.2Do 3 Ro
to fabricate a torispherical
ri=0.063Do 0.1575 ro
head for this vessel. In this
0.52083 m
two fully compensated
6.88625
openings are provided with
0.37583 m
diameters of 0.lm and
0.19688
0.2m . Consider R-' = 1.2 DOf r-I
0.44371 m
= 0.06300 , St = 60mm . Carry
0.37583 m
out only one iteration.
0.15033 m
Solution
(a) Thickness of plate used
to fabricate a torispherical
head for thi s vessel . In this
two fully compensated
openings are provided with
diameters of 0.lm and 0.2m.
=
Consider Ri 1.2 0 0 , ri=
0.06300 , St= 60mm . Carry t = 0.041506 ✓
out only one iteration. 0.043996 ,1
t s = 45
 (b} What is the maximum diameter of uncompensated opening can be
Solution
made if 2:1 ellipsoidal head (hE=0.25O0 } of same thickness as computed in
Part (a) is used.

'f-- 200fJ
pDoC with Uncompensated Openlog5

0.008235 d/yt Do
t/DOC =
hE/Do = 0.25 hs/Do 0.5 1.0 2.0 3.0 4.0
-.- -5.0
C= 2.016 0.15 1.67 l.86 2.15 2.65 3.1(, ·3.60
12.23529 0.20 1.28 1.45 1.85 2.30 2.15 3.25
d/sqrt(t* D0 ) = 2.924444 ·0.25 J.00 I.] 5 l.60 2.05 2.50 2.95
d = 0.942037 m 0.30 0.83 1.00 1.45 J. 88 2.28 2.70
0.50 0.60 0.80 I.IO 1.50 l.85 2.15
 (c) Th ickness of flat formed head when flanged heads are butt welded
Solution
to the shell.

I
CD • /p
•7o 'VJ

C= 0.45
D= Di = ~
p/f = 0.014
t= 0.13045
0.13828
139 mm