DESIGN OF TALL TOWERS

Prepared by : group 2 ( enroll. 42 to 82 )

Prepared by: Group B (Enrollment 42-82)
Branch: Chemical
No. of slides:
Teacher In Charge: Dr. Asma Iqbal
Date: 25th October 2021
Presentation made by:
Khubaan Kullah (065), Riya (058), Abhishek Sharma (071), Muzzamil Showket Wani (082), Sikha
Kumari (067), Devananda Pt (056), Shakti Singh Rathore (075), Raunit Kumar Ravi (073), Arun
Rai (077), Kunwar Vikrant (057), Gaurav Kumar (080), Musaib Bashir (053), Nikhil Rewatkar
(065)
 INTRODUCTION TO TALL VESSELS
Self supporting tall equipments are widely used in chemical process industries. Tall
vessels may or may not be designed to be self supporting. Distillation column,
fractionating columns, absorption tower, multistage reactor, stacks, chimneys etc. comes
under the category of tall vertical vessels. In earlier times high structure (i.e. tall vessels)
were supported or stabilized by the use of guy wires. Design of self supporting vertical
vessels is a relatively recent concept in equipment design and it has been widely accepted
in the chemical industries because it is uneconomical to allocate valuable space for the
wires of guyed towers. Often the vertical vessels/columns are operated under severe
conditions, and type of the material these columns handles during operation may be toxic,
inflammable or hazardous in other ways. Structural failure is a serious concern with this
type of columns. As a result the, the prediction of membrane stresses due to internal or
external pressure will not be sufficient to design such vessels. Therefore, special
considerations are necessary to take into account and predict the stresses induced due to
dead weight, action of wind and seismic forces.
 STRESSES IN THE TALL VERTICAL
VESSELS:
The 2 main types of stresses in a shell or a tall vertical vessel are:
1. a) Circumferential stresses.
b) Axial stresses.
c) Radial Stresses.
These are due to internal pressure or vacuum inside the vessel.
2. Compressive stresses.
These are caused by the dead load e.g. self weight of the vessel including insulation,
attached equipment and weight of the contents.
 DEALOAD, LIVE LOAD & D WIND LOAD:
Dead Load:
It is the weight of a structure itself, which includes the weight of fixtures or
equipment permanently attached to it.
Live Load:
It is the moving or movable external load on a structure. This includes the
weight of furnishing of building, of the people, of equipment etc.
Note: The dead load or the live load does not take into consideration the Wind
Load which is a very important factor in determining the stresses and loads
on the vessel.
Wind load acts upon the vessel when it is located in open. The wind crates a
pressure on the vessel and the column acts as cantilever beam (as shown in
figure).
To ensure safety of the vessel, equipment and the surroundings, we therefore have to
consider the various parameters e.g. :
Compressive and tensile stress induced due to bending moment caused by wind load
acting on the vessel and its attachments.
Stress induced due to eccentric and irregular load distributions from piping, platforms
etc.
Stress induced due to torque about longitudinal axis resulting from offset piping and
wind loads.
Stress resulting from seismic forces.

Apart from that, always there are some residual stresses due to methods of fabrication
used like cold forming, bending, cutting, welding etc.
AXIAL AND CIRCUMFERENTIAL PRESSURE
STRESSES
The stresses developed by the internal pressure or vaccum are given below:
1.Circumeferential stress: Circumferential stress is the stress in a pipe wall, acting circumferentially in a
plane perpendicular to the longitudinal axis of the pipe. It is produced by the pressure of the fluid in the
pipe. It is also called as Hoop stress.
2.Longitudinal stress: Longitudinal stress is the stress in a pipe wall, acting along the longitudinal axis of
the pipe. And it is produced by the pressure of the fluid in the pipe.
3.Radial stress: The radial stress for a thick-walled cylinder is equal and opposite to the gauge pressure
on the inside surface, and zero on the outside surface. The circumferential stress and longitudinal
stresses are usually much larger for pressure vessels, and so for thin-walled instances, radial stress is
usually neglected
 LONGITUDINAL STRESS
In case of longitudinal stress ,if the analysis limits to pressure only ,the longitudinal
force ,p, resulting from an internal pressure, p ,acting on a thin cylinder of thickness t, length
l , internal diameter d is :
P=force tending to rupture the vessel longitudinally
pd 2
P
4
a=area of metal resisting longitudinal rupture
= td
stress=pressure/area
pd 2 / 4 pd
 (induced stress)
t d 4f

pd .....................(1)
t
4f
 CIRCUMFERENTIAL STRESSES
If we consider that circumferential stresses are induced by internal pressure only then the
following analysis may be developed.
P=force tending to rupture vessel circumferentially=p*d*l
a=area of resisting force=2*t*l

f=stress= P  pdl  pd
a 2tl 2t
Or pd …………(2)
t 
2f
Equation (1) and (2) indicates that for a specific allowable stress, fixed diameter and
given pressure, the thickness required to restrain the pressure for the condition of eq. (2) is
double than that of the equation (1). Therefore, the thickness as determined by equation
(2) is controlling and is the commonly used thin walled equation referred to in the various
codes for vessels. The above equation makes no allowances for corrosion and does not
recognize the fact that welded seams or joints may cause weakness. Experience has shown
that an allowance may be made for such weakness by introducing a joint efficiency factor
“j” in the equations. The thickness of metal, c, allowed for any anticipated corrosion is
then added to the calculated required thickness, and the final thickness value rounded off
to the nearest nominal plate size of equal or greater thickness.(1) and (2) rewritten as eq
(3) and (4).
 pd ……….. (3)
t  c
4fj t= thickness of shell
P=internal pressure
d=inside diameter
pd ……….... (4) f=allowable working stress
t  c
2fj E=joint efficiency factor
C=corrosion allowance
 COMPRESSIVE STRESS CAUSED
BY DEAD LOADS:
Dead load : weight of shell, insulation, heads, attachments etc.
The major sources of the load acting over tall vertical vessel are the weight
of the vessel shell and weight of the vessel fittings which includes the
internal, external and auxiliary attachments. Internal fittings: trays,
packing, heating and cooling coils. External fittings: platforms, piping,
insulation, ladders. Auxiliary attachments: instruments, condenser etc.
Therefore, Stresses caused by dead loads may be considered in three
groups for convenience: (a) stress induced by shell and insulation, (b)
stress induced by liquid in vessel and (c) stress induced by the attached
equipment.
 COMPRESSIVE STRESS CAUSED BY
DEAD LOADS:
Stress induced by shell and insulation: Stress due to weight of shell and insulation at
any distance, X from the top of a vessel having a constant shell thickness,
W shell =(П/4)(Do2 –Di2)×ρs×X
Where, W = weight of shell above point X from top
Do & Di= outside and inside diameter of shell
X = distance measured from the top of the vessel
ρs= density of shell material,
 COMPRESSIVE STRESS CAUSED BY
DEAD LOADS:
And stress due to weight of insulation at height “X”
W insulation = П Dins×ρins×X×tins
Where, Wins = weight of insulation
Dinsmean diameter of insulation =
X = height measured from the top of the column
tins = thickness of insulation
ρ ins = density of insulation
Compressive stress is force per unit area,
fdwt shell ={[(П/4)(Do2 –Di2)×ρs×X]/[(П/4)(Do2 –Di2)]} =X ρs
 COMPRESSIVE STRESS CAUSED BY
DEAD LOADS:
Similarly, the stress due to dead weight of the insulation is:
fdwt ins ={[П (D t ρ)ins X]/ П Dm ts }
Dm = mean diameter of shell (Dm = (Do + Di)/2)
Dins = diameter of insulated vessel
ts= thickness of shell without corrosion allowance
Therefore,
fdwt ins = {[(t ρ)ins X]/ ts }
 COMPRESSIVE STRESS CAUSED BY
DEAD LOADS:
Stress induced due to liquid retained in column. It will be depend upon
internal e.g. in tray column, total number of plates, hold up over each tray,
liquid held up in the down comer etc. will give the total liquid contents of
the column.
fd liquid=∑WLiquid/ П Dm ts
Dm = mean diameter of shell,feet
ts= thickness of shell without corrosion allowance
 COMPRESSIVE STRESS CAUSED BY
DEAD LOADS:
Stress induced by the attachment, like trays, over head condenser, instruments,
platform, ladders etc.
fd attachment =∑Wattachments / П Dm ts

The total dead load stress, ftotal, acting along the longitudinal axis of the shell is then
the sum of the above dead weight stresses.
ftotal = fdead wt shell + fdead wt ins + fdead wt liq + fdead wt attach.
THE AXIAL STRESSES DUE TO WIND
LOADS ON SELF SUPPORTING TALL
VERTICAL VESSEL
LOAD ACTING IN BOTTOM PART OF
VESSEL AND UPPER PART OF VESSEL
Pbw=K1K2p1h1Do
Where,
Pbw – Total force acting in bottom part of vessel ( length equal or less than 20 meter)
Do – Outer diameter of vessel including insulation thickenes
H1 – Height of vessel equal to less than 20 meter
K1 – coefficient depending upon shape factor

Puw=K1K2p2h2Do
Puw –total force acting in upper part of vessel
K2-Coefficient depending upon period of oscillation.
H2 - Height of upper part of vessel
SEISMIC DESIGN
CONSIDERATIONS
In this Seismic Design consideration, calculation of Shear Forces and Bending Moments
at different elevations can be calculated
Seismic consideration is purely related to intensity of vibration. Vibrational intensity is
directly proportional to time interval (no. of cycles per second). At first, time period of
vibration due to possible earthquake intensity or according to seismic zone as per given
specification, has to be calculated. Design Base Shear is inversely proportional to time
period, subsequently it can be calculated. Time period varies with height and weight of
section. So time period at primarily and design base shear secondarily are different for
various sections
STRESS ACTING ON VESSEL TO SKIRT
JUNCTION
• The vessel to skirt junction is subjected to the following stresses:
• Stress due to dead weight of the vessel,
• Stress due to Seismic/Wind loads
• The Seismic load is assumed to be distributed in a triangular fashion, minimum at the base of the column
and maximum at the top of the column.
• To simplify the design procedure, the vertical component of the earthquake is neglected, and the
horizontal component is reduced to equivalent static forces.
Numerical Method
• The seismic load acting on the vessel considered upto (2/3)H form the bottom of
the vessel, F is given by Load, F=ScW
Where W is the weight of the vessel
Sc is the seismic coefficient

Seismic coefficient depends on the intensity and period of vibrations. For example if the
vibration lasts for more than one second seismic coefficient value varies from minimum,
moderate to maximum Sc = 0.02, 0.04, and 0.08 respectively.
Now, stress induced due to bending moment (by wind load) upto height X from the top of the column
is given by: MsX=(ScWX2/3)*(3H-X/H2)
So, the maximum bending moment is at the bottom of the vessel where X=H and is given by
MsH=2/3*ScWH
• The resulting bending stress due to seismic bending moment is given by: fsb=4MsX/πD2t
Now, the maximum bending moment is located at the base of the vessel where X=H, substituting this
in the above equation, we get:
fsb=2ScWH/3πR2t

Note: The possibility of the wind load and seismic load acting simultaneously over the column is rare.
So both the loads are computed separately and whichever is more severe is used to calculate the
maximum resultant stress.
Maximum tensile stress at the bottom of the skirt f tensile = (fwb or fsb) - fdb
Maximum compressive stress on the skirt fcompressive = (fwb or fsb) + fdb, here, fdb = dead load stress
 STRESS DUE TO ECCENTRIC LOADS
ECCENTRIC LOAD: It is the load whose line of action does not pass
through the axis of column. In tall vessels the externally attached equipment
and parts usually acts as eccentric load.
 Stress due to eccentric load,
fe = 4 ∑Me/t(Di+t)Di
Where,
∑Me= W1e1+W2e2+ …….
e = Eccentricity, the distance from the column axis
to the line of action of eccentric load.
t = Shell thickness
Di = Inner diameter of vessel
ESTIMATION OF HEIGHT OF
THE TALL VESSEL(X)
•  
• aX2 + bX + c= 0
• from which
Once the value of ‘X’ is estimated,it is described to adjust the
plate thickness,t,for the top portion of column,so that the height
of portion X will be multiple of plate width used.
The plate thickness which is originally selected is satisfactory up to a
considerable height.Trays below the distance X of the column must have an
increased thickness. If the above condition does not satisfy then calculation of
axial stress with an increase in the thickness according to the equation
and W shell =(П/4)(Do2 –Di2)×ρs×X and are repeated,and this repetitive steps in
calculation helps to estimate subsequent height ranges to corresponds with
increase thickness.
The procedure is repeated till the entire height of the vessel is
covered.
Where,
• W=weight of shell above point X from top
• D0 and Di = outside and inside diameter of shell
• X= distance measured form top of vessel
• ρs= density of shell material
 SKIRT SUPPORTS
Skirt supports are cylindrical or conical steel shells attached to the bottom tangent of the vertical
vessels. These supports are found to be most suitable for tall vessels subjected to longitudinal
bending stresses, wind, seismic and other loadings, which cause bending moment at the base of
the vessel. It is to be noted that the skirts are not subjected to operating conditions as in the case
of pressure vessels, and therefore, the selection of material is not limited to the steels permitted by
the pressure-vessel codes. The structural steels with corresponding allowable stress may be used
for the skirt, and this will be economical
SKIRT WALL THICKNESS
 
 DESIGN OF BEARING PLATE FOR SKIRT
Thickness of bearing plate for skirt support is given by :
THICKNESS OF BEARING PLATE, WITH
GUSSET.
First, the value of tgp is calculated by equation 1, and if it comes out to be > 20mm, then tgp has to be calculated
by equation 2.
The value of M has to be taken from table 10.1 BC Bhattacharyya {corresponding to the value of L/b, values
for Mx and My can be found, and maximum of the two will be taken as the value of M}.
b is the gusset spacing, and the no. of gussets required is given by πDos/b.
 SUPPORT ANCHORING
Anchoring is the method of providing strong fixture to mechanical equipment including supports,
so there is less chance for overturning of supports. It’s done by inserting a portion of the bolt into
the concrete foundation, on the remaining length of the bolt, the bearing plate is fixed and is
tightened by nut.
 ANCHORING REQUIREMENT
For this we need to find the minimum stress between the bearing
plate and concrete foundation.
σmin = Wmin - M
A Z
M = bending moment , when this increase there is more chance for overturning
Wmin = Wshell + Whead (stability of the support increases with load weight)
If: σmin < 0
(this case we should anchor the support)
If: σmin ≥ 0
(check the stability factor j in this case)
j = Wmin * 0.42 * Dos
M
If j < 1.5 we need to provide anchoring for the support, in all other cases there is no need of
anchoring.
 PROBLE
M
A fractionating tower has following specifications: Shell outside diameter =2.5m Shell length tangent to
tangent = 40 m; Skirt height =5.0 m; Operating temperature = 300 oC; Design temperature = 320oC;
Design pressure = 1.2MN/m2; Allowable stress =100MN/m2; density of shell material = 9000 kg/m 3 ;
Weld joint efficiency factor = 1; Corrosion allowances = NIL; Tray spacing = 0.75 m all trays; Top
disengaging space =1m; bottom separator space = 2m; Weir height = 75 mm all tray; Downcomer
clearance = 25mm all trays; Weight of each head = 12 kN; Tray loading excluding liquid (alloy steel
Trays) = 1kN/m2 of tray area; Tray supporting rings = 60 mm×60 mm ×10mm angles; Insulation =
100mm asbestos; density of insulating material = 650kg/m 3; accessories = one caged ladder having a
loading of 1.0kN/m of ladder. A cylinder skirt support is to be designed for the fractionating tower.
The skirt is made of material of construction having allowable design stress value of 100MN/m 3 and
E = 2×105 MN/m2. Also given that the width of bearing plate (l) = 100mm Assume l/b =1.
(a) Determine the weight of shell, insulation, water during test and operating condition, trays
(excluding liquid) and all attachments.
(b) Determine the stress due to wind load in fractionating tower located in coastal area.
(c) Determine the stress due to seismic load in a fractionating tower assuming tower in severe zone.
Solution:
(a) Wshell   ( Do  t s )t s L  g
PDo 1.2  2.5
tmin    0.0149 m
2 fJ  P 2  1 100  1.2
ts  0.016 m
Wshell   (2.5  0.016)0.016  40  9000  9.81  440.953 kN
Winsul   ( Dins ,o  tinsul )tinsul L  g ,
Dins ,o  Do  2t  2.5  2  0.1  2.7 m
Winsul   (2.7  0.1)0.1 40  650  9.81  208.337 kN

Wliquid  n  ( Do  2t ) 2 (weir height)  liq g

 40  1  2  2
n  1    50.33  50, W liquid  50 
(2.5  2  0.016) 0.075 1000  9.81  175.987 kN
 0.75 
 (Test condition):
 
Wl  ( Do  2t ) 2 L liq g  (2.5  2  0.016) 2  40  1000  9.81  1877.194 kN
4 4
Whead  no. of head  wt per head  2 12  24 kN
Wladder  wt of ladder per unit length  height  1 45  45 kN
(height  skirt height  shell height  40  5  45 m)

Wtrays  no. of trays  tray loading excluding liq per unit area  ( Do  2t ) 2
4

 50  1  (2.5  0.032) 2  239.194 kN
4
Wattachment  308.194 kN

(b) W  Wshell  Wattachment  Winsul  Wliquid  1133.471 kN

3 1 3 1
5  H  2
 w 2
5  45  2
1133.471  2
Period of vibration, T  6.35 10    t   6.35 10 
D 
 i t  2.5  0.016   0.016 
=1.3s  0.5s
 Pbw  k1k2 p1h1 Dins ,o  0.7  2 1 20  2.7  75.56 kN (Pbw  Bottom wind pressure)
Puw  k1k2 p2 h2 Dins ,o  0.7  2 1.15625  25  2.7  109.265 kN
 p2  pressure at mid-point of upper part (At 32.5m from the foundation) 
 
 up to 20m  1 kN
m2
; up to 100m  2 kN
m2
; up to 32.5m  ? 
 By interpolation, p  1.15625 kN 2 
 2 m 

h1  h 
M w  Pbw  Puw  h1  2   4307.1125 kN
2  2
4M w
 z , w, m  2
 59.59 MN m2
 ( Di  t ) t  Seismic zone   Seismic Co-  
efficient, CS
(c) M s  2 3 CsWH (Cs  0.08)
 2 3 0.08 1133.471  45  2720.33 kNm T<0.4 0.4<T<1 T>1

4M s
 z , s ,m  2
 37.64 MN m2 MILD 0.05 0.02/T 0.02

 ( Di  t ) t MEDIUM 0.1 0.04/T 0.04

SEVERE 0.2 0.08/T 0.08