International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024

International Journal of Research Publication and Reviews

Journal homepage: www.ijrpr.com ISSN 2582-7421

Design of Horizontal Pressure Vessel in PVELITE Software

Prachi H. Kasved1, Harsh S. Jadhav2, Gautam G. Kulal3, Soham N. Thakur4, Anand P. Joshi5,
Ragwendra P. Singh6
1,2,3,4
Students, Mechanical Engineering, Datta Meghe College of Engineering, Airoli, India
5
Assistant Professor, Mechanical Engineering, Datta Meghe College of Engineering, Airoli, India
6
Assosiate General Manager, Worley Services India Private Limited, Airoli, India

ABSTRACT:

Pressure vessels are integral to numerous industries, facilitating the storage and processing of pressurized liquids, gases, chemicals, and more. This research focuses
on the design of a horizontal pressure vessel, emphasizing safety and regulatory compliance to enhance industrial efficiency. The methodology involves identifying
the problem statement, determining specifications including dimensions and materials, and utilizing PVELITE Software for design. References to standards such
as ASME Sec VIII Div 1, ASME Sec II, IS 875, and IS 1893 are incorporated for material selection, manufacturing methods, and stress calculations considering
wind and seismic loads. Proper design is paramount to prevent accidents and extend vessel lifespan, considering factors like corrosion resistance, suitable location,
mounting, material choice, and maintenance. Furthermore, incorporating ANSYS structural analysis augments the depth of the study, providing additional insights
into structural integrity and performance metrics. Results derived from these analyses are rigorously compared against industry standards to ensure compliance
with safety regulations, thereby affirming the robustness and reliability of the designed horizontal pressure vessel.
Keywords: PVELITE, Horizontal Pressure Vessel, ASME Sec VIII Div 1, Design.

1. Introduction

Pressure vessels are very important across various industries, serving as containers for storing pressurized liquids, gases, chemicals, and other substances.
There are various types of pressure vessels used in industries like horizontal, vertical, spherical, etc. The design of these vessels is very important, making
sure they meet strict safety standards, regulatory requirements, and performance criteria while also being cost-effective. In this context, the focus is on
using PVElite Software, a widely used tool in the industry, to simplify and improve the design process of pressure vessels. PVElite Software offers
advanced capabilities for analyzing pressure vessel designs, allowing engineers to efficiently go through design iterations and optimize vessel design.
Pressure Vessel Types are as follows: Types by Application: Storage Tanks, Process vessels, Heat exchangers; Types by Geometry: Vertical Pressure
Vessels, Horizontal Pressure Vessels, Conical Pressure Vessels, Spherical Pressure Vessels; Types by Orientation: Available space, Manufacturing and
installation, Seismic and wind, Stress distribution.

Fig. 1 - Horizontal Pressure Vessel

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8004

Nomenclature

Fig. 2 - Nomenclature

Tan Line- The Tangent Line (TL) is defined as the common theoretical line between the straight.

Weld Line- A weld line (WL) in a vessel is the point where the closures attach to the shell.

Straight Face- Straight Face is straight section height provided in shell section to weld with Dish end.

Dish end- Dish ends are welded to the main body of a pressure vessel to seal pressure vessels and prevent leaks and spills. They can be produced in
different shapes by Spinning method, during spinning there are always reduction in thickness of plate therefore always takes 10% minimum margin above
required thickness obtained by calculation. There three major type of Dish end:

1. Tori spherical: The most common type of dish end, with a shape resembling a torus(donut).

2. Ellipsoidal: Has a shape resembling an ellipse, and is preferred for applications where the pressure constraint on the component is above 10 bars.

3. Hemispherical: Completely round like a hemisphere, with a maximum radial section that gives it the largest pressure dispersion zone.

Nozzles- Nozzles are crucial openings in pressure vessels for fluid entry or exit. They typically consist of a flange, nozzle neck, and reinforcing element
if needed. Common types include inlet, outlet, instrumentation, and manway nozzles. Inlet and outlet nozzles accommodate fluid flow, while
instrumentation nozzles are for installing instruments like gauges and sensors. Manways allow access for inspection and maintenance. Standard flanges,
such as ASME B16.5, are commonly used for connection, ensuring precise assembly and construction.

Saddle Support- Saddle supports are U-shaped structures that support horizontal pressure vessels from below, providing excellent stability and weight
distribution. They are made up of two half-round supports that extend along the length of the vessel, welded or bolted to the bottom, and rest on a pedestal
or structural member.

1.1. ASME

ASME, organized in 1880 as an educational and technical society for mechanical engineers, took up the task. After years of development and public
feedback, the first edition of the ASME Boiler and Pressure Vessel Code was published in 1914 and formally adopted in 1915. Subsequently, in 1925,
the first Code rules for pressure vessels, titled "Rules for the Construction of Unfired Pressure Vessels," were introduced. Over time, the Code evolved
into its present twelve-section document, with numerous subdivisions, parts, and subsections.

Sections Description

I Rules for Construction of Power Boilers (ASME-Part 1)

II Materials (ASME-Part 2)

Part A — Ferrous Material Specifications

Part B — Nonferrous Material Specifications

Part C — Specifications for Welding Rods, Electrodes, and Filler Metals

Part D — Properties (Customary)

Part D — Properties (Metric)

III Rules for (Construction of Nuclear Facility Components ASME-Part 3)

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8005

Subsection NCA — General Requirements for Division 1 and Division 2

Division 1

Subsection NB — Class 1 Components

Subsection NC — Class 2 Components

Subsection ND — Class 3 Components

Subsection NE — Class MC Components

Subsection NF — Component Supports

Subsection NG — Core Support Structures

Subsection NH — Class 1 (Components in Elevated Temperature Service)

Appendices

Division 2 — Code for Concrete Containments

Division 3 — Containments for Transportation and Storage of Spent Nuclear Fuel and High-Level Radioactive Material and Waste

IV Rules for Construction of Heating Boilers (ASME-Part 4)

V Non-destructive Examinations (ASME-Part 5)

VI Recommended Rules for the Care and Operation of Heating Boilers (ASME-Part 6)

VII Recommended Guidelines for the Care of Power Boilers (ASME-Part 7)

VIII Rules for Construction of Pressure Vessels (ASME-Part 8)

Division 1: Rules for Construction of Pressure Vessels

Division 2: Alternative Rules

Division 3: Alternative Rules for Construction of High-Pressure Vessels

IX Welding and Brazing Qualifications (ASME-Part 9)

X Fiber-Reinforced Plastic Pressure Vessels (ASME-Part 10)

XI Rules for In-service Inspection of Nuclear Power Plant Components (ASME-Part 11)

XII Rules for Construction and Continued Service of Transport Tanks (ASME-Part 12)

2. Literature Review

2.1. ASME SEC VIII Div 1

ASME Section VIII Division 1 establishes the requirements for the design, fabrication, inspection, testing, and certification of pressure vessels. This
division is divided as per below diagram given.

ASME Section VIII – DIV 1

Subsection A Subsection B Subsection C Mandatory Appendices Non Mandatory Appendices

General Specific Requirements - Specific Requirements -

Requirements Appendix A to GG
Methods Materials Appendix 1 to 33

UG UW UCS

UF UNF

UB

Fig. 3 - ASME Section VIII – DIV 1 Bifurcation.

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8006

2.2. UG - 27 Thickness of Shells Under Internal Pressure

It covers the formulae for calculating thickness of shells under internal pressure which is as below:

For Circumferential Stress (Longitudinal Joints) as shown in Fig (a)

All dimensions in code are in corroded condition

Symbols:

t = min. required thickness

P = internal design pressure

R = inside radius of shell

S = max. allowable stress value (Sec II D)

E = joint efficiency (UW-12) Fig. 4 – Circumferential Stress

2.3. UG – 32 Formed Heads, and Sections Pressure on Concave Side

The minimum thickness required for certain types of heads, like ellipsoidal heads, under pressure on the concave side, should be calculated using specific
formulas as below:

• t/L ≥ 0.002

• Inside Depth = ¼ Inside diameter

t = minimum required thickness of head (forming)

P = internal design pressure

D = inside diameter of the head skirt, or inside length of the major axis pf an ellipsoidal head

S = max. allowable stress value in tension (Sec II D)

E = lowest efficiency of joint in the head (any)

• 2:1 ellipsoidal Head- Approximation: Knuckle Radius = 0.17D , Spherical Radius = 0.90D Fig.5 – Ellipsoidal Head.

2.4. UG - 99(c) Standard Hydrostatic Test

Hydrostatic tests are conducted on vessels after fabrication, excluding certain operations like weld end preparation. Completed vessels must pass this test,
except those exempts under UG-100 and UG-101.Vessels designed for internal pressure must undergo a hydrostatic test with a pressure at least 1.3 times
the maximum allowable working pressure, adjusted by the lowest stress ratio for vessel materials. The test considers all possible loadings and adjusts for
static head conditions. A calculated pressure hydrostatic test may be agreed upon between the user and manufacturer. The test pressure is determined by
multiplying the basis for calculated test pressure by 1.3 and adjusting for hydrostatic head. Inspectors reserve the right to review the calculations used for
determining the test pressure.

2.5. UW - 3 Welded Joint Category

The term "Category" denotes the location of a joint in a vessel, not its type. Categories A, B, C, and D define special requirements for certain welded
pressure joints based on service, material, and thickness. These requirements apply only to specified joints within each category. Category A includes
longitudinal and spiral welded joints within the main shell, among others. Category B covers circumferential welded joints within the main shell and
nozzles. Category C pertains to joints connecting flanges, tube sheets, or flat heads. Category D encompasses joints connecting communicating chambers
or nozzles to various vessel components.
 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8007

Fig. 6 Weld Joint Category.

3. Methodology

3.1. Problem Definition

Design the pressure vessels as per stated parameters with PVELITE software and calculate the thickness for shell & Heads & also calculate the weights
(empty & test). Wind and Seismic loads as per IS875(Wind), IS 1893 SCM (Seismic) applicable for foundation design.

3.2. Pressure Vessel Specification

The pressure vessel chosen for this study is a horizontal pressure vessel used to contain liquid having density 800kg/m3. This pressure vessel has 2:1
ellipsoidal heads and is designed to be used in fixed location on saddles. The pressure vessel will have an inner shell diameter 2250 mm and a shell length
5100mm. The pressure vessel is made of carbon steel SA-516 Gr70, which is the industry standard for pressure vessel design and creation.

Fig. 7 - Vessel Sketch.

Parameters Values
Design Internal Pressure 25 barg
Design external Pressure FV (Full Vacuum) 1 Bar
Design Temp (Max./Min./external) 225 ⁰C / -10 ⁰C / 65 ⁰C
Corrosion allowance 3 mm for pressure part
Joint Efficiency 1 (RT-1)
Insulation 150 mm thickness, Mineral Wool, density
120Kg/m3
Wind Load 150 Km/hr

Fig. 8 – Design Specifications.

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8008

Part Materials
Shell SA-516 Gr.70N
Heads SA-516 Gr.70N
Nozzle pipe SA-106 Gr. B / SA-516 Gr. 70N
Pipe Flanges SA-105
Reinforcement pad SA-516 Gr.70N
Saddle support SA-516 Gr.70 / SA-36
Fasteners SA-193 Gr. B7 / SA-194 Gr. 2H
Gasket Spiral wound gasket
Fig. 9 -Material Specifications.

3.3. Shell Design

When designing the pressure vessel shell, we consider two main factors: the pressure it will handle and the 3mm corrosion allowance specified by ASME
standards. This helps determine the thickness of the shell. Thickness Calculation of Shell:

PR
t= +CA
SE−0.6P

0.2549∗1125
t= +3
14.0689∗1−0.6∗0.2549

t = 23.24 mm

Fig. 10 - (a) Shell ; (b) Shell Input in PVELITE.

3.4. Dish end Design

Thickness Calculation of Dishend:

2:1 Ellipsoidal Head

Inside Depth = ¼ Inside diameter

PR
t= +3
SE−0.2P
0.2549∗1125
t= +3
14.0689∗1−0.2∗0.2549

t = 23.4569 mm

Fig. 11 - (a) Head; (b) Head Input in PVELITE.

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3.5. Nozzle Design

Fig. 12 - Nozzle. Fig. 13- Manhole

S.N. Nozzle Mark Nominal Diameter Service Flange Rating Flange Type
(DN)

1 N1 DN150 Steam outlet 600# WNRF

2 N2 DN80 Boiler feed water 600# WNRF

3 N3 DN250 Downcomer 600# WNRF

4 N4 DN80 Spare 600# WNRF

5 N5 DN250 Riser 600# WNRF

6 N6 DN80 Boiler feed water 600# WNRF

7 N7 DN100 Vent 600# WNRF

8 N8 DN80 Continuous blowdown 600# WNRF

9 N9 DN50 Intermittent blowdown 600# LWNRF

10 N10 DN50 Steam injection 600# LWNRF

11 N11 DN50 Spare 600# LWNRF

12 N12 DN80 Drain 600# WNRF

13 L1-L4 DN50 Level control 600# LWNRF

14 P1-P2 DN50 Pressure 600# LWNRF

15 T1 DN50 Temperature 600# LWNRF

16 M1 DN600 Manhole 600# WNRF

Fig. 14– Nozzle Table.

International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8010

Fig. 15 - (a) Nozzle Input in PVELITE; (b) Manhole Input in PVELITE.

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8011

3.6. Supports(Saddles) Designs

Vessel OD <2300 mm

A 2020 mm

B 880 mm

C 940 mm

T1 16 mm

T2 16 mm

T3 16 mm

T4 20 mm

K 400 mm

H (Max) Saddle Height 1450 mm

Weight Per Saddle 445 kg

Max. Load Per Saddle 24000 kg

Fig. 16 - (a) Saddle Sketch; (b) Saddle Specifications.

Fig. 17 – Saddle Input in PVELITE.

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3.7. Software Output

Internal Pressure Calculation Results

ASME Code, Section VIII Division 1, 2017

Elliptical Head From 10 To 20 SA-516 70 , UCS-66 Crv. D at 225 °C

Left Dishend

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (PDKcor)/(2SE-0.2P) Appendix 1-4(c)

= (25.1772256.00.996)/(2137.91.0-0.225.177)

= 20.5601 + 3.0000 = 23.5601 mm.

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

Less Operating Hydrostatic Head Pressure of 0.177 bars

= (2SEt)/(KcorD+0.2t) per Appendix 1-4 (c)

= (2137.91.022.0)/(0.9962256.0+0.222.0)

= 26.936 - 0.177 = 26.760 bars

Cylindrical Shell From 20 To 30 SA-516 70 , UCS-66 Crv. D at 225 °C

Shell

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (PR)/(SE-0.6P) per UG-27 (c)(1)

= (25.1771128.0)/(137.91.0-0.625.177)

= 20.8234 + 3.0000 = 23.8234 mm.

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

Less Operating Hydrostatic Head Pressure of 0.177 bars

= (SEt)/(R+0.6t) per UG-27 (c)(1)

= (137.91.022.0)/(1128.0+0.622.0)

= 26.583 - 0.177 = 26.406 bars

Elliptical Head From 30 To 40 SA-516 70 , UCS-66 Crv. D at 225 °C

Right Dishend

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (PDKcor)/(2SE-0.2P) Appendix 1-4(c)

= (25.1772256.00.996)/(2137.91.0-0.225.177)

= 20.5601 + 3.0000 = 23.5601 mm.

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

Less Operating Hydrostatic Head Pressure of 0.177 bars

= (2SEt)/(KcorD+0.2t) per Appendix 1-4 (c)

= (2137.91.022.0)/(0.9962256.0+0.222.0)
 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8013

= 26.936 - 0.177 = 26.760 bars

Hydrostatic Test Pressure Results:

Pressure per UG99b = 1.30 M.A.W.P. Sa/S 32.561 bars

Pressure per UG99b[36] = 1.30 Design Pres Sa/S 32.500 bars

Pressure per UG99c = 1.30 M.A.P. - Head(Hyd) 39.091 bars

Pressure per UG100 = 1.10 M.A.W.P. Sa/S 27.551 bars

Pressure per PED = max(1.43DP, 1.25DPratio) 35.750 bars

Pressure per App 27-4 = M.A.W.P. 25.047 bars

UG-99(b), Test Pressure Calculation:

= Test Factor MAWP Stress Ratio

= 1.3 25.047 1.0

= 32.561 bars

External Pressure Calculation Results :

ASME Code, Section VIII Division 1, 2017

Elliptical Head From 10 to 20 Ext. Chart: CS-2 at 65 °C

Left Dishend

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (PDKcor)/(2SE-0.2P) Appendix 1-4(c)

= (1.722256.00.996)/(2137.91.0-0.21.72)

= 1.4023 + 3.0000 = 4.4023 mm.

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

= ((2SEt)/(KcorD+0.2t))/1.67 per Appendix 1-4 (c)

= ((2137.91.022.0)/(0.9962256.0+0.222.0))/1.67

= 16.130 bars

Maximum Allowable External Pressure [MAEP]:

= min( MAEP, MAWP )

= min( 9.94, 16.1296 )

= 9.942 bars

Elliptical Head From 30 to 40 Ext. Chart: CS-2 at 65 °C

Right Dishend

Material UNS Number: K02700

Required Thickness due to Internal Pressure [tr]:

= (PDKcor)/(2SE-0.2P) Appendix 1-4(c)

= (1.722256.00.996)/(2137.91.0-0.21.72)

= 1.4023 + 3.0000 = 4.4023 mm.

Max. Allowable Working Pressure at given Thickness, corroded [MAWP]:

= ((2SEt)/(KcorD+0.2t))/1.67 per Appendix 1-4 (c)

= ((2137.91.022.0)/(0.9962256.0+0.222.0))/1.67
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= 16.130 bars

Maximum Allowable External Pressure [MAEP]:

= min( MAEP, MAWP )

= min( 9.94, 16.1296 )

= 9.942 bars

Weight Summary:

Fabricated Wt. - Bare Weight without Removable Internals 13127.4 kg.

Shop Test Wt. - Fabricated Weight + Water ( Full ) 36377.4 kg.

Shipping Wt. - Fab. Weight + removable Intls.+ Shipping App. 14105.2 kg.

Erected Wt. - Fab. Wt + or - loose items (trays,platforms etc 14105.2 kg.

Ope. Wt. no Liq - Fab. Weight + Internals. + Details + Weights 14105.2 kg.

Operating Wt. - Empty Weight + Operating Liq. Uncorroded 32705.2 kg.

Oper. Wt. + CA - Corr Wt. + Operating Liquid 31520.5 kg.

Field Test Wt. - Empty Weight + Water (Full) 37355.3 kg.

Wind Load Calculation:

| | Wind | Wind | Wind | Wind | Element |

From| To | Height | Diameter | Area | Pressure | Wind Load |

| | mm. | mm. | cm² | Kgs/m² | Kgf |

---------------------------------------------------------------------------

10| 20| 1450 | 3120 | 16620 | 118.219 | 139.092 |

20| 30| 1450 | 3120 | 156000 | 118.219 | 1305.56 |

30| 40| 1450 | 3120 | 16620 | 118.219 | 139.092 |

---------------------------------------------------------------------------

Seismic Analysis Results per IS-1893 (1984), Seismic Coefficient Method.

Earthquake Load Calculation:

| | Earthquake | Earthquake | Element |

From| To | Height | Weight | Ope Load |

| | mm. | Kgf | Kgf |

-------------------------------------------------

10| 20| 1125 | 6304.1 | 94.5614 |

20|Sadl| 1125 | 6304.1 | 94.5614 |

Sadl| 30| 1125 | 6304.1 | 94.5614 |

20| 30| 1125 | 6304.1 | 94.5614 |

30| 40| 1125 | 6304.1 | 94.5614 |

-------------------------------------------------

Nozzle Calculation Summary:

Description | MAWP | Ext | MAPNC | UG-45 [tr] | Weld | Areas or

| bars | | bars | | mm. | Path | Stresses

---------------------------------------------------------------------------------------------
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M1 | 25.05 | OK | ... | ... | | OK | Passed

L1 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

L1 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

L2 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

L2 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

P1 | 26.41 | ... | ... | OK | 7.80 | OK | No Calc[]

N2 | 26.09 | OK | ... | OK | 7.80 | OK | Passed

N4 | 26.27 | OK | ... | OK | 7.80 | OK | Passed

N6 | 26.41 | OK | ... | OK | 7.80 | OK | Passed

N1 | 26.03 | OK | ... | OK | 8.73 | OK | Passed

N3 | 25.24 | OK | ... | OK | 11.10 | OK | Passed

N7 | 25.84 | OK | ... | OK | 8.26 | OK | Passed

P2 | 26.41 | ... | ... | OK | 7.80 | OK | No Calc[]

N5 | 25.12 | OK | ... | OK | 11.10 | OK | Passed

N8 | 26.22 | OK | ... | OK | 7.80 | OK | Passed

N9 | 26.41 | ... | ... | OK | 7.52 | OK | No Calc[]

N10 | 26.41 | ... | ... | OK | 7.52 | OK | No Calc[]

N12 | 26.41 | OK | ... | OK | 7.80 | OK | Passed

T1 | 26.41 | ... | ... | OK | 7.52 | OK | No Calc[]

N11 | 26.41 | ... | ... | OK | 6.42 | OK | No Calc[]

L3 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

L3 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

L4 | 26.76 | ... | ... | OK | 7.80 | OK | No Calc[]

Nozzle Schedule:

Nominal or | Schd | Flg | Nozzle | Wall | Reinforcing Pad | Cut | Flg

Actual | or FVC | Type | O/Dia | Thk | Diameter Thk | Length | Class

Description Size | Type | | in | mm. | mm. mm. | mm. |

-------------------------------------------------------------------------------------------

L1 | 2.000 in | Actual | LWN| 3.202 | 15.269 | ... | ... | 240.46 | 600

L2 | 2.000 in | Actual | LWN| 3.202 | 15.269 | ... | ... | 240.46 | 600

P1 | 2.000 in | Actual | LWN| 3.310 | 16.640 | ... | ... | 225.79 | 600

P2 | 2.000 in | Actual | LWN| 3.310 | 16.640 | ... | ... | 225.79 | 600

N9 | 2.000 in | Actual | LWN| 2.602 | 7.645 | 90.00 | 26.00 | 225.49 | 600

N10 | 2.000 in | Actual | LWN| 2.602 | 7.645 | 90.00 | 26.00 | 225.49 | 600

T1 | 2.000 in | Actual | LWN| 2.766 | 9.735 | ... | ... | 225.55 | 600

N11 | 2.000 in | 160 | LWN| 2.375 | 8.738 | 70.00 | 26.00 | 225.40 | 600

L3 | 2.000 in | Actual | LWN| 3.202 | 15.269 | ... | ... | 240.46 | 600

L4 | 2.000 in | Actual | LWN| 3.202 | 15.269 | ... | ... | 240.46 | 600

N2 | 3.000 in | 160 | WNF| 3.500 | 11.125 | 120.00 | 25.00 | 225.88 | 600

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N4 | 3.000 in | 160 | WNF| 3.500 | 11.125 | 120.00 | 25.00 | 225.88 | 600

N6 | 3.000 in | 160 | WNF| 3.500 | 11.125 | 128.90 | 25.00 | 225.88 | 600

N8 | 3.000 in | 160 | WNF| 3.500 | 11.125 | 118.90 | 26.00 | 225.88 | 600

N12 | 3.000 in | 160 | WNF| 3.500 | 11.125 | 190.00 | 26.00 | 225.88 | 600

N7 | 4.000 in | 120 | WNF| 4.500 | 11.125 | 164.30 | 25.00 | 226.45 | 600

N1 | 5.000 in | 160 | WNF| 5.563 | 15.875 | 191.30 | 25.00 | 227.22 | 600

N3 | 10.000 in | 80 | WNF| 10.750 | 15.088 | 433.05 | 25.00 | 233.31 | 600

N5 | 10.000 in | 80 | WNF| 10.750 | 15.088 | 423.05 | 26.00 | 233.31 | 600

M1 | 24.000 in | 40 | WNF| 24.000 | 17.450 | 910.00 | 25.00 | 247.84 | 600

Saddle Parameters:

Saddle Width 300.000 mm.

Saddle Bearing Angle 120.000 deg.

Centerline Dimension 1450.000 mm.

Wear Pad Width 400.000 mm.

Wear Pad Thickness 25.000 mm.

Wear Pad Bearing Angle 132.000 deg.

Distance from Saddle to Tangent 1000.000 mm.

Baseplate Length 2020.000 mm.

Baseplate Thickness 25.000 mm.

Baseplate Width 300.000 mm.

Number of Ribs (including outside ribs) 4

Rib Thickness 16.000 mm.

Web Thickness 16.000 mm.

Height of Center Web 200.000 mm.

Number of Bolts in Baseplate 4

Summary of Maximum Saddle Loads, Hydrotest Case :

Maximum Vertical Saddle Load 20433.23 Kgf

Maximum Transverse Saddle Shear Load 261.32 Kgf

Maximum Longitudinal Saddle Shear Load 194.50 Kgf

Weights:

Fabricated - Bare W/O Removable Internals 13127.4 kg.

Shop Test - Fabricated + Water ( Full ) 36377.4 kg.

Shipping - Fab. + Rem. Intls.+ Shipping App. 14105.2 kg.

Erected - Fab. + Rem. Intls.+ Insul. (etc) 14105.2 kg.

Empty - Fab. + Intls. + Details + Wghts. 14105.2 kg.

Operating - Empty + Operating Liquid (No CA) 32705.2 kg.

Field Test - Empty Weight + Water (Full) 37355.3 kg.

ASME Code, Section VIII Division 1, 2017

Diameter Spec : 2250.000 mm. ID

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Vessel Design Length, Tangent to Tangent 5100.00 mm.

Specified Datum Line Distance 50.00 mm.

Internal Design Temperature 225 °C

Internal Design Pressure 25.000 bars

External Design Temperature 65 °C

External Design Pressure 1.030 bars

Maximum Allowable Working Pressure 25.047 bars

External Max. Allowable Working Pressure 6.390 bars

Hydrostatic Test Pressure 32.561 bars

Required Minimum Design Metal Temperature -10.0 °C

Warmest Computed Minimum Design Metal Temperature -29.0 °C

Wind Design Code IS-875

Earthquake Design Code IS-1893 SCM

Materials of Construction:

Component | | | | |Normal | Impact

Type | Material | Class | Thickness | UNS # | ized | Tested

---------------------------------------------------------------------------------------------

Shell | SA-516 70 | ... | ... | K02700 | Yes | No

Head | SA-516 70 | ... | ... | K02700 | Yes | No

Nozzle | SA-516 70 | ... | ... | K02700 | No | No

Nozzle | SA-106 B | ... | ... | K03006 | No | No

Nozzle | SA-105 | ... | ... | K03504 | No | No

Re-Pad | SA-516 70 | ... | ... | K02700 | No | No

Nozzle Flg | SA-105 | ... | ... | K03504 | No | No

Hrz Bolting | SA-193 B7 | ... | 2 1/2 < t <= 4 | G41400 | No | No

Normalized is determined based on the UCS-66 material curve selection and Figure UCS-66.

Impact Tested is based on material selection and material data properties.

3.8. Structural Analysis in Ansys

ANSYS Static Structural is a software widely used for analyzing pressure vessels. It helps to evaluate the stresses and deformations caused by both the
internal pressure and the weight of the vessel and the fluid it contains. SolidWorks software complements this by allowing engineers to create detailed
three-dimensional models of the pressure vessels. The mathematical model employed in this analysis encompasses various aspects such as defining
boundary conditions, formulating equations to calculate total deformation and equivalent stress, and utilizing numerical analysis methods for accurate
simulations. In summary, ANSYS Static Structural and SolidWorks together provide a comprehensive solution for designing and analyzing pressure
vessels, ensuring their safety and performance, as shown in the figure below
 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8018

Fig. 18 - Ansys.

In this study, we employed a mesh consisting of 243,204 nodes and 129,585 elements. We selected this mesh due to its excellent overall quality,
ensuring accurate results. Our analysis revealed that the cell aspect ratio was consistently low, with the vast majority of elements (99.8%) having an
aspect ratio not exceeding 0.27. This indicates that the mesh effectively captures the geometry and details of the pressure vessel without distortion.
Additionally, all three mesh quality criteria were met, further confirming the suitability of the chosen mesh for our analysis. Therefore, we confidently
adopted this mesh for our study, ensuring reliable and precise simulation results. We set a boundary condition where the pressure inside the vessel is
constant, caused by the fluid it contains. We fixed this pressure at 2.5 MPa, which represents the total pressure inside the vessel is subjected to as
shown in the figure below

Fig. 19 – Total Pressure.

The highest equivalent elastic stress experienced by the pressure vessel is 42.18% as shown in the figure is lower than the maximum tensile strength of
the material, which is 481.6 MPa. The total deformation experienced by the pressure vessel is 2.617mm
 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8019

Fig. 20 - (a) Equivalent Stress; (b) Total Deformation.

The maximum principle stress experienced by the pressure vessel is 54.45% as shown in the figure is lower than the maximum tensile strength of the
material, which is 527.27MPa.

Fig. 21 – Maximum Principal Stress.

4. Result

The experimentation calculations yielded the following results:

Parameters Values (Kg)

Erected Weight 14100

Operating Weight 32700

Field Test Weight 37400

Shear Forces (lbf)

Wind 306.65

Seismic 208.47

Fig. 22 - (a) Weights, Wind & Seismic Load;

 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8020

(b) Horizontal Pressure Vessel In PVELITE.

Parameters Shell Dishend

Nominal thickness 25 mm 28 mm

Actual Stress at
130.606 128.891
given Design
N/mm2 N/mm2
temperature

Max. Allowable 30.239 30.575

Pressure bars bars

Max. Allowable 26.406 26.760

Working Pressure bars bars

Fig. 23 - (a) Horizontal Pressure Vessel In PVELITE; (b) Shell & Dishend Summary

Nozzle Mark Nozzle Schedule Wall Thickness

N1 600 15.875 mm

N2 160 11.125 mm

N3 80 15.088 mm

N4 160 11.125 mm

N5 80 15.088 mm

N6 160 11.125 mm

N7 120 11.125 mm

N8 160 11.125 mm

N9 NONE 7.645 mm

N10 NONE 7.645 mm

N11 160 8.738 mm

N12 160 11.125 mm

L1 to L4 NONE 15.269 mm

P1 & P2 NONE 16.640 mm

T1 NONE 9.735 mm

M1 40 17.450 mm

Fig. 24 – Nozzle Summary.

5. Conclusion

During this study, we designed a horizontal pressure vessel using PVELITE software as per the ASME Sec VIII Div I and calculated thickness of shell
and head and weights. Also calculated wind and seismic loads. Then, we used ANSYS Static Structural to model, mesh, and simulate the vessel to test
its strength and study how stress and deformation are distributed across it. Hence, from result obtained from PVELITE, it's evident that the design of
Horizontal Pressure Vessel ensures that stresses, pressures, and loads are within safe limits which is crucial for maintaining the safety of the vessel.
Nozzle loads were within allowable limits, ensuring the integrity of the vessel connections and attached components. In Ansys, our study employed a
high-quality mesh with 243,204 nodes and 129,585 elements, ensuring accurate results. The mesh effectively captured the pressure vessel's geometry,
with low cell aspect ratios indicating minimal distortion. All mesh quality criteria were met, confirming the suitability of the chosen mesh. A constant
pressure boundary condition of 2.5 MPa was applied to represent internal pressure. Results showed that the highest equivalent elastic stress and maximum
 International Journal of Research Publication and Reviews, Vol 5, no 4, pp 8003-8021 April 2024 8021

principle stress were both below the material's maximum tensile strength, ensuring structural integrity. The total deformation experienced by the vessel
was 2.617mm, confirming its ability to withstand pressure within safe limits.

REFERENCES

[1] https://www.iqsdirectory.com/articles/pressure-vessel/pressure-tanks/pressurevessel.jpg?hl=en_US

[2] ASME Boiler and Pressure Vessel Code

[3] ASME SEC II Materials

[4] Worley Services India Pvt Ltd

[5] Pressure_Vessel_Design_Manual-4th_Ed-Dennis_R._Moss_and_Michael_Basic

[6] BEDNAR Pressure Vessel Design Handbook_2nd Edition

[7] Pressure_Vessel_Handbook_-E._Megyesy10th._Ed.

[8] ASME Section VIII Div 1 – 2019, “Rules for construction of Pressure Vessels”

[9] ASME Section II – 2019, “Materials”

[10] IS 875 – 1987, “Design loads other than Earthquake for building and structure”

[11] IS 1893 – 2005, “Criteria for Earthquake Resistant Design of Structures”

[12] Forged Vessel Connection an Ameri-Forge Group company

[13] PVELITE Software

[14] AutoCad Software

[15] https://images.app.goo.gl/fcsudeq2pSw6bv8H8

[16] Jacobs Engineering India Pvt. Ltd (Saddle support for Horizontal Vessel - For Vessel OD. 2000 to 3500)