Design of Horizontal Type Pressure Vessel: For Propane Gas
A Project Report
By:
Name of Student: ID No.
Name of Student: ID No.
Project Code:
Submitted in partial fulfilment of the requirements for the award of the Degree of
Bachelor of Science
In
Mechanical Engineering, for the course of Machine Design Project (MEng4112)
Submitted to
Addis Ababa Science and Technology University
College of Electrical and Mechanical Engineering,
Department of Mechanical Engineering
Project Supervisor and Evaluator: Dawit G.
Lecturer, Mechanical Engineering Department
April 19, 2024
Executive Summary
1
Table of Contents
Executive Summary.................................................................................................................1
List of Figures..........................................................................................................................4
List of Tables...........................................................................................................................5
Chapter 1 Introduction............................................................................................................6
1.1. Identification of Need................................................................................................................6
1.1.1. Customer Meetings and Interviews...........................................................................................................6
1.2. Background Research................................................................................................................6
1.2.1. Summary of Technical Literature...............................................................................................................6
1.2.2. Pressure Vessels........................................................................................................................................6
1.3. Classification of pressure vessels...............................................................................................6
1.3.1. Properties of containing fluids...................................................................................................................6
1.3.2. Properties of materials selection for vessels construction (tensile stress, yield stress, corrosion
resistance, weld ability).......................................................................................................................................6
1.3.3. General design considerations (Design pressure, temperature and load, material for the vessel, design
stress, welded joints, efficiency and corrosion allowance)..................................................................................6
1.4. Codes, Standards and Regulations.............................................................................................6
1.5. Definition of the problem/ Goal Statement................................................................................6
1.5.1. Problem Statement...................................................................................................................................6
1.5.2. Quality Function Deployment....................................................................................................................6
1.6. Objective of the Project.............................................................................................................6
1.7. Performance specifications........................................................................................................6
1.7.1. Define what the system must do...............................................................................................................6
Chapter 2 Concept Design Development.................................................................................7
2.1. Design Process and Considerations............................................................................................7
2.2. Design Specification/ Requirement List (Define how the System must do it)..............................7
2.3. Concept Models.........................................................................................................................7
2.3.1. Functional Description...............................................................................................................................7
2.4. Selected Concepts......................................................................................................................7
2.4.1. Design objectives, key features of a solution.............................................................................................7
2.4.2. Alternative design concepts for achieving the goal...................................................................................7
2.4.3. Evaluation and comparison of competing design concepts (Decision Matrices).......................................7
2.4.4. Presentation and comments on the concepts...........................................................................................7
Chapter 3 Analysis and Results Discussion..............................................................................8
3.1. Functional Description...............................................................................................................8
3.2. Material Selection.....................................................................................................................8
2
3.3. Mathematical Modelling and Supporting Analysis......................................................................8
3.3.1. Construction of Mathematical model that simulates real system using sketches and drawings.............8
3.3.2. Use of Design Equations and Formulas of for Design of different Components of the Pressure Vessel....8
3.3.3. Assumptions made, making sure to justify your design decisions.............................................................8
3.3.4. Supporting Analysis...................................................................................................................................8
3.3.5. Material Selection.....................................................................................................................................8
3.3.6. Manufacturing Plan...................................................................................................................................8
3.3.7. Safety Maintenance and Repair.................................................................................................................8
3.4. Cost Analysis.............................................................................................................................8
Chapter 4 Detailed Design......................................................................................................9
4.1. Part Drawings and Detail Drawings............................................................................................9
4.2. Assembly drawing of the Pressure vessel...................................................................................9
4.3. Assembly Procedure and User Manual.......................................................................................9
4.4. Manufacturing Plan...................................................................................................................9
Chapter 5 Conclusions and Recommendations......................................................................10
References.....................................................................................................................................12
Appendices....................................................................................................................................13
3
List of Figures
Fig 1.1……………………………………………………………………………8
Fig 1.2……………………………………………………………………………13
Fig 1.3……………………………………………………………………………14
4
List of Tables
Table 3.1……………………………………………………………………………9
Table 3.2……………………………………………………………………………9
Table 3.3……………………………………………………………………………10
Table 3.4……………………………………………………………………………11
Table 3.5……………………………………………………………………………12
Table 3.6……………………………………………………………………………13
Table 3.7……………………………………………………………………………14
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Chapter 3Analysis and Results Discussion
1.1. Functional Description
Propane gas is a highly flammable and potentially hazardous substance that is commonly used
as a fuel source in various industrial and residential applications. In the design of a horizontal
type pressure vessel for storing and transporting propane gas, several key functional
requirements must be considered:
1.Pressure Containment/Rating
The primary function of the pressure vessel is to withstand the maximum pressure of the
propane gas it will store or transport without rupturing or leaking.
2.Material Selection
The material used for the construction of the Pressure Vessel should be compatible with
propane gas and resistant to corrosion and other forms of chemical degradation.
3.Thermal Insulation
Propane gas is stored and transported at low temperature to maintain its liquid state.The
Pressure Vessel must be equipped with thermal insulation to prevent heat transfer and
maintain the temperature of the gas within the recommended range.
4.Safety features
Propane gas pressure vessels should be equipped with safety features.These devices should be
sized and located in accordance with industry standards.
5.Trans-portability and Handling
The horizontal type pressure vessel must be designed for easy transport and insulation, with
features such as lifting lugs, skid- mounted support structures, and appropriate transport
fittings or connections.
6.Structural Design
The Pressure Vessel should be designed to ensure structural integrity and prevent any
potential leakage or failure.
7.Leak Detection and Prevention
Propane gas is highly flammable, so it is crucial to incorporate robust leak detection and
prevention mechanisms into the pressure vessel design. This can include features such as
pressure gauges, level sensors, and leak detection systems to ensure early detection of any
leaks and prevent accidents or hazardous situations.
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8.Ventilation and ventilation Systems
Proper Ventilation is important to prevent the accumulation of propane gas vapors in an
enclosed space. The pressure vessel design should include provisions for Ventilation system,
such as pressure relief vents or exhaust fans, to ensure the safe release of any propane gas
vapors.
9.Regulatory Compliance
The design of the pressure vessel should comply with all relevant safety standards, codes, and
regulations for propane gas storage or transportation.
1.2. Material Selection
Choosing the right material is critical for vessel integrity and safe operation,so we'll select a
material that meets the following criteria.
1. Corrosion Resistance
Stainless Steel: The superior choice for corrosion resistance. Its chromium content forms a passive oxide
layer, protecting the underlying metal from propane and environmental factors.
Carbon Steel (Consider limitations): A more affordable option, but susceptible to corrosion in moist or
contaminated environments. May require additional protective coatings or be unsuitable for long-term
service in harsh conditions.
2.Strength and Toughness
The material should have sufficient strength to withstand the pressure exerted by the propane gas
inside the vessel. Factors like yield strength, tensile strength, and toughness are important
considerations.
3. Fatigue Resistance
Both Stainless Steel and Carbon Steel can offer adequate fatigue resistance for typical propane pressure
vessel applications.
4.Weld-ability
Consider the ease of welding and fabricating the chosen materials may require special welding
procedures or post-weld heat treatment to maintain integrity.
5.Temperature Resistance
Propane gas is typically stored at moderate temperatures, but the material should still be able to
withstand the temperature ranges experienced during operation without losing its mechanical
properties.
6.Compliance with codes and standards
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Common materials used for horizontal pressure vessels design for propane gas storage include Carbon
steel (SA-516 Gr 70),low alloy steels (SA-387),Stainless steel (e.g., 304,316) and nickel alloys(e.g.,
Inconel)
Carbon steel: Cost-effective but may require corrosion protection.
Stainless Steel: Provides good corrosion resistance and strength.
Aluminum: Lightweight and corrosion-resistant but may not be suitable for high-pressure applications.
Nickel Alloys: Offer excellent corrosion resistance but come at a higher cost.
1.3. Mathematical Modelling and Supporting Analysis
1.3.1. Construction of Mathematical model that simulates real system using sketches
and drawings
A simplified free-body diagram of the vessel under pressure.
Figure 1:Free-body diagram of the vessel under pressure
The pressure vessel chosen for this study is a pressure vessel used to contain fluid propane
gas (LPG). This pressure vessel has hemispherical heads and cylinderical shell. The pressure
vessel will have an inner shell diameter (Di)mm and a shell length (Ls)mm. This vessel was
originally designed to hold 10m3 of LPG at a design pressure (Pd) MPa. The pressure vessel
is made of stainless steel, which is the industry standard for pressure vessel design and
creation
Table1:Pressurevessel specification
Parameter Value
ShellinnerDiameter(Di) 1600mm
8
Shelllength(Ls) 4500mm
Designpressure(Pd) 1.61MPa
Vesselmaterial 304
Table 2:Mechanicalpropertiesof304 stainless steel
Parameter Value
Tensile strength 515 MPa
Yieldstrength 205MPa
1.3.2. Use of Design Equations and Formulas of for Design of different Components of
the Pressure Vessel
The designing of the horizontal vessels, is according to the minimum requirements of design
without any flaws in the vessel parts. The designed studied pressure vessel is composed of:
Heads, Shell, Manway, Nozzles, Saddles.
Shell Design
Thedesignofthepressurevesselshellincludesthedeterminationoftheshell'sthicknessalsoitslength.
Theshell’sthicknessisdetermined by two main aspects, which are the design pressure andthe
corrosion allowance. The corrosion allowance is 3mm. Before calculating the shell thickness, itis
necessarytodeterminethe total pressureinsidethe vessel,which is the sum of the design
pressure and static head pressure.
This can be expressed into the following equations:
The obtained total pressure inside the vessel by using those equations is 1.63MPa. the minimum shell
thickness is determined by longitudinal section (ta) or the shell thickness along the circumferential
section (tb), which are expressed in the following equations:
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the maximum allowable pressure achieved by this thickness is calculated to ensure that the
pressure vessel can contain the contained fluid at the design pressure. Equation (2-6) and (2-7)
are used to calculate the maximum pressure at the longitudinal and circumferential sections
respectively.
Using both these equations results in a longitudinal maximum pressure of 425.28MPa and a
circumferential maximum pressure of 208.96MPa, which are both much higher than the total
pressure. This shows that the chosen shell thickness is safe and will be adopted in this study.
Table3:Shell designparameters.
Parameter Value
Totalpressure(Pt) 1.63MPa
Safety factor(sf) 4
Jointefficiency (E) 1
Maximumallowablestress 120.66MPa
Corrosionallowance(c.a.) 3mm
Finalshellthickness(tf) 14mm
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Longitudinal maximumpressure(Pa) 425.28MPa
Circumferentialmaximumpressure(Pb) 208.96MPa
Heads design
For the design of the pressure vessel’s head, the same material and allowable stress will be
used. The pressure vessel used in this study has elliptical heads. The head's inner crown height
(hi) and its thickness are calculated according the following equation:
Thisresultsinaninsidecrownheightof0.4m.Asforthehead’sminimumthickness(𝑡ℎ,𝑚𝑖𝑛),equation(2-
9)isused:
Where𝐸𝐿=theheadlongitudeefficiency,whichis≤1inthisstudy.
K=factorwhichiscalculatedusingthefollowingequation:
Tocalculatethemaximumpressureallowedbythisthickness,thefollowing equation is used:
Thisresultsinamaximumallowablepressureof1.65MPa,whichishigherthanthe
total pressureactingon the head.
Table4:Headdesignparameters
Parameter Value
Insidecrownheight (hi) 400mm
Headlongitudeefficiency(EL) 1
K-factor(k) 1.002
Headthickness(th) 14mm
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Manway design
The purpose of a manway is to provide an entry to workers for easy access to vessels or storage
tanks for the cleaning and maintenance purposes. The ASME standard states that all pressure
vessels with diameters exceeding 450mm must have a manway but it does not provide a
minimum standard size. The minimum required thickness based on the pressure at the
longitudinal and circumferential sections are given in the following equations:
The minimum area required (Am) is calculated by using the following equation:
Where Dim= the internal diameter of the manway calculated using the following equation:
fr = the ratio of allowable stress, which in this study ≤ 1.
Table 5: Manway design parameters
Parameter Value
Finalmanwayexternaldiameter (𝑫𝒐,𝒎) 609.6mm
Finalmanwaythickness(𝒕𝒏,𝒎) 9.53mm
Ratioofallowable stress (𝒇𝒓) 1
No.boltholes 15
Nozzles design
12
There are total of four nozzles used in this pressure vessel layout, each of these nozzles serves a
different purpose. the design procedures and the design parameters mentioned in Table 7, also
the figure 2 illustrates the nozzles positions on the vessel.
Table 6: Nozzle design parameters
Outerdiameter Thickness Minimumarea
(Do)(mm) (tf)(mm) (A)(mm2)
Chargeinlet 60.33mm 3.91mm 819.1mm2
Outlet 88.9mm 5.49mm 1175mm2
Drain 60.33mm 3.91mm 819.1mm2
Pressuret
60.33mm 3.91mm 819.1mm2
ransmitter
1.3.3. Assumptions made, making sure to justify your design decisions.
The vessel is considered a thin-walled pressure vessel.
The material exhibits linear elastic behavior.
The pressure is uniformly distributed throughout the vessel.
1.3.4. Supporting Analysis
The support for the here is the saddle. It is an important component of a horizontal pressure
vessel since it provides a stable base to the vessel as well as spreading the weight of the vessel
in a uniform manner. All the dimensions required for this study are shown in Table 7,
meanwhile all criteria designing standards are shown in Figure 3.
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The design of saddles is according to the ASME standards, the minimum contact angle between
the shell and the saddle needs to 120° and should be supported by two saddles.
Table 7: Values of saddle's dimensions
Dimension Value
A 1460.44mm
B 1066.76mm
C 152.40mm
D 279.40mm
E 558.79mm
G 19.05mm
H 9.53mm
K 9.53mm
Equations (2-17) and (2-18) are used to calculate the weight of the vessel and contained fluid
respectively:
14
It is necessary to calculate horizontal force caused by this weight, asexpressed in the following
equation:
Where:
Q = load on one saddle,
which given by:
Where g is the earth’s gravitational acceleration is 9.81m/s2.
The stress caused by this force is:
Where H is the web plate thickness.
1.3.5. Material Selection
Stainless steel:
Advantages:
Stainless steel offers excellent resistance to corrosion from propane gas and various
environmental factors, making it a good choice for applications with moisture, contaminants,
or harsh environments.
It also provides a clean and professional appearance compared to carbon steel.
Disadvantages:
Stainless steel is generally more expensive than carbon steel. And, welding stainless steel
requires specific procedures and skilled welders to ensure proper weld quality and minimize
the risk of sensitization (formation of brittle chromium carbides).
Also, compared to some high-grade carbon steels, certain types of stainless steel may have
slightly lower strength.
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1.3.6 Manufacturing Plan
1. Material Preparation
Material Selection: Based on the design calculations and code requirements, the appropriate
material plates for the shell, heads, and nozzles will be procured.
Plate Cutting: The raw material plates will be cut to the desired dimensions based on the design
drawings.
Plate Edge Beveling: Edges of the plates may require beveling to prepare them for welding.
2. Shell and Head Forming
Shell Rolling: Large, dedicated rolling machines will be used to form the plates into cylindrical
shapes for the pressure vessel shell. Rolling procedures will ensure the shell meets the specified
diameter and maintains dimensional accuracy.
Head Forming: Depending on the chosen head type (hemispherical, dished), dedicated forming
machines or hydraulic presses will be used to shape the plates into the desired head profile.
3. Assembly and Welding:
Fit-Up and Tack Welding: The formed shell sections and heads will be carefully positioned and
temporarily tack welded to ensure proper alignment and dimensional accuracy before final welding.
Welding Procedures: Shielded Metal Arc Welding (SMAW) or Gas Tungsten Arc Welding (GTAW)
are common processes used for pressure vessel construction. Welders must be qualified
according to relevant codes (e.g., ASME) for the specific material and welding procedure used.
Non-Destructive Testing (NDT): After each major welding stage, NDT methods like Radiographic
Testing (RT) or Ultrasonic Testing (UT) will be employed to inspect the weld quality for any
defects like cracks or incomplete fusion. Repairs or re-welding may be necessary if defects are
identified.
4. Nozzle Attachment:
Nozzle Welding:Nozzles will be attached to the shell using qualified welding procedures and
NDT inspections as described above.
Nozzle Openings: Openings for nozzles will be created in the shell using precise cutting
procedures.
5. Finishing
Surface Finishing: The pressure vessel may undergo sandblasting or other cleaning methods to
remove any surface contaminants or mill scale.
Painting: An appropriate protective coating will be applied to the external surface of the vessel
to prevent corrosion and ensure a professional finish.
Final Inspection and Pressure Testing: A final inspection will be conducted to ensure all welds,
surfaces, and dimensions meet the design specifications.
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1.3.6. Safety Maintenance and Repair
Propane gas pressure vessels require careful attention to safety throughout their lifecycle.
1.3.7.1. Safety Considerations
Material Compatibility: The chosen material for the pressure vessel must be compatible with
propane gas to prevent degradation or corrosion.
Material selection standards like ASME BPVC provide guidelines for suitable materials for
propane storage.
Pressure Relief Valve (PRV): A properly sized and maintained PRV is the primary safety feature
of the pressure vessel. It should be designed to automatically vent excess pressure if it exceeds
the vessel's maximum allowable working pressure (MAWP).
Pressure Gauges and Level Indicators: These instruments provide critical information for safe
operation.
Level indicators can be visual or electronic, ensuring operators don't overfill the vessel.
Filling and discharge procedures
Emergency response protocols in case of leaks or pressure relief
Personal protective equipment (PPE) requirements
Location and Signage: The pressure vessel should be located in a well-ventilated area away
from ignition sources.
Clear signage should warn of the contents and potential hazards.
1.3.7.2. Maintenance
Inspection Schedule: A documented inspection plan should be established based on relevant
codes and standards (e.g., ASME BPVC). This may include:
Periodic pressure testing to verify the vessel's integrity
External visual inspections for signs of corrosion, leaks, or damage.
Internal inspections (performed by qualified personnel) may be required depending on the
vessel size, age, and operating conditions.
Maintenance Procedures are:
Cleaning and draining of condensate or debris from the pressure vessel.
Replacement of worn-out components like gaskets or safety valves.
Maintaining proper ventilation around the pressure vessel.
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Recording details of inspections, maintenance performed, and test results should be
maintained for future reference.
1.3.7.3. Repair
Repairs on pressure vessels should only be performed by qualified personnel with experience in
pressure vessel repair procedures. The specific repair method will depend on the nature and
extent of the damage. It's crucial to follow relevant repair codes and standards to ensure the
restored vessel's integrity and safety.
1.4. Cost Analysis
A significant cost factor and depends on the chosen material, vessel size, and wall thickness.
Stainless Steel is generally the most expensive option due to its higher material cost per unit
weight compared to carbon steel. Plate thickness directly affects material quantity and cost.
Fabrication Costs:
This includes labor costs for:
Plate cutting and forming
Welding and assembly
Non-destructive testing (NDT)
Non-Destructive Testing (NDT) Costs is like radiographic testing (RT) or ultrasonic testing (UT)
depends on the extent of testing required by the code and project specifications.
Safety equipment costs like the cost of the pressure relief valve (PRV) will depend on its
capacity, design, and manufacturer.
Additional safety features like level indicators and pressure gauges may also contribute to the
cost.
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References
[1] Timoshenko, S., “Strength of Materials, Part II” D. Van No strand Co., Princeton, N. J., 1930
[2] D. B. M. Moss ،"Pressure Vessel Design Manual.،" 2013.
[3] A. Yahya ،"Design of Vertical Pressure Vessel Using ASME Codes" First Conference for Engineering
Sciences and Technology CEST-2018 ،Tripoli ،September 2018.
[4] Dekker C.J. and Bos H.J. “Nozzles-on external loads and internal pressure International Journal of
pressure vessel and piping 72 (1997) I-18.
[5] Petropedia ،"What does Manway mean،" GC ،18 July 2016. Available:
https://www.petropedia.com/definition/7477/manway.
[6] ABSA ،"The pressure Equipment safety authority،" 2017. Available: http://www.absa.ca.
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