1.

Design problem

Design a suitable vessel for storing 10 ton LPG (Liquefied Petroleum Gas) at a temperature of 25 ○. Consider
LPG to be a mixture of propane and butane in the ratio 9.5:1. The shape and the material of construction of
the vessel are to be selected. The vessel should be provided with a suitable head (cover), required number
of nozzle, suitable joints and supports. The design report should contain:

 Design of the shell

 Design of head or cover
 Design of the nozzles
 Design of the joints
 Design of the supports
 A detailed drawing of the equipment done with a suitable scale and with proper dimensioning.

1
 2. Design of the internals
A) Estimation of saturation vapour pressure of n-propane and n- butane at 298K

Operating temperature = (25+273) = 298K (given)

From Antoine equation:

𝐵
log10Psat = A - 𝑇+𝐶
where Psat is saturated vapour pressure (torr)
T is temperature in ○C
A, B, C is Antonie Constant
Table-1

Substance A B C
n- propane 6.82972 813.20 248
n-butane 6.83029 945.9 240

[Smith, Van-ness, Abbot: Introduction to Chemical Engineering Thermodynamic; table-6.1]

1 bar = 105 N/m2 = 760 torr

sat 813.20 sat 945.9

log10Ppropane = 6.82972 - log10Pbutane = 6.83029 -
25+248 25+240
sat sat
Ppropane = 7094.14 torr Pbutane = 1823.29 torr
sat sat
Ppropane = 9.45 bar Pbutane = 2.43 bar

Hence
sat
Ppropane = 9.45 bar
sat
Pbutane = 2.43 bar

B) Estimating the number of moles and the mole fraction of n-propane and n-butane
In LPG weight ratio is given as 9.5:1
Assuming ideal solution
Total capacity 10 ton = 10000 kg

Table-2

Substance Molecular mass TC (K) VC (cm3/mol) PC (bar)

(g/mol)
n-propane 44.097 369.8 200 42.48
n-butane 58.123 425.1 255 37.96

[Smith, Van-ness, Abbot: Introduction to Chemical Engineering Thermodynamic; table: B-1]

2
 9.5×10000
Amount of propane = kg
9.5+1
= 9047.6 kg

1×10000
Amount of butane = kg
1+9.5
= 952.38 kg

9047.6×10000
Moles of propane =
40.097
ηpropane = 225642.8

952.38×10000
Moles of butane = 58.123
ηbutane = 16385.59

225642.8
Mole fraction of propane (yp) =
225642.8+16385.59
yp = 0.88

Mole fraction of butane (yb) = (1 − 0.88)

yb = 0.12

Hence yp = 0.88
yb = 0.12

C) Calculation of the design pressure

In table-2
VC = critical volume (cm3/mol)
TC = critical temperature (K)
PC = critical pressure (bar)

sat
Pmix = Partial pressure of the above liquid
sat sat
= yp Ppropane + yb Pbutane
= (0.88× 9.45) + (0.12 × 2.43)
= 8.60 bar
An allowance of 5% of the working pressure is added to the working pressure to obtain the design
pressure.
Design pressure = working pressure + 5% allowance pressure
= 9.03 bar

D) Calculation of the critical temperature of the mixture

TCM = Critical temperature of the mixture
= ypTCP + ybTCB

3
 = (0.88× 369.8) + (0.12 × 425.1)
= 376.436K

TCM = 376.436K

E) Calculation of reduced temperature of the mixture

T 25+273
Trm = = = 0.79
TCM 376.436

Trm = 0.79

F) Calculation of the critical pressure of the mixture

PCM = Critical pressure of the mixture

= ypPCP + ybPCB
= (0.88× 42.48) + (0.12 × 37.96)
= 41.93 bar
G) Calculation of reduced pressure of the mixture
Prm = reduced pressure of the mixture
𝑃
=
𝑃𝐶𝑀
9.03
=
41.93

Prm = 0.215

H) Calculation of density
Using Lydersen, Greenkorn and Hougen correlation :
ρ𝑀 𝑉𝐶𝑀
ρr = =
ρ𝐶𝑀 𝑉𝑀

[Smith, Van-ness, Abbot : Introduction to Chemical Engineering Thermodynamic; properties of fluid]

ρr = reduced density
ρ𝑀 = density of the mixture
ρ𝐶𝑀 = critical density of the mixture
VCM = critical volume of the mixture
VM = volume of the mixture
Average molecular weight of the mixture = Mav

4
 Mav = ypMpropane + ybMbutane

= (0.88× 44.097) + (0.12 × 58.123)

= 45.78 gm/ mol
Calculation of critical volume of the mixture = VCM

VCM = ypVpropane + ybVbutane

= (0.88× 200) + (0.12 × 255) = 206.6 (cm3/mol) (from table-2)
Now,
[Smith, Van-ness, Abbot : Introduction to Chemical Engineering Thermodynamic; fig 3.17]

For Prm = 0.215; Trm = 0.79,

We get, ρr = 2.5 (approximately)

Calculation of critical density :
𝑦𝑝 𝑦𝑏
ρ𝐶𝑀 = +
𝑉𝐶𝑃 𝑉𝐶𝐵
0.88 0.12
= +
200 255

= 4.87×10-3 mol.cm-3
Then ρ𝐶𝑀 = (4.87×10-3 mol.cm-3) × Mav
= (4.87×10-3 mol.cm-3) × (45.78 gm.mol-1)
= 0.2229 gm.cm-3
= 222.9 kg.m-3

ρ𝑀 = ρ𝐶𝑀 × ρr
= 222.9 kg.m-3 × 2.5
= 557.25 kg.m-3
= 0.557 g.cm-3
Hence

ρ𝑀 = 0.557 g.cm-3

I) Calculation of the volume of the mixture

VM = volume of the mixture
10000 kg
=
557.25 kg.m−3

= 17.94 m3

5
 VM = 17.94 m3

J) Calculation of the optimum length and diameter of the vessel

Shape : Cylindrical (assumed)
𝜋
× D2L = 17.94
4
17.94×4
L=
πD2
17.94×4
D = √( )
πL

D = diameter of the vessel

L = length of the vessel

Several iteration are performed to obtain Dcalculated from Lcalculated. A few of them are shown here

L (assumed) D (calculated)
12 1.37
11 1.43
10 1.50
9 1.59

Similarly several iteration are performed to find the optimum L and D

D (assumed) L (Calculated) Inference Accepted

1.35 12.53 LCAL>LASSUM NO
1.45 10.86 LCAL<LASSUM YES
1.50 10.15 LCAL>LASSUM NO
1.55 9.50 LCAL>LASSUM NO

So we choose

L = 11 m
D = 1.45 m

K) Calculation of the number of vessel required

𝜋
Volume of each vessel = 4 × (1.45)2× 11 m3

= 18.16 m3
volume of the mixture
Total number of vessel required = N =
volume of the each vessel

6
 17.94
N=
18.16

N = 0.98 ~ 1
Hence
N=1

3. Mechanical design

a) Design temperature calculation

Tdesign = Maximum temperature + 10℃ allowance

= 25℃ +10℃
= 35℃

b) Design of the shell

Shape: Cylindrical (assumed)

Code: IS 2825–1969
Material: Stainless Steel
Design: 05Cr18Ni11Mo3 [Joshi: Process Equipment Design]
The internal pressure in the shell give rise to stresses in the shell thickness, are in the circumferential
and the other in the longitudinal direction.

PD
Circumferential Stress, fp =
2t

PD
Longitudinal Stress, fa =
4t
P = internal pressure
D = mean internal diameter of the shell
Both the above stresses are tensile, since the circumferential stress is greater; this is taken as the design
pressure. The shell is generally formed by a joint in the longitudinal direction, which is consider in terms
of joint efficiency.

t = thickness of the shell

PD PDi PDo
t= = =
2fJ 2fJ−P 2fJ+P

P = design pressure
D = mean diameter
J = Joint efficiency
f = design or permissible stress at design temperature
Di = internal diameter
Do = outside diameter

7
 Permissible stress at 35℃ ∶
f = allowable stress = 160 N/mm2
J = Joint efficiency = 0.85 [Joshi: Process Equipment Design; Table E-2]

PDi
t=
2fJ−P
0.903 N/mm2 ×1450 mm
= (2×160×0.85−0.903)
N/mm2
= 4.82 mm

t = 4.82mm

PDo
Also t= [Joshi: Process Equipment Design, Equation 6.3, Page - 128]
2fJ+P

For vessel diameter 1-2m, minimum shell thickness must be 7mm. this value include a corrosion allowance
of 2mm.
Hence, outer diameter Do = Di + 2t
= 1450 + (2× 7)
= 1464 mm

Do = 1464 mm

Calculation of stresses
[Joshi: Process Equipment Design; 6.8.1.2; Page-129]
Stress in circumferential direction due to internal pressure, fp. This is also known as tangential or hoop stress.
P (Di +t)
ft =
2t
N
(0.903 ) ×(1450+7)
mm2
=
2×7
= 93.97 N/mm2

ft =93.97 N/mm2

Stresses in longitudinal or axial direction –

a. Due to internal pressure –

PDi
f1 = (tensile)
4t
N
0.903 2 ×1450
mm
f1 =
4×7
f1 = 46.76 N/mm2

8
 b. Due to weight of the vessel and contents (vertical only) –

𝑊
f2 = (compressive)
𝜋𝑡(Di +𝑡)
10000kg ×10 m/s2
f2 =
π × 7 ×(1450+7)
f2 = 3.12 N/mm2

c. f3 = fS = 0 due to the absence of any wind load.

d. Total stress in the longitudinal or axial direction; fa
fa = f1+f2+f3
= [46.76 + (-3.12) + 0]
= 43.63 N/mm2 (tensile)

Combining the stresses on the basis of shear strain energy theory criterions, the equivalent stress is–
1⁄
2
fR = [(f2t − ft fa + f2a + 3f2s ] [Joshi: Process Equipment Design; Equation 6.11]

= 81.14 N/mm2 (tensile)

Checking the condition for satisfactory design –

fR (81.14 N/mm2) < ft (93.97 N/mm2) (permissible)

fa (43.63 N/mm2) < ft (93.97 N/mm2) (permissible)

c) Design of head

To close either end of the cylindrical shell a cover or a closure is essential.

Material: Carbon Steel

 Formed and Dished heads –

For cylindrical shells, dished heads with torispherical or elliptical shapes are commonly used.
Torispherical heads are used in pressure range between 1-15 kg/cm2 gauge. Elliptical heads are
used in pressure over 15 kg/cm2.

 Shallow dished and torispherical head –

These head have the dish radius or crown radius equal to or less than the diameter of the head.
To reduce the stresses at the corner of the head, a knuckle is formed, with a radius of atleast 6%
of the inside diameter. The thickness of such head is given by –

PRc W
th = [Joshi: Process Equipment Design; Equation 6.23]
2fJ
Where, P = design pressure
R c = Crown radius

9
 W = stress intensification factor
1 R
= 4 (3 + √Rc )
1

R1 = knuckle radius
= 6% of Di
= 0.06 × 1450
= 87 mm

For crown radius (R c ), it is equal to or less than the diameter of the head.
R c = Di = 1450 mm
Then

1 R
W = 4 (3 + √Rc )
1

1 1450
= 4 (3 + √ )
87

= 1.77
PRc W
th =
2fJ
N
0.903×1450×1.77
mm2
=
2×160×0.85

= 8.52
However, a standard value is chosen for designing purpose of th = 10 mm

Outer diameter Do = Di + 2th

= 1450 + 2× 10
= 1470 mm

d) Design of nozzles
As in the pressure vessel, the total diameter Do = 1470 mm = 57.87 inch
According to IS 2825, for Do> 39 inch;
Internal diameter of nozzle ID = 10 inch
Nozzle thickness is taken as th = 6mm
Hence, Do = 254 mm + (2× 6) mm [10 inch = 254 mm]
= 266 mm

e) Gasket design
Gasket are used to make the metal to metal surface leak proof. Gasket are elasto-plastic material and
relatively softer than the flange material. A preliminary estimation of gasket is done using the following
expression:
Residual gasket force = (Gasket seating force) – (Hydrostatic pressure force)
The residual gasket force should be greater than that required to prevent the leakage of internal fluid.
This condition results the final expression in the form of –

10
 DOG Y−pm
=√ [Joshi: Process Equipment Design; page-174]
DIG Y−p(m+1)
𝑤ℎ𝑒𝑟𝑒, DOG = outside gasket diameter
DIG = inside gasket diameter
p = design pressure
Y = minimum design seating stress
m = gasket factor
From the above equation we get outside gasket diameter 1490 mm for a flat asbestos gasket of internal
diameter 1450 mm and 3.2 mm thickness is used to cover the raised face.

Y = 11.2 N/mm2; m=2 [Joshi: Process Equipment Design; Table-6.7]

1490−1450
Width of the gasket = = 20 mm
2

1 DOG −DIG
Basic gasket setting width, bo = [Joshi: Process Equipment Design; Table-6.7]
2 2
1 1490−1450
=
2 2
= 10 mm
Since bo > 6.3 mm [Joshi: Process Equipment Design; page-175; fig: 6.33]

Effective gasket seating width,

b = 2.5√bo
= 2.5× √10
= 7.9 mm

f) Bolt design and calculation of number of bolts

The minimum initial bolt load (Wm1) at atmospheric pressure and temperature is given by –

Wm1 = 𝜋bGYa [Joshi: Process Equipment Design; page-174; fig: 6.36]

Where, G = diameter of gasket load reaction
Ya = gasket seating stress
Now,
Wm1 = 𝜋bGYa
1490+1450
= π × 7.9mm × ( ) mm × 11.2N/mm2
2
= 408.613 KN

The gasket is compressed under tight pressure. So required bolt load is given by –

π
Wm2 = π(2b)Gmp + 4 G2 p [Joshi: Process Equipment Design; page-175; fig: 6.37]
Where, 2b = effective gasket or joint contact surface width under pressure
m = gasket factor
p = design pressure

11
 π
Wm2 = π(2b)Gmp + 4 G2 p
𝜋
= (𝜋 × 2 × 7.9 × 1470 × 2 × 0.903) + ( 4 × 14702 × 0.903)
= 1664.319 KN

Wm1 Wm2
 To calculate the required (minimum) bolt cross-sectional area, Am1 = and Am1 =
fa fb
[Joshi: Process Equipment Design; page-175; fig: 6.38]

Where, Am1 and Am2 are the cross-section of bolt

fa = permissible tensile stress in bolt under atmospheric condition
fb = permissible tensile stress in bolt under operating condition

Material: Hot rolled carbon steel

Permissible stress: Upto 50℃ fa = 58.7 N/mm2
Permissible stress: Upto 200℃ fa = 54.5 N/mm2
[Joshi: Process Equipment Design; page-185]

Wm1 Wm2
Therefore, Am1 = and Am2 =
fa fb
408.613 KN 1664.319 𝐾𝑁
= =
58.7 N/mm2 54.5 N/mm2
= 69.610 cm2 = 305.37 cm2
Since, Am2 > Am1, we consider Am2 is the cross section of the bolt.

 The total number of the bolts may be approximately equal to mean diameter of gasket in cm
divided by 2.5 and should be multiple of 4.

1470
Number of bolts, nb =
10×2.5
= 58.8
~ 60 (𝑎𝑠 𝑖𝑡 𝑠ℎ𝑜𝑢𝑙𝑑 𝑏𝑒 𝑚𝑢𝑙𝑡𝑖𝑝𝑙𝑒 𝑜𝑓 4)

nb = 60 since 60 is multiplied of 4
π
Area of the bolts, Am2 = D2 nb
4
Am2×4
D=√
π×nb

305.37×4
=√
𝜋×60
= 2.54 cm

Specification:
Using M/8 bolts
Pitch diameter: 16.375 mm
Minor diameter: 14.480 mm

12
 𝜋 1 16.3752 14.482
Actual Bolt area = [ + ] × 60
42 102 102

= 112.58 cm2
Bolt area is given by –

2πGNYa
Ab = [Joshi: Process Equipment Design; page-176; Equation-6.40]
fa

N
2𝜋×11.2 ×1470mm×20mm
mm2
= N
58.7
mm2
= 352.45 cm2
The bolt area suggested hence satisfactory.

From, [Joshi: Process Equipment Design; page-188]

Pitch of the bolt = 4.75× 18

= 85.6

Pitch of the bolt ×60

Pitch circle diameter, B =
π
85.6×60
=
𝜋
= 1634.83 mm
~ 1635 mm

Or, B = outside diameter of gasket + (2× bolt diameter) + 12 mm

= 1490 mm + (2× 25.4 mm) + 12 mm
= 1553 mm

Outside diameter of the flange = Pitch circle diameter + (2× bolt diameter)
= 1553 + (2× 25.4 mm)
= 1603.8 mm

g) Design of flange
Flange thickness is given by –

p
tf = G√Kf + C [Joshi: Process Equipment Design; Equation-6.41]

1
Where, K= 1.5 Wm hG
[0.3+ ]
HG

hG = Radial distance from gasket load reaction to bolt circle

B−G 1533−1470
hG = = = 31.5 mm
2 2
π π
H = Total hydrostatic end force = G2 p = 4 × 14702 mm2 × 0.903 N/mm2
4

= 1532.54 KN

13
Now Wm = Wm1 + Wm2
= (408.613 + 1664.319) KN
= 2072.932 KN
Therefore
1
K= 1.5 Wm hG
[0.3+ HG ]

1
= 1.5×2072.932×31.5
[0.3+ 1532.4×1470 ]

= 2.91
Then

p
tf = G√Kf

0.903
= 1470 √
2.91×95

= 84 mm

14
 Summary

Mechanical design summary –

Category Subcategory Dimension

Length 11 m
Pressure vessel
Diameter 1.45 m
Material Stainless steel
Shell 05Cr18Ni11Mo3
Thickness 7 mm
OD 1464 mm
Type Torispherical
Head Cover Material Carbon steel
Thickness 10 mm
OD 1464 mm
Material Carbon steel
Nozzle Thickness 6 mm
OD 266 mm
Material Carbon steel flange with a stainless
Gasket steel lining, asbestos gasket
OD 1490 mm
Width 20 mm
Mean diameter 1470 mm
Effective gasket seating width 7.9 mm
Material Hot rolled carbon steel
Quantity 60
Bolts
Nominal thread diameter M18
Diameter 18 mm
Pitch circle diameter 1553 mm
Material Carbon steel
Flange Thickness 84 mm

15