Structural analysis and design of process equipment / by Maan H Jawad, Global Engineering and Technology, LLC, US, James R Farr, Purdue University, US.
By: Jawad, Maan H [author.]
Contributor(s): Farr, James R [author.]
Language: English Publisher: Hoboken, NJ, USA : Wiley, 2018Edition: Third editionDescription: 1 online resourceContent type: text Media type: computer Carrier type: online resourceISBN: 9781119311515Subject(s): Chemical plants -- Equipment and supplies -- Design and constructionGenre/Form: Electronic booksDDC classification: 660 LOC classification: TP155.5 | .J34 2018Online resources: Full text is available at Wiley Online Library Click here to view| Item type | Current location | Home library | Call number | Status | Date due | Barcode | Item holds |
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COLLEGE LIBRARY | COLLEGE LIBRARY | 660 J329 2018 (Browse shelf) | Available |
About the Author
MAAN H. JAWAD, PHD is President of Global Engineering & Technology, consulting on boilers and pressure vessels for the power generation and petrochemical industries. He was Director of Engineering at the Nooter Corporation in St. Louis prior to retiring. He is a graduate of the University of Kansas and Iowa State University and a Fellow of the American Society of Mechanical Engineers. He was awarded the ASME's J. Hall Taylor Medal in 1992 for major contributions to the advancement of Boiler and Pressure Vessel Technology.
JAMES R. FARR (Deceased) was Manager of Codes and Regulation at the Babcock and Wilcox Company, a Fellow of the American Society of Mechanical Engineers, and a member of the American Institute of Chemical Engineers. He is a graduate of Purdue University and served on numerous National and International Committees on pressure vessels.
Includes bibliographical references and index.
Table of contents
Preface to the Third Edition xv
Preface to the Second Edition xvii
Preface to the First Edition xix
Acknowledgements xxi
Part I Background and Basic Considerations 1
1 History and Organization of Codes 4
1.1 Use of Process Vessels and Equipment 4
1.2 History of Pressure Vessel Codes in the United States 4
1.3 Organization of the ASME Boiler and Pressure Vessel Code 6
1.4 Organization of the ANSI B31 Code for Pressure Piping 6
1.5 Some Other Pressure Vessel Codes and Standards in the United States 6
1.6 Worldwide Pressure Vessel Codes 7
References 7
Further Reading 7
2 Selection of Vessel, Specifications, Reports, and Allowable Stresses 10
2.1 Selection of Vessel 10
2.2 Which Pressure Vessel Code is Used 10
2.3 Design Specifications and Purchase Orders 10
2.4 Special Design Requirements 11
2.5 Design Reports and Calculations 11
2.6 Materials Specifications 11
2.7 Design Data for New Materials 11
2.8 Factors of Safety 12
2.9 Allowable Tensile Stresses in the ASME Code 12
2.10 Allowable External Pressure Stress and Axial Compressive Stress in the ASME Boiler and Pressure Vessel Code 13
2.11 Allowable Stresses in the ASME Code for Pressure Piping 14
2.12 Allowable Stress in Other Codes of theWorld 14
2.12.1 European Union (EN) Countries 14
2.12.2 Japanese Code 15
2.12.3 People?s Republic of China 15
2.12.4 Indian Code 15
2.12.5 Australian Code 16
References 16
3 Strength Theories, Design Criteria, and Design Equations 18
3.1 Strength Theories 18
3.2 Design Criteria 18
3.3 Design Equations 19
3.4 Stress?Strain Relationships 19
3.5 Strain?Deflection Equations 20
3.6 Force?Stress Expressions 22
References 23
Further Reading 23
4 Materials of Construction 26
4.1 Material Selection 26
4.1.1 Corrosion 26
4.1.2 Strength 26
4.1.2.1 Specified Minimum Yield Stress 27
4.1.2.2 Specified Minimum Tensile Stress 28
4.1.2.3 Creep Rate 28
4.1.2.4 Rupture Strength 28
4.1.3 Material Cost 30
4.2 Nonferrous Alloys 31
4.2.1 Aluminum Alloys 31
4.2.1.1 Annealing 31
4.2.1.2 Normalizing 31
4.2.1.3 Solution Heat Treating 31
4.2.1.4 Stabilizing 31
4.2.1.5 Strain Hardening 31
4.2.1.6 Thermal Treating 32
4.2.2 Copper and Copper Alloys 32
4.2.3 Nickel and High-Nickel Alloys 32
4.2.4 Titanium and Zirconium Alloys 33
4.3 Ferrous Alloys 34
4.3.1 Carbon Steels 34
4.3.2 Low-Alloy Steels 34
4.3.3 High-Alloy Steels 34
4.3.3.1 Martensitic Stainless Steels 34
4.3.3.2 Ferritic Stainless Steels 34
4.3.3.3 Austenitic Stainless Steels 34
4.4 Heat Treating of Steels 35
4.4.1 Normalizing 35
4.4.2 Annealing 35
4.4.3 Postweld Heat Treating 35
4.4.4 Quenching 35
4.4.5 Tempering 35
4.5 Brittle Fracture 35
4.5.1 Charpy V-Notch Test (Cv) 36
4.5.2 Drop-Weight Test (DWT) 37
4.5.3 Fracture Analysis Diagram (FAD) 37
4.5.4 Theory of Fracture Mechanics 39
4.5.5 Relationship Between KIC and CV 41
4.5.6 Hydrostatic Testing 42
4.5.7 Factors Influencing Brittle Fracture 42
4.5.8 ASME Pressure Vessel Criteria 43
4.6 Hydrogen Embrittlement 50
4.7 Nonmetallic Vessels 50
References 50
Further Reading 51
Part II Analysis of Components 53
5 Stress in Cylindrical Shells 56
5.1 Stress Due to Internal Pressure 56
5.2 Discontinuity Analysis 60
5.2.1 Long Cylinders 61
5.2.2 Short Cylinders 66
5.3 Buckling of Cylindrical Shells 69
5.3.1 Uniform Pressure Applied to Sides Only 70
5.3.2 Uniform Pressure Applied to Sides and Ends 71
5.3.3 Pressure on Ends Only 72
5.4 Thermal Stress 72
5.4.1 Uniform Change in Temperature 75
5.4.2 Gradient in Axial Direction 76
5.4.3 Gradient in Radial Direction 77
Nomenclature 80
References 81
Further Reading 81
6 Analysis of Formed Heads and Transition Sections 84
6.1 Hemispherical Heads 84
6.1.1 Various Loading Conditions 86
6.1.2 Discontinuity Analysis 88
6.1.3 Thermal Stress 91
6.1.4 Buckling Strength 91
6.2 Ellipsoidal Heads 93
6.3 Torispherical Heads 95
6.4 Conical Heads 95
6.4.1 Unbalanced Forces at Cone-to-Cylinder Junction 96
6.4.2 Discontinuity Analysis 97
6.4.3 Cones Under External Pressure 98
6.5 Nomenclature 99
References 100
Further Reading 100
7 Stress in Flat Plates 102
7.1 Introduction 102
7.2 Circular Plates 102
7.3 Rectangular Plates 106
7.4 Circular Plates on Elastic Foundations 107
Nomenclature 109
Reference 109
Further Reading 109
Part III Design of Components 111
8 Design of Cylindrical Shells 114
8.1 ASME Design Equations 114
8.2 Evaluation of Discontinuity Stresses 115
8.3 ASME Procedure[2] for External Pressure Design in VIII-1 121
8.4 Design of Stiffening Rings 126
8.5 Allowable Gaps in Stiffening Rings 129
8.6 Out-of-Roundness of Cylindrical Shells Under External Pressure 129
8.7 Design for Axial Compression 132
Nomenclature 132
References 133
Further Reading 133
9 Design of Formed Heads and Transition Sections 136
9.1 Introduction 136
9.1.1 Flanged Heads 136
9.1.2 Hemispherical Heads 136
9.1.3 Elliptical and Torispherical (Flanged and Dished) Heads 136
9.1.4 Conical and Toriconical Heads 136
9.1.5 Miscellaneous Heads 136
9.2 ASME Design Equations for Hemispherical Heads 137
9.3 ASME Design Equations for Ellipsoidal, Flanged, and Dished Heads 139
9.4 ASME Design Equations for Conical Heads 143
9.4.1 Internal Pressure 143
9.4.1.1 Discontinuity Analysis for Internal Pressure 143
9.4.2 External Pressure 145
9.4.2.1 Discontinuity Analysis for External Pressure 145
Nomenclature 147
References 148
Further Reading 148
10 Blind Flanges, Cover Plates, and Flanges 150
10.1 Introduction 150
10.2 Circular Flat Plates and Heads with Uniform Loading 151
10.3 ASME Code Formula for Circular Flat Heads and Covers 153
10.4 Comparison ofTheory and ASME Code Formula for Circular Flat Heads and CoversWithout Bolting 154
10.5 Bolted Flanged Connections 154
10.6 Contact Facings 155
10.7 Gaskets 155
10.7.1 Rubber O-Rings 155
10.7.2 Metallic O- and C-Rings 155
10.7.3 Compressed Fiber Gaskets 158
10.7.4 Flat Metal Gaskets 158
10.7.5 Spiral-Wound Gaskets 158
10.7.6 Jacketed Gaskets 158
10.7.7 Metal Ring Gaskets 158
10.7.8 High-Pressure Gaskets 158
10.7.9 Lens Ring Gaskets 159
10.7.10 Delta Gaskets 159
10.7.11 Double-Cone Gaskets 159
10.7.12 Gasket Design 160
10.8 Bolting Design 161
10.9 Blind Flanges 163
10.10 Bolted Flanged Connections with Ring-Type Gaskets 164
10.11 Reverse Flanges 170
10.12 Full-Face Gasket Flange 171
10.13 Flange Calculation Sheets 176
10.14 Flat-Face Flange with Metal-to-Metal Contact Outside of the Bolt Circle 177
10.14.1 Classification of Assembly 177
10.14.2 Categories of Flanges 177
10.15 Spherically Dished Covers 177
Nomenclature 184
References 184
Further Reading 185
11 Openings, Nozzles, and External Loadings 188
11.1 General 188
11.2 Stresses and Loadings at Openings 188
11.3 Theory of Reinforced Openings 192
11.4 Reinforcement Limits 193
11.4.1 Reinforcement Rules for ASME Section I 195
11.4.1.1 No Reinforcement Required 195
11.4.1.2 Size and Shape of Openings 195
11.4.2 Reinforcement Rules for ASME Section VIII, Division 1 198
11.4.3 Reinforcement Rules for ASME, Section VIII, Division 2 204
11.4.3.1 Nomenclature 204
11.4.4 Reinforcement Rules for ANSI/ASME B31.1 210
11.4.4.1 No Reinforcement Calculations Required 210
11.4.5 Reinforcement Rules for ANSI/ASME B31.3 212
11.4.5.1 Nomenclature 213
11.5 Ligament Efficiency of Openings in Shells 215
11.6 Fatigue Evaluation of Nozzles Under Internal Pressure 217
11.7 External Loadings 218
11.7.1 Local Stresses in the Shell or Head 218
11.7.2 Stresses in the Nozzle 226
11.7.2.1 Nomenclature 227
References 230
Bibliography 231
12 Vessel Supports 234
12.1 Introduction 234
12.2 Skirt and Base-Ring Design 234
12.2.1 Anchor-Chair Design 239
12.3 Design of Support Legs 241
12.4 Lug-Supported Vessels 242
12.5 Ring Girders 243
12.6 Saddle Supports 245
Nomenclature 248
References 249
Further Reading 249
Part IV Theory and Design of Special Equipment 251
13 Flat-Bottom Tanks 254
13.1 Introduction 254
13.2 API 650 Tanks 254
13.2.1 Roof Design 254
13.2.1.1 Dome Roofs 254
13.2.1.2 Conical Roofs 256
13.2.1.3 Small Internal Pressure 256
13.2.2 Shell Design 258
13.2.3 Annular Plates 261
13.3 API 620 Tanks 263
13.3.1 Allowable Stress Criteria 266
13.3.1.1 Compressive Stress in the Axial Direction with No Stress in the Circumferential Direction 266
13.3.1.2 Compressive Stress with Equal Magnitude in the Meridional and Circumferential Directions 266
13.3.1.3 Compressive Stress with Unequal Magnitude in the Meridional and Circumferential Directions 267
13.3.1.4 Compressive Stress in One Direction and Tensile Stress in the Other Direction 267
13.3.2 Compression Rings 267
13.4 Aluminum Tanks 270
13.4.1 Design Rules 270
13.5 AWWA Standard D100 271
References 273
Further Reading 273
14 Heat-Transfer Equipment 276
14.1 Types of Heat Exchangers 276
14.2 TEMA Design of Tubesheets in U-tube Exchangers 276
14.3 Theoretical Analysis of Tubesheets in U-tube Exchangers 280
14.4 ASME Equations for Tubesheets in U-tube Exchangers 283
14.4.1 Nomenclature 283
14.4.2 Preliminary Calculations 285
14.4.3 Design Equations 288
14.5 Theoretical Analysis of Fixed Tubesheets 291
14.6 ASME Equations for Fixed Tubesheets 293
14.6.1 Nomenclature 293
14.6.2 Preliminary Calculations 294
14.6.3 Design Equations 294
14.7 Expansion Joints 300
14.8 Tube-to-Tubesheet Junctions 303
References 305
Further Reading 305
15 Vessels for High Pressures 308
15.1 Basic Equations 308
15.2 Prestressing (Autofrettaging) of Solid-Wall Vessels 309
15.3 Layered Vessels 311
15.4 Prestressing of Layered Vessels 315
15.5 Wire-Wound Vessels 317
Nomenclature 317
References 318
Further Reading 318
16 Tall Vessels 320
16.1 Design Considerations 320
16.2 Earthquake Loading 320
16.2.1 Lateral Loads 320
16.2.2 Numerical Method for Calculating Natural Frequency 324
16.3 Wind Loading 331
16.3.1 External Forces fromWind Loading 332
16.3.2 Dynamic Analysis ofWind Loads 332
16.4 Vessel Under Internal Pressure Only 336
16.5 Vessel Under Internal Pressure and External Loading 338
16.6 Vessel Under External Pressure Only 340
16.7 Vessel Under External Pressure and External Loading 341
References 342
Bibliography 342
17 Vessels of Noncircular Cross Section 344
17.1 Types of Vessels 344
17.2 Rules in Codes 345
17.3 Openings in Vessels with Noncircular Cross Section 345
17.4 Ligament Efficiency for Constant-Diameter Openings 345
17.5 Ligament Efficiency for Multidiameter Openings Subject to Membrane Stress 349
17.6 Ligament Efficiency for Multidiameter Openings Subject to Bending Stress 350
17.7 Design Methods and Allowable Stresses 352
17.8 Basic Equations 353
17.9 Equations in the ASME Code, VIII-1 356
17.10 Design of Noncircular Vessels in Other Codes 360
17.10.1 Method of the British Code BS 1113 360
17.10.2 Method of the European Standards EN 12952 and EN 13445 360
17.11 Forces in Box Headers due to Internal Pressure 361
17.11.1 Square Headers 362
17.11.2 Rectangular Headers 362
References 364
Further Reading 364
18 Power Boilers 366
18.1 General 366
18.2 Materials 366
18.3 General Design Requirements 366
18.3.1 Allowable Stress Values 366
18.3.2 Cylinders under Internal Pressure 366
18.4 Formed Heads under Internal Pressure 368
18.5 Loadings on Structural Attachments 368
18.6 Watertube Boilers 369
18.6.1 Special Design Requirements and Rules 369
18.7 Firetube Boilers 373
18.7.1 Special Design Requirements and Rules 373
References 373
A Guide to ASME Code 375
B Sample of Heat-Exchanger Specification Sheet 383
C Sample of API Specification Sheets 387
D Sample of Pressure Vessel Design Data Sheets 393
E Sample Materials for Process Equipment 407
F Required Data for Material Approval in the ASME Code 411
G Procedure for Providing Data for Code Charts for External-Pressure Design 413
H Corrosion Charts 415
I Various ASME Design Equations 431
J Joint Efficiency Factors 433
K Simplified Curves for External Loading on Cylindrical Shells 445
L Conversion Tables 453
Index 455
This edition of the classic guide to the analysis and design of process equipment has been thoroughly updated to reflect current practices as well as the latest ASME Codes and API standards. In addition to covering the code requirements governing the design of process equipment, the book supplies structural, mechanical, and chemical engineers with expert guidance to the analysis and design of storage tanks, pressure vessels, boilers, heat exchangers, and related process equipment and its associated external and internal components.
The use of process equipment, such as storage tanks, pressure vessels, and heat exchangers has expanded considerably over the last few decades in both the petroleum and chemical industries. The extremely high pressures and temperatures involved with the processes for which the equipment is designed makes it potentially very dangerous to property and life if the equipment is not designed and manufactured to an exacting standard. Accordingly, codes and standards such as the ASME and API were written to assure safety. Still the only guide covering the design of both API equipment and ASME pressure vessels, Structural Analysis and Design of Process Equipment, 3rd Edition:
Covers the design of rectangular vessels with various side thicknesses and updated equations for the design of heat exchangers
Now includes numerical vibration analysis needed for earthquake evaluation
Relates the requirements of the ASME codes to international standards
Describes, in detail, the background and assumptions made in deriving many design equations underpinning the ASME and API standards
Includes methods for designing components that are not covered in either the API or ASME, including ring girders, leg supports, and internal components
Contains procedures for calculating thermal stresses and discontinuity analysis of various components
Structural Analysis and Design of Process Equipment, 3rd Edition is an indispensable tool-of-the-trade for mechanical engineers and chemical engineers working in the petroleum and chemical industries, manufacturing, as well as plant engineers in need of a reference for process equipment in power plants, petrochemical facilities, and nuclear facilities.
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