Structural Analysis and Design of Process Equipment

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.

• Preface to the Third Edition xvPreface to the Second Edition xviiPreface to the First Edition xixAcknowledgements xxiPart I Background and Basic Considerations 11 History and Organization of Codes 41.1 Use of Process Vessels and Equipment 41.2 History of Pressure Vessel Codes in the United States 41.3 Organization of the ASME Boiler and Pressure Vessel Code 61.4 Organization of the ANSI B31 Code for Pressure Piping 61.5 Some Other Pressure Vessel Codes and Standards in the United States 61.6 Worldwide Pressure Vessel Codes 7References 7Further Reading 72 Selection of Vessel, Specifications, Reports, and Allowable Stresses 102.1 Selection of Vessel 102.2 Which Pressure Vessel Code is Used 102.3 Design Specifications and Purchase Orders 102.4 Special Design Requirements 112.5 Design Reports and Calculations 112.6 Materials Specifications 112.7 Design Data for New Materials 112.8 Factors of Safety 122.9 Allowable Tensile Stresses in the ASME Code 122.10 Allowable External Pressure Stress and Axial Compressive Stress in the ASME Boiler and Pressure Vessel Code 132.11 Allowable Stresses in the ASME Code for Pressure Piping 142.12 Allowable Stress in Other Codes of the World 14References 163 Strength Theories, Design Criteria, and Design Equations 183.1 Strength Theories 183.2 Design Criteria 183.3 Design Equations 193.4 Stress–Strain Relationships 193.5 Strain–Deflection Equations 203.6 Force–Stress Expressions 22References 23Further Reading 234 Materials of Construction 264.1 Material Selection 264.2 Nonferrous Alloys 314.3 Ferrous Alloys 344.4 Heat Treating of Steels 354.5 Brittle Fracture 354.6 Hydrogen Embrittlement 504.7 Nonmetallic Vessels 50References 50Further Reading 51Part II Analysis of Components 535 Stress in Cylindrical Shells 565.1 Stress Due to Internal Pressure 565.2 Discontinuity Analysis 605.3 Buckling of Cylindrical Shells 695.4 Thermal Stress 72Nomenclature 80References 81Further Reading 816 Analysis of Formed Heads and Transition Sections 846.1 Hemispherical Heads 846.2 Ellipsoidal Heads 936.3 Torispherical Heads 956.4 Conical Heads 956.5 Nomenclature 99References 100Further Reading 1007 Stress in Flat Plates 1027.1 Introduction 1027.2 Circular Plates 1027.3 Rectangular Plates 1067.4 Circular Plates on Elastic Foundations 107Nomenclature 109Reference 109Further Reading 109Part III Design of Components 1118 Design of Cylindrical Shells 1148.1 ASME Design Equations 1148.2 Evaluation of Discontinuity Stresses 1158.3 ASME Procedure[2] for External Pressure Design in VIII- 1 1218.4 Design of Stiffening Rings 1268.5 Allowable Gaps in Stiffening Rings 1298.6 Out-of-Roundness of Cylindrical Shells Under External Pressure 1298.7 Design for Axial Compression 132Nomenclature 132References 133Further Reading 1339 Design of Formed Heads and Transition Sections 1369.1 Introduction 1369.2 ASME Design Equations for Hemispherical Heads 1379.3 ASME Design Equations for Ellipsoidal, Flanged, and Dished Heads 1399.4 ASME Design Equations for Conical Heads 143Nomenclature 147References 148Further Reading 14810 Blind Flanges, Cover Plates, and Flanges 15010.1 Introduction 15010.2 Circular Flat Plates and Heads with Uniform Loading 15110.3 ASME Code Formula for Circular Flat Heads and Covers 15310.4 Comparison of Theory and ASME Code Formula for Circular Flat Heads and Covers Without Bolting 15410.5 Bolted Flanged Connections 15410.6 Contact Facings 15510.7 Gaskets 15510.8 Bolting Design 16110.9 Blind Flanges 16310.10 Bolted Flanged Connections with Ring-Type Gaskets 16410.11 Reverse Flanges 17010.12 Full-Face Gasket Flange 17110.13 Flange Calculation Sheets 17610.14 Flat-Face Flange with Metal-to-Metal Contact Outside of the Bolt Circle 17710.15 Spherically Dished Covers 177Nomenclature 184References 184Further Reading 18511 Openings, Nozzles, and External Loadings 18811.1 General 18811.2 Stresses and Loadings at Openings 18811.3 Theory of Reinforced Openings 19211.4 Reinforcement Limits 19311.5 Ligament Efficiency of Openings in Shells 21511.6 Fatigue Evaluation of Nozzles Under Internal Pressure 21711.7 External Loadings 218References 230Bibliography 23112 Vessel Supports 23412.1 Introduction 23412.2 Skirt and Base-Ring Design 23412.3 Design of Support Legs 24112.4 Lug-Supported Vessels 24212.5 Ring Girders 24312.6 Saddle Supports 245Nomenclature 248References 249Further Reading 249Part IV Theory and Design of Special Equipment 25113 Flat-Bottom Tanks 25413.1 Introduction 25413.2 API 650 Tanks 25413.3 API 620 Tanks 26313.4 Aluminum Tanks 27013.5 AWWA Standard D 100 271References 273Further Reading 27314 Heat-Transfer Equipment 27614.1 Types of Heat Exchangers 27614.2 TEMA Design of Tubesheets in U-tube Exchangers 27614.3 Theoretical Analysis of Tubesheets in U-tube Exchangers 28014.4 ASME Equations for Tubesheets in U-tube Exchangers 28314.5 Theoretical Analysis of Fixed Tubesheets 29114.6 ASME Equations for Fixed Tubesheets 29314.7 Expansion Joints 30014.8 Tube-to-Tubesheet Junctions 303References 305Further Reading 30515 Vessels for High Pressures 30815.1 Basic Equations 30815.2 Prestressing (Autofrettaging) of Solid-Wall Vessels 30915.3 Layered Vessels 31115.4 Prestressing of Layered Vessels 31515.5 Wire-Wound Vessels 317Nomenclature 317References 318Further Reading 31816 Tall Vessels 32016.1 Design Considerations 32016.2 Earthquake Loading 32016.3 Wind Loading 33116.4 Vessel Under Internal Pressure Only 33616.5 Vessel Under Internal Pressure and External Loading 33816.6 Vessel Under External Pressure Only 34016.7 Vessel Under External Pressure and External Loading 341References 342Bibliography 34217 Vessels of Noncircular Cross Section 34417.1 Types of Vessels 34417.2 Rules in Codes 34517.3 Openings in Vessels with Noncircular Cross Section 34517.4 Ligament Efficiency for Constant-Diameter Openings 34517.5 Ligament Efficiency for Multidiameter Openings Subject to Membrane Stress 34917.6 Ligament Efficiency for Multidiameter Openings Subject to Bending Stress 35017.7 Design Methods and Allowable Stresses 35217.8 Basic Equations 35317.9 Equations in the ASME Code, VIII- 1 35617.10 Design of Noncircular Vessels in Other Codes 36017.11 Forces in Box Headers due to Internal Pressure 361References 364Further Reading 36418 Power Boilers 36618.1 General 36618.2 Materials 36618.3 General Design Requirements 36618.4 Formed Heads under Internal Pressure 36818.5 Loadings on Structural Attachments 36818.6 Watertube Boilers 36918.7 Firetube Boilers 373References 373A Guide to ASME Code 375B Sample of Heat-Exchanger Specification Sheet 383C Sample of API Specification Sheets 387D Sample of Pressure Vessel design data Sheets 393E Sample Materials for Process Equipment 407F Required Data for Material Approval in the ASME Code 411G Procedure for Providing Data for Code Charts for External-Pressure Design 413H Corrosion Charts 415I Various ASME Design Equations 431J Joint Efficiency Factors 433K Simplified Curves for External Loading on Cylindrical Shells 445l Conversion Tables 453Index 455