Structural Analysis and Design of Process Equipment

Still the only book offering comprehensive coverage of the analysis and design of both API equipment and ASME pressure vessels 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.

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 the World 14 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 4.2 Nonferrous Alloys 31 4.3 Ferrous Alloys 34 4.4 Heat Treating of Steels 35 4.5 Brittle Fracture 35 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 5.3 Buckling of Cylindrical Shells 69 5.4 Thermal Stress 72 Nomenclature 80 References 81 Further Reading 81 6 Analysis of Formed Heads and Transition Sections 84 6.1 Hemispherical Heads 84 6.2 Ellipsoidal Heads 93 6.3 Torispherical Heads 95 6.4 Conical Heads 95 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 9.2 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 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 of Theory and ASME Code Formula for Circular Flat Heads and Covers Without Bolting 154 10.5 Bolted Flanged Connections 154 10.6 Contact Facings 155 10.7 Gaskets 155 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 10.15 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 11.5 Ligament Efficiency of Openings in Shells 215 11.6 Fatigue Evaluation of Nozzles Under Internal Pressure 217 11.7 External Loadings 218 References 230 Bibliography 231 12 Vessel Supports 234 12.1 Introduction 234 12.2 Skirt and Base-Ring Design 234 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 13.3 API 620 Tanks 263 13.4 Aluminum Tanks 270 13.5 AWWA Standard D 100 271 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 14.5 Theoretical Analysis of Fixed Tubesheets 291 14.6 ASME Equations for Fixed Tubesheets 293 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 16.3 Wind Loading 331 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 17.11 Forces in Box Headers due to Internal Pressure 361 References 364 Further Reading 364 18 Power Boilers 366 18.1 General 366 18.2 Materials 366 18.3 General Design Requirements 366 18.4 Formed Heads under Internal Pressure 368 18.5 Loadings on Structural Attachments 368 18.6 Watertube Boilers 369 18.7 Firetube Boilers 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

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.