EQUIPMENT DESIGN

1. A steel cable of uniform cross-section of 3 cm

2
and length of 200 meters is suspended vertically.
Calculate the total elongation of the steel cable if steel weighs 1.5 kg/m. E=2.1x10
6
kg/ cm
2
.
( )( )
( )( )( )
m
x
AE
wL
dL
AE
wL
d
A
wL
A
W
S But dL
E
S
d
E
SL
L
004762 . 0
10 1 . 2 3 2
200 5 . 1
2
: ;
6
2
2
0 0

2. A steel bar 5 wide, 1 thick, & 12 long is stressed by a tensile load of 80,000 pounds along the Y-
axis. The modulus of elasticity is 30,000 pounds/ in
2
. Calculate the dimensions of the stressed bar
and the equivalent lateral stress. Take Poissons Constant k,
0.3
y

( )( )
( )
( )
( )( ) ( )
( ) ( )
( ) ( )
2
in / lb 797 , 4
6
10 x 30
4
10 x 599 . 1 E
x z
S
x
S Stress Lateral
inch 9998401 . 0
4
10 x 599 . 1 1
z
L Thickness Final
n compressio inch
4
10 x 599 . 1 1
4
10 x 599 . 1
z
L
z z
Thickness in duction Re
inch 9992005 . 4
4
10 x 995 . 7 5
f
x
L Width Final
n compressio inch
4
10 x 995 . 7 5
4
10 x 599 . 1
x
L
x x
Width in duction Re
4
10 x 599 . 1
4
10 x 33 . 5 3 . 0
y
k
z x
Strain Lateral
inches 0064 . 12 0064 . 0 12
f
y
L , Lenght Final
inches 0064 . 0 inches 12
4
10 x 33 . 5
y
L
y y
Elongation Total
tension
4
10 x 33 . 5
6
10 x 30
000 , 16
E
y
S
y
Strain Axial
2
in
lb
000 , 16
2
in 1 5
lb 000 , 80
A
P
y
S Stress Axial
f

,
_

,
_

,
_

,
_

,
_

+

,
_

1
Length = y =12
Thickness=Z= 1
Width= x = 5
P=80,000 lb
P=80,000 lb
3. A tapered round post, 5 meters high, 25 cm diameter at the top and 40 cm at the base, is fixed at its
base. If a horizontal force of 1000 N were applied to the top of the post;
a) What would be the maximum stress in the post?
b) How far up from the base of the base would this maximum stress be?
5 . 12 y 015 . 0 5 . 7 x r
y 015 . 0
500
y 5 . 7
x
5 . 7
500
x
y
Similar
+ +

( ) ( ) ( ) ( )
( ) ( )
( )
( )
( ) ( ) ( )
( )
( )
( )
( )( ) [ ]
cm Base from Height b
cm N S a
cm y
y y
y
y y y
dt
dS
y
y
y
y
y
A
P
S
y
y
r
y
P
r P y
Mo
33 . 83 67 . 416 500 .
/ 12 . 20
5 . 12 67 . 416 015 . 0
67 . 416 10000
.
67 . 416
045 . 0 5 . 12 015 . 0
5 . 12 015 . 0
015 . 0 5 . 12 015 . 0 3 5 . 12 015 . 0 1000
0
5 . 12 015 . 0
1000
5 . 12 015 . 0
5 . 12 015 . 0
1000
5 . 12 015 . 0
1000 1000
0 1000
0
2
2
6
2 3
3 2
max

+
1
]
1

+
+ +

+

+
+

+

2
25 cm
5 meters
40 cm
1000 Newtons
y
x
o
r




7
.
5


c
m





1
2
.
5

c
m
P
4. A steel tube made of No. SAE 9255 is subjected to a tensile load of 8,000 pounds. If the thickness of
the tube is 10 percent of its outside diameter find the outside diameter of the tube if factor of safety is
4 based on the ultimate strength of 135,000 psi.
( )
inch . D
D . D .
D . d but ;
d D
A
in .
,
,
S
P
A
in / lb ,
,
S
S
N Safety of Factor
w
w
w
u
S
916 0
8 0
4
237 0
8 0
4
237 0
750 33
000 8
2
750 3
4
000 135
2 2
2 2
2

1
]
1

,
_

5. A horizontally installed cylindrical tank is to be used as sulfuric acid storage tank. Tank dimension
being; diameter=4 m, length=5 m. What is the stored weight of sulfuric acid inside the tank when the
gauge glass level reads 1.75 m? Assume the density of sulfuric acid=1.85 kg/liter.
Filled Area = Area of the segment
= Area of the sector-Area of the triangle
Area of the sector =
360
r
2

Area of the triangle =

( )
2
h r b
But:
r
2
b
2
sin

3
D
d
h
r-h
b
r
r
And
r
h r
cos
2
1

Therefore: Filled Area
( )

,
_

,
_

,
_

,
_

r
h r
cos sin r
360
r
h r
2
sin r
360
r A
1 2
2
f
Volume of liquid:
( ) ( )
( )
( ) ( )
( )( ) mt . . . acid sulfuric of mass
m .
.
.
cos sin
.
cos
L h r
r
h r
cos sin r
r
h r
cos
r
L h r
r
h r
cos sin r
r
h r
cos
r V
f
9 48 85 1 43 26
43 26
5 75 1 2
2
75 1 2
2
2
75 1 2
180
2
180 360
2
3
1 1
2
1 1
2
1
1
2

1
1
]
1

,
_

1
1
1
]
1

,
_

1
1
1
1
]
1

,
_

,
_

6. A steel wire accurately graduated in centimeter was used to measure the depth of a deep-well. The
cross-sectional area of the wire was 0.195 cm
2
and a 115 kg weight was attached to the wire to lower
it into the well. According to the graduated scale, the measurement read 600 meters. The steel wire
weighs 0.10 kg/m. What is the depth of the well? Assume E=2.1x10
6
kg/cm
2
.
T
2
1
T
600 d
weight kg 115 of mass to due elongation
wire of weight to due elongation
elongation total
depth d
: Let
+

( )( )
( )( )( )
( )( )
( )( )
meters 21246 . 600 21246 . 0 600 depth d
m 21246 . 0
1685 . 0 04396 . 0
10 x 1 . 2 195 . 0
600 115
10 x 1 . 2 195 . 0 2
600 1 . 0
AE
WL
AE 2
wL
6 6
2
2 1 T
+

+
+ + +
2
7. A storage tank is to store a compressed air whose pressure is to be maintained at 190 psig at a
maximum temperature of 150
o
F. The tank has an inside diameter of 10 ft. The material to be used is
S-1 steel. It is desired to use a triple riveted butt joint. Determine the following:
a) Plate thickness
4
b) Strap thickness
c) Rivet hole diameter
d) Pitch
e) Joint efficiency
()()
()()
( )
( )
% 4 . 83 Eff int Jo . e
inch 4 / 3 4 p , Pitch . d
inch 16 / 7 1 d , diameter hole rivet .. c
inch 4 / 3 o , thickness strap . b
inch 1 thickness Plate . a
62 pp , 2 6 Table From
OK 829 . 0 834 . 0 834 . 0 1 te
% 4 . 83 e , " 1 t : Assume
acceptable not 829 . 0 6145 . 0 855 . 0
32
23
te
62 pp , 3 2 Table % 5 . 85 e , 32 / 23 t : Assume
R % 10 te , thickness plate selecting in
applicable therefore R % 10 thickness 829 . 0
000 , 11
48 190
S
Pr
te
steel 1 S , F 150 T For in / lb 000 , 11 S
Rushton and Hesse , Design Equipment ocess Pr , 1 3 Table 60 pp From
r % 10 t when cylinder walled thin for
Se
Pr
t
inches 48
2
12 8
R
psi 190 P
: Given
o 2
a

>

<

,
_

<
<

<

8. A low carbon steel sheet 3/8 thick, lined with aluminum 1/8 thick is used to form a low pressure
receiver 10 inches inside diameter. A force of 5000 lb is evenly distributed in the circumferential
shell. Find the stress in both the steel and aluminum. Assume Esteel=30x10
6
Ealuminum=10.3 x10
6
psi.
5
5,000 lb
Aluminum
1/8 thick
Carbon steel
3/8 thick
( ) ( )
( ) ( )
( ) ( )
psi 46 . 125
2725 . 4
77 . 535
S
psi 24 . 365
223 . 12
23 . 464 , 4
S
lb 77 . 535 23 . 464 , 4 000 , 5 P
lb 23 . 464 , 4 P
10 x 30 223 . 12
P
10 x 3 . 10 2725 . 4
P 000 , 5
in 223 . 12 5 8 / 3 5 r A
in 2725 . 4 8 / 3 5 8 / 1 8 / 3 5 r A
AE
P
AE
P 000 , 5
P P P : But
AE
PL
AE
PL
A
S
A
S
6
S
6
s
2 2 2 2
S
2 2 2 2
A
S
S
A
S
S A
S A
S A

,
_

,
_

1
]
1

1
]
1

+ + +

,
_

,
_

,
_

,
_

9. A trader finds that he needs a storage tank for alcohol. He wants to economize. He locates a steels
scrap dealer with one piece of scrap 1/8 thick rectangular steel plate measuring 5x25.
a) What will be the diameter of the largest cylindrical tank with flat top and hemi spherical bottom
that can make?
b) What will be the capacity of the tank in liters?
c) How many kilos of alcohol can be stored in the tank assuming that maximum alcohol temperature
will be 95
o
F (neglect expansion of steel assume density of alcohol=0.80gm/cc).
6
I.D. =10
I.D. =10
( )( )
( )
( )
( )
( )( ) ( ) liters ft V
ft H
ft r
r
dr
dV
r r r r r r
r
r
r V
r H r V V
r
r
H
rH r r ft ft ft A
S
326 , 3 54 . 117 82 . 2
6
5
82 . 2 5 . 62
82 . 2
82 . 2 2
82 . 2 3 125
82 . 2
5 . 2 5 . 62 0
6
5
5 . 62
3
2
2
3
2
125
3
2
2
3 125
3
4
2
1
tank of olume
2
3 125
2 2 125 25 5
bottom cal hemispheri top flat with tank cylindical of area Total plate steel of Area
3 3
2
2
3 3 3 3
2
2
3 2
2
2 2 2

+ +

,
_

,
_

+ +

10. A spherical carbon steel storage tank for ammonia has an inside diameter of 30ft. All joints are
welded with backing strip. If the tank is to be used at a working pressure of 50 psig and at a
temperature of 80
o
F, estimate the required wall thickness. Assume no corrosion allowance is
necessary and joint efficiency = 80%. Express your answer to the nearest 1/8
th
of an inch.
For S-1 carbon steel at 80
o
F, pp 62, Table 3-1 Hesse and Rushton
0.2P 2Se
PR
t
psi

000 11, S
( ) ( ) ( )
( ) ( ) ( )
" 5/8 " 0.584
11,000 0.2 0.80 11,000 2
12 30/2 50
0.2P 2Se
PR
t

11. A vertical cylinder 8 feet high and 5 ft diameter is to sit on 4 equally spaced concrete posts. The outer
edge of the concrete posts are flushed with the outer perimeter of the tank. When full, the tank and its
content weighs 15,000lb.The compressive strength of the concrete mix is 1000 psi. A factor of safety
of 4 is required by the building code.
7
Diameter=
30 ft
a) Calculate the diameter of the posts.
b) Calculate the minimum horizontal force to topple the tank.
( )( )
( )
ft 3.536 S
2S 5 D
inches 4.37

15 4
d
d
4

in 15
4
60
A
in 60
250
15,000
S
P
A ;
A
P
S
psi 250
4
1000
safety of factor
S
2 2 2
2 2
post
2
a
a
c

a
S
12. A chemical engineer was commissioned to design a vertical cylindrical tank with flat bottom and a
conical roof. The tank must be able to hold a maximum 4,500 m
3
of water for firefighting purposes.
Ease of climbing the tank and bearing capacity allows a maximum height of 16.5 meters from the
bottom of the tank up to the rim of the tank cylinder. Normal working practice dictates that the
8
F
8 ft
L
15,000 lb
D =5 ft
S
( ) ( ) ( ) ( )
( )
lb
h
L W
F
L W h F
M
o
315 , 3
8
2
536 . 3
000 , 15
0
0

,
_

normal working capacity of the tank is 90%of the total tank volume. The tank roof has a 10%incline.
Suitable steel plates available for construction the tank are in 4x 8sheets.
a) What are the complete tank dimensions?
b) What is the total area of steel plate needed?
c) What is the number of sheets needed?
( )
( ) ( )( ) ( ) ( )
( )( )
plates say .
,
plates of Number
ft , m , A
. . . . .
R rH r A
meters . r
. r , H r V
meers . H , height the Setting
,
.
,
Volume Gross
548 34 547
8 4
515 17
515 17 627 1
82 9 005 1 5 16 82 9 2 2 9
2
82 9
5 16 000 5
5 16
000 5
9 0
500 4
2 2
2 2 2
2 2
2 2


+ +
+ +

13. Determine the number of bags of cement and the quantities of other aggregates (m
3
) required for a
pyramide structure with a base of 10 meter square and a height of 12 meters. The concrete mix used is
class AA (12:0.5:1.0) and the following data can be used. Specific gravity: cement=3.1, sand=2.65,
gravel=2.5, Voids: cement=0.51, sand=0.38, gravel=0.33 Use 20 liters water per bag cement. Note:
1 bag cement= 40 kg
Aggregate Quantity/batch True Volume,
m
3
True mass
mt
Cement 12 bags [(12)(40)]/[(1000)(3.1)] 0.1548 (0.1548)(3.1) 0.48
Sand 0.50m
3
(0.50)(1-0.38) 0.31 (0.31)(2.65) 0.8215
Gravel 1.00m
3
(1.00)(1-0.33) 0.67 (0.67)(2.5) 1.675
Water 20lit/bag cement (20)(12)/1000 0.24 0.24
total 1.3748 3.2165
( ) ( )
( ) mt W
m
Bh
V
structure
structure
85 . 935 400
3748 . 1
2165 . 3
400
3
12 10
3
3
2

,
_

Aggregate Quantity, total
Cement (12 /1.3748)(400 3,492 bags
Sand (0.5/1.378)(400) 145.5 m
3
Gravel (1/1.378)(400) 291 m
3
Water (0.24/1.378)(400) 71.2 m
3
14. A continuous evaporator is operated with a given feed material under conditions in with the
concentration of the product remains constant. The feed rate at the start of a cycle after tubes have
been cleaned has been found to be 10,000lbs/h. After 48 hours of continuous operation, test have
show that the feed rate decreases to 5000lbs/h. The reduction in capacity is due to true scale
9

R
r
r .
. Cos
r
Cos
r
R
R
r
Cos
. . tna
. Tan
o
o
005 1
71 5
71 5 1 0
1 0
1

formation. If the down time per cycle for emptying, evaporation be operated between cleaning in
order to obtain the maximum of product per 30 days?
( )( )( )

t F
F
dt K dF
K
dt
dF
N t F P
o
0
( )( )
( )( )( )
( )
( )( ) ( )
( )
( )( ) ( ) ( )( )( )
( )
hr 74 . 18 t
+ t

+
1
]
1

+
+

1
]
1

,
_

104.17 2
10,000 6 104.17 4 12x104.12 104.17 12
2a
4ac b b
t
0 6F 12Kt Kt
6 t
Kt t F 2Kt F 6 t
720 0
dt
dP
6 t
Kt t F
720
6 t
720
t Kt) (F P
N t F P
cycles
6 t
720
hr/cycle 6) (t
hr/day 24 days 30
N
104.17
48
5,000 10,000
t
F F
K
condition; 1st using : K for Solving
Kt F F
Kt ) F (F
2
2
o
2
2
2
o o
2
o
o
0
o
o
15. Analyze the stresses involved in riveted lap joint shown. The diameter d is ; the plate width w is 2; the plate
thickness t is and the marginal distance m is . Asssume the ultimate stresses for the plate and rivet
materials:
Tensile stress, ST = 60,000 psi
Bearing, compressive stress, SB;C= 90,000 psi
Shearing stress, SS = 45,000 psi
a. Failure of rivet by single shear:
10

w =2
4
2
d
A
s

2
d A
S

t=
t=
d m m

F=SSd
2
/4 = (45,000)(1/2)
2
/4 = 8,836 lb
b. Failure by tearing of plate: (tensile stress)
F=ST(w-d) t = 60,000(2-0.5)(0.25) = 22,500 lb
c. Failure by shearing out of end-plate
F= SS(t)(m)(2) = (45,000)(1/4)(3/4)(2) = 16,875 lb
x 2 (both sides)
d. Failure by crushing of rivet or plate (bearing stress)
F=SC;B (d)(t)= (90,000)(1/2)(1/4)= 11,250 lb
Joint Efficiencies:
Solid Plate=100%
F= (60,000)(1/4)(2) = 30,000 lb
a. Shearing of Rivet = 8,836/30,000= 29.5%
b. Tearing of Plate = 22,500/30,000 = 75%
c. Shearing out of End Plate = 16,875/30,000 = 56.3%
d. Crushing of Rivet or Plate = 11,250/30,000 = 37.5%
The joint that may fail firs t= (a) the shearing of rivet
11
d
w =2
t
w =2 d

t=

t=
d =