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Department of Mechanical Engineering School of Engineering Gautam Buddha University Greater Noida (U.P.)
Seminar Highlights
Introduction to Pressure Vessels and its classification Components of Pressure Vessels ASME Codes Design software and industrial applications Materials Selection Stress in Pressure Vessels Design of cylindrical shell. Calculation Program
INTRODUCTION
[1]
Vessels, tanks, and pipelines that carry, store, or receive fluids are called pressure vessels. A pressure vessel is defined as a container with a pressure differential between inside and outside. The inside pressure is usually higher than the outside, except for some isolated situations. Pressure vessels often have a combination of high pressures together with high temperatures. Because of such hazards it is imperative that the design be such that no leakage can occur. Pressure vessels and tanks are, in fact, essential to the chemical, petroleum, petrochemical and nuclear industries. It is in this class of equipment that the reactions, separations, and storage of raw materials occur.
[3]
Storage tank
Cylindrical
Monowall
Cryogenic
Process vessel
Spherical
Multi Wall
Steam
Heat Exchanger
Conical
Forged
Lethal
Horizontal/Vertical
Fired/Unfired
Shell The shell is the primary component that contains the pressure. Pressure vessel shells are welded together to form a structure that has a common rotational axis. Most pressure vessel shells are cylindrical, spherical and conical in shape Head All pressure vessel shells must be closed at the ends by heads (or another shell section). Heads are typically curved rather than flat. Curved configurations are stronger and allow the heads to be thinner, lighter, and less expensive than flat heads. Heads are usually categorized by their shapes.
Support The type of support that is used depends primarily on the size and orientation of the pressure vessel. the pressure vessel support must be adequate for the applied weight, wind, and earthquake loads. Typical kinds of supports are as follow:
a. Skirt b. Leg c. Saddle d. Lug
Saddle
Leg
Lug Skirt
Nozzle A nozzle is a cylindrical component that penetrates the shell or heads of a pressure vessel. The nozzle ends are usually flanged to allow for the necessary connections and to permit easy disassembly for maintenance or access. Nozzles are used for attaching piping for flow into or out of the vessel and attach instrument connections, (e.g., level gauges, thermowells, or pressure gauges). Stiffener Rings Rings made of flat bar or plate or structural shapes welded around the Circumference of the vessel. These rings are installed on vessels operating under external pressure to prevent collapse of the vessel.
Following parts of ASME Code SECTION VIII DIV-1 are used in design [5]
U-1 UG-16 UG-20 UG-21 UG-22 UG-23 UG-27 UG-28 UG-29 UG-32 Scope for the design of pressure vessels General regarding design Design temperature Loadings Maximum allowable stresses Maximum allowable stresses Thickness of shells under internal pressure Thickness of shells under external pressure Stiffening rings for cylindrical shells under external pressure Formed heads, pressure on concave side
UG-33
UG-45 UW-12 UG-45 UW-12 Appendix V
2. Materials Selection
Selection of materials
The broad classification of these materials can be done in following categories: 1. Boiler Quality Materials 2. Structural Quality Materials 1. Boiler Quality Materials [5] These are the materials employed for pressure carrying components.
a) Carbon Steel Principal element is carbon, generally ranging from 0.2 to 0.4. b) Low Alloy Steel Alloying elements are used, but the total alloy content is limited to generally 5 %. c) High alloy steel heavy alloying is done for example Stainless Steels.
Commonly used stainless steels for refinery, petrochemical services are: Austenitic Stainless Steels Ferritic Stainless Steels.
[5]
1. PWHT Post Weld Heat Treatment. Radiographic testing is done of the welding joints according to the pressure vessel. If Vessel is designed according to ASME sec 8 div only spot radiography will be done for ASME sec 8 div 2 full radiographic testing is being done. After this test heat treatment is done on the welding joints to relieve the stresses.
Recommended for corrosive services like HS, amine, caustic services etc.
2. Impact Testing The impact testing of materials is done to take care of low temperature service. This is because the material tend to become more brittle at low temperature. Charpy V notch impact test is the most common type of test used.
2. Secondary stress Secondary mean stresses are developed at the junctions of major components of a pressure vessel and are produced by sustained loads other than internal or external pressure. Types of secondary stresses: 1. Secondary membrane stress, Q
These are the stress which are
a. Thermal stresses. b. Membrane stress in the knuckle area of the head. c. Membrane stress due to local loads. 2. Secondary bending stress, QL
These include :
a. Bending stress at a gross structural discontinuity: b. The stress variation of the radial stress due to internal pressure. d. Discontinuity stresses at stiffening or support rings.
2. Maximum shear stress theory This theory asserts that the breakdown of material depends only on the maximum shear stress attained in an element. It is mainly used for Ductile material
4. CREEP: Creep is a failure of material due to constant loading and unloading of material kept at one place for long time. It arises due to periodic loading and loading. It starts initially from grain boundary where abnormal grains are there. It increases to cracks in the material after some time and finally material fails on load much lower than the yield point stress. 5. CORROSION: If excessive corrosion occurs than material thickness will decrease constantly and after a certain limit the material will fail Due to this the vessels are provided with corrosion allowance thickness. Generally taken 3mm at inside boundary layer. At outside some corrosion resistant material are used to prevent the rusting.
4. Design of Shell
VESSEL NOMENCLATURE
E = Joint Efficiency Factor P = internal pressure (kg/cm2). Ri, Ro = inside and outside radius with corrosion allowance. (in) Di, Do = inside and outside diameter. S = allowable stress in the material t = thickness of the cylinder (mm) =Density of liquid H=Height of liquid level CA = Corrosion allowance n = number of stiffening rings Leff = Overall effective length of pressure vessel L = Length of pressure vessel hoop= Hoop or circumferential stresses long= Longitudinal stresses Pa, Pa1, Pa2 = Allowable external pressure
Shell Design
Basically the design of shell consists of following steps-
Pe
Pi 1 2
HOOP STRESS
Classical Equation =
ASME CODE EQUATION
LONGITUDINAL STRESS
Classical Equation = 2
ASME CODE EQUATION
( . )
( + . )
1. 2.
0 0
10 < 10
Steps [9]1) Assume a value of t for the cylinder. 2) Calculate the quantities L/Do and Do/t. 3) Use Fig. with the calculated values of L/Do and Do/t and establish an A value. 4) Use an External Pressure Chart to determine the A value and determine the B value from the appropriate temperature chart. 5) Calculate the allowable external pressure from the equation
= 4 3 2 3
6)
When A falls to the left of the curves, the value of Pa is determined from
=
7)
Compare the calculated value of Pa (Allowable Pressure) obtained in Steps 6 or 7 with P. If Pa is smaller than P, select the thickness. if Pa > P assumed thickness is optimum
<
For values of Do/t less than 4, the value of factor A can be calculated using the following formula [9]: 1.1 = 2 For values of A greater than 0.10, use a value of 0.10. When Do/t is less than 10, the allowable external pressure is taken as the smaller of the values determined from the following two equations: 1 2.167 = 0.0833
Total internal pressure, P = pressure inside the vessel+ pressure due to liquid
Pressure due to liquid level = /2 6 10
Step-2: Calculate the minimum shell thickness considering hoop or circumferential stress when the shell is under internal pressure. = , < 0.5 < 0.385 ( 0.6) , = + () = + . .
= + ()
= + . .
Step-4: Select the maximum thickness as obtained from the step-1 & 2. t = maximum (thoop ,tlong)
10 < 10
Follow the steps as described in the section design of cylindrical shell under external pressure.
But if Pallowable < Pexternal Either (a) select a new thickness and start the procedure from the beginning to satisfy the design. or (b) Elect to use stiffening rings to reduce the L dimension.
Step-6(a) Select a new thickness and repeat step-4 to 6 for calculating allowable pressure Step-6(b) Calculation for the use of stiffening rings i) Taking number of stiffening rings = n ii) Now, =
+1
iii) Repeat step-4 to 6 for calculating allowable pressure using new value of L.
Design of Stiffening rings Design of Heads Design of Nozzles Design of various types of supports Programming the various design procedure and calculation involved. Sample data results, comparison and validation Conclusion
References
1. Nitant M. Tandel, Jigneshkumar M. Parmar, A Review on Pressure Vessel Design and Analysis, Paripex - Indian Journal Of Research, May 2013 2. J. Philip Ellenberger PE, Robert Chuse, Bryce E. Carson Sr., Pressure Vessels The ASME code simplified, 8th edition, Mc Graw- Hill Professional Engineering 3. B.S.Thakkar, S.A.Thakkar, DESIGN OF PRESSURE VESSEL USING ASME CODE, SECTION VII DIVISON 1, International Journal of Advanced Engineering Research and Studies, 2012. 4. Ghader Ghanbari, Mohammad Ali Liaghat, Ali Sadeghian, Pressure Vessel Design, Guides & Procedures 5. Dennis R. Moss, Pressure Vessel Design Manual, 3rd Edition-2004, Gulf Professional Publishing (An imprint of Elsevier) 6. 7. 8. 9. Dr. R. K. Bansal, A Textbook of Strength of Materials, 4th Edition-2009. Somnath Chattopadhyay, Pressure Vessel Design and Practice, CRC Press. Henry H. Bednar, Pressure Vessel Design Handbook, 2nd Edition-1991. Krigerer Publishing company James R. Farr and Maan H. Jawad, Guidebook for the design of ASME Section VIII pressure vessels, 2nd Edition-2001, ASME Press New York. 10. An international code 2010 ASME Boiler & Pressure Vessel Code, 2010 Edition, VII Section VIII, Div.1, Rules for Construction of Pressure Vessels, ASME New York
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