PVEng

Design Conditions
Code: ASME VIII-1 Year: 2007 Addenda: 2009 MAWP: 1500 MEAWP: 0 Max. Temp.: 500 MDMT: -40 MDMT Press.: 1500 Min. Thk. (UG-16b): 0.0625 Corrosion Allowance: 0 Hydrotest: 2201 Impact Testing: None Impact Exemption: UHA-51(d) Radiography: None psi psi F F psi in in psi

Pressure Vessel Engineering Ltd.

ASME Calculations - CRN Assistance - Vessel Design - Finite Element Analysis

Finite Element Analysis Report - VIII-1

File: Desc: Dwg: Date: PVEfea-4472.0 Tri-Clamp FEA PVEdwg-4472.0 August 16, 2010

UG-22 Loadings Considered

Internal Press.: Yes External Press.: No Vessel Weight: No Weight of Attachments: No Attachment of Internals: No Attachment of Externals: No Cyclic or Dynamic Reactions: No Wind Loading: No Seismic Loading: No Fluid Impact Shock Reactions: No Temperature Gradients: No Differential Thermal Expansion: No Abnormal Pressures: No Hydrotest Loads: No

Author: Cameron Moore Reviewer: Laurence Brundrett

Conclusion: The Tri-Clamp meets VIII-2 design rules using VIII-1 allowable stresses and is acceptable.

www.pveng.com info@pveng.com Phone 519-880-9808

Pressure Vessel Engineering Ltd. 120 Randall Drive, Suite B Waterloo, Ontario, Canada, N2V 1C6

Table of Contents Description Cover Table of Contents Executive Summary Stress Limits Model Mesh Error Restraints Loads Bolt Loads Page 1 2 3 4 5 6 7 8 9 10 Description Reaction Area Reaction Forces Displacement Stress Clamp Stress Ferrule Stress Stress Linearization Bolt Stress Component Cycle Life

23-Aug-10

Page 2 of 20 Page 11 12 13 14 15 16 17 18 19

Rev 0 Release

Revision(s) Description

Date By 16-Aug-10 CBM

Executive Summary ver 4.00

Goal:

Page 3 of 20

The Tri-Clamp will be used under ASME VIII-1 service. This product cannot be calculated to code rules due to the complexity of its geometry. Instead the rules of ASME VIII-2 are used with ASME VIII-1 allowable stresses to determine its acceptability. Summary Conclusions: Materials Material strength properties used in this report are obtained from ASME IID, Table 1A, and are suitable for VIII-1 components. The rules of ASME VIII-2 are used to set the stress limits. Model Information The model used in the analysis represents 1/2 of the Tri-Clamp due to symmetry. A global mesh size of 0.09375" has been applied using 3D tetrahedral solid elements. The mesh size results in a reported error of less than 5%. Restraints & Loads A symmetry restraint is applied to compensate for the use of a 1/2 model. A single point on the clamp is fixed to prevent rigid body motion in all directions. Internal pressure is applied up to the pressure boundary and bolt loads simulated with a "bolt connector" feature. The resulting reaction forces closely match the theoretical reaction forces. The model is in balance and may be used for displacement and stress analysis. Results Through the FEA we found a 0.0009" maximum displacement as acceptable. A 22,817 psi peak stress results in an infinite cycle life. All general areas are within the allowable stress limits. Analysis Conclusion: The Tri-Clamp meets VIII-2 design rules using VIII-1 allowable stresses and is acceptable.

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Material Stress Limits ver 4.01 ASME VIII-2 Fig 5.1

Material Input Chart: 500 Temperature [F] Material 1 Material = SA-182 F316L Application = Clamps/Ferrules Sm [psi] = 14,800 Sy [psi] = 16,400 E1 = 1.0 E2 = 1.0 E [psi] = 25,900,000 v = 0.30 Coef [/F]= Cond [btu/hr-ft-F]= Pm [psi] = Pl [psi] = Pl+Pb [psi] = Pl+Pb+Q [psi] = Material = Application = Sm [psi] = Sy [psi] = E1 = E2 = E [psi] = v= Coef [/F]= Cond [btu/hr-ft-F]= Pm [psi] = Pl [psi] = Pl+Pb [psi] = Pl+Pb+Q [psi] = Comments Variable Descriptions: VIII-2 5.13 Sm (basic allowable) E1 (weld efficiency) E2 (casting efficiency) Cond (Thermal Conductivity) - IID Table TCD Stress Limit Equations: VIII-2 Figure 5.1 Pm = Pl = Pl+Pb = Pl+Pb+Q = Pl+Pb+Q+F = Comments:
(1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it. (2) The thermal expansion and conductivity coefficients are only required for studies including thermal stresses (3) Refer to VIII-2 5.15 Figure 5.1 and following for the Pm, Pl, Q and F stress limits (4) Refer to VIII-2 5.14 Table 5.6 for the correct application of the calculated stress limits (5) Use IID tables 5A and 5B for Sm for VIII-2 studies (6) Use IID tables 1A and 1B for Sm values (S) for VIII-1 studies (7) Use B31.1 Table A for Sm values for B31.1 studies (8) Use B31.3 Table A for Sm values for B31.3 studies

Page 4 of 20

Material 2 SA-403 316L Pipe Caps 14,800 16,400 1.0 1.0 25,900,000 0.30

Bolting 3 SA-193 B7 Bolts 25,000 88,500 1.0 1.0 27,400,000 0.30

Material 4

14,800 22,200 22,200 44,400 Material 5

14,800 22,200 22,200 44,400 Material 6

50,000 0 75,000 0 Material 7

Bolting 8

E (modulus of elasticity) - IID Table TM-1 v (Poison's ratio) - IID Table PRD Coef (coefficient of thermal expansion) - IID Table TE-1

E1*E2*Sm~~general primary membrane stress intensity limit 1.5*E1*E2*Sm~~local membrane stress intensity limit 1.5*E1*E2*Sm~~primary membrane + primary bending stress intensity limit Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity Use fatigue curves~~peak stress intensity limit

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Model

Page 5 of 20

Fig-A An exploded view of the Tri-Clamp assembly. The clamp, ferrules and bolts will be analyzed in this report. Refer to drawing PVEdwg-4472.0 for details.

Fig-B Due to symmetry, a half model will be analyzed. Ferrules have been capped to simulate loads caused by a closed loop system. The nuts and bolts have been replaced by a "bolt connector" feature.

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Mesh

Page 6 of 20

Fig-A A view of the mesh applied to the model. A global mesh size of 0.09375" is used with second order tetrahedral solid elements.

Fig-B A view of the mesh on the opposite side of the assembly. "No Penetration" contact sets are applied between the two clamp faces and the ferrule to clamp interaction. The caps are treated as bonded to the ferrules.

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Error

Page 7 of 20

Fig-A A view of Error plot, capped at 5% error No general areas are observed in excess of 5% . Error results are acceptable, the mesh selected is appropriate.

Fig-B An alternative view of Fig-A.

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Restraints

Page 8 of 20

Fig-A A view of the symmetry restraint applied. This condition restrains the sectioned faces to the "XY" plane wile permitting movement in the "X" & "Y" directions. This restraint compensates for the use of a half model and provides results identical to a full model.

Fig-B A close-up of Fig-A. A point is restrained from translation in the Y and X directions. The model is now restrained from rigid body motion in all directions.

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Loads

Page 9 of 20

Fig-A 1,500 psi is applied to all internal faces up to the pressure boundary.

Fig-B A close-up of Fig-A.

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Bolt Loads

Page 10 of 20

Fig-A Simulated bolt connectors are applied to the clamp. This simulates a bolt using beam elements rather than including the bolt in the model. An axial preload of 1,262 lb has been applied. Refer to the bolt results page for the preload calculation.

Fig-B A "No Penetration" contact set is applied. A friction factor of 0.7 for steel on steel is incorporated.

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Reaction Area

Page 11 of 20

Fig-A The reaction normal to the XY plane is measured. This area is used to compute the reaction force acting in the Z-direction.

Fig-B The reaction area measured in the Z-direction is 6.977 sq. in. This area will be multiplied by the design pressure to determine the reaction force in the Z-direction.

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Reaction Forces ver 4.08

Page 12 of 20

View showing Global Reaction Forces from analysis 'X' = -0.00158 lb, 'Y' = 0.0078 lb, 'Z' = 10467 lb Calculated Reaction Forces = Analysis Reaction Forces within 2% Model is balanced, results are valid. 1,500 P [psi] - Pressure X Axis: reaction forces on the YZ plane caused by loads in the X direction 0.000 0.0 -0.002 TReactionX [lbs] = XArea [in2] - Pressurized area on YZ plane XForce [lbs] - Added force in the X direction XReaction [lbs] - Reaction force in X direction reported by FEA program XArea*P+XForce ~~ Theoretical X reaction force 0*1500+0 = 0

Y Axis: reaction forces on the XZ plane caused by loads in the Y direction 0.000 0.0 0.008 TReactionY [lbs] = YArea [in2] - Pressurized area on XZ plane YForce [lbs] - Added force in the Y direction YReaction [lbs] - Reaction force in Y direction reported by FEA program YArea*P+YForce ~~ Theoretical Y reaction force 0*1500+0 = 0

Z Axis: reaction forces on the XY plane caused by loads in the Z direction 6.977 0.0 10467.000 TReactionZ [lbs] = ZArea [in2] - Pressurized area on XY plane ZForce [lbs] - Added force in the Z direction ZReaction [lbs] - Reaction force in Z direction reported by FEA program ZArea*P+ZForce ~~ Theoretical Z reaction force 6.977*1500+0 = 10,466

Resultant of reaction forces in X, Y and Z: TResultant [lbs] = sqrt(TReactionX^2+TReactionY^2+TReactionZ^2) ~~ Theoretical resultant SQRT(0^2+0^2+10466^2) = Resultant [lbs] = sqrt(XReaction^2+YReaction^2+ZReaction^2) ~~ Actual resultant SQRT(-0.002^2+0.008^2+10467^2) = Error [%] = 100*(TResultant-Resultant)/Resultant 100*(10466-10467)/10467 = CheckError = abs(Error)<2 ~~ Error should be less than 2% ABS(0)<2 =

10,466 10,467 0.0 Acceptable

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Displacement
Axial Elongation

Page 13 of 20

Radial Expansion

Fig-A A view of the displacement plot with superimposed original geometry. Results are magnified 500x. The ferrules elongate axially and displace radially outward. The clamps rotate about the center due to the pulling force of the ferrules.

Joint separation

Fig-B A alternate view of Fig-A. The maximum displacement is 0.0009". Note the clamp displacement in the bolt head region and joint separation begins to occur. The displacement direction is as expected and the magnitude is acceptable.

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Stress

Page 14 of 20

Fig-A A view of the stress plot (von Mises) capped at the primary general membrane allowable of 14,800 psi.

Fig-B A sectioned view of Fig-A. `A peak stress of 22,817 psi is located on the clamp face in contact with the ferrule. This stress will be used to determine the cycle life of the design.

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Stress

Page 15 of 20

Fig-A A view of the clamp only stress plot (von Mises) capped at the primary general membrane allowable of 14,800 psi.

Fig-B An "ISO Clipped" view of Fig-A capped at 14,800 psi. The only stresses in excess of 14,800 psi are in peak areas. A fatigue life will be based on the maximum peak stress.

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Stress

Page 16 of 20

Fig-A A view of the ferrule only stress plot (von Mises) capped at the primary general membrane allowable of 14,800 psi.

Fig-B An "ISO Clipped" view of Fig-A capped at 14,800 psi. Stresses in the hub region in excess of 14,800 psi will be further analyzed through a stress linearization study on the following page.

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Stress Linearization ver 2.37

Stress Classification Line

Page 17 of 20

Fig-A The stress classification line is taken through the ferrule hub. The membrane stress is 2,692 psi and the membrane plus bending stress is 13,376 psi. These stresses are within the allowable limits and are acceptable.
25,000 20,000 15,000 10,000 Stress 5,000 0 -5,000 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 von Mises with all Components
Sn St Sh Tnt Tnh Tth von Mises Pm Pm+Pb

34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

-10,000
-15,000 Distance i to j

Peak

Stress Check: General Stress Classification SA-182 F316L Material Allowed Actual Check Pm [psi] = 14,800 2,692 Acceptable Pb [psi] = 11,727 Pl+Pb [psi] = 22,200 13,376 Acceptable Peak [psi] = 17,123

4 nodes found on the stress classification line 0.1533 units long - cubic spline interpolated to 71 equally spaced nodes.

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Bolt Stress ver 4.10

Tri Clamp Bolt Description Inputs:
Preload + Operating

Page 18 of 20

Load type UNC Bolt Type 1/4 Dia [in] Nominal Bolt Size (UNC) 25,000 Sm [psi] Allowable Bolt Stress File Location 0.189 0.438 0.028 45,000 90,000 1,262 PVELookup("BoltDia","Lookup","Root Dia",Dia) ~~ Root Diameter PVELookup("BoltDia","Lookup","AF",Dia) ~~ Head Diameter (*RDia^2)/4 ~~cross sectional area (3.142*0.189^2)/4 = 2*0.9*Sm ~~ bolt preload stress 2*0.9*25000 = 45000/(SQRT(Dia)) ~~bolt preload stress per App. S 45000/(SQRT(0)) = if(Spl2<(2*Sm),Spl2*A,Spl1*A) ~~bolt preload force used for fea IF(90000<(2*25000),90000*0.028,45000*0.028) =
Bolt Stresses - All Connectors

J:\4000-4999\4400-4499\4472 PVE Tri Clamp\bolt data.csv

RDia [in] = HDia [in] = A [in^2] = Spl1 [psi] = Spl2 [psi] = PL [lb] =

80000 70000 60000 Stress (psi)

50000

Pm Pm+Pb
Pm-Pb

40000 30000 20000 10000 0

Max Conn Sm 2 x Sm 3 x Sm
1 Connector 2

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

All connectors are below the allowables Type X Y Z SF (lb) 0.00 0.00 -0.09 AF (lb) 0.00 1293.90 4.87 BM (lb-in) -1.58 0.00 0.00 Shear Stress: Maximum Stressed Connector SSx [psi] = SFx/A SSy [psi] = SFy/A SSz [psi] = SFz/A Axial Stress: Maximum Stressed Connector SAx [psi] = AFx/A SAy [psi] = AFy/A SAz [psi] = AFz/A

Resultant Connector 0.09 Shear Force 1293.90 Axial Force 1.58 Counterbore with Nut-1 Bend Moment 0/0.028 = 0 0/0.028 = 0 -0.09/0.028 = -3 0/0.028 = 0 1293.9/0.028 = 46,120 4.87/0.028 = 174

Von Mises - Average Stress Across Bolt: Maximum Stressed Connector [psi] = SQRT(((SAx-SAy)^2+(SAy-SAz)^2+(SAz-SAx)^2+6*(SSx^2+SSy^2+SSz^2))/2) SQRT(((0-46120)^2+(46120-174)^2+(174-0)^2+6*(0^2+0^2+-3^2))/2) = 46,033 Check = <= 2*Sm ~~ ASME Section VIII-2 5.7.2(a) 46033<= 2*25000 = Acceptable Bending Stress: Maximum Stressed Connector M [lb-in] = 1.58 SB [psi] = M*(RDia/2)/((*(RDia/2)^4)/4) PmPb [psi] = Max(abs(+SB),abs(-SB)) = 2 2*(0.189/2)/((3.142*(0.189/2)^4)/4) = 2,381

MAX(ABS(46033+2381),ABS(46033-2381)) = 48414 CheckPmPb = PmPb<= 3*Sm ~~ ASME Section VIII-2 5.7.2(b) 48414<= 3*25000 = Acceptable

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Cycle Life ver 5.10

Page

19 of 20

Fig-A The 22,817 psi peak stress is used to determine the cycle life. An equivalent alternating stress of 12,465 psi is calculated which results in an infinite cycle life.
Stress Ranking
2.50E+04 2.00E+04 1.50E+04 1.00E+04 5.00E+03 0.00E+00 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

Stress Differential

Rank

The above chart represents the top differential von Mises stresses. These stresses are determined according to the equations listed in ASMIE VIII-2 5.5.3.2. Stresses converging to infinity tend to lie at discontinuities and are not used for cycle life calculations.

9287 Node - first node of a consecutive set vlookup(nodeselect,stressresult,2,False) Spk [psi] = vlookup(nodeselect,stressresult,2,FALSE) = Not Linearized Stress result Table3.F.4CurveA Material coefficient table

22,817 .

Series 3xx High Alloy Steels, Ni-Cr-Fe Alloy, Ni-Fe-Cr Alloy, and Ni-Cu Alloy for temperatures not exceeding 800F Sa <= 28.2ksi, Curve A - Areas not heat, affected (Pl+Pb+Q) range <= 27.2ksi

Cycle Life ver 5.10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Page

20 of 20

Inputs: VIII-2, 5.5.3 1.00 Kf - fatigue strength reduction factor 14,800 Sa [psi] - material allowable 16,400 Sy [psi] - material yield strength 500 Tav [F] - average cycle temperature 25,900,000 Et [psi] - modulus of elasticity at Tav Alternating Equivalent Stress: VIII-2, 5.5.3.2 max(3*Sa,2*Sy) Sps [psi] = if(Spk<=Sps,1,"Linearize") Kek = if(Sn1k <= Sps, 1,"ERROR") Kek = (Kf*Kek*Spk)/2 Saltk = PVELookup("EgTable","Lookup","Eg","CL_Fig511022A") EG [psi] = Saltk*EG/Et Se [psi] = PVELookup("CL_Fig511022A","CycleLifeLookup",Se) Cycles =

MAX(3*14800,2*16400) = 44,400 1.00 1.00 (1*1*22817)/2 = 11,408 28,300,000 11408*28300000/25900000 = 12,465

100,000,000,000

Stress vs. Cycles

100,000

Stress

10,000 PVELookup("","CycleLifeLookup",Se)

1,000

1.0E+03

1.0E+10

1.0E+00

1.0E+01

1.0E+02

1.0E+04

1.0E+05

1.0E+06

1.0E+07

1.0E+08

1.0E+09

Cycles

1.0E+11