DBA Design by Analysis

Specification of Examples

Page 5.1

5
5.1

Specification of examples
General

In this section the specifications are given of ten examples, dealt with by the group. The various design checks had been assigned to the members a priori, differences discussed, and, where necessary, supplemented by additional investigations and corrected. The results are summarized in the next section, the details in the section thereafter. The specifications are complete, but to follow the examples in detail or to use them as benchmarks, it is necessary to consult standards, for instance for material properties specifications or other sections of prEN13455. As a help, physical properties of materials used in the examples are collected in an annex to this section. The geometries specified in the drawings are already those to be used in the analyses, i. e. the thicknesses given are already analysis thicknesses, allowances for tolerances and, if relevant, corrosion have already been deducted. Should the corrosion allowance be required for specifying the weld regions: A value of 1.00 mm was used for ferritic steels, and 0 for austenitic ones. The proposal for Detailed Fatigue Analysis states that in the (fatigue) analysis extreme operating values of actions rather than design values should be used. For the calculation of the allowable number of action cycles an upper value for the pressure Pop, sup equal to 90% of the maximum allowable pressure PS is specified in the examples here. In cases where the maximum allowable pressure PS can be determined by the Design by Formulae (DBF) section of the CEN TC 54 proposal of an Unfired Pressure Vessel standard, PS has not been specified here. The maximum allowable pressure according to this DBF proposal - PS max DBF - shall be used as characteristic value in the design checks for Gross Plastic Deformation (GPD), Progressive Plastic Deformation (PD) or Shakedown (SD): Pc = PS max DBF In the other cases values for PS are specified. Note: Unfortunately, because of the combination of ideas and designations from Euronorm 3 on one hand, and those from the Pressure Equipment Directive (PED) and EN 764 on the other hand, one has to distinguish between the design values of (the action) pressure obtained by multiplying the characteristic values of pressure by the relevant partial safety factors and the design pressure Pd - the maximum pressure at the top of the equipment specified by the manufacturer and used for the determination of the calculation pressures, mainly within the framework of DBF.

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Specification of Examples

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To minimize the possibility of confusing the two, the notion design pressure relevant to DBF is never used here. The specified values for PS or those determined by DBF shall be used as upper characteristic values; the design value for (the action) pressure shall not be called design pressure and especially not be denoted by Pd ! (It could be denoted by APd ). In all cases the admissibility of the design shall be checked and proven first by the simplest means possible for the example to show that quite often DBA can be quite short and simple, if only the admissibility is to be be proven. In all examples a normal hydraulic test is presupposed, i. e. the checks against GPD for testing conditions do not require separate calculations. Specified pressures and temperatures are to be considered as pairs. If other actions are specified, they are considered to form, with pressures and temperatures, triplets, etc. Should the alternative of using any primary stress field be used in the check against GPD, the principal strains corresponding to this primary stress field shall be limited by 5% - as specified in the tangent intersection procedure. In general, this requires primary stress fields obtained by (inelastic) FEM. 5.2 General notations

Where possible, the notations of the CEN proposal for the Unfired Pressure Vessel Standard, prEN 13445, are used, and shall be used: Analysis thickness: Nominal thickness minus allowances manufacturing, e , and corrosion, erosion, c : ea = en e c Maximum allowable pressure: The maximum pressure (on top of the vessel) specified (by the manufacturer) for design, for normal operating conditions: PS . This pressure PS constitutes an upper limit for the set-pressure of the safety valve if there is only one -, or for the maximum pressure (at the top of the compartment) that can occur under reasonably foreseeable conditions if no safety valve is required. It shall be used in the design checks against GPD and PD, or SD. Maximum operating pressure: Pop, sup This value specified directly, or as being equal to 90% of PS max DBF - shall be used as upper value (of full pressure cycles) for cases with cyclic pressure. Maximum allowable pressure according to prEN 13445-3, Annex 5.B: PS max DBF Maximum allowable pressure according to DBA: PS max DBA For GPD and PD/SD checks, and, if relevant, for checks against instabilty (I), only. Characteristic value of moment: Maximum reasonably foreseeable value of external moment; (in general equal to the "usual" design moment): M c Allowable number of cycles: Number of cycles (for specified actions) allowed by prEN 13445-3, Section Detailed Fatigue Analysis.

DBA Design by Analysis Modulus of elasticity: E E at 100C, say: E100

Specification of Examples

Page 5.3

Mean coefficient of (linear) thermal expansion: between 20C and 100C, say: 20, 100

Weld symbols according to EN 22553. 5.3 Designations Design by Analysis Design by Formulae Gross Plastic Deformation Progressive Plastic Deformation Shakedown Instability Fatigue Non-Linear Geometry Maximum alloxable pressure Maximum allowable pressure according to prEN 13445-3 Section DBF Maximum allowable pressure according to Gross Plastic Deformation using DBA Maximum allowable pressure according to Progressive Plastic Deformation using DBA Maximum operating pressure. Design value for the pressure action Applied pressure to elastic compensation analysis Characteristic value of moment Calculation temperature Modulus of elasticity Mean coefficient of (linear) thermal expansion Heat conduction coefficient Heat transfer coefficient Thermal diffusivity (temperature conductivity) Stress..... ij , i , e , e, max , nom Strain..... ij , e

DBA. DBF GPD PD SD I F NLG PS PSmaxDBF PSmaxGPD PSmaxSD: Pop, sup APd Pap Mc Tc E h a

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Specification of Examples

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5.4

Specifications of examples

Example No. 1.1: Thick unwelded flat end 1. Material: P280GH according to EN 10222-2 The relevant heat treatment dimension is specified as 101.6 mm (in deviation from EN 10222-1). Pressure PS = PS max DBF = 17 MPa x) Temperature Tc = 20C 3. Operational cycles: 4. Geometry: T = const , p varying from 0 to Pop ,sup = 0.9 PS See Fig. 5.1

2. Actions:

Fig. 5.1

x)

A not very reasonable result: The end thickness is large and the ratio of admissible pressure to nominal design stress is outside the graphs and the scope of DBF. Extrapolation was necessary.

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Specification of Examples

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Example No. 1.2: Thin unwelded flat end 1. Material: P280GH according to EN 10222-2 The relevant heat treatment thickness is specified as 101.6 mm (in deviation from EN 10222-2). Pressure PS = PS max DBF = 4.2 MPa Temperature Tc = 20C T = const , p varying from 0 to Pop ,sup = 0.9 PS See Fig. 5.2

2. Actions:

3. Operational cycles: 4. Geometry:

Fig. 5.2

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Specification of Examples

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Example No. 1.3: Welded-in flat end without nozzle 1. Material: P265GH according to EN 10028-2 Pressure PS = PS max DBF = 12.7 MPa Temperature Tc = 20C T = const , p varying from 0 to Pop ,sup = 0.9 PS See Fig. 5.3 and 5.4

2. Actions:

3. Operational cycles: 4. Geometry:

Fig. 5.3

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Specification of Examples

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Fig. 5.4

Example No. 1.4: Welded-in flat end with nozzle 1. Material: Plate and Shell: P265GH according to EN 10028-2 Nozzle: P265 according to prEN 10216-2 Pressure PS = PS max DBF = 7.9 MPa Temperature Tc = 20C T = const , p varying from 0 to Pop ,sup = 0.9 PS

2. Actions:

3. Operational cycles:

4. Geometry:

See Fig.5.5, 5.6 and 5.7

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Specification of Examples

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Fig. 5.5

Fig.5.6

Fig. 5.7

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Specification of Examples

Page 5.9

Example No. 2: Storage tank (cone-cylinder junctions) 1. Material: Shell: X6CrNiTi 18-10 (1.4541) according to prEN 10028-7 Reinforcing ring, foot ring: P235GH according to EN 10028-2; Note: the different thermal expansion coefficients shall be considered.

2. Actions:

Hydrostatic pressure pH , medium density M = 1000 kg m3 minimum medium level hMIN and maximum medium level hMAX see Fig. 5.8. Note: no longitudinal stress in the main cylindrical shell caused by hydrostatic pressure. Temperature in service Tc = 60C ; Temperature before complete filling of the vessel 20C. Internal pressure during draining (see also Fig. 5.9) PS = 0.06 MPa ; Note: longitudinal stress in the main cylindrical shell caused by internal pressure acting on the upper end of the vessel. Dead load (self weight and insulation): Insulation: qd = 220 N m 2 (weight force / surface of the vessel), insulation thickness 200 mm; dead weight of roof including insulation and reinforcing ring 26,15 kN. Wind load (limit value): stagnation pressure qW depending on qW = 0.81 kN / m 2 height h: 0 m h 6 m: 6 m < h 10 m : 10 m < h 15 m : 15 m < h 25 m : Wind force: Wi = c qW ,i Ai qW = 0.88 kN / m 2 qW = 0.94 kN / m 2 qW = 1.02 kN / m 2

where c = 0.44 and Ai = projection of the surface of the vessel in wind direction. 3. Detail to be investigated: wide and narrow ends of cone 4. Operational cycles: See Figure 5.9. Note: It is ascertained that internal pressure can be increased only if the medium height is below hMIN. The internal pressure increases slowly; for safety reasons both extremes shall be considered, the very slow (dotted line) and very fast (full line) pressure increases. See Fig.5.8.

5. Geometry:

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Specification of Examples

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Fig. 5.8

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Specification of Examples

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Fig. 5.9

Example No. 3.1: Thin-walled cylinder-cylinder intersection 1. Material: 2. Actions: P295GH according to EN 10028-2 Pressure PS = PS max DBF = 0.28 MPa Nozzle longitudinal moment M c = 15644.4 Nm (moment vector normal to plane through both cylinder axes). Temperature Tc = 50C 3. Operational cycles: A) T = const , p varying from 0 to Pop, sup = 0.9 PS , M c = const and B) T = const , M varying from 0 to 26400 Nm, p = const = 1.28MPa (for comparison with experimental results). Crotch corner surface machined: R z = 50 m

DBA Design by Analysis 4. Geometry: See Fig.5.10.

Specification of Examples

Page 5.12

Note: Checks against GPD and PD, or SD, to be performed for constant longitudinal moment only.

Fig. 5.10

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Specification of Examples

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Example No. 3.2: Thick-walled cylinder-cylinder intersection 1. Material: 2. Actions: Shell: P265GH according to EN 10028-2 Nozzle: 11CrMo9-10 according to prEN 10216-2 Pressure PS = PS max DBF = 14.09 MPa Nozzle longitudinal moment M c = 711.1 Nm (moment vector normal to plane through both cylinder axes). Temperature Tc = 50C 3. Operational cycles: A) T = const , p varying from 0 to Pop, sup = 0.9 PS , M c = const and B) T = const , M varying from 0 to1200 Nm, p = const = 24MPa (for comparison with experimental results). Crotch corner surface machined: R z = 50 m 4. Geometry: See Fig 5.11.

Note: See note in Example No. 3.1.

Fig. 5.11

Fig. 5.11

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Specification of Examples

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Example No. 4: Dished end with nozzle in knuckle region 1. Material: 2. Actions: X6CrNiMoTi 17-12-2 (1.4571) according to prEN 10028-7 Pressure PS = PS max DBF = 0.583 MPa Temperature Tc = 180C 3. Operational cycles: 4. Geometry: T = const , p varying from 0 to Pop,sup = 0.9 PS See Fig. 5.12 and 5.13.

Fig. 5.12

Fig. 5.13

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Specification of Examples

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Example No. 5: Nozzle in spherical end with cold medium injection 1. Material: Shell: 11CrMo9-10 according to EN 10028-2 Nozzle reinforcement: 11CrMo9-10+QT according to prEN 10216-2 Nozzle: P265 according to prEN 10216-2 Pressure PS = 0.9 PS max DBF = 0.9 13.01 = 11.71 MPa Temperature of medium inside the vessel TS = 325C (constant in operation). Temperature of injected cold medium TN = 80C . Location of different heat transfer coefficient for cold medium injection see Fig. 5.15. The outer surface of the vessel is insulated ideally. Heat transfer coefficients: -) medium to vessel wall, and to nozzle if there is no injection: hS = 1.16 kW m 2 K -) cold (injection) medium to nozzle wall during injection: hN = 10.8 kW m 2 K . 3. Operational cycles: See Fig. E 5.15. Cold medium injection takes place for 10 minutes. The time between the injection cycles is long enough such that temperature reaches , stationarity. After 500 injection cycles one shutdown (and startup) should be considered. At shutdown and startup, pressure and temperature are decreased or increased in phase, respectively. Temperature changes during shutdown and startup are slow, and therefore thermal stresses can be neglected. 4. Geometry: See Fig. 5.14

2. Actions:

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Specification of Examples

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Fig. 5.14

Fig. 5.15

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Specification of Examples

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Example No. 6: Jacketed vessel with jacket on cylindrical shell only, and flat annular end plates 1. Material: 2. Actions: X6CrNiTi 18-10 (1.4541) according to prEN 10028-7 Inner space: Outer space: 3. Operational cycles: See Fig. 5.18. Inner space: Outer space: Pressure PS = 0.1 / + 1.3 MPa Temperature Tc = TS = 160C Pressure PS = 0 / + 0.5 MPa Temperature Tc = TS = 160C

Pop ,sup = 1.1 MPa Top,sup = TS Pop ,sup = 0.45 MPa Top,sup = TS

Pop ,inf = 0 MPa Top ,inf = 20C . Pop ,inf = 0 MPa Top,inf = 10C

A pressure in the inner space below atmospheric can occur independently and repeatedly in operation, and an underpressure will occur concurrently with an outer space temperature of 10C (whereby an inner space temperature value of 160C shall be used). This case shall be included as a normal operating condition in the check against GPD, I, PD, or SD, but not in the fatigue check. A pressure in the outer space below atmospheric cannot occur, but a minimum pressure of 0 bar cannot be excluded. This case shall also be included as a normal operating condition in the check against GPD, I, PD, or SD (with temperatures in the inner and outer space of 160C). Note: Top ,sup and Top ,inf are medium temperatures. The wall temperatures shall be determined using heat transfer coefficients of h i = 1.16 kW m 2 K on inside of inner vessel wall and

h o = 14.4 kW m 2 K on all surfaces of the inside of the jacket. Jacket and main vessel outside of jacket are insulated ideally.
Note: checks against GPD, I, PD or SD shall be performed usingthe PS values. Note: only steady state thermal stresses shall be considered. The maximum allowable out-of-roundness of the inner cylindrical shell is specified in prEN13445-3 as (D+1250) / 200 = (2780 + 1250) / 200 = 20,15 mm, where D is the mean shell diameter. 4. Details to be investigated: 5. Geometry: Jacket and jacketed part of inner vessel See Fig. 5.16 and 5.17.

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Specification of Examples

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Fig. 5.16

Fig. 5.17

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160C

160C

Fig. 5.18

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Specification of Examples

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5.5 Appendix: Physical properties of some materials P 235 GH

P 265 GH

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Specification of Examples

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P 295 GH

11CrMo9-10

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Specification of Examples

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1.4541

1.4571