Final Compilition

DESIGN AND ANALYSIS OF
PRESSURE VESSEL
BY JIMIT PATEL
GUIDED BY : DR. ZHENG LI
University of Bridgeport Page 1
ACKNOWLEDGEMENT

Certainly, help and encouragement from others are always
appreciated, but in diferent times, such magnanimity is valued even
more. This said, this Dissertation would never have been completed
without the generous help and support that I received from numerous
people along the way.
I wish to express my deepest thans and gratitude to my elite guide
!heng "#eremy$ %i, &echanical 'ngineering Dept., (niversity of
)ridgeport, Connecticut, for his invaluable guidance and advice,
without that the Dissertation would not have appear in present shape.
*e also motivated me at every moment during entire dissertation.
I also hearty thanful and express deep sense of gratitude to senior
manager at +&& P,auder, for provide me very useful information.
-pecial thans to Mr. Ankit Prajapati, Design 'ngineer, at +&&
P,auder, for his een interest and guidance in carrying out the wor.
#imit Patel.

ABSTRACT
The significance of the title of the project comes to front with designing structure of the
pressure vessel for static loading and its assessment by Ansys , is basically a project
concerned with design of different pressure vessel elements such as shell, ish end
,operating manhole ,support leg based on standards and codes ! and evolution of shell and
dish end analy"ed by means of ansys #The $ey feature included in the project is to chec$
the behavior of pressure vessel in case of fluctuating load #The %procedural step includes
various aspects such as selecting the material based on AS&' codes ,and then designing
on the standards procedures with referring standard manuals based on AS&' #(urther we
have included the different manufacturing methods practice by the industries and
different aspects of it # And step by step approaches to the )T method practice by the
industries followed with standards and also included within the report wor$# This will be
ma$ing a clear picture of this method among the reader #
conclusively, this modus operandi of design based on technical standard and
codes #, can be employed on practical design of pressure vessel as per re*uired by the
industry or the problem statement given associated to the field of pressure vessel#
INTRODUTION:
The pressure vessels +i#e# cylinder or tan$s, are used to store fluids under pressure# The
fluid being stored may undergo a change of state inside the pressure vessel as in case of
steam boilers or it may combine with other reagents as in a chemical plant# The pressure
vessels are designed with great care because rupture of pressure vessels means an e-plosion
which may cause loss of life and property# The material of pressure vessels may be brittle
such that cast iron or ductile such as mild steel#
Cylindrical or spherical pressure vessels +e#g#, hydraulic cylinders, gun barrels, pipes,
boilers and tan$s, are commonly used in industry to carry both li*uids and gases under
pressure# .hen the pressure vessel is e-posed to this pressure, the material comprising the
vessel is subjected to pressure loading, and hence stresses, from all directions# The normal
stresses resulting from this pressure are functions of the radius of the element under
consideration, the shape of the pressure vessel +i#e#, open ended cylinder, closed end cylinder,
or sphere, as well as the applied pressure#
Two types of analysis are commonly applied to pressure vessels# The most
common method is based on a simple mechanics approach and is applicable to /thin wall0
pressure vessels which by definition have a ratio of inner radius, r, to wall thic$ness, t, of
r1t234# The second method is based on elasticity solution and is always applicable regardless
of the r1t ratio and can be referred to as the solution for /thic$ wall0 pressure vessels# Both
types of analysis are discussed here, although for most engineering applications, the thin wall
pressure vessel can be used#

Classification of 5ressure 6essels
7nfired Cylindrical 5ressure 6essels
+Classification Based on 8S 9:9;<3=>=,

a, Class 3 ?
6essels that are to contain lethal or to-ic substances#
6essels designed for the operation below <94 C and
6essels intended for any other operation not stipulated in the code#
b, Class 9?
vessels which do not fall in the scope of clas3 and class @ are to be termed as
class9 vessels# The ma-imum thic$ness of shell is limited to @: mm#
c, class @?
there are vessels for relatively light duties having plate thic$ness not in e-cess of
3> mm,
and they are built for wor$ing pressures at temperatures not e-ceeding 9;4 c and
unfired #
class@ vessels are not recommended for services at temperatutre below 4c#
Categories Af .elded Boints
The term categories specifies the location of the joint in a vessels, but not the
type of joint# These categories are intended for specifying the special re*uirements
regarding the joint type and degree of inspection# 8S<9:9; specifies C categories of welds#
+Refer fig#,
a, category A? longitudinal welded joints within the main sheet, communicating
chambers ,no""les and any welded joints within a formed or flat head#
b, Category B? circumferential welded joints with in the main shell, communicating
chambers, no""les and transitions in diameter including joints between the
transtations and a cylinder at either the large of small end, circumferential welded
joints connecting from heads to main shells to no""les and to communicating
chambers#
c, Category c? welded joints connecting flanges, tubes sheets and flat heads to main
shells , to formed heads , to no""les or to communicating chambers and any
welded joints connecting one side plate to another side plate of a flat sided vessel#
d, Category d? welded joints connecting communicating chambers or no""les to
main sheels ,to heads and to flat sided vessels and those joints connecting no""les
to communicating chambers#
STRESS
Types of Stresses
Tensile
Compressie S!e"r
#en$in% #e"rin%
A&i"l Dis'ontin(ity
)em*r"ne Tensile
Prin'ip"l T!erm"l
T"n%enti"l Lo"$ in$('e$
Str"in in$('e$ Cir'(mferenti"l
Lon%it($in"l R"$i"l
Norm"l
Classes of stress
5rimary Stress
Deneral?
5rimary general membrane stress 5m
5rimary general bending stress 5b
5rimary local stress, 5E
Secondary stress?
Secondary membrane stress# Fm
Secondary bending stress Fb
5ea$ stress# (
Definition "n$ E&"mples
PRI)ARY GENERAL STRESS:
These stress act over a full cross section of the vessel# 5rimary stress are
generally due to internal or e-ternal pressure or produced by sustained e-ternal
forces and moments# 5rimary general stress are divided into membrane and
bending stresses# Calculated value of a primary bending stress may be allowed to
go higher than that of a primary membrane stress#
Prim"ry %ener"l mem*r"ne stress+ Pm
Circumferential and longitudinal stress due to pressure#
Compressive and tensile a-ial stresses due to wind#
Eongitudinal stress due to the bending of the hori"ontal vessel over the saddles#
&embrane stress in the centre of the flat head#
&embrane stress in the no""le wall within the area of reinforcement due to
pressure or e-ternal loads#
A-ial compression due to weight#
5rimary general bending stress, 5b
Bending stress in the centre of a flat head or crown of a dished head#
Bending stress in a shallow conical head#
Bending stress in the ligaments of closely spaced openings#
EACAE 5R8&ARG &'&BRA)' ST'SS, 5E
5mH membrane stress at local discontinuities?
Iead<shell juncture
Cone<cylinder juncture
)o""le<shell juncture
Shell<flange juncture
Iead<s$irt juncture
Shell<stiffening ring juncture
5mH membrane stresses from local sustained loads?
Support legs
)o""le loads
Beam supports
&ajor attachments
S'CA)ARG STR'SS
Secondary membrane stress Fm
A-ial stress at the juncture of a flange and the hub of the flange
Thermal stresses#
&embrane stress in the $nuc$le area of the head#
&embrane stress due to local relenting loads#
Secondary bending stress, Fb
Bending stress at the gross structural discontinuity? no""le, lugs, etc#, +relenting
loadings only,#
The nonuniform portion of the stress distribution in a thic$<walled vessels due to
internal pressure#
The stress variation of the radial stress due to internal pressure in thic$<walled
vessels#
iscontinuity stresses at stiffening or support ring#
5ea$ Stress (
Stress at the corner of discontinuity#
Thermal stress in a wall caused by a sudden change in the surface temperature#
Thermal stresses in cladding or weld overlay#
Stress due to notch effect# +stress concentration,#
EAA8)DS
Eoadings or forces are the /causes0 of stress in pressure vessels# Eoadings may be
applied over a large portion +general area, of the vessel or over a local area of the
vessel# Deneral and local loads can produce membrane and bending stresses#
These stresses are additive and define the overall state of stress in the vessel or
component#
The stresses applied more or less continuously and uniformly across an entire
section of the vessel are primary stresses#
The stresses due to pressure and wind are primary membrane stresses#
A the other hand, the stresses from the inward radial load could be either a
primary local stress or secondary stress# 8t is primary local stress if it is produced
from an unrelenting load or a secondary stress if produced by a relenting load#
8f it is a primary stress, the stress will be redistributed! if it is a secondary stress,
the load will rela- once slight deformation occurs#
Basically each combination of stresses + stress categories will have different
allowables, i#e#,
5rimary stress? 5m J S'
5rimary membrane local +5E,?
5EK5mH 5E J3#; S'
5EK5mHFmJ 3#;S'
5rimary membrane H secondary +F,?
5mHFJ @S'
Eoading can be outlined as follows?
Categories of loadings
Deneral loadsLApplied more or less continuously across a vessel section#
5ressure loadsL8nternal or e-ternal pressure +design, operating,
hydrotest, and hydrostatic head of li*uid,#
&oment loadsLue to wind, seismic, erection, transportation#
Compressive1tensile loadsLue to dead weight, installed
e*uipment, ladders, platforms, piping and vessel contents#
Thermal loadsLIot bo- design of s$irt<head attachment#
Eocal loadsLue to reactions from supports, internal, attached
5iping, attached e*uipment, i#e#, platforms, mi-ers, etc#
a# Radial loadL8nward or Autward#
b# Shear loadLEongitudinal or circumferential#
c# Torsional load#
d# Tangential load#
e# &oment loadLEongitudinal or circumferential#
f# Thermal load#
Types of Eoadings
3, Steady loadsLEong<term duration, continuous#
a# 8nternal1e-ternal
pressure#
b# ead weight#
c# 6essel contents#
d# Eoading due to attached
piping and e*uipment#
e# Eoadings to and from vessel
supports#
f# Thermal loads#
g# .ind Eoads
Types of Eoadings
3, )on<steady loads< Short<term duration, 6ariable#
Shop and field hydro<test
'arth*ua$e
'rection
Transportation
7pset, emergency
Thermal Eoads
Startup, shut down
(A8E7R' 8) 5R'SS7R' 6'SS'ES
Categories of (ailures?
&aterial<<8mproper Selection of materials! defects in material#
esignL8ncorrect design data! inaccurate or incorrect design methods!
inade*uate shop testing#
(abrication M 5oor *uality control! improper or insufficient fabrication procedures
including welding! heat treatment or forming methods#
ServiceLChange of service condition by the user! ine-perienced operations or
maintenance personnel! upset conditions# Some types of services which re*uires
special attention both for selection of materials, design details, and fabrication
methods are as follows?
Eethal
(atigue +cyclic,
Brittle +low temperature,
Iigh Temperature
Iigh shoc$ or vibration
6essel contents
Iydrogen
Ammonia
Compressed air
Caustic
Chlorides
TG5'S A( (A8E7R'S
'lastic deformationL'lastic instability or elastic buc$ling, vessel geometry, and
stiffness as well as properties of materials are protecting against buc$ling#
Brittle fractureLCan occur at low or intermediate temperature# Brittle fractures
have occurred in vessels made of low carbon steel in the C4<;4 ( range during
hydrotest where minor flaws e-ist#
'-cessive plastic deformationLThe primary and secondary stress limits as
outlined in AS&' Section 6888, ivision 9, are intended to prevent e-cessive
plastic deformation and incremental collapse#
Stress ruptureLCreep deformation as a result of fatigue or cyclic loading, i#e#,
progressive fracture# Creep is a time<dependent phenomenon, whereas fatigue is a
cyclic<dependent phenomenon
o TG5'S A( (A8E7R'S
o 5lastic instabilityL8ncremental collapse! incremental collapse is cyclic strain
accumulation or cumulative cyclic deformation# Cumulative damage leads to
instability of vessel by plastic deformation#
o Iigh StrainLEow cyclic fatigue is strain<governed and occurs mainly in lower<
strength1high<ductile materials#
o Stress corrosionL8t is well $now that chlorides cause stress corrosion crac$ing in
stainless steels! li$ewise caustic service can cause stress corrosion crac$ing in
carbon steel# &aterials selection is critical in these services#
o Corrosion fatigueLAccurs when corrosive and fatigue effects occur
simultaneously# Corrosion can reduce fatigue life by pitting the surface and
propagating crac$s# &aterial selection and fatigue properties are the major
considerations#
S5'C8AE 5RABE'&S
Thic$ .alled 5ressure 6essels
&ono<bloc< Solid vessel wall#
&ultilayerLBegins with a core about N in# thic$ and successive layers are
applied# 'ach layer is vented +e-cept the core, and welded individually with no
overlapping welds#
&ulti<wallLBegins with a core about N in# to 9 in# thic$# Auter layers about the
same thic$ness are successive / shrun$ fit0 over the core# This creates
compressive stress in the core, which is rela-ed during pressuri"ation# The process
of compressing layers is called auto<frettage from the (rench word meaning /self<
hooping#0
&ultilayer auto<frettageLBegins with a core about N in# thic$# Bands or forged
rings are slipped outside and then the core is e-panded hydraulically# The core is
stressed into plastic range but below ultimate strength# The outer rings are
maintained at a margin below yield strength# The elastic deformation residual in
the outer bands induces compressive stress in the core, which is rela-ed during
pressuri"ation#
.ire wrapped vessels? Begin with inner core of thic$ness less than re*uired for
pressure# Core is wrapped with steel cables in tension until the desired auto<
frettage is achieved#
Coil wrapped vessels? Begin with a core that is subse*uently wrapped or coiled
with a thin steel sheet until the desired thic$ness is obtained# Anly two
longitudinal welds are used, one attaching the sheet to the core and the final
closures weld# 6essels ; to > ft in diameter for pressure up to ;444psi have been
made in this manner#
TI'R&AE STR'SS
.henever the e-pansion or contraction that would occur normally as a result of
heating or cooling an object is prevented, thermal stresses are developed# The
stress is always caused by some form of mechanical restrain#
Thermal stresses are /secondary stresses0 because they are self<limiting# Thermal
stresses will not cause failure by rupture# They can however, cause failure due to
e-cessive deformations#
8SCA)T8)78TG STR'SS'S
6essel sections of different thic$ness, material, diameter and change in directions
would all have different displacements if allowed to e-pand freely# Iowever, since they
are connected in a continuous structure, they must deflect and rotate together# The
stresses in the respective parts at or near the juncture are called discontinuity stresses#
iscontinuity stresses are / secondary stresses0 and are self<limiting#
iscontinuity stresses do become an important factor in fatigue design where
cyclic loading is a consideration#
(AT8D7' A)AEGS8S
.hen a vessel is subject to repeated loading that could cause failure by the
development of a progressive fracture, the vessel is in cyclic service#
(atigue analysis can also be a result of thermal vibrations as well as other
loadings#
8n fatigue service the locali"ed stresses at abrupt changes in section, such as at a
head junction or no""le opening, misalignment, defects in construction, and
thermal gradients are the significant stresses#
)AOOE' R'8)(ARC'&')T
(ig ? no""le reinforcement
Eimits#
a# )o reinforcement other than that inherent in the construction is re*uired for
no""les#
@<in# pipe si"e and smaller in vessel walls @1: in# and less#
9<in# pipe si"e and smaller in vessel walls greater than @1: in#
b# )ormal reinforcement methods apply to
6essels >4<in# diameter and less<319 the vessel diameter but not to e-ceed 94 in#
6essels greater than >4<in# diameter<31@ the vessel
diameter but not to e-ceed C4#in
a# 3b, reinforcement shall be in accordance with para# 3<P of AS&' Code#
9# Strength
8t is advisable but not mandatory for reinforcing pad material to be the same as the
vessel material#
a# 8f a higher strength material is used, either in the pad or in the no""le nec$, no
additional credit may be ta$en for the higher strength#
@# Thic$ness
8t is recommended that pad be not less then P;Q nor more than 3;4Q of the part to
which they are attached#
C# .idth
.hile no minimum is stated, it is recommended that re<pads be atleast 9in wide#
;# (orming?
Reinforcing pads should be formed as closely to the contour of the vessel as
possible# .hile normally put on the outside of the vessel, re<pads can also be put
inside providing they do not interfere with the vesselRs operation#
:# Apenings in flat heads?
Reinforcements for the openings in the flats heads and blind flanges shall be as
follows
a# Apenings J N head diameter< area to be replaced e*uals 4#;+tr,, or thic$ness of
head or flange may be increased by?
oubling C value
7sing CK4#P;
8ncreasing head thic$ness by 3#C3C
b# ApeningsS319 head diameter Mshall be designed as a bolted flange connection#
=# Apenings in torispherical heads#
.hen a no""le openings and all its reinforcement fall within the dished portion,
the re*uired thic$ness of head for reinforcement purpose shall be computed using
&K3
34# Apenings in elliptical heads
.hen a no""le openings and all its reinforcement fall within 4#: of an elliptical
head, the re*uired thic$ness of the head for reinforcement purpose shall be e*ual to the
thic$ness re*uired for a seamless sphere of radius T+,#
33# Deneral
Reinforcement should be calculated in the corroded condition assuming ma-imum
tolerance +minimum t,
39# Apenings through seams#
a# Apenings that have been reinforcement may located in a welded joint# AS&'
code, division 3, does not allow a welded joint to have two different weld joint
efficiencies
3@# Re<pads over seams
8f at all possible, pads should not cover weld seams# .hen unavoidable, the seam
should be ground flush before attaching the pad#
3C# Apenings near seams
Small no""les + for which the code does not re*uire, the reinforcement to be chec$ed,
shall not be located closer than N in# to the edge of a main seam#
3;# '-ternal pressures#
Reinforcement re*uired for openings subject to e-ternal pressure only or when
longitudinal compression governs shall only be ;4 Q of that re*uired for internal pressure
and tr, is thic$ness re*uired for e-ternal pressure
3># Eigaments
.hen there is a series of closely spaced openings in a vessel shell and it is
impractical to reinforce each opening, the construction is acceptable, provided the
efficiency of the ligaments between the holes is acceptable#
3P# &ultiple openings?
a# (or two openings closer than 9 times the average diameters and where limits of
reinforcement overlap, the area between the openings shall meet the following
3# &ust have a combined area e*ual to the sum of the two areas
9# )o portion of the cross<section shall apply to more than one openings#
@# Any overlap area shall be proportional between the two openings by the ratio of
the diameters#
b# .hen more than two openings are to be provided with combined reinforcement?
3P b# .hen more than two openings are to be provided with combined reinforcement?
3# The minimum distance between the two centers is 3 31@ the average diameters#
9# The area of reinforcement between the two no""le shall be atleast ;4Q of the area
re*uired for the two openings#
c# &ultiple openings may be reinforced s an opening e*ual in diameter to that of a
circle circumscribing the multiple openings#
3:# 5lane of reinforcement#
A correction factor f may be used for / integrally reinforced0 no""le to compensate
for differences in stress from longitudinal to circumferential a-is of the vessel# 6alue of f
vary from 3#4 for the longitudinal a-is to 4#; for circumferential#
CIA5T'R 9
ENGINEERING GUIDELINES FOR
DESIGN OF PRESSURE VESSELS

En%ineerin% Desi%n G(i$elines For Press(re Vessels
,-. SCOPE
This specification covers the design basis for following e*uipment?
< 6essels
< Columns
< Reactors
< Spheres
< Storage Tan$s
< Steel silos, Bins# Ioppers
< Steel (lare Stac$s
/-. CODES AND STANDARDS
The following codes and standards shall be followed unless otherwise specified?
AS&' S'C# 6888 86#3 1 (or 5ressure vessels
8S? 9:9;

AS&' S'C# 6888 86#9 (or 5ressure vessels +Selectively for high
pressure 1 high thic$ness 1 critical service,
AS&' S'C# 6888 86#9 (or Storage Spheres
AS&' S'C# 6888 86#@ (or 5ressure vessels +Selectively for high pressure,
A58 >;4 1 8S? :4@ (or Storage Tan$s#
A58 >94 (or Eow 5ressure Storage Tan$s,
A58 >94 1 BS PPPP Cryogenic Storage Tan$s +ouble .all,
AS&' S'C# 688886#3 (or wor$manship of 6essels not categori"ed under
any other code#
8SA R:@31 8BR (or Steam producing, steam storage catch water
vessels, condensate flash drums and similar vessels
8S? =3P: 1 8) 34;; (or Silos Ioppers and Bins
BS? C==C 1 AS&' S'C U (R5 vessels 1 tan$s#V
AS&'? B =>#3 .elded Aluminium Alloy Storage Tan$s#
AS&' S'C#88 (or material specification
AST& 1 8S (or material specification +Tan$s,
8S? :P; 1 S8T' ATA (or wind load consideration
8S? 3:=@ 1 S8T' ATA (or seismic design consideration
AS&' S'C# 8U (or welding#
.RC B7EE'T8)W
34P, 9=P 1 5 ;;44 (or Eocal load 1 stress analysis
0-. DESIGN CRITERIA
'*uipment shall be designed in compliance with the latest design code re*uirements, and
applicable standards1 Specifications#
1-. )INI)U) S2ELL32EAD T2IC4NESS
&inimum thic$ness shall be as given below
"5 (or carbon and low alloy steel vessels< >mm +8ncluding corrosion allowance not
e-ceeding @#4mm,, but not less than that calculated as per following?
(AR 8A&'T'RS E'SS TIA) 9C44mm
6"ll t!i'7ness 8 Di"3,... 9,-: 9 Corrosion Allo;"n'e
(AR 8A&'T'RS 9C44mm A) ABA6'
.all thic$ness K ia13444 H9#; H Corrosion Allowance
All dimension are in mm#
*5 (or stainless steel vessel and high alloy vessels <@ mm, but not less than that
calculated as per following for diameter more than 3;44mm#
.all thic$ness +mm, K ia13444 H 9#;
Corrosion Allowance, if any shall be added to minimum thic$ness#
'5 Tangent to Tangent height +I, to iameter +, ratio +I1, greater than ; shall be
considered as column and designed accordingly#
$5 (or carbon and low alloy steel columns 1 towers <:mm +including corrosion allowance
not e-ceeding @#4mm#
e5 (or stainless steel and high alloy columns 1 towers <;mm#
Corrosion allowance, if any, shall be added to minimum thic$ness#
:-. GENERAL CONSIDERATIONS
:-, Vessel si<in%
All Columns Based on inside diameter
All Clad1Eined 6essels Based on inside diameter
6essels +Thic$nessS;4mm, Based on inside diameter
All Ather 6essels Based on outside diameter
Tan$s X Spheres Based on inside diameter
:-/ Vessel En$ Clos(res :
< 7nless otherwise specified eep Torispherical ished 'nd or 9?3 'llipsoidal ished
'nd as per 8S < C4C= shall be used for pressure vessels# Seamless dished end shall be used
for specific services whenever specified by process licensor#
< Iemispherical 'nds shall be considered when the thic$ness of shell e-ceeds P4mm#
< (lat Covers may be used for atmospheric vessels
< 5ipe Caps may be used for vessels diameter J >44mm having no internals#
< (langed Covers shall be used for 6essels 1Columns of iameter J =44mm having
internals#
< All columns below =44mm shall be provided with intermediate body flanges# )umbers
of 8ntermediate flanges shall be decided based on column height and type of internals
:-0 Press(re
5ressure for each vessel shall be specified in the following manner?
:-0-, Oper"tin% Press(re
&a-imum pressure li$ely to occur any time during the lifetime of the vessel
:-0-/ Desi%n Press(re
"5 .hen operating pressure is up to P4 Tg#1cm9 g , esign pressure shall be e*ual to
operating pressure plus 34Q + minimum 3Tg#1cm9 g ,#
*5 .hen operating pressure is over P4 Tg#1cm9 g , esign pressure shall be e*ual to
operating pressure plus ;Q + minimum P Tg#1cm9g,#
'5 esign pressure calculated above shall be at the top of vertical vessel or at the highest
point of hori"ontal vessel#
$5 The design pressure at any lower point is to be determined by adding the ma-imum
operating li*uid head and any pressure gradient within the vessel#
e5 6essels operating under vacuum 1 partial vacuum shall be designed for an e-ternal
pressure of 3#4;; Tg#1cm9 g#
f5 6essels shall be designed for steam out conditions if specified on process data sheet#
:-0-0 Test Press(re
"5 5ressure 6essels shall be hydrostatically tested in the fabricators shop to 3#; 13#@1 3#9;
+depending on design code, times the design pressure corrected for temperature#
*5 8n addition, all vertical vessels 1 columns shall be designed so as to permit site testing
of the vessel at a pressure of 3#;1 3#@ 1 3#9; +depending on design code, times the design
pressure measured at the top with the vessel in the vertical position and completely filled
with water# The design shall be based on fully corroded condition#
'5 6essels open to atmosphere shall be tested by filling with water to the top#
$5 ,- 5ressure Chambers of combination units that have been designed to operate
independently shall be hydrostatically tested to code test pressure as separate vessels i#e#
each chamber shall be tested without pressure in the adjacent chamber#
/- .hen pressure chambers of combination units have their common elements
designed for ma-imum differential pressure the common elements shall be subjected to
3#;1 3#@ times the differential pressure#
0- Coils shall be tested separately to code test pressure#
e5 7nless otherwise specified in applicable design code allowable stress during hydro test
in tension shall not e-ceed =4Q of yield point#
f5 Storage tan$s shall be tested as per applicable code and specifications#
:-1 Temper"t(re
Temperature for each vessel shall be specified in the following manner?
:-1-, Oper"tin% Temper"t(re
&a-imum 1 minimum temperature li$ely to occur any during the lifetime of vessel#
:-1-/ Desi%n temper"t(re
"5 (or vessels operating at
4
C and over?
esign temperature shall be e*ual to ma-imum operating temperature plus 3;
4
C#
*5 (or 6essels operating below
4
C?
esign temperature shall be e*ual to lowest operating temperature#
'5 &inimum esign &etal Temperature +&&T, shall be lower of minimum
atmospheric temperature and minimum operating temperature#
:-: Corrosion "llo;"n'e :
7nless otherwise specified by 5rocess Eicensor, minimum corrosion allowance shall be
considered as follows ?
< Carbon Steel, low alloy steel column, 6essels, Spheres ? 3#; mm
< Clad 1 Eined vessel? )il
< Storage Tan$, shell and bottom ? 3#; mm
< Storage tan$, (i-ed roof 1 (loating Roof ? )il
(or alloy lined or clad vessels, no corrosion allowance is re*uired on the base metal# The
cladding or lining material +in no case less than 3#; mm thic$ness, shall be considered for
corrosion allowance#
Cladding or lining thic$ness shall not be included in strength calculations#
Corrosion allowance for flange faces of Dirth 1 Body flanges shall be considered e*ual to
that specified for vessel#
:-= 6in$ Consi$er"tion
.ind load shall be calculated on the basis of 8S ? :P; 1 site data#
"5 rag coefficient for cylindrical vessels shall be 4#P minimum#
*5 rag coefficient for spherical vessel shall be 4#> minimum#
:-> E"rt!?("7e Consi$er"tion :
'arth*ua$e load shall be calculated in accordance with 8S ? 3:=@ 1 site data if specially
developed and available
:-@ C"p"'ity
:-@-, T"n7
Capacity shall be specified as )ominal capacity and stored capacity
)ominal capacity for fi-ed roof tan$s be volume of cylindrical shell#
)ominal capacity for floating roof tan$s shall be volume of cylindrical shell minus free
board volume#
Stored capacity shall be =4Q of )ominal capacity#
:-@-/ Sp!ere
Stored capacity shall be :;Q of nominal capacity#
:-A )"n!oles :
"5 6essels and columns with diameter between =44 and 3444 mm shall be
provided with C;4 )B manhole# 6essels and columns with diameter greater than
3444mm shall be provided with ;44 )B manhole# Iowever, if re*uired vessels and
columns with diameter 3944mm and above may be provided with >44)B manhole#
*5 (or storage tan$s minimum number of manholes +Si"e ;44mm, shall be as
follows?
Tan$ iameter Shell Roof
ia# J :m 3 3
S :m dia# J @> dia 9 9
ia# S @>m C 9
(loating roofs +pontoon or double dec$ type, shall be provided with manholes to inspect
the entire interior of the roofs# Si"e of manhole shall be ;44 mm minimum#
:-,. Flo"tin% Roof :
:-,.-, 7nless otherwise specified floating roof shall be of following construction#
Tan$ iameter Type of Roof
39 & J ouble ec$ Type
S39 & J >4& 5ontoon Type
S >4& ouble ec$ Type
:-,.-/ (loating roof design shall be in fabricators scope having proven trac$ record#
(oam seal of proven ma$e shall be provided unless otherwise specified#
:-,, )o""le si"e ? 7nless otherwise specified
< &inimum no""le Si"e ? C4 )B
< &inimum )o""le Si"e, Column ? ;4 )B
< Safety 6alve )o""le ? Based on 8##
< Self Reinforced )o""le )ec$ ? Based on 8##
:-,,-, "5 All no""les and man<ways including self<reinforced type shall be Yset inY type
and attached to vessel with full penetration welds#
*5 Self reinforced no""les up to :4mm )B may be Yset onY type#
:-,/ Fl"n%es
:-,/-, 7nless otherwise specified no""le flanges up to >44)B shall be as per AS&'
1A)S8 B3>#; and above >44 )B shall be as per AS&' 1A)S8 B 3>#CP +S'R8'S
YBY,
:-,/-/ (or no""les 344 )B and below, only weld nec$ flange shall be used# Slip on
flanges may be used for no""les above 344)B in Class 3;4 rating only# All
flanges above Class 3;4 rating shall be weld nec$ type
:-,/-0 Slip on flanges shall not be used in Eethal, Iydrogen, caustic, severe cyclic
service and corrosive service +where corrosion allowance is in e-cess of @mm,#
:-,0 Intern"ls :
Removable internals shall be bolted type and bolting shall be stainless steel Type @4C,
unless specified otherwise#
:-,1 Sp"res :
Das$ets ? Two sets for each installed gas$et#
(asteners? 34 Q +&inimum two in each si"e, of installed fasteners#
Sight1Eight Dlass? C sets for each installed glass#
:-,: Vent3Dr"in Conne'tions:
6essel shall be provided with one number each, vent1drain connection as per following ?
6'SS'E 6AE7&', m@ 6')T S8O', )B +mm, RA8) S8O', )B
+mm,
>#4 and smaller C4 C4
>#4 to 3P#4 C4 ;4
3P#4 to P3#4 ;4 :4
P3#4 and larger :4 344
:-,= Pipe D"it :
6ertical 6essel 1 Column having safety valve si"e S :4 )B and or having internals, shall
be provided with pipe davit per relevant standard#
=-. INSULATION T2IC4NESS :
As indicated on process data sheet by process licensor
>-. PAINTING
As per Standard Specification, unless otherwise stated#
@-. )ATERIAL SELECTION :
&aterial of various parts of e*uipment shall be selected per process data sheet guidelines
and proper care shall be ta$en for the points as given in Anne-ure< 8 or as specified#
A-. SPECIAL CONSIDERATION FOR TALL COLU)N DESIGN
&echanical design of self supporting Tall Column 1 Tower shall be carried out for
various load combinations as per Anne-ure<88
,.-. STATUTORY PROVISIONS :
)ational laws and statutory provisions together with any local byelaws for the state shall
be complied with#
Anne&(re : I
,- 5R'SS7R' 6'SS'E ST''E 5EAT'S AR' 57RCIAS' TA TI'
R'F78R'&')T A( TI' STA)AR AS&' SA<94, .I8CI R'F78R'S T'ST8)D
A( 8)8687AE 5EAT'S (AR EA. T'&5'RAT7R' S'R68C'# CARBA) ST''E
&AT'R8AE 8S AR'R' TA &''T TI' 8&5ACT R'F78R'&')TS A(
S755E'&')T A( STA)AR AS&' SA 94# TG58CAE &AT'R8AE
S5'C8(8CAT8A) 8S AS (AEEA.S SA ;3> DR#>4# )AR&AE8S' TA &''T
8&5ACT R'F78R'&')TS 5'R S755E'&')T SS A( SA 94 AT<;4(
/- AEE 5'R&A)')T ATTACI&')TS .'E' 8R'CTEG TA = Q )8CT'E
ST''E SIA7E B' A( TI' SA&' &AT'R8AE AR A( A) A7ST')T8C
STA8)E'SS ST''E TG5' .I8CI CA))AT B' IAR')' BG I'AT
TR'AT&')T#
0- CI'CT (AR 8&5ACT T'ST8)D R'F78R'&')T AS 5'R 7CS<>> (AR
CA8)C8')T T'&5'RAT7R' A) 5ART TI8CT)'SS#
1- S'E'CT8A) A( STA8)E'SS ST''E &AT'R8AE SIAEE B' BAS' A)
5RAC'SS R'CA&&')AT8A)15RAC'SS E8C')SAR#
:- AT&AS5I'R8C1EA. 5R'SS7R' STARAD' TA)TS# &AT'R8AE SIAEE
B' S'E'CT' AS 5'R A58 >;4 1A58 >94 AS A55E8CABE'#
=- &AT'R8AES (AR CA7ST8C S'R68C' SA7R S'R68C' AR SA7R H I8C
SIAEE B' S'E'CT' BAS' A) S5'C8(8C R'CA&&')AT8A) A( 5RAC'SS
E8C')SAR#
>- &AT'R8AE (AR 5R'SS7R' 6'SS'ES 'S8D)' ACCAR8)D TA AS&'
S'CT8A) 6888 868S8A) 9 SIAEE B' D86') S5'C8AE CA)S8'RAT8A) AS
5'R CA'#
@- AEE 585'S SIAEE B' A( S'A&E'SS CA)STR7CT8A)#
A- )A)('RRA7S &AT'R8AE A) S75'R AEEAGS SIAEE B' S'E'CT'
BAS' A) S5'C8(8C R'CA&&')AT8A)#
,.- &AT'R8AE (AR 6'SS'E 1CAE7&) ST8RT SIAEE B' TI' SA&'
&AT'R8AE AS A( 6'SS'E1 CAE7&) SI'EE (AR TI' 755'R 5ART .8TI A
&8)8&7& A( ;44&&#
Anne-ure <88
DESIGN P2ILOSOP2Y OF TALL COLU)NS
&echanical design of self<supporting tall column and its anchorage bloc$ shall be carried
out considering combination of various loads#
,-. Lo"$in%s
The loadings to be considered in designing a self<supporting tall column1tower shall
include?
,-, 8nternal and or e-ternal design pressure specified on process data sheets#
,-/ Self weight of column inclusive of piping, platforms, ladders, manholes, no""les,
trays, welded and removable attachments, insulation and operating li*uid etc# The
weight of attachments to be considered shall be as per Table <3 enclosed
Ather loading as specified in 7D<99 of AS&' Code Sec, 6888 iv#3# wherever
applicable#
,-0 Seismic forces and moments shall be computed in accordance with 8S 3:=@ +latest
edition,# 7nless otherwise specified importance factor and damping coefficient
shall be considered as 9 and 9Q respectively#
,-1 Basic wind pressure and wind velocity +including that due to winds of short
duration as in s*ualls, for the computation of forces 1 moments and dynamic
analysis respectively shall be in accordance with 8S :P; +latest edition,#
Additional wind loading on column due to e-ternal attachments li$e platforms,
ladders piping and attached e*uipment should be given due consideration#
,-: Eoadings resulting in localised and gross stresses due to attachment or mounting
of reflu- 1 reboiler 1 condenser etc#
/-. Lo"$in% Con$ition
Analysis shall be carries out for following conditions ?
/-, Ere'tion Con$ition? Column +un<corroded, erected on foundation without
insulation, platforms, trays etc# but with welded attachments plus full wind on
column#
/-/ Oper"tion Con$ition: Column +in corroded condition, under design pressure,
including welded items, trays removable internals, piping, platforms, ladder,
reboiler mounted on column, insulating and operating li*uid etc# plus full wind on
insulated column with all other projections open to wind, or earth*ua$e force#
/-0 Test Con$ition: Column +in corroded condition, under test pressure filled with
water plus @@Q of specified wind load on uninsulated column considered#
/-1 'ARTIF7AT' A) .8) SIAEE B' CA)S8'R' )AT ACT8)D
CA)C7RR')TEG
0-. Defle'tion of Col(mn
&a-imum allowable deflection at top of column shall be e*ual to height of the column
divided by 944#
0-, 8f the deflection of column e-ceeds the above allowable limit the thic$ness of
s$irt shall be increased as first trial up to a ma-imum value e*ual to the column
thic$ness and this e-ercise shall be stopped if the deflection falls within allowable
limit#
0-/ 8f the above step is inade*uate, s$irt shall be gradually flared to reduce the
deflection# (laring of s$irt shall be stopped if the deflection falls within limits or
half angle of cone reaches ma-imum limit of = deg#
0-0 8f the above two steps prove inade*uate in limiting the deflection within
allowable limits, the thic$ness of shell courses shall be increased one starting
from bottom course above s$irt and proceeding upwards till the deflection falls
within allowable limits#
1-. Stress Limits
The stresses due to pressure weight wind 1 seismic loads shall be combined using
ma-imum principle stress theory for AS&' Section 6888 iv# 8# Thic$nesses are
accordingly chosen to $eep the within limits as per Table<9#
:-. S7irt S(pport #"se
Base supporting including base plate, anchor chairs compression ring, foundation bolting
etc# shall be designed based on overturning moment +greater of seismic or wind,# A
minimum number of : foundation bolts shall be provided# )umbers of foundation bolts
shall be in multiple of four#
=-. )inim(m 2y$rotest Press(re
&inimum Iydrotest 5ressure +in Iori"ontal position, shall be e*ual to 3#@ - design
pressure - temperature correction factor as specified in AS&' Code Section 6888 iv# 8
+Clause 7D<==, at top of column#
>-. Dyn"mi' An"lysis
ynamic analysis of each column shall be carried out for stability under transverse wind
induced vibrations as per standard design practice# The recommended magnification
amplitude shall be limited to tower diameter divided by five#
TA#LEB,
DETAILS AND 6EIG2T OF COLU)N ATTAC2)ENT
3# Shape factor for shell +for wind force calculation, ? 4#P
9# .eight of trays +with li*uid, to be considered# ? 394 Tg#1m9
@# .eight of plain Eadder? 3; Tg#1m
C# .eight of caged ladder? @P Tg#1m
; '*uivalent projection to be considered for wind load on caged ladder ? @44 mm
># istance of platform below each manhole ? Appro-# 3444 mm
P# &a-imum distance between consecutive platform ? ;444 mm
:# 5rojection of 5latform ? =44mm up to 3meter dia# column! 3944 mm for column
dia#S 3 meter, from column insulation surface#
=# '*uivalent height of platform +for wind load computation, ? 3444 mm
34# .eight of platforms ? 3P4 Tg#1m
9
#
33# 5latform shall be considered all around
TA#LE B/
ALLO6A#LE STRESSES FOR CO)#INED LOADING
6'SS'E CA)8T8A) 1 T'&5#1 CA)8T8A)S
TYPE OF STRESSES ERECTION
OPERATING TEST
)'. AR CARRA' )'. CARRA'
CARRA'
T'&5'RAT7R' A&B8')T 'S8D)
A&B8')T
EA)D8T78)AE T-S-' T-S-'
4#=4-G#5-'
EA)D8T78)AE CA&5R'SS86'
STR'SS T-B T-B B
.here
S K Basic allowable Tensile Stress as per Clause 7D 9@ +a, of AS&' Code Sec# 6888
iv#3#
B K YBY value calculated as per Clause 7D<9@ +b,#
' K .eld joint efficiency of circumferential weld, depending on e-tent of radiography#
T K (actor for increasing basic allowable value when wind or seismic load is present, 3#9
as per AS&' Sec 6888 iv 3#
Note : Allowable stresses in s$irt to shell joint shall be as per following ?
a, 4#C=S, if joint is shear type#
b, 4#P4S, if joint is compression type#
C2APTER 0
DESIGN PROCEDURE AND
CALUCULATION

DESIGN T2EORY
Cir'(mferenti"l or 2oop Stress
A tensile stress acting in a direction tangential to the circumference is called
Circumferential or Ioop Stress# 8n other words, it is on longitudinal section+or on the
cylinder walls,#

Eet,
p K 8ntensity of internal pressure,
d K 8nternal diameter of the cylinder shell,
l K length of cylinder,
t K Thic$ness of the shell, and

t3
K hoop stress for the material of the cylinder#

)ow,
.e $now that total force on a longitudinal section of the shell
K 8ntensity of pressure Z projected Area K p Z d Z l [##i
and the total resisting force acting on the cylinder walls
K
t3
Z 9t Z l [#+
.
of two section, [
ii
(rom e*uation +i, and +ii, , we have

t3
Z 9t Z l K p Z d Z l or
t3
K
p d
9t
or t K
t3
p d
9
[##ii
Lon%it($in"l Stress
A tensile stress acting in a direction of the a-is is called longitudinal stress# 8n
other words, it is a tensile stress acting on the transverse or circumferential section#

(ig of Eongitudinal stress
Eet
t 9
K Eongitudinal stress#
8n this case, the total force acting on the transverse section
K 8ntensity of pressure Z Cross< sectional Area
K p Z
C
+d,\ [[[i
and total resisting force K
t 9
Z ]d#t [[[ii
(rom e*uation +i, and +ii,, we have

t 9
Z ]d#t K p Z
C
+d, \

t 9
K
p d
Ct
or t K
t 9
p d
C

Desi%n of S!ell D(e to Intern"l Press(re
As discussed in article on thin vessel are cylindrical pressure vessel is subjected to
tangential +
t
, and longitudinal +
L
, stresses#

9
i i
t
P D
t

= and
C
i i
L
P D
t

= where K mean diameter
K
i
D
H t
R(le
The design pressure is ta$en as ;Q to 34Q more than internal pressure, where as
the test pressure is ta$en as @4Q more than internal pressure#
Considering the joint efficiency,
The thic$ness of shell can be found by following procedure,

+ ,
9
i i
P D t
t

+
=

9 + ,
i i
t P D t = +

9+ ,
i i
i
P D
t
P
=

Desi%n of Ellipti'"l 2e"$:
'lliptical heads are suitable for cylinders subjected to pressures over 3#; &5a# The
shallow forming reduces manufacturing cost# 8tRs thic$ness can be calculated by the
following e*uation?
t K
9
i i
p d W
J

where,

i
d
K &ajor a-is of ellipse
.K Stress intensification factor

9
3
+9 ,
>
W k = +
.here , $ K
&ajor A-is iameter
&ajor A-is iameter
K
i
4#;d
c
R(le
/
Denerally, $ K 9 + how ever $ should not be greater than 9#>,

9
3
+9 9 ,
>
W = +
K 3

9
Pi di W
t
J

=

Desi%n of )"n!ole
Eet,

i
d
K internal dia# Af no""le
d K
i
d
H 9 CA
where, CA K corrosion Allowance in mm
t K Actual thic$ness of shell in mm
tr K re*uire thic$ness as per calculation in mm#
tn K Actual thic$ness of no""le
trn K Re*uired thic$ness as per calculation in mm

9
rn
Pi Di
Pi
t

=

3actual
h
K Ieight of the no""le above the shell in mm

9actual
h
K Ieight of the no""le below the shell in mm

3
h
K Ieight till where the effect of the no""le persists above the shell in mm

9
h
K Ieight till where the effect of the no""le persists below the shell in mm
To calculate
3
h
and
9
h
consider a term ^hR
h K 9#; + t M CA, or h K 9#; + tn M CA, +whichever is smaller,

3
h
K h or
3actual
h
+whichever is smaller,

9
h
K h or
9actual
h
+whichever is smaller,
U K istance where the effect of the no""le persists in mm on each side of the
centre line
U K d#
or U K
i
d
9
H t H tn <@CA +whichever is ma-imum,

op
d
K outer dia# Af Reinforcing 5ad in mm

ip
d
K inner dia# Af Reinforcing 5ad in mm

p
t
K Thic$ness of Reinforcing 5ad in mm
Are" C"l'(l"tion
Area pertaining to material removed, A K d
tr
'-cess area in the Shell, A3 K +9U M d , + t M tr MCA,
'-cess area in the )o""le, A9 K 9h3+tn M trn M CA,
'-cess area in the no""le inside the shell A@ K 9 h9 +tn M 9CA,
Area Re*uired,
r
A
K +
op
d
<
ip
d
,
p
t
Area re*uired, Ar K A M + A3 H A9 H A@,
.hen Ar K 4 or negative, no reinforcement is necessary as the vessel thic$ness self
compensates#
Desi%n of Le%:
A5 Le%s s(pport
8n certain cases, legs can be made detachable to the vessel# These legs can
be bolted to plates# The design for leg supports is similar to that for brac$et support# 8f
the legs are welded to the shell, then the shear stresses in the weld will be given by?
9
9 3 9
9
4#P4P
W o
W W
W
w P KPH D mm
t L n

= =

4#P4P
W
W W
W
t L n

=

.here,
W
t
K .eld Ieight

W
L
K .eld Eength#
These types of supports are suitable only for small vessels as there is a concentrated
local stress at the joint#
#5 6in$ Lo"$
.ind load can be estimated as ?

w3
5
K T
5
3
I
o
This e*uation is valid for heights upto 94m# Beyond 94m, the wind pressure is
higher and hence for heights above 94m#

9 9 9 w o
P KP H D =
Denerally,
3
P
lies between C44 )1
9
mm and
9
P
may be upto 9444 )1
9
m #
Therefore, the bending moment due to wind at the base will be
+8( I _ 94 m,
w
&
K
w3 3
5 h
9
+8( IS 94m,
w
&
K
w3 3
5 h
9
H
w9
5
+
3
h
H
9
h
9
,
Therefore, bending stress will be,

bw
K
w
&
"
.here OK section &odulus
The wind load would create tensile stress on the wind side and compressive on the other
side#

Desi%n C"l'(l"tion
,5 T!i'7ness of 'ylin$er
Gien $"t"
8nternal pressure +5, K 4#;:: &5a
8nternal iameter +i, K C=>mm
Corrosion Allowance +CA, K )il#
Boint 'fficiency for shell K 3#
As per '*uation,

9
Pi Di
t
Pi
=

H CA

+4#;::, +C=>,
9 3@P 3 4#;::
t

=

+
.
CA is )8E,
K 3#4>>

t K 3#4>>mm
/5 Ellipti'"l 2e"$

9
3
+9 ,
>
W k = +
where ,
$ K
&ajor A-is iameter
&ajor A-is iameter
K
i
4#;d
c
$ K 9
R(le
/
Denerally, $ K 9 + how ever $ should not be greater than 9#>,

9
3
+9 9 ,
>
W = +
K 3

9
Pi di W
t
J

=

where,
di K &ajor a-is of ellipse K C=>mm
. K Stress intensification factor K 3

9
Pi di W
t
J

=

4#;:: C=> 3
9 3@P 3
t

=

K 3#4> mm

t K 3#4> mm
05 Desi%n Of )"n!ole
8)E'T )AOOE' +)3,
GIVEN DATA
8nternal pressure +5i, K 4#;:: )1
9
mm
8nternal diameter +i, K C=> mm
Thic$ness +t, K > mm#
CA K )8E
Boint 'fficiency +
, K 3
8nternal diameter of no""le +di, K 9;C#;3 mm
d K di H CA K 9;C#;3 mm#
tr K re*uire thic$ness K 3#4>> mm#
tn K Actual thic$ness of no""le K =#9P mm#
trn K Re*uired thic$ness as per calculation in mm#

3
4#;:: 9;C#;3
9 3@P 3 4#;::
A

=
9
rn
Pi Di
Pi
t

=


4#;:: 9;C#;3
9 3@P 3 4#;::
rn t

=

8 4#;CP mm#

rn t
8 4#;CP mm#
Are" C"l'(l"tion
Area 5ertaining to material removed, A K d
tr
K 9;C#;3
3#4>>
K 9P3#@
9
mm
'-cess area in the shell, A3 K +9U M d , + t M tr MCA,
Denerally,
U K d K 9;C#;3 mm#
U K di H t H tn <@CA
9
K 9;C#;3 H > H=#9P M 4
9
K 3C9#;9 mm#
+ Ta$e U whichever ma-imum,
Therefore,
A K +9
9;C#;3<9;C#;3,+><3#4>><4,
K 39;;#P;
9
mm
'-cess area in the no""le, A9 K 9h3+tn M trn M CA,
h K 9#; + t M CA, or h K 9#; + tn M CA,
K 9#;
> K 9#; +=#9P,

K 3;mm K 9@#3P; mm
C T"7e D ;!i'!eer sm"ller5
h3 K h9 K h K 3; mm#
Therefore,
A9 K 9
3; + =#9P M 4#;CP M 4,
K 9>3#>=
9
mm
'-cess area in the no""le inside the shell A@ K 9 h9 +tn M 9CA,
K 9
3; C =#9P<4,
K 9P:#3
9
mm
Area re*uired Ar K A M + A3 H A9 H A@,
K <3;9C#9C
As Ar is Mve or "ero reinforcement is not necessary#
15 Desi%n of le%
6in$ lo"$
Iere ,
T K Coefficient depending on shape factor K 4#P

5
3
K .ind pressure K >0. N3
9
mm
I K Ieight of the vessel above foundation K9C3@ mm

o
K Auter iameter Af 6essels

.ind load can be estimated as ?

w3
5
K T
5
3
I
o
K 4#PZP@4Z9#C3@Z4#;4:
K >9>#@: )
+8( I _ 94 m,
w
&
K
w3 3
5 h
9
+8( IS 94m,
w
&
K
w3 3
5 h
9
H
w9
5
+
3
h
H
9
h
9
,
Iere we use ,

w
&
K
w3 3
5 h
9
K >9>#@: Z 394>#CP
K P;;#C3 )#m
Iere we use 8< Section,
Therefore, O K section &odulus
O K
@ @
3 3
bh b h
>h
K
@ @
Ct+;t, @t+@t,
>+;t,
K 3@#=>
@
t
Therefore, Bending Stress will be ,

bw
K
w
&
"
+as
bw
K @;4 )1mm\,
@;4Z
>
34 K
@
P;;#C3
3@#=>t
t K ;#@> Z
@
34
E K
39@
@
H
39@
@
H 3:@C
K 3=3> mm

SU))ARY

I0T'102% DI2&'T'1
"Di$ 345mm
-*'%% %'0+T* "%$ 6783mm
T*IC90'-- "t$ 5mm
*'2D T*IC90'-- "t$

5mm
*'I+*T "h$

678mm
&20 *:%'
DI2&'T'1 :; :P'0I0+
"di$ <=3.=6

T*IC90'-- :; 0:!!%'
"tn$ 4.<7
1'I0;:1C'&'
0T
2- 21'2 C2%C(%2T'D I-
>ve 1; P2D I- 0:T
1'.(I1'D
P2D

%'+ T*IC90'-- :; %'+-
= .
85mm
DESIGN APPROC2 / #Y AS)E
CODES
DESIGN T2EORY
5R'SS7R' 6'SS'E I'A 'S8D) 7)'R 8)T'R)AE 5R'SS7R' 5R'SS7R' 6'SS'E I'A 'S8D) 7)'R 8)T'R)AE 5R'SS7R'
TI8CT)'SS A( I'AS1 CEAS7R'S?
'EE85SA8AE I'A?
t K 5#i 1 +9S'< 4#95, H CA
ATI'RS!
t K 5#T#i1 +9S'<4#95, H CA
T KCA)STA)T BAS' A) TI' RAT8A A(
&ABAR X &8)AR AU8S +19I,
/6AE7'S A( (ACTAR T0 /6AE7'S A( (ACTAR T0
19I @#4 9#: 9#> 9#; 9#C 9#9 9#3 9#4
T 3#:@ 3#>C 3#C> 3#@P 3#9= 3#3C 3#4P 3#44
19I 3#: 3#> 3#; 3#C 3#9 3#4
T 4#:P 4#P> 4#P3 4#>> 4#;P 4#;4
TAR8S5I'R8CAE I'A?
t K 4#::; 5E1 +S'<4#35, H CA
(AR T)7CTE' RA87S, r K >Q A( CRA.) RA87S +E,
t K5E&1 +9S#'< 4#95, H CA
where EKCRA.) RA87S
&KCA)STA)T BAS' A) RAT8A A( CRA.) A) T)7CE'
RA87S+E1r,

/6AE7'S A( (ACTAR &0 /6AE7'S A( (ACTAR &0
E1r 3#4 3#;4 9#44 9#;4 @#44 @#;4 C#4
& 3#44 3#4> 3#34 3#3; 3#3: 3#99 3#9;
E1r ;#4 >#4 P#4 :#4 =#4 34#4 33#4
& 3#@3 3#@> 3#C3 3#C> 3#;4 3#;C 3#;:
E1r 39#4 3@#4 3C#4 3;#4 3>#4 3>#>P
& 3#>9 3#>; 3#>= 3#P9 3#P; 3#PP
+7S' )'AR'ST 6AE7' A( E1r! 8)T'R5AEAT8A) 7))'C'SSARG,
)AT'?
M &AU8&7& RAT8A AEEA.' BG 7D<@9 +j, .I') E 'F7AES TI'
A7TS8' 8A&'T'R A( TI' ST8RT A( TI' I'A# T)7CTE'
RA87S, r SIAEE )AT B' E'SS TIA) @t#
CA)8CAE I'A?
t K 5i1 9 CAS ` +S'<4#>5, H CA
` K half ape- angle
I'&8S5I'R8CAE I'A?
t K 5#Ri1 +9S'< 4#95, H CA
(EAT I'AS X CA6'RS +7D< @C,
C8RC7EAR CA6'R1 I'AS
t K i a SFRT+C51S', H CA
.here C K (actor, dependent on joint geometry of head cover to shell +range 4#3
M 4#@@,
ABRA7)1 )A)<C8RC7EAR I'AS
+8)CE78)D SF7AR'1 R'CTA)D7EAR,
t K i a SFRT+OaC51S', H CA
where O K @#C < +9#C d 1 ,
5R'SS7R' 6'SS'E SI'EE CA&5A)')T 'S8D) 7)'R 5R'SS7R' 6'SS'E SI'EE CA&5A)')T 'S8D) 7)'R
8)T'R)AE 5R'SS7R' 8)T'R)AE 5R'SS7R'
5ressure 6essel efinition?
M Cont"iners of Press(re
Intern"l
E&tern"l
M Press(re So(r'e
E&tern"l
Appli'"tion of 2e"t
Co$e Coer"%e:
M S(*se'tions
R(le+ G(i$elines+ Spe'ifi'"tions
M )"n$"tory Appen$i'es
Spe'ifi' Import"nt S(*Ee'ts to S(pplement S(*se'tions
M NonB)"n$"tory Appen$i'es
A$$ition"l Inform"tion+ S(%%este$ Goo$ Pr"'ti'es
In'l(sions:
M Unfire$ Ste"m #oilers3 Gener"tors
E"por"tors
2e"t E&'!"n%ers
M Dire't Fire$ Vessels
G"s Fire$ F"'7ete$ Ste"m 4ettlesCF"'7et Press(re less t!"n :.
PSI5
A$$ition"l Interpret"tion:
M T!e 'o$e r(les m"y not 'oer "ll $esi%ns G 'onstr('tions pro'e$(res-
S('! "$$ition"l $esi%n G 'onstr('tion pro'e$(re m"y *e
"$opte$ ;!i'! "re s"fe "n$ "''ept"*le-
M Fiel$ f"*ri'"tion "re "''ept"*le-
M Ot!er st"n$"r$s for 'omponents "re "''ept"*le
G(i$elines for Desi%ne$ T!i'7ness CTo *e "$opte$5:
M C,3,=5H e&'l($in% 'orrosion "llo;"n'e for s!ell G !e"$ C)in-5
M T!e "*oe ;ill not "pply to !e"t tr"nsfer s(rf"'e
M C,315H min- for (nfire$ ste"m *oiler s!ell
M C030/5H min- e&'l($in% 'orrosion "llo;"n'e for 'ompresse$ "ir3 ste"m3
;"ter seri'eCfor CS3AS5
M Corrosion "llo;"n'e s!"ll *e *"se$ on e&perien'e3 fiel$ $"t"CNo "l(e3
'o$e re'ommen$e$5-
T2IC4NESS CALCULATIONS
UNDER INTERNAL PRESSURE+ CYLINDRICAL S2ELL:
Cir'(mferenti"l stress:
t 8 P-Ri 3 CSEB .-=P5 9 CA
Lon%it($in"l stress:
t 8 P-Ri 3 C/SE9.-1P5 9 CA
SP2ERICAL S2ELL:
t 8 P-Ri 3 C/SEB .-/P5 9 CA
CONICAL SECTION: CINTERNAL PRESSURE5
t 8P-Di3 /COSICSEB .-=P5 9 CA
Stress C"l'(l"tion
UNDER INTERNAL PRESSURE+
CYLINDRICAL S2ELL:
Cir'(mferenti"l stress:
S' 8 P CRi 9 .-=t53 Et
Lon%it($in"l stress:
Sl 8 P CRi B .-1t53 /Et
SP2ERICAL S2ELL:
S' 8 P CRi 9 .-/t53 /Et
CONICAL S2ELL SECTION:
S' 8P CDi 9 ,-/ tCOSI53/Et COSI
Sl 8P CDi J .-@tCOSI531Et COSI
ANALYSIS OF PRESSURE VESSEL
ProEe't
A(t!or
jimit
S(*Ee't
shell analysis
Prep"re$ For
project report
ProEe't Cre"te$
Saturday, April 3P, 9434 at 34?4C?9P 5&
ProEe't L"st )o$ifie$
Saturday, April 3P, 9434 at 34?4C?9P 5&
, Intro$('tion
The A)SGS CA' +Computer<Aided 'ngineering, software program was used in
conjunction with @ CA +Computer<Aided esign, solid geometry to simulate the
behaviour of mechanical bodies under thermal1structural loading conditions# A)SGS
automated ('A +(inite 'lement Analysis, technologies from A)SGS, 8nc# to generate the
results listed in this report#
'ach scenario presented below represents one complete engineering simulation# The
definition of a simulation includes $nown factors about a design such as material
properties per body, contact behavior between bodies +in an assembly,, and types and
magnitudes of loading conditions# The results of a simulation provide insight into how
the bodies may perform and how the design might be improved# &ultiple scenarios allow
comparison of results given different loading conditions, materials or geometric
configurations#
Convergence and alert criteria may be defined for any of the results and can serve as
guides for evaluating the *uality of calculated results and the acceptability of values in
the conte-t of $nown design re*uirements#
So!tion "i#tor$ provides a means of assessing the *uality of results by e-amining how values change during successive
iterations of solution refinement# %on&'r('n)' )rit'ri* sets a specific limit on the allowable change in a result between
iterations# A result meeting this criteria is said to be bconvergedb#
A'rt )rit'ri* define ballowableb ranges for result values# Alert ranges typically represent $nown aspects of the design
specification#
All values are presented in the +SI M'tri) ,m- k(- .- /%- #- 0- A1+ unit system#
Noti'e
o not accept or reject a design based solely on the data presented in this report# 'valuate
designs by considering this information in conjunction with e-perimental test data and
the practical e-perience of design engineers and analysts# A *uality approach to
engineering design usually mandates physical testing as the final means of validating
structural integrity to a measured precision#
/- S'en"rio ,
/-,- K)o$elK
+Mod'+ obtains geometry from the 5ro1')D8)''R
c
part +H:2#"*' *nd
)$ind'r2SHEEL.PRT.3+#
The bounding bo- for the model measures 3#P@ by 4#;9 by 4#;9 m along the global -, y and " a-es, respectively#
The model has a total mass of 34=#>= $g#
The model has a total volume of 3#CZ34
<9
md#
T"*le /-,-,- #o$ies
N"me )"teri"l Nonline"r )"teri"l Effe'ts #o(n$in% #o&Cm5 )"ss C7%5 Vol(me CmL5 No$es Elements
+SHEEL+ +Str!)t!r* St''+ Ges 3#P@, 4#;9, 4#;9 34=#>= 3#CZ34
<9
C=>: >:C
/-,-,- )es!
+M'#"+, associated with +Mod'+ has an overall relevance of 4#
+M'#"+ contains C=>: nodes and >:C elements#
)o mesh controls specified#
/-/- KEnironmentK
Sim(l"tion Type is set to St"ti'
An"lysis Type is set to St"ti' Str('t(r"l
+En&ironm'nt+ contains all loading conditions defined for +Mod'+ in this scenario#
/-/-,- Str('t(r"l Lo"$in%
T"*le 0-/-,-,- Str('t(r"l Lo"$s
N"me Type )"%nit($e Ve'tor
Re"'tion
For'e
Re"'tion For'e
Ve'tor
Re"'tion
)oment
Re"'tion )oment
Ve'tor
+Pr'##!r'+ 5ressure >44,444#4 5a )1A )1A )1A )1A )1A
/-/-/- Str('t(r"l S(pports
T"*le 0-/-/-,- Str('t(r"l S(pports
N"me Type
Re"'tion
For'e
Re"'tion For'e Ve'tor
Re"'tion
)oment
Re"'tion )oment Ve'tor
+4i5'd
S!pport+
(i-ed
Surface
3#P3Z34
<@
)
%<3#P3Z34
<@
) -, 3#3>Z34
<P
) y,
@#>PZ34
<=
) "e
3#:3Z34
<;
)fm
%3#:3Z34
<;
)fm -, @#3>Z34
<=
)fm y,
3#4>Z34
<P
)fm "e
/-0- KSol(tionK
Soler Type is set to Pro%r"m Controlle$
6e"7 Sprin%s is set to Pro%r"m Controlle$
L"r%e Defle'tion is set to Off
+So!tion+ contains the calculated response for +Mod'+ given loading conditions defined
in +En&ironm'nt+#
Thermal e-pansion calculations use a constant reference temperature of 99#4 gC for +SHEEL+# Theoretically, at a uniform
temperature of 99#4 gC no strain results from thermal e-pansion or contraction#
/-0-,- Str('t(r"l Res(lts
T"*le 0-0-,-,- V"l(es
N"me Fi%(re S'ope )inim(m )"&im(m
)inim(m O''(rs
On
)"&im(m O''(rs
On
Alert
Criteri"
+E6!i&*'nt Str'##+ A3#3 +Mod'+ :#>Z34
>
5a @#;Z34
P
5a SI''E SI''E )one
+M*5im!m S"'*r
Str'##+
)one +Mod'+ C#=>Z34
>
5a 3#:PZ34
P
5a SI''E SI''E )one
+Tot* D'7orm*tion+ A3#9 +Mod'+ 4#4 m C#9PZ34
<;
m SI''E SI''E )one
Convergence trac$ing not enabled#
/-0-/- E?(i"lent Stress S"fety
T"*le 0-0-/-,- Definition
N"me Stress Limit
+Str'## Too+ Gield strength per material#
T"*le 0-0-/-/- Res(lts
N"me S'ope Type )inim(m Alert Criteri"
+Str'## Too+ +Mod'+ Safety (actor P#3@ )one
+Str'## Too+ +Mod'+ Safety &argin >#3@ )one
/-0-0- S!e"r Stress S"fety
T"*le 0-0-0-,- Definition
N"me S!e"r Limit S!e"r F"'tor
+Str'## Too 3+ Gield strength per material# 4#;
T"*le 0-0-0-/- Res(lts
N"me S'ope Type )inim(m Alert Criteri"
+Str'## Too 3+ +Mod'+ Safety (actor >#>= )one
+Str'## Too 3+ +Mod'+ Safety &argin ;#>= )one
S'e
n
"
ri
o
,
Fi%(res
deformation
Fi%(re A,-/- "Total Deformation" Conto(rs
stress
Fi%(re A,-,- "Equivalent Stress" Conto(rs
Appen$i'esA,-
A/- Definition of KStr('t(r"l SteelK
T"*le A/-,- "Structural Steel" Const"nt Properties
N"me V"l(e
Compressive 7ltimate Strength 4#4 5a
Compressive Gield Strength 9#;Z34
:
5a
ensity P,:;4#4 $g1md
5oissonYs Ratio 4#@
Tensile Gield Strength 9#;Z34
:
5a
Tensile 7ltimate Strength C#>Z34
:
5a
GoungYs &odulus 9#4Z34
33
5a
Thermal '-pansion 3#9Z34
<;
31gC
Specific Ieat C@C#4 B1$gfgC
Thermal Conductivity >4#; .1mfgC
Relative 5ermeability 34,444#4
Resistivity 3#PZ34
<P
Ahmfm
T"*le A/-/- Altern"tin% Stress
&ean 6alue 4#4
T"*le A/-0- "Alternating Stress"
Cy'les Altern"tin% Stress
34#4 C#4Z34
=
5a
94#4 9#:@Z34
=
5a
;4#4 3#=Z34
=
5a
344#4 3#C3Z34
=
5a
944#4 3#4PZ34
=
5a
9,444#4 C#C3Z34
:
5a
34,444#4 9#>9Z34
:
5a
94,444#4 9#3CZ34
:
5a
344,444#4 3#@:Z34
:
5a
944,444#4 3#3CZ34
:
5a
3,444,444#4 :#>9Z34
P
5a
T"*le A/-1- Str"inBLife P"r"meters
T"*le A/-:- "Strain-Life Parameters"
Strength Coefficient =#9Z34
:
5a
Strength '-ponent <4#33
uctility Coefficient 4#93
uctility '-ponent <4#CP
Cyclic Strength Coefficient 3#4Z34
=
5a
Cyclic Strain Iardening '-ponent 4#9
Project
A!t"or Bimit vyas and mahavir solan$i
S!89')t 'llipsoidal dish end
Pr'p*r'd 7or project analysis
4ir#t S*&'d Sunday, &ay 9;, 944:
L*#t S*&'d Sunday, &ay 9;, 944:
Prod!)t 0'r#ion 33#4 Release
Contents
)o$el
o Deometry
'E85T8CAEI'A
o &esh
C(U<&esh &ethod
o St"ti' Str('t(r"l
Analysis Settings
Eoads
Solution
Solution 8nformation
Results
&a- '*uivalent Stress
Results
&a- Shear Stress
Results
)"teri"l D"t"
o Structural Steel
Units
TA#LE ,
Unit S$#t'm &etric +m, $g, ), gC, s, 6, A,
An(' egrees
Rot*tion* 0'o)it$ rad1s
)o$el
Geometry
TA#LE 0
)o$el M Geometry M P"rts
:89')t .*m' ELIPTI%ALHEAD
St*t' &eshed
Graphics Properties
0i#i8' Ges
Tr*n#p*r'n)$ 3
Definition
S!ppr'##'d )o
M*t'ri* Structural Steel
Sti77n'## B'"*&ior (le-ible
.onin'*r M*t'ri*
E77')t#
Ges
Bouning Bo!
L'n(t" ; 4#;4: m
L'n(t" Y 4#;4: m
L'n(t" < 4#3P@ m
Properties
0o!m' 3#=9P3e<44@ md
M*## 3;#39: $g
%'ntroid ; <:#33>:e<43P m
%'ntroid Y 3#4=>9e<43P m
%'ntroid < <@#P==>e<449 m
Mom'nt o7 In'rti* Ip= 4#@CC3P $gfm\
Mom'nt o7 In'rti* Ip3 4#@C@ $gfm\
Mom'nt o7 In'rti* Ip> 4#>3P: $gfm\
Statistics
.od'# 99:=
E'm'nt# >9@9
)es!
TA#LE 1
)o$el M )es!
:89')t .*m' M'#"
St*t' Solved
Defaults
P"$#i)# Pr'7'r'n)' C(
R''&*n)' 4
Avance
R''&*n)' %'nt'r (ine
E'm'nt Si?' efault
S"*p' %"')kin( C(
Soid E'm'nt Mid#id'
.od'#
ropped
Str*i("t Sid'd E'm'nt#
Initi* Si?' S''d Active Assembly
Smoot"in( &edium
Tr*n#ition Slow
Statistics
.od'# 99:=
E'm'nt# >9@9
TA#LE :
)o$el M )es! M )es! Controls
:89')t .*m' %4;@M'#" M't"od
St*t' (ully efined
Scope
S)opin( M't"od Deometry Selection
G'om'tr$ 3 Body
Definition
S!ppr'##'d )o
M't"od C(U<&esh
E'm'nt Mid#id'
.od'#
ropped
St"ti' Str('t(r"l
TA#LE =
)o$el M An"lysis
:89')t .*m' St*ti) Str!)t!r*
St*t' (ully efined
Definition
P"$#i)# T$p' Structural
An*$#i# T$p' Static Structural
"ptions
R'7'r'n)' T'mp 99# gC
TA#LE @
)o$el M St"ti' Str('t(r"l M Lo"$s
:89')t .*m' Pr'##!r' 4i5'd S!pport 3
St*t' (ully efined
Scope
S)opin(
M't"od
Deometry Selection
G'om'tr$ C (aces 3 (ace
Definition
D'7in' B$ )ormal To
T$p' 5ressure (i-ed Support
M*(nit!d' >#eH44; 5a +ramped,
S!ppr'##'d )o
FIGURE ,
)o$el M St"ti' Str('t(r"l M Press(re
Sol(tion
TA#LE A
)o$el M St"ti' Str('t(r"l M Sol(tion
:89')t .*m' So!tion
St*t' Solved
Aaptive #esh $efinement
M*5 R'7in'm'nt
Loop#
3#
R'7in'm'nt D'pt" 9#
TA#LE ,.
)o$el M St"ti' Str('t(r"l M Sol(tion M Sol(tion Inform"tion
:89')t .*m' So!tion In7orm*tion
St*t' Solved
Solution %nformation
So!tion :!tp!t Solver Autput
.'wton@R*p"#on
R'#id!*#
4
Upd*t' Int'r&* 9#; s
Di#p*$ Point# All
TA#LE ,,
)o$el M St"ti' Str('t(r"l M Sol(tion M Res(lts
:89')t .*m' E6!i&*'nt Str'## M*5im!m S"'*r Str'## Tot* D'7orm*tion
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
T$p' '*uivalent +von<&ises, Stress &a-imum Shear Stress Total eformation
Di#p*$ Tim' 'nd Time
$esults
Minim!m @#343eH44> 5a 3#>3@3eH44> 5a 4# m
M*5im!m @#3@P:eH44P 5a 3#>=>@eH44P 5a C#34@9e<44; m
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
FIGURE /
)o$el M St"ti' Str('t(r"l M Sol(tion M E?(i"lent Stress M Fi%(re
e?(i"lent stress
FIGURE 0
)o$el M St"ti' Str('t(r"l M Sol(tion M )"&im(m S!e"r Stress M Fi%(re
m"&im(m s!e"r stress
TA#LE ,/
)o$el M St"ti' Str('t(r"l M Sol(tion M Stress S"fety Tools
:89')t .*m' M*5 E6!i&*'nt Str'##
St*t' Solved
Definition
T"'or$ &a- '*uivalent Stress
Str'## Limit T$p' Tensile Gield 5er &aterial
TA#LE ,0
)o$el M St"ti' Str('t(r"l M Sol(tion M )"& E?(i"lent Stress M Res(lts
:89')t .*m' S*7't$ 4*)tor S*7't$ M*r(in
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
T$p' Safety (actor Safety &argin
$esults
Minim!m P#=>PC >#=>PC
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
TA#LE ,1
:89')t .*m' M*5 S"'*r Str'##
St*t' Solved
Definition
T"'or$ &a- Shear Stress
4*)tor 4#;
TA#LE ,:
)o$el M St"ti' Str('t(r"l M Sol(tion M )"& S!e"r Stress M Res(lts
:89')t .*m' S*7't$ 4*)tor S*7't$ M*r(in
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
$esults
Minim!m P#@>= >#@>=
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
)"teri"l D"t"
Str('t(r"l Steel
TA#LE ,=
Str('t(r"l Steel M Const"nts
Structural
Yo!n(A# Mod!!# 9#eH433 5a
Poi##onA# R*tio 4#@
D'n#it$ P:;4# $g1md
T"'rm* E5p*n#ion 3#9e<44; 31gC
T'n#i' Yi'd Str'n(t" 9#;eH44: 5a
%ompr'##i&' Yi'd Str'n(t" 9#;eH44: 5a
T'n#i' Utim*t' Str'n(t" C#>eH44: 5a
%ompr'##i&' Utim*t'
Str'n(t"
4# 5a
Thermal
T"'rm* %ond!)ti&it$ >4#; .1mfgC
Sp')i7i) H'*t C@C# B1$gfgC
Electromagnetics
R'*ti&' P'rm'*8iit$ 34444
R'#i#ti&it$ 3#Pe<44P Ahmfm
FIGURE 1
Str('t(r"l Steel M Altern"tin% Stress
TA#LE ,>
Str('t(r"l Steel M Altern"tin% Stress M Property Attri*(tes
Int'rpo*tion Eog<Eog
M'*n %!r&' &ean Stress
T$p'
TA#LE ,@
Str('t(r"l Steel M Altern"tin% Stress M Altern"tin% Stress C(re D"t"
M'*n 0*!' P*
4#
TA#LE ,A
Str('t(r"l Steel M Altern"tin% Stress M Altern"tin% Stress s- Cy'les
%$)'# At'rn*tin( Str'## P*
34# @#===eH44=
94# 9#:9PeH44=
;4# 3#:=>eH44=
344# 3#C3@eH44=
944# 3#4>=eH44=
9444# C#C3eH44:
34444 9#>9eH44:
94444 9#3CeH44:
3#eH44; 3#@:eH44:
9#eH44; 3#3CeH44:
3#eH44> :#>9eH44P
FIGURE :
Str('t(r"l Steel M Str"inBLife P"r"meters
TA#LE /.
Str('t(r"l Steel M Str"inBLife P"r"meters M Property Attri*(tes
Di#p*$ %!r&'
T$p'
Strain<Eife
TA#LE /,
Str('t(r"l Steel M Str"inBLife P"r"meters M Str"inBLife P"r"meters
Str'n(t" %o'77i)i'nt P* =#9eH44:
Str'n(t" E5pon'nt <4#34>
D!)tiit$ %o'77i)i'nt 4#93@
D!)tiit$ E5pon'nt <4#CP
%$)i) Str'n(t" %o'77i)i'nt P* 3#eH44=
%$)i) Str*in H*rd'nin(
E5pon'nt
4#9
FATIGUE ANALYSIS
Project
A!t"or B8&8T A) &AIA68R
S!89')t (AT8D7' A)AEGS8S
Pr'p*r'd 7or 'S8D) A) A)AEGS8S A( 5R'SS7R' 6'SS'E
4ir#t S*&'d &onday, &arch 3P, 944:
L*#t S*&'d Tuesday, &arch 3:, 944:
Prod!)t 0'r#ion 33#4 Release
Contents
)o$el
o Deometry
(AT8D7'A)AEGS8S
o &esh
o St"ti' Str('t(r"l
Analysis Settings
Eoads
Solution
Solution 8nformation
Results
&a- '*uivalent Stress
Results
&a- Shear Stress
Results
(atigue Tool
Results
Result Charts
goodman stress life rl
Results
)"teri"l D"t"
o Structural Steel 9
Units
TA#LE ,
Unit S$#t'm &etric +m, $g, ), gC, s, 6, A,
An(' egrees
Rot*tion* 0'o)it$ rad1s
)o$el
Geometry
TA#LE
)o$el M Geometry
:89')t .*m' G'om'tr$
St*t' (ully efined
Definition
So!r)' ?hpressurevesselanalysishfatigueanalysish(AT8D7'A)AEGS8S#5RT#@
T$p' 5ro'ngineer
L'n(t" Unit &illimeters
E'm'nt %ontro 5rogram Controlled
Di#p*$ St$' 5art Color
Bouning Bo!
L'n(t" ; 4#P>9 m
L'n(t" Y 4#P:9 m
L'n(t" < 9#4: m
Properties
0o!m' 4#@4:CP md
M*## 9C93#; $g
Statistics
Bodi'# 3
A)ti&' Bodi'# 3
.od'# 393:3
E'm'nt# >3=3
TA#LE
)o$el M Geometry M P"rts
:89')t .*m' 4ATIGUEA.ALYSIS
St*t' &eshed
Graphics Properties
0i#i8' Ges
Tr*n#p*r'n)$ 3
Definition
S!ppr'##'d )o
M*t'ri* Structural Steel 9
Sti77n'## B'"*&ior (le-ible
.onin'*r M*t'ri*
E77')t#
Ges
Bouning Bo!
L'n(t" ; 4#P>9 m
L'n(t" Y 4#P:9 m
L'n(t" < 9#4: m
Properties
0o!m' 4#@4:CP md
M*## 9C93#; $g
%'ntroid ; <9#@>=>e<44@ m
%'ntroid Y 9#3P4=e<44@ m
%'ntroid < <:#@9=;e<44C m
Mom'nt o7 In'rti* Ip= ;99#P; $gfm\
Mom'nt o7 In'rti* Ip3 ;99#: $gfm\
Mom'nt o7 In'rti* Ip> :4#C;= $gfm\
Statistics
.od'# 393:3
E'm'nt# >3=3
Common ecisions to Both Types of (atigue Analysis
Ance the decision on which type of fatigue analysis to perform, Stress Eife or Strain Eife,
there are C other topics upon which your fatigue results are dependent upon# 8nput decisions
that are common to both types of fatigue analyses are listed below?
i Eoading Type
i &ean Stress 'ffects
i &ultia-ial Stress Correction
i (atigue &odification (actor
.ithin &ean Stress 'ffects, the available options are *uite different# 8n the following
ections, we will e-plore all of these additional decisions# These input decision trees for
both Stress Eife and Strain Eife are outlined in (igures 3 and 9# fatigue analysis in both
predicted life and types of post processing available# .e will loo$ at each of these choices
in detail below#
)es!
TA#LE
)o$el M )es!
:89')t .*m' M'#"
St*t' Solved
Defaults
P"$#i)# Pr'7'r'n)' &echanical
R''&*n)' 4
Avance
R''&*n)' %'nt'r Coarse
E'm'nt Si?' efault
S"*p' %"')kin( Standard &echanical
Soid E'm'nt Mid#id'
.od'#
5rogram Controlled
Str*i("t Sid'd E'm'nt# )o
Initi* Si?' S''d Active Assembly
Smoot"in( Eow
Tr*n#ition (ast
Statistics
.od'# 393:3
E'm'nt# >3=3
St"ti' Str('t(r"l
TA#LE
)o$el M An"lysis
:89')t .*m' St*ti) Str!)t!r*
St*t' (ully efined
Definition
P"$#i)# T$p' Structural
An*$#i# T$p' Static Structural
"ptions
R'7'r'n)' T'mp 99# gC
TA#LE
)o$el M St"ti' Str('t(r"l M An"lysis Settin%s
:89')t .*m' An*$#i# S'ttin(#
St*t' (ully efined
Step &ontrols
.!m8'r :7 St'p# 3#
%!rr'nt St'p
.!m8'r
3#
St'p End Tim' 3# s
5rogram Controlled
TA#LE
)o$el M St"ti' Str('t(r"l M Lo"$s
:89')t .*m' Pr'##!r' 4i5'd S!pport
St*t' (ully efined
Scope
S)opin(
M't"od
Deometry Selection
G'om'tr$ 34 (aces 9 (aces
Definition
D'7in' B$ )ormal To
T$p' 5ressure (i-ed Support
M*(nit!d' <>#eH44; 5a +ramped,
S!ppr'##'d )o
FIGURE
)o$el M St"ti' Str('t(r"l M Press(re
Sol(tion
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion
:89')t .*m' So!tion
St*t' :8#o't'
Aaptive #esh $efinement
M*5 R'7in'm'nt
Loop#
=.
R'7in'm'nt D'pt" 3.
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M Sol(tion Inform"tion
:89')t .*m' So!tion In7orm*tion
St*t' .ot So&'d
Solution %nformation
So!tion :!tp!t So&'r :!tp!t
.'wton@R*p"#on
R'#id!*#
B
Upd*t' Int'r&* 3.C #
Di#p*$ Point# A
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M Res(lts
:89')t .*m' E6!i&*'nt Str'## M*5im!m S"'*r Str'## Tot* D'7orm*tion
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
T$p' '*uivalent +von<&ises, Stress &a-imum Shear Stress Total eformation
$esults
Minim!m C#PP:9 5a 9#P;P 5a 4# m
M*5im!m >#CP99eH44P 5a @#;@C3eH44P 5a C#C3@@e<44C m
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
TA#LE
:89')t .*m' M*5 E6!i&*'nt Str'##
St*t' Solved
Definition
T"'or$ &a- '*uivalent Stress
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M )"& E?(i"lent Stress M Res(lts
:89')t .*m' S*7't$ 4*)tor S*7't$ M*r(in
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
$esults
Minim!m @#:>9P 9#:>9P
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
TA#LE
:89')t .*m' M*5 S"'*r Str'##
St*t' Solved
Definition
T"'or$ &a- Shear Stress
4*)tor 4#;
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M )"& S!e"r Stress M Res(lts
:89')t .*m' S*7't$ 4*)tor S*7't$ M*r(in
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
$esults
Minim!m @#;@P 9#;@P
%nformation
Tim' 3# s
Lo*d St'p 3
S!8#t'p 3
It'r*tion
.!m8'r
3
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tools
:89')t .*m' 4*ti(!' Too
St*t' Solved
#aterials
4*ti(!' Str'n(t"
4*)tor ,K71
3#
Loaing
T$p' Iistory ata
Hi#tor$ D*t*
Lo)*tion
C?h5rogram (ileshAnsys 8nchv334hA8SAEhCommon(ileshEanguagehen<
ush'ngineeringatahEoad IistorieshsampleIistory9#dat
S)*' 4*)tor ;#e<44@
Definition
"ptions
An*$#i# T$p' Stress Eife
M'*n Str'## T"'or$ Doodman
Str'## %ompon'nt '*uivalent +6on &ises,
Bin Si?' @9
U#' D!i)k R*in7ow
%o!ntin(
Ges
In7init' Li7' 3#eH44= cycles
M*5im!m D*t*
Point# To Pot
;444#
Life 'nits
Unit# .*m' cycles
= 8o)k i# '6!* to 3#eH44> cycles
)on<constant amplitude, 5roportional Eoading
)on<constant amplitude, proportional loading also needs only one set of (' results# But
instead of using a single load ratio to calculate alternating and mean values, the load ratio
varies over time# Thin$ of this as coupling an (' analysis with strain<gauge results
collected over a given time interval# Since loading is proportional, the critical fatigue
location can be found by loo$ing at a single set of (' results# Iowever, the fatigue
loading which causes the ma-imum damage cannot easily be seen# Thus, cumulative
damage calculations +including cycle counting such as Rainflow and damage summation
such as &inerRs rule, need to be done to determine the total amount of fatigue damage and
which cycle combinations cause thatdamage# Cycle counting is a means to reduce a
comple- load history into a number of events, which can be compared to the available
constant amplitude test data# )on<constantAmplitude, proportional loading within the
A)SGS (atigue &odule uses a /*uic$ counting0 techni*ue to substantially reduce runtime
and memory# 8n *uic$ counting, alternating andmean stresses are sorted into bins before
partial damage is calculated# .ithout *uic$ counting, data is not sorted into bins until after
partial damages are found# The accuracy of *uic$
counting is usually very good if a proper number of bins are used when counting# The bin
si"e defines how many divisions the cycle counting history should be organi"ed into for the
history data loading type# Strictly spea$ing, bin si"e specifies the number of divisions of the
rainflow matri-# A larger bin si"e has greater precision but will ta$e longer to solve and use
more memory# Bin si"e defaults to @9, meaning that the Rainflow &atri- is @9 - @9 in
dimension#
(or Stress Eife, another available option when conducting a variable amplitude fatigue
analysis is the ability to set the value used for infinite life# 8n constant amplitude loading,
if the alternating stress is lower than the lowest alternating stress on the fatigue curve, the
fatigue tool will use the life at the last point# This provides for an added level of safety
because many materials do not e-hibit an endurance limit# Iowever, in non<constant
amplitude loading, cycles with very small alternating stresses may be present and may
incorrectly predict too much damage if the number of the small stress cycles is high
enough# To help control this, the user can set the infinite life value that will be used if the
alternating stress is beyond the limit of the S) curve# Setting a higher value will ma$e
small stress cycles less damaging if they occur many times# The Rainflow and damage
matri- results can be helpful in determining the effects of small stress cycles in your
loading history#
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool M Res(lts
:89')t
.*m'
Li7' S*7't$ 4*)tor D*m*('
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
T$p' Eife Safety (actor amage
D'#i(n Li7' 3#eH44= cycles
$esults
Minim!m 9#eH44P cycles 4#
M*5im!m ;4#
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool M Res(lt C!"rts
:89')t .*m' R*in7ow M*tri5 D*m*(' M*tri5
St*t' Solved
Scope
G'om'tr$ All Bodies
"ptions
%"*rt 0i'win(
St$'
Three imensional
$esults
Minim!m R*n(' 4# 5a
M*5im!m R*n(' 3#=9C>eH44: 5a
Minim!m M'*n <@#9@9:eH44: 5a
M*5im!m M'*n >#3>9:eH44P 5a
Definition
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool M R"inflo; )"tri&
R"inflo; )"tri& C!"rt R"inflo; )"tri& C!"rt is " plot of t!e r"inflo; m"tri& "t t!e
'riti'"l lo'"tion- T!is res(lt is only"ppli'"*le for nonB'onst"nt "mplit($e lo"$in% ;!ere
r"inflo; 'o(ntin% is nee$e$- T!is res(lt m"y *e s'ope$- In t!is 0BD !isto%r"m+
"ltern"tin% "n$ me"n stress is $ii$e$ into *ins "n$ plotte$- T!e NB"&is 'orrespon$s
to t!e n(m*er of 'o(nts for " %ien "ltern"tin% "n$ me"n stress *in- T!is res(lt %ies
t!e (ser " me"s(re of t!e 'omposition of " lo"$in% !istory- CS('! "s if most of t!e
"ltern"tin% stress 'y'les o''(r "t " ne%"tie me"n stress-5 From t!e r"inflo; m"tri&
fi%(re+ t!e (ser '"n see t!"t most of t!e "ltern"tin% stresses !"e " positie me"n
stress "n$ t!"t in t!is '"se t!e m"Eority of "ltern"tin% stresses "re ?(ite lo;-
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tool M D"m"%e )"tri&
amage &atri- Chart
D"m"%e )"tri& C!"rt is " plot of t!e $"m"%e m"tri& "t t!e 'riti'"l lo'"tion on t!e
mo$el- T!is res(lt is only "ppli'"*le for nonB'onst"nt "mplit($e lo"$in% ;!ere
r"inflo; 'o(ntin% is nee$e$- T!is res(lt m"y *e s'ope$- T!is res(lt is simil"r to t!e
r"inflo; m"tri& e&'ept t!"t t!e per'ent $"m"%e t!"t e"'! of t!e R"inflo; *in '"(se is
plotte$ "s t!e NB"&is- As '"n *e seen from t!e O'orrespon$in% $"m"%e m"tri& for t!e
"*oe r"inflo; m"tri&+ in t!is p"rti'(l"r '"se "lt!o(%! most of t!e 'o(nts o''(r "t t!e
lo;er stress "mplit($es+ most of t!e $"m"%e o''(rs "t t!e !i%!er stress "mplit($es#
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M F"ti%(e Tools
:89')t .*m' (oodm*n #tr'## i7' r
St*t' Solved
#aterials
4*ti(!' Str'n(t" 4*)tor
,K71
3#
Loaing
T$p' (ully Reversed
S)*' 4*)tor 3#
Definition
"ptions
An*$#i# T$p' Stress Eife
M'*n Str'## T"'or$ Doodman
Str'## %ompon'nt '*uivalent +6on &ises,
Life 'nits
Unit# .*m' cycles
= )$)' i# '6!* to 3#eH44> cycles
Types of Cyclic Eoading
7nli$e static stress, which is analy"ed with calculations for a single stress state, fatigue
damage occurs when stress at a point changes over time# There are essentially four classes
of fatigue loading, with the A)SGS (atigue &odule currently supporting the first three?
i Constant amplitude, proportional loading
i Constant amplitude, non<proportional loading
i )on<constant amplitude, proportional loading
i )on<constant amplitude, non<proportional loading
8n the above descriptions, the amplitude identifier is readily understood#
8s the loading a variant of a sine wave with a single load ratio or does the
loading vary perhaps erratically, with the load ratio changing with timej
The second identifier, proportionality, describes whether the changing
load causes the principal stress a-es to change# 8f the principal stress
a-es do not change, then it is proportional loading# 8f the principal stress
a-es do change, then the cycles cannot be
counted simply and it is non<proportional loading#
Constant amplitude, 5roportional Eoading
Constant amplitude, proportional loading is the classic, /bac$ of the envelope0
calculation describing whether the load has a constant ma-imum value or continually
varies with time# Eoading is of constant amplitude because only one set of (' stress
results along with a loading ratio is re*uired to calculate the alternating and mean values#
The loading ratio is defined as the ratio of the second load to the first load +ER K E91E3,#
Eoading is proportional since only one set of (' results are needed +principal stress a-es
do not change over time,# Common types of constant amplitude loading are fully reversed
+apply a load, then apply an e*ual and opposite load! a load ratio of <3, and "ero<based
+apply a load then remove it! a load ratio of 4,# Since loading is proportional, loo$ing at a
single set of (' results can identify critical fatigue locations# Ei$ewise, since there are
only two loadings, no cycle counting or cumulative damage calculations need to be done#
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M %oo$m"n stress life rl
6alue of 8nfinite Eife
Another available option when conducting a variable amplitude fatigue analysis is the
ability to set the value used for infinite life# 8n constant amplitude loading, if the
alternating stress is lower than the lowest alternating stress on the fatigue curve, the
fatigue tool will use the life at the last point# This provides for an added level of safety
because many materials do not e-hibit an endurance limit# Iowever, in non<constant
amplitude loading, cycles with very small alternating stresses may be present and may
incorrectly predict too much damage if the number of the small stress cycles is high
enough# To help control this, the user can set the infinite life value that will be used if
the alternating stress is beyond the limit of the S) curve# Setting a higher value will
ma$e small stress cycles less damaging if they occur many times# The rainflow and
damage matri- results can be helpful in determining the effects of small stress cycles in
your loading history# The rainflow and damage matrices shown in (igure 3@ illustrates
the possible effects of infinite life# Both damage matrices came from the same loading
+and thus same rainflow matri-,, but the first damage matri- was calculated with an
infinite life if 3e> cycles and the second was calculated with an infinite life of 3e=
cycles#
FIGURE
)o$el M St"ti' Str('t(r"l M Sol(tion M %oo$m"n stress life rl
TA#LE
)o$el M St"ti' Str('t(r"l M Sol(tion M %oo$m"n stress life rl M Res(lts
:89')t
.*m'
Li7' D*m*(' S*7't$ 4*)tor E6!i&*'nt At'rn*tin( Str'##
St*t' Solved
Scope
G'om'tr$ All Bodies
Definition
T$p' Eife amage Safety (actor '*uivalent Alternating Stress
$esults
Minim!m 3#eH439 cycles :#:=; C#PP:9 5a
M*5im!m 3#e<44@ >#CP99eH44P 5a
)"teri"l D"t"
Str('t(r"l Steel /
TA#LE
Str('t(r"l Steel / M Const"nts
Structural
Yo!n(A# Mod!!# 9#eH433 5a
Poi##onA# R*tio 4#@
D'n#it$ P:;4# $g1md
T"'rm* E5p*n#ion 3#9e<44; 31gC
T'n#i' Yi'd Str'n(t" 9#;eH44: 5a
%ompr'##i&' Yi'd Str'n(t" 9#;eH44: 5a
T'n#i' Utim*t' Str'n(t" C#>eH44: 5a
%ompr'##i&' Utim*t'
Str'n(t"
4# 5a
Thermal
T"'rm* %ond!)ti&it$ >4#; .1mfgC
Sp')i7i) H'*t C@C# B1$gfgC
Electromagnetics
R'*ti&' P'rm'*8iit$ 34444
R'#i#ti&it$ 3#Pe<44P Ahmfm
FIGURE
Str('t(r"l Steel / M Altern"tin% Stress
TA#LE
Str('t(r"l Steel / M Altern"tin% Stress M Property Attri*(tes
Int'rpo*tion Eog<Eog
M'*n %!r&'
T$p'
&ean Stress
TA#LE
Str('t(r"l Steel / M Altern"tin% Stress M Altern"tin% Stress s- Cy'les
%$)'# At'rn*tin( Str'## P*
34# @#===eH44=
94# 9#:9PeH44=
;4# 3#:=>eH44=
344# 3#C3@eH44=
944# 3#4>=eH44=
9444# C#C3eH44:
34444 9#>9eH44:
94444 9#3CeH44:
3#eH44; 3#@:eH44:
9#eH44; 3#3CeH44:
3#eH44> :#>9eH44P
FIGURE Str('t(r"l Steel / M Str"inBLife P"r"meters
TA#LE
Str('t(r"l Steel / M Str"inBLife P"r"meters M Property Attri*(tes
Di#p*$ %!r&'
T$p'
Strain<Eife
TA#LE
Str('t(r"l Steel / M Str"inBLife P"r"meters M Str"inBLife P"r"meters
Str'n(t" %o'77i)i'nt P* =#9eH44:
Str'n(t" E5pon'nt <4#34>
D!)tiit$ %o'77i)i'nt 4#93@
D!)tiit$ E5pon'nt <4#CP
%$)i) Str'n(t" %o'77i)i'nt P* 3#eH44=
%$)i) Str*in H*rd'nin(
E5pon'nt
4#9
6in$ "n"lysis
Contents
3# (ile Report
Table 3 (ile 8nformation for windanalysiscf-33k443
9# &esh Report
Table 9 &esh 8nformation for windanalysiscf-33k443
@# 5hysics Report
Table @ omain 5hysics for windanalysiscf-33k443
Table C Boundary 5hysics for windanalysiscf-33k443
C# Solution Report
Table ; Boundary (lows for windanalysiscf-33k443
;# 7ser ata
(igure 9
(igure @
(igure C
(ig? .ind analysis
,- File Report
T"*le ,- (ile 8nformation for windanalysiscf-33k443
C"se windanalysiscf-33k443
File P"t! ?1pressurevesselanalysis1windanalysiscf-33k443#res
File D"te 3; &arch 944:
File Time 4@?C>?4: 5&
File Type C(U;
File Version 33#4
Fl(i$s Air at 9; C
Soli$s )one
P"rti'les )one

(igure 9# pressure distributation on face of vessel
/- )es! Report
T"*le /- &esh 8nformation for windanalysiscf-33k443
Dom"in No$es Elements
pressurevessel P@@: 9:@4:

(igure @# streamline and pressure representation

0- P!ysi's Report
T"*le 0- omain 5hysics for windanalysiscf-33k443
N"me Lo'"tion Type )"teri"ls )o$els
pressurevesse
l
BC (luid Air at 9; C
Ieat Transfer &odel K 8sothermal
Turbulence &odel K SST
Turbulent .all (unctions K Automatic
Buoyancy &odel K )on Buoyant
omain &otion K Stationary

T"*le 1- Boundary 5hysics for windanalysiscf-33k443
Dom"in N"me Lo'"tion Type Settin%s
pressurevesse
l
inlet inlet 8nlet
(low Regime K Subsonic
)ormal Speed K CP %m sl<3e
&ass And &omentum K )ormal
Speed
'ddy Eength Scale K 4#3 %me
(ractional 8ntensity K 4#4;
Turbulence K 8ntensity and Eength
Scale
pressurevesse
l
outlet outlet Autlet
(low Regime K Subsonic
&ass And &omentum K Static
5ressure
Relative 5ressure K 4 %5ae
pressurevesse
l
symp symp Symmetry
pressurevesse
l
body body .all .all 8nfluence An (low K )o Slip
pressurevesse
l
freewalls freewalls .all
.all 8nfluence An (low K (ree
Slip
pressurevesse
l
pressurevessel
efault
(C3#C, (C;#C .all .all 8nfluence An (low K )o Slip

1- Sol(tion Report
T"*le :- Boundary (lows for windanalysiscf-33k443
Lo'"tion Type )"ss Flo;
)oment(m
D Y N
body Boundary 4#4444eH44 <3#P;>3eH4@ 9#P>4;eH49 <:#@PP>eH43
freewalls Boundary 4#4444eH44 <3#C=;@eH49 4#4444eH44 4#4444eH44
inlet Boundary 3#PC4;eH49 <;#3:33e<4P <:#;99=eH4@ 3#;;P=e<4>
outlet Boundary <3#PC4;eH49 3#@39=eH43 :#3=9=eH4@ <9#@3;3eH44
pressurevessel
efault
Boundary 4#4444eH44 <3#=@9;e<49 ;#CCCPeH43 :#;=>PeH43
symp Boundary 4#4444eH44 3#:=99eH4@ 4#4444eH44 4#4444eH44
#y interpol"tion ;e %et: for 1, m3s of
;in$ spee$ t!e ;in$ press(re is >0. N3
9
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t"*le ;e 'omp"re t!e res(lt ;!i'! is
ery "''(r"te-
INTRODUCTION TO GLASS LINING
8ntroduction of Dlass lining +Dlasteel,
8n recent years, because of the e-pansion of the chemical process and pharmaceutical
industries world<wide and increased concerns for safety and *uality control, 5faudler
began investigating new approaches in glass development that would lead to a glass
composition that could be made available to all users of glass<lined e*uipment#
Together with the chemical process industry and with the co<operation of 5faudler
divisions around the world, 5faudler established the criteria for a new composition?
A non<crystalline structure#
8ncreased resistance to acid and al$ali corrosion#
Iigh resistance to impact#
Iigh resistance to thermally induced stresses#
A formulation that could be easily produced by all 5faudler manufacturing plants#
The result is Dlasteel =344c, 5faudlerYs first binternational glassb, offering an unmatched
combination of corrosion resistance, impact strength, thermal shoc$ resistance, non<
adherence and heat transfer efficiency#
)ow D&& 5faudler customers, regardless of where their processing operations are
located, can purchase a single glass system and be assured of getting the same high
*uality worldwide# .ith Dlasteel =344 c, D&& 5faudler sets a standard the world can
depend on#
glass# Iowever, these are very recipe sensitive and general statements cannot usually be
made# An e-ception to this are chemistries that involve the element silicon +Si,, especially
when ionised, e#g# Si, SiA# Relatively small amounts of dissolved SiA can be highly
effective in reducing the corrosion rate of the Dlasteel =344 system, thereby greatly
e-tending its usage range# 8t has also been shown that colloidal silica additions to recipes
containing the highly corrosive fluorine ion +(<, can drastically reduce the corrosive rate#
.ater
5ure .ater
5ure water in the li*uid phase is not very aggressive# 8ts behaviour resembles highly
diluted acid and corrodes only the surface layer of the glass +bion e-change processb,# At
3P4gC, a corrosion rate of 4#3 mm1year can be e-pected#
But because this water is an unbuffered, pI<unstable system, even a slight al$ali"ation
can change the situation# 8f there is a shift toward higher pI values, the isocorrosion
curves for diluted al$aline solutions have to be consulted for orientation purposes#
Dlasteel =344 c is highly resistant to condensing water vapour# Iowever, to counter the
possible danger of the condensate shifting to an al$aline pI, it is recommended that the
vessel contents be slightly acidified with a volatile acid, e#g# hydrochloric or acetic acid#
8t is also highly recommended that the unjac$eted top head be insulated or heat traced to
reduce condensation formation#
Agueous )eutral pI&edia
.ith these type media, e#g# tap water, salt solutions, corrosion rate depends greatly on the
type and *uantity of the dissolved substance# Carbonates and phosphates usually increase
the rate while alcohols and some ionic species, e#g# A3@H, On9H Ca9H, may reduce it#
Al$alis
As al$ali concentration rises, corrosion rate increases# Also, the temperature gradient for
al$aline glass corrosion, is steeper# The result is that concentrated al$alis re*uire a more
definite setting of the temperature limits#
The corrosion rate of concentrated al$aline solutions cannot be e-pressed by the pI value
alone# (or a*ueous solutions of al$aline materials with a pI value of 3C, the particular
concentration must also be considered to establish appropriate operating temperatures#
Ather factors affecting al$aline corrosion are the specific reaction and the dissolving
ability of the chemical, the influence of the nature and amount of other dissolved
substances and agitation#
8socorrosion curves for sodium hydro-ide, potassium hydro-ide, sodium carbonate and
ammonia ta$e into account technically relevant parameters influencing the rate of
corrosion! for e-ample, the volume1 surface area ratio, inhibition effects by calcium ions,
al$aline concentration and temperature#
7nder actual operating conditions, even very slight contamination +tap water in sodium
hydro-ide, for e-ample, can cause major changes in the rate of corrosion# Ather factors,
such as product velocity and splash "one, can affect the corrosion rate as well# ue to
these interactive comple-ities, meaningful testing is strongly advised#
To eliminate the influence of the testing e*uipment on the rate of corrosion, procedures
are carried out in polypropylene bottles# (or solutions above the boiling point, autoclaves
with 5T(' inserts were used# By comparing the results with control e-periments, it is
proven that the testing e*uipment does not have an inhibiting effect#
5faudler 7ltra<Dlas >;44 c
3 # '-tends the range of Dlasteelc applications#
9# Allows safe and easy handling of high temperature processes
never before approved for Dlasteel e*uipment#
@# 5rovides potential for reduced cycle time compared to conventional
vessel glass#
C# 5rovides e-tended thermal shoc$ protection for faster heating
and cooling#
;# 5rovides increased operating safety margin through its enhanced
thermal protection#
># 8s ideal for the higher temperatures re*uired by todayYs chemical
process applications#
The features of D&& 5faudler 7ltra<Dlas >;44 c are the result of changes in glass
composition and material preparation, altered applications and firing procedures, as well
as changes in e*uipment design and materials of construction# These changes permit
trouble<free application of the re*uired high<stress coating and provide the highly
corrosive<resistant glass<lined surface for which 5faudler has been respected for years#
Technical details of corrosion rates in common chemicals and thermal operation limits are
available on re*uest#
Temperature Eimits

Although 7ltra<Dlas >;44 c has a high degree of helpful compressive stress in the glass
layer there are definite limits to the level of thermal stress which the glass can withstand
without incurring damage?
Anly two thermal conditions must be considered when determining the temperature
limits?
A# 8ntroduction of media into a vessel#
B# 8ntroduction of media into a jac$et#
CA7T8A)? bSafeb operating temperatures vary with conditions# Because so many
variables are involved, temperature ranges are given only as a guide# .here in practical,
operation below the ma-imum and above the minimum is recommended# Contact
5faudler for details#
Type C@44 Dlass Coatings
Type C@44 c glass coatings represent a new aspect of this tradition and are designed to
bridge a perceived gap in the application range# D&& 5faudler Type C@44 c glass is still
an acidic type of glass, but its primary application is based on improved al$ali resistance#
Type C@44 glass coatings are advisable wherever al$aline conditions prevail during the
cycle, or as a result of concentration and temperature, or where concentration and1or
temperature conditions e-ceed permissible limits for conventional glass#
8n addition, Type C@44 c glass coatings are advisable where any of the following
conditions e-ist?
5rotection of al$aline products against metal contamination#
anger of discoloration of al$aline products due to incorporation of metals#
Stabili"ation of high<molecular al$alis sensitive to metal contact#
8nade*uate redo- stability of the vessel material in the al$aline range#
Compared to our world renowned standard glass, Type C@44 c has three times better
al$ali resistance# This means that higher process temperatures can be used, or that, under
otherwise e*ual conditions, these glass coatings will have three times the life
e-pectations#
The Type C@44 c glass does ma$e a slight concession in the area of acid resistance#
Although it is ade*uate for mild service, it is not recommended for aggressive acid
conditions#
Corrosion Resistance
(or pure acids and bases most commonly used in the chemical industry , technically
relevant parameters influencing the rate of corrosion +for e-ample, the volume1surface
area ratio, inhibition effects, concentration, and temperature, are considered#
8n practical operation these materials are always encountered with li*uid additives,
dissolved substances or gases which may have positive or negative effects on resistance#
.e therefore recommend performing corrosion tests or contacting a 5faudler consultant
to assure material suitability for individual processes#
The )eed (or 55D
.hen the re*uirements of the Bul$ rug industry were studied recently, in conte-t of the
stringent re*uirements of D&5 and (A, the need for a different glass was evident# Two
of the re*uirements of the pharmaceutical industry are increased purity in order to comply
with the (A and D&5 re*uirements and alternating al$ali1acid operation#
The process e*uipment of the chemical and pharmaceutical industries has so far been
very similar < especially in terms of glasslined reactors and components# 8n light of the
survey, 5faudlerYs response was a novel glass tailored to the needs of manufacturing
pharmaceutical products, vitamins and fine chemicals#

Appendi-
#I#LOGRAP2Y
Dennis )oss
2i"$ri F"r<$"7
C-S S!"rm"
Somn"t! '!"top"$!"y
For Ansys :
T(tori"ls of 'f& ,,-.


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DESIGN AND ANALYSIS OF

K hoop stress for the material of the cylinder#

> K 9#; +=#9P,

K Auter iameter Af 6essels

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