Stress and Fatigue Analysis of ASME Pressure Vessels Using PDF

Adrian Jensen, Predictive Engineering | Brian Reiling, Endeavor Analysis
Stress and Fatigue Analysis of ASME Pressure

Vessels using Femap API and Fatigue Essentials
FEMAP SYMPOSIUM 2014

Femap Symposium 2014
May 14-16, Atlanta, GA, USA Discover New Insights
Unrestricted © Siemens AG 2014
Abstract
The application of the ASME Section VIII, Division 2 pressure vessel code is
becoming increasingly more popular since it facilitates the optimization of
pressure vessels via detailed stress and fatigue analysis.
The basis of this analysis is the creation of a high quality plate and/or solid mesh
followed by accurate load application and then the extraction and classification of
stresses per code.

Page 2 2014-05-15 Siemens PLM Software
Abstract
Much of this work is algebraic in nature

and is well suited for automation.
Through the use of Femap’s Application
Programing Interface (API) and
customized spreadsheets, the analysis
of ASME-type pressure vessels can be
accelerated from days to minutes.
In many cases, once the vessel has

passed its baseline load requirements, a
fatigue analysis is required to address
cyclic mechanical and thermal loads.

Abstract
Although fatigue analysis can be

quite basic and almost an
accounting exercise, the more
stringent ASME requirements of
specialized fatigue curves and
stress output as stress intensity
complicates the procedure.
To simplify this calculation, the software program Fatigue Essentials is used and
a brief example is presented on how this program automates the fatigue
calculation.

Modeling, Analysis and Post Processing
ASME VIII Pressure Vessels

ASME Section VIII Pressure Vessels
• What happened in Massachusetts?

• Pressure Loads (>15 psig)
• Nozzle Loads
• Fluid Dead Weight
• Thermal Loads
• Seismic Loads
• Highly Ductile Stainless Steel
• Stress Analysis Method
• Specialized Post Processing

What happened in Massachusetts?
On March 10, 1905, a catastrophic boiler explosion occurred in a shoe factory in

Brockton, Massachusetts, that killed 58 and injured 150 people. At about 8:00
AM there were around 400 employees at the R. B. Grover & Company shoe
factory in Campello, when the boiler exploded, shot through the roof, and caused
the building to collapse.

What happened in Massachusetts?
The boiler traveled several hundred feet, damaging a number of buildings and
coming to rest in the wall of a house. Thirty-six of the victims were never
identified and were buried in a common grave, where a monument to the victims
was later erected by the city.
This and similar explosions brought

about the development of the ASME
Boiler and Pressure Vessel Code in
1915.
Balmer, Robert T (2010). Modern Engineering Thermodynamics. 13.10 Modern Steam Power Plants: Academic Press.

Stress Analysis Method
• Surface Stress
• Membrane Stress
• Localized Stress
• Thermal Stress
Post Processing
• Stress Intensity Calculator

• Membrane Stress Calculator
• Stress Linearization Tool

Loading Conditions
• Pressure loads (external or internal) in excess of 15 psig

• Fluid dead weight loads (hydrostatic pressure)
• Thermal loads (hot/cold fluid, cooling jackets, local/general)
• Seismic Loads (requires analysis even if the vessel is Div. 1)
Materials
• Highly ductile stainless steel

• Excellent fatigue properties
• “Allowable Stress” based on σy

Development and Load Application
Transient Thermal Analysis

• Transient Temperature Profile

• Transient Boundary Conditions
• Heat Transfer Coefficients
• Modeling Considerations
• Femap API

• Transient Temperature Profile

• The thick wall vessel has a significant thermal gradient
though wall thickness and along the length of the vessel
Negligible ΔT,
• Transient Boundary Conditions Negligible h
• The vessel is filling throughout the analysis

• Gas, Boiling Liquid and Non-boiling Liquid have different Low ΔT, High h
temperature deltas and heat transfer coefficients
• The inside surface was meshed with membrane elements

• This allows for easy thermal load application High ΔT, Low h
• Also provides better stress recovery

Stress Life Made Easy
Fatigue Essentials

Fatigue Analysis Using Fatigue Essentials
Fatigue Essentials is intended to provide a user friendly tool for conducting

Stress-Life analysis either using classical stress calculations or linked with
FEMAP and using the finite element generated stresses.

More advanced techniques to account for high strain – low cycle (Strain-Life) are
available as well as more advanced models of crack initiation and multi-axial
stress situations but in most cases these are not necessary for the design of
durable structure.
Fatigue Essentials is intended to

provide a user friendly tool for
conducting Stress-Life analysis
either using classical stress
calculations or linked with FEMAP
and using the finite element
generated stresses.

Fatigue Essentials is set up to guide the

user through the analysis by following a
tree structure.
General analysis options are selected

following loads, materials, and spectrum
branches. Within each branch are
options for analysis variations or input
methods.
When the model solves there are

multiple options for selecting output to
the screen. For large models (usually
FEA based) it is usually best to push a
damage plot back to FEMAP to view.
• Analysis Options
• Load Cases
• Material Definition
• Mean Stress Correction
• Spectrum Definition
• Fatigue Damage Calculation
• Material Plot
• Report Generation

Analysis Options
• Scatter Factor
o Easy way to add reliability
• Stress Units
• Rainflow per ASTM E1049

o Rainflow
o Peak Counting
• Stress Modification
o Stress Multipliers

Load Cases (Details)
• Enter inter-actively within

GUI
`
• Load from CSV file
• Load from FEMAP

Material Definition
• Choose from existing library

or create new material curve
• Flexible input allows user to

input any curve and account
for confidence and reliability
vs using a mean curve.

Material Definition
• Curve can be created three

different ways
• Tabulated
o Log-Log interpolation
• Estimated
o Based on percentages of
material ultimate strength
• Walker Equation (MMPDS)

Mean Stress Correction
Four methods of correcting for mean stress (stress ratio)

Material Assignment
• Once material is created
and/or selected it is
assigned to the analysis
detail(s)
• Can have multiple details

and multiple materials in
the same analysis if desired

Spectrum Definition
• Spectrum can either be

entered in using the GUI or
can be read in from CSV
file.
• The number of spectrum

repeats is entered here
• Multiple spectrums can be

used and the damages for
each spectrum are added
together

Fatigue Damage
• Options for report

generation are entered
here
• For large models it is best

to have minimal reporting
• Small models it can be

useful to view additional
data

Material Plot
• The material curve is

plotted for reference at
three stress ratios:
o R = -1
o R=0
o R = 0.5

Report Generation
• The report can generate

plots and tables of:
o Details and stresses

o Spectra plot
o Spectra table
o Rainflow pairs
o Damage summary
o Margin of safety


Contact Information
Adrian Jensen
Sr. Staff Engineer
Predictive Engineering, Inc.
Phone: (503) 206-5571
E-mail:
adrian.jensen@predictiveengineering.com
Brian Reiling
Partner / Principal Engineer
Endeavor Analysis, LLC
Phone: (206) 805-9030
E-mail:
brian.reiling@endeavoranalysis.com


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Adrian Jensen, Predictive Engineering | Brian Reiling, Endeavor Analysis

Stress and Fatigue Analysis of ASME Pressure

FEMAP SYMPOSIUM 2014

Unrestricted © Siemens AG 2014

Much of this work is algebraic in nature

In many cases, once the vessel has

Unrestricted © Siemens AG 2014

Although fatigue analysis can be

Unrestricted © Siemens AG 2014

ASME VIII Pressure Vessels

Unrestricted © Siemens AG 2014

• What happened in Massachusetts?

Unrestricted © Siemens AG 2014

What happened in Massachusetts?

On March 10, 1905, a catastrophic boiler explosion occurred in a shoe factory in

Unrestricted © Siemens AG 2014

What happened in Massachusetts?

This and similar explosions brought

Unrestricted © Siemens AG 2014

Stress Analysis Method

• Stress Intensity Calculator

Unrestricted © Siemens AG 2014

• Pressure loads (external or internal) in excess of 15 psig

• Highly ductile stainless steel

Unrestricted © Siemens AG 2014

Transient Thermal Analysis

Unrestricted © Siemens AG 2014

• Transient Temperature Profile

Unrestricted © Siemens AG 2014

• Transient Temperature Profile

• The vessel is filling throughout the analysis

• The inside surface was meshed with membrane elements

Unrestricted © Siemens AG 2014

Unrestricted © Siemens AG 2014

Fatigue Essentials is intended to provide a user friendly tool for conducting

Unrestricted © Siemens AG 2014

Fatigue Essentials is intended to

Unrestricted © Siemens AG 2014

Fatigue Essentials is set up to guide the

General analysis options are selected

When the model solves there are

Unrestricted © Siemens AG 2014

• Rainflow per ASTM E1049

Unrestricted © Siemens AG 2014

Load Cases (Details)

• Enter inter-actively within

• Load from FEMAP

Unrestricted © Siemens AG 2014

• Choose from existing library

• Flexible input allows user to

Unrestricted © Siemens AG 2014

• Curve can be created three

• Walker Equation (MMPDS)

Unrestricted © Siemens AG 2014

Mean Stress Correction

Four methods of correcting for mean stress (stress ratio)

Unrestricted © Siemens AG 2014

• Can have multiple details

Unrestricted © Siemens AG 2014

• Spectrum can either be

• The number of spectrum

• Multiple spectrums can be

Unrestricted © Siemens AG 2014