Fea Pressure Vessel

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FE Analysis : Pressure Vessel

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INDEX 1. INTRODUCTION 2. OBJECTIVE 3. ASSUMPTIONS 4. CAD MODEL

5. MESHED MODEL 6. FE MODEL INFORMATION 7. MATERIAL PROPERTIES 8. LOADS AND BOUNDARY CONDITIONS

9. PROCEDURE 10. RESULTS – DEFLECTIONS AND STRESSES 11. RESULTS SUMMARY 12. OBSERVATIONS AND CONCLUSION 3

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1. INTRODUCTION This Report consists of Results and Conclusions for FE Structural Stress Analysis of Vessel carried out to evaluate the Design adequacy for various loads like Design Pressure, Hydro Test Pressure & Nozzles External Loads. Based on the Inputs, Vessel dish end from flange with 9 Nos. Nozzles, 2 Stiffener Rings and 2 Sliding Saddles are considered for the Analysis. Analysis is carried out for 3 Load Cases : Load Case-1 - First is for Internal Pressure, Temperature and Nozzles Loads; Load Case-2 – Second is for Nozzle Loads NO Internal Pressure; Load Case-3 - Third is for Hydro Test for the Pressure of 7.2 Bars.

2.0

OBJECTIVE

To evaluate the design of Vessel Nozzles, Saddles and Stiffeners under various Loads.

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3.0 ASSUMPTIONS 1. Material Properties are correct as per ASME Sec-II D. 2. Linear Material of Steel are taken for the Analysis Purpose. 3. Loads and Boundary Conditions applied as per the Supplied Inputs.

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4. CAD MODEL : Assembly considered for FEA Nozzles S3, S4, S5, S8, S9, S1A , S6A, S2A are areas of interest. STIFFNER RING-2 S6A

S5

STIFFNER RING-1

S2A

S4

S9 S1A

S8

S3 SLIDING SADDLE

FIXED SADDLE 6

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5. MESHED MODEL : Assembly considered for FEA

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6. FE MODEL INFORMATION : The Vessel with nozzles is meshed with 2nd Order Tetrahedral Elements. No. of Nodes in the Model = 3,73,787 No. of Elements in the Model = 1,98,188 The quality of elements is qualifying following criteria:From all the components in the FE Model Assembly, 99% of elements Qualify for :Achieved Tetra Collapse Skew Jacobian Vol. Aspect Ratio Min. Angle Tria Faces Max. Angle Tria Faces For reference only

> 0.1 < 60 > 0.5 < 9.75 > 15 < 130

(0% failed) (0% failed) (0% failed) (0% failed) (0% failed) (0% failed)

7. MATERIAL PROPERTIES : MATERIAL

Young’s Modulus (MPA)

Poisson's Ratio

Yield Strength (MPa)

Tensile Strength (MPa)

Steel SA 516 Gr 65

198,000

0.29

240

450

Properties of SA 516 Gr 65, as per ASME Sec-II, Part-D, Table-5A •Thermal conductivity : 0.0479 W/mm/oC •Thermal Expansion : 12.4 E-6 / oC •Elongation : 19% min in 8” 23% min in 2” •Max. Allowable Stress (Sm) : 144 MPa

2010 ASME Boiler and pressure vessel code, Section II, Part D 8

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8. Loads and Boundary Conditions

S6A

inner surface of vessel and nozzles S2A Design pressure applied on all the S5

S4

S9 S1A

S8

No external loads on S3 & S4 9

S3 Hydro Test Pressure = 7.2Bar, Design Temp. 159Deg. C

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9.0 PROCEDURE • 2D drawing is converted to 3D model as per the drawings.

• The model is imported into Hyper mesh and meshed using solid tetra elements. • These elements were imported to ANSYS and assigned the Material Properties to each component as specified in drawings. • The boundary conditions are applied as per Section-8 in this report. • Design pressure of 5.5 Bars is applied over the inner surfaces of vessel and nozzles. • Nozzle loads were applied as per nozzle loads table. • For load cases, temperature of 159oC is applied over the inner surfaces of vessel.

• Model is solved for 3 different load cases as specified in Introduction section in this report.

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10. RESULTS Load Case-1 : Internal pressure, Temperature & nozzles loads

CONSTRAINTS ON SLIDING SADDLE

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9.1 Stress Analysis Results : Load Case-1 Deflection Plot (mm)

Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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9.2 Stress Analysis Results : Load Case-1 Deflection Plot (mm)

Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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9.3 Stress Analysis Results : Load Case-1 Deflection Plot (mm)

Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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9.4 Stress Analysis Results : Load Case-1 Deflection Plot (mm)

Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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9.5 Stress Analysis Results : Load Case-1 Stress Plot (MPa) : Von-Mises Stresses S6A S5

S2A

S4 S9 S3

S2A

S8

S1A

Stress linearization

S5 Stress (Pl+Pb+Q) = 358 MPa

Stress (Pl+Pb+Q) = 291 MPa

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16 Stress (Pl+Pb+Q) = 50 MPa

9.6 Stress Analysis Results : Load Case-1 Stress Plot (MPa) : Von-Mises Stresses S6A S5

S2A

S4 S9 Stress linearization

S8

S3

S8

S1A

S6A

Stress (Pl+Pb+Q) = 396 MPa

Stress (Pl+Pb+Q) = 73 MPa Stress (Pl+Pb+Q) = 302 MPa

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9.7 Stress Analysis Results : Load Case-1 Stress Plot (MPa) : Von-Mises Stresses S4

S6A

S5

S2A

S4 S9 Stress linearization

S3

S8

S1A

S9

Stress (Pl+Pb+Q) = 58 MPa

Stress (Pl+Pb+Q) = 95 MPa

Stress (Pl+Pb+Q) = 31 MPa

Stress (Pl+Pb+Q) = 129 MPa Stress (Pl+Pb+Q) = 101 MPa

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9.8 Stress Analysis Results : Load Case-1 S6A

Stress Plot (MPa) : Von-Mises Stresses S3

S5

S2A

S4 S9 Stress linearization

S3

S8

S1A

S1A Stress (Pl+Pb+Q) = 345 MPa

Stress (Pl+Pb+Q) = 35 MPa 19

07/10/2011

Stress (Pl+Pb+Q) = 248 MPa

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9.9 Stress Analysis Results : Load Case-1 S5 S6A

S2A

Stress Plot (MPa) : Von-Mises Stresses S4

R1

R2

S9

S3

S8

S1A

R1 R2

Stress (Pl+Pb+Q) = 342 MPa

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Stress (Pl+Pb+Q) = 91 MPa

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9.10 Stress Analysis Results : Load Case-1 Stress Plot (MPa) : von-Mises Stresses

Sliding Saddle

Fixed Saddle

Stress (Pl+Pb+Q) = 1055 MPa

Stress (Pl+Pb+Q) = 985 MPa

After masking localized stress areas 21

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10. RESULTS Load Case-2 : Nozzles loads, NO Internal Pressure & Temperature

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10.1 Stress Analysis Results : Load Case-2

Deflection Plot (mm)

Nozzles loads only

Max. Deflection = 3 mm

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10.2 Stress Analysis Results : Load Case-2

Deflection Plot (mm)

Nozzles loads only

Top View

Bottom View

Max. Deflection = 0.87mm

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10.3 Stress Analysis Results : Load Case-2 S6A

Stress Plot (MPa) : Von-Mises Stresses

S5

S2A

S4 S9 S3

S2A

S8

S1A

Stress linearization

S5 Stress (Pl+Pb+Q) = 227 MPa

Stress (Pl+Pb+Q) = 7 MPa

Stress (Pl+Pb+Q) = 154 MPa

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10.4 Stress Analysis Results : Load Case-2 Stress Plot (MPa) : Von-Mises Stresses

S6A

S5

S2A

S4 S9 S3

S8

S8

S1A

Stress linearization

S6A Stress (Pl+Pb+Q) = 321 MPa

Stress (Pl+Pb+Q) = 2.5 MPa 26

Stress (Pl+Pb+Q) = 227 MPa

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10.5 Stress Analysis Results : Load Case-2 Stress Plot (MPa) : Von-Mises Stresses

S6A

S5

S2A

S4

S4 S9 S3

S8

S1A

Stress linearization

S9

Stress (Pl+Pb+Q) = 17 MPa

Stress (Pl+Pb+Q) = 4 MPa

Stress (Pl+Pb+Q) = 1 MPa

Stress (Pl+Pb+Q) = 14 MPa

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10.6 Stress Analysis Results : Load Case-2 Stress Plot (MPa) : Von-Mises Stresses

S6A

S5

S2A

S4

S3

S9

Stress linearization

S3

S8

S1A

S1A Stress (Pl+Pb+Q) = 209 MPa

Stress (Pl+Pb+Q) = 125 MPa

Stress (Pl+Pb+Q) = 12 MPa

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10.7 Stress Analysis Results : Load Case-2 S5 S6A

S2A

Stress Plot (MPa) : Von-Mises Stresses S4

R1

R2

S9

S3

S8

S1A

R1 R2

S1A

Stress (Pl+Pb+Q) = 72 MPa

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29 Stress (Pl+Pb+Q) = 32 MPa

10.8 Stress Analysis Results : Load Case-2 Stress Plot (MPa) : Von-Mises Stresses R2

R1

S1A

Sliding Saddle

Fixed Saddle

Stress (Pl+Pb+Q) = 28 MPa

Stress (Pl+Pb+Q) = 15 MPa

After masking localized stress areas 30

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11. RESULTS Load Case-3 : Hydro Test

Hydro Pressure=7.2 bar

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11.1 Deflection Analysis Results : Load Case-3 Deflection Plot (mm)

Max. Deflection = 19mm

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11.2 Deflection Analysis Results : Load Case-3 Deflection Plot (mm)

Max. Deflection = 19mm

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11.3 Deflection Analysis Results : Load Case-3 Deflection Plot (mm)

Max. Deflection = 19mm

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11.4 Deflection Analysis Results : Load Case-3 Deflection Plot (mm)

Max. Deflection = 19mm

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11.5 Stress Analysis Results : Load Case-3 Stress Plot (MPa) : Von-Mises Stresses

S6A

S5

S2A

S4 S9 S3

S2A

S8

S1A

Stress linearization

S5 Stress (Pl+Pb+Q) = 335 MPa

Stress (Pl+Pb+Q) = 257 MPa Stress (Pl+Pb+Q) = 106 MPa 36

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11.6 Stress Analysis Results : Load Case-3 Stress Plot (MPa) : Von-Mises Stresses S6A S5

S2A

S4 S9

Stress linearization

S3

S8

S8

S1A

S6A Stress (Pl+Pb+Q) = 207 MPa

Stress (Pl+Pb+Q) = 76 MPa Stress (Pl+Pb+Q) = 164 MPa

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11.7 Stress Analysis Results : Load Case-3 Stress Plot (MPa) : Von-Mises Stresses

S6A

S5

S2A

S4

S4

Stress linearization

S9 S3

S8

S1A

S9

Stress (Pl+Pb+Q) = 137 MPa Stress (Pl+Pb+Q) = 69 MPa

Stress (Pl+Pb+Q) = 137 MPa Stress (Pl+Pb+Q) = 157 MPa

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11.8 Stress Analysis Results : Load Case-3 Stress Plot (MPa) : Von-Mises Stresses S3

S5

S6A

S2A

S4 S9

Stress linearization

S3

S8

S1A

Stress (Pl+Pb+Q) = 254 MPa

S1A

Stress (Pl+Pb+Q) = 71 MPa

Stress (Pl+Pb+Q) = 271 MPa

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11.9 Stress Analysis Results : Load Case-3 S5 S6A

S2A

Stress Plot (MPa) : Von-Mises Stresses S4

R1

R2

S9

S3

S8

S1A

R1 R2

Stress (Pl+Pb+Q) = 342MPa

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Stress (Pl+Pb+Q) = 114 MPa

11.10 Stress Analysis Results : Load Case-3 Stress Plot (MPa) : Von-Mises Stresses R2

Sliding Saddle

Fixed Saddle Stress (Pl+Pb+Q) = 1104 MPa

After masking localized stress areas

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Stress (Pl+Pb+Q) = 861 MPa

12.0 Result Summary:Stress Categories

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12.1 Stress Result Summary:Nozzle No.

S3

S4

S5

S8

Stress Category

Load Case No.

Stresses Baseline Iteration (MPa)

Pl+Pb <1.5*Sm (207 MPa)

LC-2

209

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

38

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

254

Pl+Pb <1.5*Sm (207 MPa)

LC-2

17

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

58

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

137

Pl+Pb <1.5*Sm (207 MPa)

LC-2

7

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

50

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

106

Pl+Pb <1.5*Sm (207 MPa)

LC-2

321

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

396

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

207

Stress Sm = 144 MPa For reference only

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12.2 Stress Result Summary:Nozzle No.

S6A

S9

S1A

S2A

Stress Category

Load Case No.

Stresses Baseline Iteration (MPa)

Pl+Pb <1.5*Sm (207 MPa)

LC-2

2.5

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

73

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

76

Pl+Pb <1.5*Sm (207 MPa)

LC-2

1

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

31

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

69

Pl+Pb <1.5*Sm (207 MPa)

LC-2

12

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

35

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

71

Pl+Pb <1.5*Sm (207 MPa)

LC-2

227

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

358

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

335

Stress Sm = 144 MPa For reference only

12.3 Stress Result Summary:Nozzle No.

Stress Category

Load Case No.

Sliding Saddle

Pl+Pb <1.5*Sm (207 MPa)

LC-2

28

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

1055

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

1104

Pl+Pb <1.5*Sm (207 MPa)

LC-2

15

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

985

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

861

Pl+Pb <1.5*Sm (207 MPa)

LC-2

32

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

91

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

114

Pl+Pb <1.5*Sm (207 MPa)

LC-2

72

Pl+Pb+Q <3*Sm (414 MPa)

LC-1

342

Pl+Pb+Q <3*Sm (414 MPa)

LC-3

342

Fixed Saddle

Stiffener Ring R1

Stiffener Ring R2

Stress Sm = 144 MPa For reference only

Stresses Baseline Iteration (MPa)

12.4 OBSERVATIONS AND CONCLUSION

1. Stresses in all the Nozzles are below respective Allowable Stresses as per the Stress Categories of ASME Section-II D for all load cases, hence design is safe to carry these loads.

2. Stresses in both Saddles exceeds respective Allowable Stresses, hence Saddle Design needs the modification to carry various loads. 3. Stresses in both Stiffener Rings are below respective Allowable Stresses, hence Stiffener Ring Design is safe to carry various loads.

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