Академический Документы
Профессиональный Документы
Культура Документы
This module should take the user through pressure vessel design
application (PVDA). The necessary background is built by the modules “
Mechanical Design Fundamentals” and “Reinforcement Calculations”.
Shape
Size
The spatial dimensions of each of these shapes can be defined in terms
of a few size primitives. For example, a sphere is completely defined by
its diameter. A cylinder is completely defined by its diameter and length etc.
OD = ID – 2t.
The values for essential size parameters for each of the shapes comprising
the composite vessel shape need to be provided by the user. Connectivity of
shapes in adjacent layers allows internal fixation of sizes of some shapes.
Wall Thickness
Design codes provide formulae for calculating the minimum wall
thickness for the standard shapes. The application of the formula for any
specific shape requires the user to provide design temperature, design
pressure, material of construction and its allowable stress at the design
temperature, fabrication and inspection procedure and weld quality
factor or weld joint efficiency. The thickness calculated using
applicable code formula is the regulation thickness. This much thickness
must be available uniformly everywhere in the vessel body.
Available wall thickness is the thickness left after deducting the mill
tolerance and corrosion allowance from the recommended wall thickness.
This is obviously more than or at least equal to the regulation thickness. The
maximum pressure that the shape can withstand with this available thickness
while still complying with the regulation thickness formula is calculated.
This is the Maximum Working Pressure (MWP) allowed by the
recommended wall thickness.
After fabrication and assembly, the vessel is tested for its pressure
integrity. The test if often carried out at a pressure higher than the design
pressure as well as the maximum working pressure. It is rated so as to
develop in the weakest vessel portion stresses equivalent to the yield stress
of the material of construction. The hydrotest pressure is obtained by
multiplying the MWP by a factor greater than 1. Logically it is 1-5, the
safety factor used in getting allowable stress from material’s yield stress.
Thermal Insulation
A process vessel operating at super-ambient or sub-ambient
temperature needs to be insulated to minimize heat egress or ingress
respectively. Insulation also is needed as a safety measure so that the skin
temperature (exposed surface temperature) of the vessel parts is not very
high. The insulation thickness can be calculated on one or more of the three
criteria, namely, based on maximum allowable skin temperature, maximum
tolerable rate of heat egress/ ingress or economic criteria (considering the
capital investment vis-a-vis cost of heat energy lost). PVDA supports the
three design criteria.
Theoretical Basis
Consider an infinite, flat, uniformly thick plate of a metal subjected to
tensile load along one direction. The load is such that it develops tensile
stresses σ y all along its skin as shown
σy σy σy σy
σy σy σy σy
σt
r
σ a 2 σ 3a 4
σt = 1 + − 1 + 4 cos 2θ
2 r 2 2 r
1 2 3 4 5
The calculations and the stress profiles offer important insights into
the implications of making an opening.
The situation along the 12 O’clock axis is even more interesting. The
tangential position along this axis is transverse to the original stress lines.
There were no stresses along this direction initially. Cutting of a hole,
however, induced a compressive stress σ y at the edge of the opening. The
compressive stress reverses within one radius, becomes tensile and then dies
down fast.
Sy
Sa =
1.5
This, when coupled with the observed stress intensification around the
opening, indicates the engineering unacceptability of stress intensification.
For example, let the plate be stretched initially such that the tensile stresses
reach the allowable level for the MoC. When the hole is punctured, a stress
intensification factor of 3 would mean that the stresses would reach a level
of 3 Sa or 2 Sy. The plate would thus yield plastically and deform around the
opening. This may not be acceptable. Something therefore needs to be done
around the opening to keep the intensified stresses within the allowable as
much as possible.
Let us now revisit some of the assumptions behind the theory giving
us the formula that led to above conclusions.
One of the assumptions was regarding the plate being flat. Pressure
vessels and their closures are essentially not so. However the dimensions of
the shape on which an opening for the nozzle is made is much larger as
compared to the nozzle diameter. The nozzle thus sees a reasonably flat
surface around it, if not a perfectly flat one. We therefore persume that the
assumption is not that restrictive as to make the theory inapplicable in
practical situations.
(High Low)
d
The load bearing metal cross-section that would be lost because of
removing a disc of diameter ‘d’ is clearly not the area of the circle. Instead it
is a rectangle of width ‘d’ and thickness ‘t’.
t
t d
2d
d t
Another point is regarding the choice of the formula to be used for the
regulation thickness itself. It should be the code formula for a shape ‘seen’
by the nozzle. It may not make difference if the nozzle is placed on a sphere,
hemisphere, cylinder, flat plate or an ellipsoidal closure. For a dished
(torispherical) closure or a cone housing a nozzle, it does make a difference.
Similar is the case for nozzle on a cone. The thickness of the cone is
arrived at using the base diameter of the cone. As one moves towards the tip
of the cone, the regulation thickness requirement decreases and extra
thickness increases. To avail of this extra thickness in reinforcement
calculation, one should calculate the regulation thickness afresh using cone
diameter at a level corresponding to the center of the opening. Note that this
consideration also reduces the value of regulation thickness, thereby
lowering the estimate of area lost. In fact, a properly located nozzle on a
cone can often be made ‘self compensating’.
Let us now put together the balance sheet of the load bearing metal
area affected due to an opening.
Area Lost
AL = ( d i + 2 ∈)TR
Area Available
From Header:
A1A = ( d i + 2 ∈)( T − TR − ∈ − M T )
M
MT = T
100
AA2 = 2 H 1 ( t − t R − ∈ − mT )
m
( mT = t )
100
AA3 = 2 H 2 ( t − 2 ∈ −mT )
H 2 = (d i + 2ε )(t − 2ε )
The balance sheet attempts to hammer down the estimate of area lost.
The area available is estimated by looking for as much area available in the
vicinity as possible. In fact, even ‘weldment’ area in the affected rectangle is
accounted for in area available if such estimates are available.
(
AD = AL − A1A + AA2 + AA3 + AA4 )
The deficit area is provided in the affected zone welding a reinforcing pad of
thickness t P given as
AD
tP =
(d i + 2 ∈)
The formula is self explanatory in view of the discussions above and the
figure.
AD AD Sa
t P = max , pad
di + 2 ∈ di + 2 ∈ Sa