International Journal of Advanced Engineering Research and Studies

E-ISSN22498974

Research Paper

THERMAL ANALYSIS FOR SKIRT DISHED END JOINT OF PRESSURE VESSEL USING FINITE ELEMENT ANALYSIS APPROACH
Kiran D. Parmar1, Kiran A. Patel2, Dinesh D Mevada3

Address for Correspondence

M. E. Student, 2Asst. Prof., Mechanical Engineering Department L.D.R.P-institute of Technology and Research and Technology, Gandhinagar, India ABSTRACT
This paper presents the guideline in thermal analysis for skirt to dished end joint of pressure vessel. Pressure vessel in which gases of high pressure and temperature are admitted through nozzle connections to shell to a dished end. So by these loading (internal pressure and temperature) there is several cracks/failure are developed in skirt dished end joint. The examples of crack/failure of skirt dished end joint are: cracking due to internal or external load, cracking due to lack of penetration, cracking due to chemical attack. In order to minimize the engineering effort on these systems it is desirable to develop standard maximum loads for skirt dished end joint configuration by Finite Element analysis approach. So for designing the pressure vessel stresses should have to be reduced. By using a proper design method and analysis there may be stresses developed parameters are find out. After analyzing by finite element method (FEM) the stress parameter are find out which should be consider as a maximum parameter for these one and it can be reduced by optimization. After optimization reduce the stresses of this joint due to change the weld size of skirt to dished end joint and also increase the life of pressure vessel. KEYWORDS FEM; pressure vessel; Skirt dished end joint; Thermal
1, 3

1 INTRODUCTION Pressure vessel is a closed cylindrical vessel for storing gaseous, liquids or solid products. The stored medium is at a particular pressure and temperature. The cylindrical vessel is closed at both ends by means of dished end, which may be hemispherical, ellipsoidal and torispherical. The pressure vessels may be horizontal or vertical. The skirt supporting system of this vertical vessel plays an important role in the performance of the equipment. Proper skirt supporting system gives the safety and better efficiency. The bottom skirt supports are critical components since they are to be designed with much care to avoid failure due to internal pressure with temperature. Vessel is mostly used in storage or pressure vessel in industry. In pressure vessel whenever expansion or contraction would occur normally as result of heating or cooling an object is prevented, thermal stresses are developed. The stress is always caused by some form of mechanical restraint. There are many types of stresses are developed in the element but they are categorized into primary stresses and secondary stresses. Primary stresses are generally due to internal or external pressure or produced by sustained external force and moments these are not self limiting. Thermal stresses are secondary stresses because they are self limiting. That is yielding or deformation of the part relaxes the stress (except thermal stress ratcheting).Thermal stresses will not cause failure by rupture in ductile materials except by fatigue over repeated applications. In pressure vessel mostly cracks are developed in skirt dished end joint. (5) Metallic pressure vessel components such as dished ends show different modes of failure depending upon the geometrical and loading conditions. These are mainly gross plastic deformation under static load, loss of stability (buckling), fatigue crack initiation at highly stressed locations under cyclic loading, progressive plastic deformation (ratcheting) and creep at high temperatures. Existing codes are mostly used to determine necessary wall thickness (design by rule) based on the static load-carrying capacity. He was also present that all the failure modes IJAERS/Vol. I/ Issue III/April-June, 2012/184-187

mentioned can be estimated by carrying out linear and non-linear finite elements analyses. A dished end in the Klopper shape with a central nozzle submitted to internal Pressure and supplementary axial forces (tensile and compressive) will be used in the frame work. This kind of dished end is widely used as a component in pressure vessels of chemical plants (e.g. reactors at high temperature). It is normally not possible to use design by rule for all possible failure modes because codes do not and cannot consider any special case. In this case, general guidelines for design by analysis are normally available. It is the responsibility of the design engineer to choose the appropriate means of strength analysis (analytical, experimental or numerical methods).Nowadays, it should be common practice to apply numerical instruments of analysis such as the finite elements method (FEM) because of steadily improving computer technology and sophisticated software (detailed modelling, non-linear features). Computer-aided simulation of the strength behaviour of structures is much more precise than the application of analytical methods and cheaper than experimental verification.

Figure 1 Meshing of a torispherical end with a centred nozzle The structure to be considered is symmetrical with respect to the main axis of rotation and with respect to applied loads. It is possible to use plane elements with an axisymmetric option in the Finite Element model of the dished end with a central nozzle (Fig. 1) which will considerably save the time for modeling and computation. For the fatigue analysis in particular, the model must be detailed enough to

International Journal of Advanced Engineering Research and Studies include local stress concentration effects (e.g. weld seams). The finite elements program package ANSYS5.0 was used to carry out the different analyses. As per result we include other modes of failure (loss of stability, progressive plastic deformation, creep, fatigue) caused by special geometrical and/or loading conditions. By and large, these supplementary failure modes are normally not treated on a design by rule basis in codes; Guidelines given for design by analysis are more or less general.The finite elements method provides a universal instrument of analysis. All the failure modes mentioned can be modelled after reasonable simplification of the materials laws. Results for design against gross plastic deformation and against fatigue failure can be depicted in the form of factors based on parametric studies using the programming environment of the FE program. These results can be used directly for design by rule. In cases where ratcheting is possible, special non-linear finite elements analyses should be carried out, these analyses are still rather time-consuming. The hardening behaviour of the material should be modelled as precisely as possible because of its significant influence on progressing plastic strains. Creep is a very dangerous failure mode for metallic structures at high temperatures. It is possible to implement creep laws within finite elements programs. The time-dependent behavior of the component can be estimated in this way. (1) Pressure vessel is a closed cylindrical vessel for storing gaseous, liquids or solid products. The stored medium is at a particular pressure and temperature. The cylindrical vessel is closed at both ends by means of dished head, which may be hemispherical, ellipsoidal. The pressure vessels may be horizontal or vertical. The supporting system of this vertical vessel plays an important role in the performance of the equipment. Proper supporting system gives better efficiency. The bottom supports are critical components since they are to be designed with much care to avoid failure due to internal pressure with temperature. In this analysis, skirt support for vertical vessel was analyzed as per the guidelines given in the ASME (American Society of Mechanical Engineering) section VIII division 2 and IBR (Indian Boiler Regulations) standards. The stress analysis was carried out for this support using a general purpose FEM code, ANSYS macros. The coupled field (Structural and Thermal) Analysis was carried out for skirt support to find out the stresses in the support. The analysiss results were compared with ASME code allowable stress values. The pressure vessel design codes all use the design by formula approach, which is essentially now used in section VIII, Division1 of the ASME Code. The design by formula method provides explicit rules for calculating the vessel parts. The skirt support is supporting the vessel which is subjected to the internal pressure of 0.68 kg / mm2 and the design temperature is 3400C. The material used is carbon steel, SA 516 GR 70. The localized stress effects due to combined loads acting on structural attachment such as skirt support are being analyzed using FEM. The skirt support is shown in Figure 2. IJAERS/Vol. I/ Issue III/April-June, 2012/184-187

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Figure 2 Skirt support As per result we obtained maximum and minimum stress values are obtained. The stresses induced in the supports are within the allowable limit. ANSYS analysis confirms the safety of the support. The analysis may prove to be the most economical in the long term. (2) A simple method of estimating limit loads using a sequence of elastic finite element analyses and the lower bound theorem, termed elastic compensation, is demonstrated on the problem of the estimation of the limit behavior of torispherical pressure vessel heads. Two possible techniques of elastic compensation are discussed, one which has general application and one possibly specific to heads. The results are compared to a series of detailed elasticplastic finite element analyses and to classical solutions.

Figure 3 Torispherical head geometry The general pattern of behavior of torispherical ends under internal pressure is thus well understood. As pressure builds up, it tends to force the spherical cap outwards along the axis and the meridional membrane tensions pull the toroidal knuckle inwards towards the axis.

Figure 4 Torispherical head deformation mechanism In order to determine the elasto-plastic behavior and limit pressure in representative torispherical heads, four geometries are employed. The models are analysed independently here using the finite element analysis system ANSYS. The elasto plastic analysis undertaken here includes large deformation effects. (3)

International Journal of Advanced Engineering Research and Studies 2 DESIGN SPECIFICATIONS 2.1 CYLINDRICAL SHELL: Input Values:
Internal Design Pressure P Shell Diameter D Shell Material Shell Allowable Stress at Temperature S Shell Allowable Stress At Ambient S Shell Thickness t Joint Efficiency of shell E Corrosion Allowance C.A. 41.801 bar 4030 mm SA-516 70 1406.14 kgf/cm 1406.14 kgf/cm 67 mm 1 3 mm

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3. GEOMETRY AND FEM MODEL

2.1.1) Required Pressure [tr]: =

S

Thickness

due

to

Internal

Figure 5 Assembly of Skirt Dished end joint 4. BOUNDARY CONDITION 4.1 3-D Model in ANSYS

= 63.98 mm 2.1.2) Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: =
S R.

P R per UG-27 (c) (1) E. P

E per UG-27 (c) (1) = 45.84 bar

Figure 6 Model in ANSYS Workbench 4.2 Define Temperature The temperature considering for steady state thermal analysis is 250 C.

2.1.3) Maximum Allowable Pressure, New and Cold [MAPNC]: =

= 47.85 bar 2.1.4) Actual stress at given pressure and thickness, corroded [Sact]: =
P

E per UG-27 (c) (1) R.

S

R. E

= 1282.23 kgf/cm 2.2 HEMISPHERICAL DISHED END: Input values:

Internal Design Pressure P Dished end Diameter D Bottom head allowable Stress at Temperature S Dished end Thickness t Bottom dished end Material SA 41.801 bar 4036 mm 1406.14 kgf/cm 33 mm 516Gr 70

2.2.1 Required Thickness due to Internal Pressure [tr]: =

P R per UG-27 (d) S E. P

Figure 7 Temperature inside the surface of model 4.3 Apply convective heat transfer co-efficient at the inner side

= 33.08 mm 2.2.2 Max. Allowable Working Pressure at given Thickness, corroded [MAWP]: =
R.

= 45.84 bar 2.2.3) Maximum Allowable Pressure, New and Cold [MAPNC]: =
R.

S E per UG-27 (d)

S E per UG-27 (d)

= 50.07 bar 2.2.4) Actual stress at given pressure and thickness, corroded [Sact]: =
P

R . E

= 1282.28 kgf/cm 2.3 SKIRT SUPPORT: Input values

Skirt Outside Diameter at Base O.D. Skirt Thickness t Skirt Internal Corrosion Allowance CA Skirt External Corrosion Allowance CA Skirt Material 4088 mm 22 mm 0 mm 1 mm SA-285 C

Figure 8 Apply Convective Heat Transfer Coefficient 5 THERMAL ANALYSIS The ANSYS Workbench environment is a Finite Element Analysis tool that is used in conjunction with CAD systems and/or Design Modeler. ANSYS Workbench is a software environment for performing structural, thermal and electromagnetic analysis. The focuses on attaching existing geometry, setting up the Finite Element model, solving and reviewing results. Define Type of Analysis : Thermo Structural Analysis Method : Steady State Thermal Analysis When the flow of heat does not vary with time, heat transfer is referred to as steady-state condition.

IJAERS/Vol. I/ Issue III/April-June, 2012/184-187

International Journal of Advanced Engineering Research and Studies Since the flow of heat does not vary with time, the temperature of the system and the thermal loads on the system also do not vary with time From the First Law of Thermodynamics, the steady-state heat balance can be expressed simply as: Energy in - Energy out = 0 For steady-state heat transfer, the differential equation expressing thermal equilibrium is: 6.2.2 Results Table
Weld size 45 Von Misses stresses 121.04

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Maximum Shear stresses 66.909

The corresponding finite element equation expressing equilibrium is 6 RESULT AND DISCUSSION 6.1 Run the Analysis 6.1.1 Temperature Results

7 CONCLUSION The study shows that in pressure vessel different types of cracks/failure are developed. After investigating different methods it should be concluded that skirt to dished end joint is part of pressure vessel in which maximum cracks are developed. The analyzing by different finite element methods gives different parameters. After analyzing the maximum parameters are find out which gives maximum strength for skirt to dished end joint. The analysis for skirt to dished end joint of pressure vessel by finite element method which can reduce the stresses and crack/failure of skirt dished end joint. After analysis the optimum parameters should be considered which can minimize the stresses in these joint. This can increase the life of pressure vessel and reduce the cost of pressure vessel which is benefit for applicant. It should be concluded that stress and other parameters are also decreased by changing the weld size of the skirt to dished end joint. ACKNOWLEDGEMENT Authors are grateful to Hindustan Dorr-Oliver limited (HDO), Ahmedabad for allowing them to carry out the project work during the course of study. REFERENCES
[1] A.Lietzmann, J. Rudoiph, E. Weib , Failure modes of pressure vessel components and their consideration in analyses , Chemical Engineering and Processing 35 (1996) 287-293. K.Tamil Mannan, Rakesh Saxena,R. Murugavel an P.L.Sah, Stress Analysis of Conical Shell Skirt Support For High Pressure Vessel Using Finite Element Method, Multidiscipline Modeling in Mat. and Str.5(2009)355-362 Jinhua Shi,D.Mackenzie & J.T.Boyle, A Method of Estimating Limit Loads by Iterative Elastic Analysis. Torisphericai Heads Under Internal Pressure , Int. J. Pres. Ves. & Piping 53 (1993) 121-142. ASME Code, Section VIII, Division 1,2007 A-08. Moss D.R.Pressure Vessel design manual Third edition.

Figure 9 Temperature Contour 6.1.2 Heat flux Results

[2]

[3]

[4] [5]

Figure 10 Total Heat Flux 6.2 Structural Analysis Above Analysis Data is transfer to Static Structural Module for Structural Analysis. Apply internal Pressure 0.1 Mpa inside the model. 6.2.1 Run the Structural Analysis Equivalent Von Misses Stresses and shear stresses :

Figure 11 Equivalent Von Misses Stresses Figure 12 Shear Stresses IJAERS/Vol. I/ Issue III/April-June, 2012/184-187