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    M e N 12 92

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    Mechanical Engineering News COADE, Inc. For the Power, Petrochemical and Related Industries ele ue The COADE Mechanical Engineering News Bulletin is published periodically from the COADE offices in Houston, ‘Texas. The Bulletin is intended to provide information aboutsoftware applications and development for Mechanical Engincers serving the power, petrochemical and related industries. Additionally the Bulletin will serve as the official notification vehicle for software errorsdiscoveredin those Mechanical Engineering programs offeredby COADE. TABLE OF CONTENTS PC Hardware for the Enginceting User Part 15) “Malkple Versions of COADE Software. SLs and 486/66 Machines CADPIPE Interface Update CCALSAR HI Global vs Local Coordinate Systems CAESAR TI Development proVESSEL and CoseCale Development Pressure Vessel Torispherical Head Equations ‘ASME External Presture Chart Name Changes Flange Stresses FE/PIPE SIPs and Flexibilities in a CAESAR TT ‘Analysis of an Elliptical Vessel Head 8 ‘The Role of Stress Analysis in the Life Extension of, Piping Systems — Evaluation of Fatigue Stresses... 12 COADE Seminars versa VV CAESAR Il Specifications 0 PC Hardware for the Engineering User (Part 15) DOS 5.0 Memory Management DOS 5.0 enables the 386/486 PC user to configure the ‘operating environment in a manner which can provide more available conventional memory than any previous DOS version. Unfortunately the standard DOS documentation offers litle in the way of guidance for the user to optimize PC memory usage. A recent book, PC Magazine Guide to DOS 5 Memory Management, by Jeff Prosise, offers one of the clearest explanations for optimizing the PC memory configuration, Errata The ast sue of Mechantcal Enginering News (August 1992) contained an article on Elastic Follow-Up. The tas paragraph of hs arte eft phrase out ofthe second sentence, which sigif- ‘anty changes the conclusions, The sentence Should read: “That i, the piping must not be 30 ontrrained tha self sires relteving ofthe thermal expansion stresses cannot occu.” In an effort provide COADE users with an overview of DOS5.0memory management and system optimization, the pertinent points of this book are surmmarized below. A basic intuductiou (o memory describes te differ ence between RAM and ROM. The major emphasis of the bouk is bow to maximize RAM to provide the largest amount for applications programs. ‘The various types of RAM are then defined and illus- uated in diagrams, RAM cau be divided into: conve tional memory 0-640k, upper memory 640k-IM, ex- ended memory IMou, andexpanded ineaury whichis ‘outside the processors normal address space. By using DOS 5.0 commands in the start up files AUTOEXEC.BAT and CONFIG.SYS, the user can place most of DOS and many TSRs and Device drivers above the G40k botder. This procedure van tesult in a system with over 615k of free RAM! ‘The first step in optimizing the system is to place two ‘vonimands in the CONFIG.SYS file. These commands DEVICE=C:\DOS\HIMEM.SYS DOS-IHIGH,UMB COADE Mechanical Engineering News December, 1992 AUTOEXEC.BAT file contains the following statements: PATH=C:;C:\DOS; ... D\CAESAR; SET CAESAR=D:\CAESAR ‘The user has been using Version 3.17 for several months from a variety of data directories. When Version 3.18 is received, the user wants to keep Version 3.17 around while testing Version 3.18. The user installs Version 3.18 in a directory on drive “E” named C2NEW. ‘What happens when the user then moves to a data directory and invokes the program? Since nothing was changed — in AUTOEXEC.BAT, Ver- sion 3.17 is invoked. As- sume the user notices that Version 3.17 isactive the version number is dis- played at the top of the ‘main menu), and then re- issues the PATH com- ‘mand so that EAC2NEW is searched instead of DACAESAR. Now when CAESAR Il is invoked, the C2.COM program from E\C2NEW is started. However, since the environment variable (initialized with the “SET” com- ‘mand) still points to DACAKSAK, Version 3.17 1s still invoked. The C2.COM module uses the environment to invoke all of the CAESAK I modules. ach module and file name is prepended with the environment string, inthis case DCAESAK, results are as follows: cpu Rating 249 166 m AF you want more than a single version of any CUADE, software product on your computer, insure that both the ‘PATH statement and the setting of the environment variable are pointing to the version you want to run, ESLs and 486/66 Machines COADE was recently informed by the ESL vendor of potential compatibility problems between the ESLs and some 486/66 computers. The problem revolves around the self timing routines in the software and the speed of these new machines. It is quite possible for these computers to “run away” from the software, and therefore not find the ESL. CPU Speed Comparisons ‘The December 8, 1992 issue of PC Magazine listed a CPU speed| ‘comparison as determined by Intel. These results are in the form of COMP ratings, where a faster CPU has a higher rating. The| Updated modules are available upon request, fr those users current on their updates, which should resolve this problem. CADPIPE Interface Update International Software Systems has released Version 2.21 of, their CADPIPE drafting software. Unfortunately the timing of this release coincided with the release of CAESAR II Version3.18, ISS madeachangeto the entity attribute string in their neutral file, which the CAESAR IT interface to CADPIPE utilizes. Therefore, the CAESAR II Version 3.18 interface is not compatible with CADPIPE Version 2.21. COADE has obtained fromISS the updated neu- tral file documentation, and theinterface program has been revised. Users sammy veenx 6g (| (current on their 2sMi se0Dx 49—~—«| CAESAR IT updates) zo | whoneed this revised in- terface should contact, COADE and request it, cpu Rating 20MH 4868X 78 20Mile 386K CAESAR II Global Vs Local Coordinate Systems CAESAR II Version 3.18 provides a new output report to aid the user in evaluating piping components. This new report details the local forces and moments acting on the piping elements. This has raised the question: “What is a local coordinate system?” Essentially, the global coordinate system can be though of as the “world” coordinate system. In the CAESAR IT input sraphics, the user typically aligns either the global X or global axis withthe “North” arrow on he piping icometric. The global coordinate system, once so defined, is fixed for the piping model, Conversely, the local element coordinate system is defined by the orientation of each element. The local x axis is directed along the length ofthe element in the “FROM-TO" direction. Local y and 2 are normal to each other and local x, and follow the right hand rule. In CAESAR IT the local “y" axis can be determined at follows. Extend your open right hand along the pipe in the COADE Mechanical Engineering News December, 1992 “FROM-TO" direction. Then curl your fingers toward the global “Y” axis. Your thumb will point in the direction of positive local “y”, The right hand rule then defines local 2". (This procedure is not valid for vertical pipes, w! local “x” aligns with global “Y". In this case, the local axis is aligned with the global "X” axis.) The following figures all represent cantilever beams, mod- eled in different global directions, subjected to end dis- placements. The resulting local element force report from CAESAR II shows the relationship between the local and global coordinate systems for each model. In the figures, the “large” axis in bold is the “global” coordinate system. ‘The “small” axis isthe “local” coordinate system for the specific cantilever shown. EXAMPLE 1: CASE 1: Deflection in the negative ¥-direction. CASE 2: Deflection in the positive Z-direction, x CASEI case? EXAMPLE 3: CASE 1: Deflection in the positive X-direction. CASE 2: Deflection in the positive Z-direction, CAESAR RESULTS ‘Gobal x Ww) R % & case: | 25 0 «00 | 0 256 0 casez | 0 0 sit ost EXAMPLE 4: CASE 1: Deflection in the positive X-direction, EXAMPLE 2: CASE 1: Deflection in the negative ¥- jointefficiency as specified in UW-12 + = inside knuckle radius ‘The only remaining value to be determined isthe factor M. ‘Values for factor M may be taken from the chart in Table 1- 4.2 or may be directly computed from the following equa- tion: M=1/4* (3 +Sqnt(Lir)) In CodeCale version 5.1 the dimensions L and r are com- puted directly from the vessel dimension basis (ID or OD), the user specified values of L and r, and the corrosion allowance. For the correct value of Tr CodeCale will adjust the L and r dimension to inside dimensions if the vessel lameter basis was specified ws OD (this is necessary ‘because the torispherical head equations require that L and 1 be inside dimensions). Obviously the corrosion allow- ‘ance must also be considered in this adjustment, except for the MAWP new and cold calculation. If you are specifying ‘outside dimensions, L and r must also be specified on this same basis, Le. outside dimensions, otherwise you will get ‘an erroneous value of Mf. ‘To add to the confusion, head catalogues list these heads as being “OD" heads and then proceed tw list Land r ou a ID basis. Furthermore, in many instances the inside crown radius L of the head is eyual (© the OD of the heal. To conclude all dimensions for torispherical heads mustuse the same basis, preferably the inside diameter basis ASME External Pressure Chart Name Changes ‘The 1992 edition of ASME Section VIII, Division 1 no longer contains the material property appendices as it did in previous editions. Users must now acquire ASME Section Tl Part D in order to reference material properties. ‘This new publication contains all of the material data previous editions of Section VIII, Division 1 contained. The ‘external pressure chart names however, have been changed. Listed below is across reference table showing the old chart ‘names matched tothenew chart names. All current versions of COADE software (CAESAR II Version 3.18, COADE Mechanical Engineering News December, 1992 PROVESSEL Version 2.6, and CodeCale Version 5.1) use the old chart names. ‘The next release of each of these Programs will use the new chart names. new ota new ole s-1 weg uvF-28.18f 3-2 Neato. UF-28.20 | a3 Nel UWF-28:22 os Wein UnF-28!23 fee Meg) UMe-28:94 ira Wr? UNF-28: 25 iat Neg UNE-28-27 fae tere One-28°08 | as Whig UNE-28:08 | Hara NEAC12 UNF-20.30 ed wWraci3OMe-28. 3 Nw Neacla UME-28-32 Mad UNege:2 MNO UMe-28°33 Nea‘? UNE26.3 | MENCLUNF-28.34 Nees UNregs@ = MPD. Unroae.3e Neaca UNF-26:8 MENS UNF28.39 NPK-2 UNF-26.6 | MFN-I6 UNF- 28.40 tens Umegesy MEE) UnFooscay Niwa UNF-28-8 eta UNF2B.42 Weel Uwege.s | Wes. WNF-20.43 Nre:2 UNF-28.10 © WPN-I7UNF-28.4 WFC} UNF-28.11 © WFN-IBUNF-28.45 Neca Unregecde timely Unease Weacs UNF-28.13, N20 a7 eae Mros.ta = Mre-e)UNF-26-48 NEWS UNF-28.15 FNL UNe=20. 38 NPAC? UNF-28c17 NLL UNF-28. 37 Nace Nroecla | NiMede OMe-es ca Flange Stresses Several users have contacted COADE requesting assistance ‘with the tlange computation modulesin our software, There questions revolved around an increase in flange stresses and @ decrease in the MAWP when the bolt allowables were increased. One would normally think thatthe stresses would remain the same or decrease with an increase in these allowables: Fora given flange geometry, temperature, and pressure, the resulting flange stresses are @ function of the total flange moment Mo. The flange moment is dependant on many ‘geometry related terms, and the tlange design bolt load, W. ‘The flange design bolt load for the operating condition, Wm, isa function of the flange geometry andthe equivalent ‘lange design pressure. This load divided by the allowable design bolt stress yields the bolt area required for the ‘operating case. ‘The tlange design bolt load for the seating condition, Wm2, is a function of the required bolt area, the actual bolt area, and the allowable ambient bolt stress. ‘When designing a tlange, many designers attempt to resolve an over stressed condition by increasing the allowable bolt stresses (by changing materials). ‘This can cause the stress to increase through out the flange, when the seating condi- tion governs the flange design bolt load. This phenomenon can be easily understood by reviewing the equations shown im the table below. ‘Operating Conaition Seating Condition Was totp wna nsneory sion Pearvepeormey ox Ace Do Ani ng: Dg Bat an ‘ann tL Ta Page Mamet a Fg Hoe Moe Mie Me ourpegity baeregiaye cepa owe Leer se ‘Tog Fuge es Note that the three stress values Sh, Sr, and Stare linearly ‘dependant on Mo. For the seating condition, Mo = W *hg. For the stresses to increase, Mo must increase. For Mo to increase, W must increase. The table shows that W is a function of the required boltarea, the actual boltarea, and the allowable ambient bol stress. By increasing Sa,the value of Wincreases (Ab remains fixed and Am? either remains the same or has no affect on the increase of W), resulting in higher flange stresses overall ‘Asan example, consider the CodeCale flange input shown below. This input describes a32" Weld Neck Flange at 300 psiand 750 degrees. The initial analysis used a bolt material of SA-193-B7-2, with an allowable of 22200 psi. The resulting stresses and MAWP follow the input in the figure. COADE Mechanical Engineering News December, 1992 Gofal So, Afene: cae Flange Analysis + 1. WELO FLANGE TER: 1, T0:60en, 13/09/82 INPUT Eom, FLANGE MIAER 1, beserspeions 3. MELO FLANGE eseripeton of Flange tay inaigets Sty reign Precsure 3.00 pets Design Teperature Hae Flange Insige ataneer 3 e.g00 Fange Thickness 1 1 igasa" fn. enh Sa figs fe Flange watertol saset-70 Flange Ailowble Stress #t Awlent 500, st OIE Allowable stress At Temper 22200, pst oie Aouable Stress At hmotent SBA 23000. pet nal ole Dlaneter be 13600" 00 34.5000 fn at ouet otneter 204.2090. ket Design Seit ing Stress ee Colum for Gasket esting 1, ede Colann 1 Stress Comutation Reuss | OPEMTING AST seating tongieesnas wie ash, Masi? SR Bp fetal Flange Teo0: tease: 17500: et Tegereel"Fioge —Saek: 14600: Tare: 0" pe seiting 68, 22200. "3606. 23000. pat Eslnated RAI: Gasket estiog') Bed Ne ‘Now re-analyze this flange, but change the bolt material to ‘SA-193-B7-1, which Increases the bolt allowable from 22200 psi to 23600 psi. The resulting stresses and MAWP. are listed in the figure below. ‘The bolt material was changed to $A-193-B7-1 which has a higher allowable operating stress than SA-193-B7-2 at 750, degrees F. SHE VILL App. 21992 FLANGE RESULTS. 2, Deecripton: 2, WELO FLANGE pa a i i ee (One can see that the increase in the stresses is due to the excess bolt area and the fact that W increases from 552632 Ibs to 589853 Ibs. We can therefore conclude that by holding all input flange values constant and changing only the bolting material to one which has higher allowables, the flange stresses can increas if the seating condition governs. It should also be noted that the MAWP can drop when the bolt area has become excessive. This situation may arise ‘when the operating pressure ina system is dropped and the geometry is reanalyzed. To compensate the gasket factors ‘mand y would need to be adjusted for the increase in the flange design bolt load W. This means that a stiffer gasket, needs to be chosen. FE/PIPE SIFs and Flexibilities ina CAESAR II Analysis of an Elliptical Vessel Head Itis often difficult fora piping or vessel designer toevaluate the effect of external loads on shell type geometries such as ‘vessel heads. The method prescribed below illustrates how this problem can be solved using both Fe/Pipe and CAESAR I The basic piping geometry is shown in the figure below. Attention will be focused on the elliptical vessel head atthe left, although a similar type of local stress and flexibility analysis could be performed on the cylindrical vessel con- nection at the right 2:1 liptical Head 96"0D 0.75" Wall Th, \ Temp = 375F &> Pipe Dia= 14" COADE Mechanical Engineering News December, 1992 AA light shaded displaced shape plot of the head is shown below, The Role of Stress An in the Life Extension of Piping Systems - ~ Evaluation of Fatigue Stresses With the aging of the world-wide infrastructure, there is a corresponding aging of our industrial base. L ‘of powerplants and chemical installations were constructed in order to support the growing economy of the 1950s and 1960s, Those plants, or more specifically, many systems \within those plants, are today nearing the end of their design lives. Asaless expensive alternative to total replacement of these systems, engineers are in many eases performing, reviews of these systems in order to gauge the extent 10 which serviceability remains, withaneyeto of the system's desiga life numbers ds extension Life extension is a fairly simple concept. The initial design criteria forasystem involves the designation ofa state which represents failure of that systeny; design life is projected as that time required for the system to reach that state, Life extension is simply the performance ofa review, conducted after a numberof years of operation, of the actual state of the system in order to determine whether it has yet attained that failure state, and if not, 10 more accurately revise the projection of how much remaining time remains before it will, ‘The system review consis of a variety of inspections and analyses, including tests to determine the extent of corro- sion, erosion, cracking, and other physical deterioration which the components of the system may have undergone. Discussion of these effects are outside of the scape of this anicle, and are best handled by a qualified metallurgist, ‘However, another important par of the review process of system components (specifically piping) involves the use of stress analysis to estimate the amount of useful life con- sumed; this process is discussed here. It must be empha- sized that many items affect the projected life of a system, so the separate elements of the review process cannot be one in isolation, ‘There ate two primary stress related mechanisms that result inthe aging of a piping system, where aging is defined as a time related (or otherwise cumulative) progression towards the loss of function, Thes creep, where ereep can cause failure due to either excessive deformation or rupture, Fatigue is usually a concern in systems which are subject to a significant number of eyclic loadings, while creep is a concern in high temperature (for example, temperatures on the order of 80°F and above for steels) systems subject to constant loadings. Under certain circumstances, there may bean interactive synergy between these effects as wel. e two mechanisms are fatigue and Due to the extent of this topic, the discussion has been divided into t40 parts, with this article covering analyses aimed at determining remaining fatigue life. A second icle, on the estimation of remaining creep life, wil follow in the next issue of Mechanical Engineering News, Each ff the vo articles will briefly describe the mechanism (fatigue orereep), then present the piping coderequirements inthis area, then explain how these requirements are used (0 determine the inital system design life, and finally, show how all ofthis can be evaluated to extend system life Fatigue Basies: Piping and vessels have been known to suffer from sudder failure following years of successful service. Research ddone during the 1940s:and 1950s (primarily advanced by A. R. C, Markl’s "Piping Flexibility Analysis", published in 1955) provided an explanation for this phenomenon, as well asdesignriteria aimed atavoiding failures of thistype. The explanation was that materials were failing due to fatigue, a process leading t0 the propagation of cracks, and subse- {quent fracture, following repeated cyclic loading Steels and other metals are made up of organized patterns of molecules, known as erystal structures. However, these patterns are not maintained throughout the steel producing an ideal homogenous material, but are found in microscopic isolated island-like areas called a grains, Inside each grain the pattern of molecules is preserved. From one grain boundary (o the next the molecular pattern is the same, but the orientation differs, Asaresult, grain boundaries are high energy borders. Plastic deformation begins within a grain thats both subject toa high stress and oriented such that the 2 COADE Mechanical Engineering News December, 1992 stress causes.a slippage between adjacent layers inthe same pattern. ‘The incremental slippages (called dislocations) ‘cause local cold-working. On the first application of the siress, dislocations will move through many of the grains that are in the local area of high stress. As the stress is repeated, more dislocations will move through their respec- tive grains. Dislocation movement is impeded by the grain boundaries, soafter multiple stress applications the disloca- tions tend to accumulate at grain boundaries, eventually becoming so dense thatthe srains “lock up”. causing a loss of ductility and thus preventing further dislocation move- ‘ment. Subsequent applications of the stress cause the grain to tear, forming cracks. Repeated stress-applications cause thecracks togrow. Unless abated, the cracks propagate with additional stress applications until sufficient cross sectional strength is lost to cause catastrophic failure ofthe material. ‘The fatigue capacity of a material can be estimated through the application of cyclic tensile/compressive displacement loads with a uniaxial test machine. A plot ofthe cycle stress capacity of a material is called a fatigue (or endurance) ‘curve. These curves are generated through multiple cyclic tests at different stress levels. The number of cycles to failure usually increases as the applied cyclic stress de- creases, often until a threshold stress (known as the endur- ance limit) is reached below which no fatigue failure occurs, regardless of the number of applied cycles. An endurance curve for carbon and low alloy steels, taken from the ASME, Section VIII Division 2 Pressure Vessel Code is shown in Figure 1 Figure 1 Code Requirements for Fatigue Loading: Cyclic loads on piping (primarily thermal expansion or vibration loadings) are found to cause fatigue failure in piping systems. The fatigue design criteria required by the piping codes today are basically identical to those proposed by Markl in the 1950s. The codes typically limit the expansion stress range in piping to a formula which gener- 13 ally fits the fatigue curve of the material, or more explicitly, as the B31.3 Chemical and Petroleum Refinery Piping Code states: S, <= S= £ [1.25(8, + 8) - 8) Where: allowable expansion stress, psi S, = calculated expansion stress range, psi f =cyclic reduction factor = 6.0[N}*? <= 1.0, oras shown in the table below: CYCLIC REDUCTION FACTOR TABLE [Green Factor | ee Lo 7001 09 14,001 : 08 2001 07 45,001 - 0.6 100.001 > 05 200001: os 700.001: 03 N = total number of expected load cycles ‘S.=basie material allowable stress at the minimum temperature, psi basic material allowable stress at the maximum temperature, psi ‘S, = sustained stress calculated at that location. psi (Often itis the case thatthe temperature ofthe piping system is not constant throughout the operating cycle, or there is potentially more than one operating cycle (ie...pump A on, ‘pump B on, both pumps on, both pumps off). In these cases, the codes provide for a means of converting each cycle toa ‘number of equivalent cycles, which can then be summed to estimate the cumulative damage done to a system. In this case, the B31.3 Chemical and Petroleum Refinery Piping Code states: NeN,+ [1 N] for 22. COADE Mechanical Engineering News December, 1992 Where: N = total number of eycies tobe used in determining the cyclic reduction factor, f umber of cycles expected for maximum expected stress range Sy ,=stress range for operating cycle i, where S,

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