Finite Element Analysis (FEA) Report

XYZ Vessel Corp.

Hydraulic Manifold Block
ABC-1234-5678
October 24, 2008

PVE-1343a rev1
Derek Verstege C.Tech
Laurence Brundrett P. Eng.
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Table of Contents ver 4.00 Page 2 of 21

Contents Page
Cover 1
Table of Contents 2
Executive Summary 3
Section - Materials 4
SA-479 316 5
SA-106B 6
Section - Model Information 7
Model 8
Mesh 9
Error 10
Section - Restraints & Loads 11
Restraints 12
Loads 13
Reaction Area 14
Reaction Forces 15
Section - Results 16
Displacement 17
Stress 1 18
Component Cycle Life 19
Drawing - Manifold Block 20
Drawing - Manifold with Pipes 21

Revision(s)
Rev Description Date By
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Executive Summary ver 4.00 Page 3 of 21

Project Information:

XYZ Vessel Corp. Customer

Hydraulic Manifold Block Vessel / Component(s)
1343a Part Number
PVE-1343a rev1 Job
SolidWorks CosmosWorks 2008 FEA Program Used
24-Oct-2008 Date

Max Pressure (psi) @Temperature (F)

Maximum Allowed Working Pressure
300 250
Max Operating Temp (F) @ Pressure (psi)
Maximum Design Metal Temperature
250 300

Goal:

The hydraulic manifold block PVE-1343a will be used under VIII-1 service. This block can not be
calculated to ASME VIII-1 code rules due to the complexity of its geometry. Here the rules of VIII-2 are
used with VIII-1 allowed stresses to determine the acceptability of the manifold block.

Summary Conclusions:

Materials
Material strength properties used in this report are obtained from ASME IID Table 1A suitable for VIII-1
components. The rules of VIII-2 are used to set the stress limits.

Model Information
The model used in this report represents the full hydraulic manifold block with added pipes. The mesh
size has been refined to reduce the reported error to less than 5%.

Restraints & Loads

One pipe has been fixed to prevent motion. All interior cavities and attached pipes are pressurized. All
measured reaction forces are as expected when calculated theoretically. The model is in balance and
can be used for displacement and stress analysis.

Results
The 0.0002" maximum displacement is acceptable. The 3,095 psi peak stress is below the 20,000 psi
allowable membrane stress. The predicted cycle life is infinite. The manifold block design and cycle life
are acceptable.

Analysis Conclusion:

The manifold block PVE-1343a meets ASME VIII-2 design rules using VIII-1 allowed stresses. The
manifold block design is acceptable.
Materials ver 4.00 Page 4 of 21

Summary:

Material strength properties used in this report are obtained from ASME IID Table 1A suitable for VIII-1
components. The rules of VIII-2 are used to set the stress limits.

Contents:

Material properties are obtained from IID table 1A because this block will be used in VIII-1 service. The
rules of VIII-2 have been applied to calculate the maximum allowed stress levels depending upon location.
See the Results section for the actual stresses.

Properties are shown for both the SA-479 stainless steel block and the SA-106B carbon steel pipes. The
stress limits for the attached pipe are not investigated in this report.
1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 5 of 21
2 Material:
3 SA-479 316 Material
4 Hydraulic Manifold Block Application

5 Strength Properties:
6 ASME VIII-IID, 2007 Source of strength properties
7 250 T [ºF] temperature
8 20,000 Sm [psi] basic allowable stress at temperature T
9 Sy [psi] yield stress at temperature T (optional)
10 1.0 k [] - stress intensity k factor
11 1.00 E1 [] - weld efficiency factor
12 1.00 E2 [] - casting efficiency factor
13 FEA Properties:
14 ASME VIII-IID, 2007 Source of FEA properties
15 28,000,000 E [psi] - modulus of elasticity (at temperature)
16 0.27 v [] - Poison's ratio
17 Stress Limits:
18 Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit
19 1*1*1*20000 = 20,000
20 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit
21 1.5*1*1*1*20000 = 30,000
22 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit
23 1.5*1*1*1*20000 = 30,000
24 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity
25 MAX(3*1*1*20000,2*1*1*0) = 60,000
26 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit
27 Comments:
28 (1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it.
29 (2) Refer to VIII-2 Table AD-150.1 for k values
30 (3) The thermal expansion coeficient is only required for studies including thermal stresses
31 (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits
32 (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits
33 (6) Use IID tables 2A and 2B for Sm for VIII-2 studies
34 (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies
35 (8) Use B31.1 Table A for Sm values for B31.1 studies
36 (9) Use B31.3 Table A for Sm values for B31.3 studies
1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 6 of 21
2 Material:
3 SA-106B Material
4 Pipes threaded into the manifold block Application

5 Strength Properties:
6 ASME VIII-IID, 2007 Source of strength properties
7 250 T [ºF] temperature
8 17,100 Sm [psi] basic allowable stress at temperature T
9 Sy [psi] yield stress at temperature T (optional)
10 1.0 k [] - stress intensity k factor
11 1.00 E1 [] - weld efficiency factor
12 1.00 E2 [] - casting efficiency factor
13 FEA Properties:
14 ASME VIII-IID, 2007 Source of FEA properties
15 28,300,000 E [psi] - modulus of elasticity (at temperature)
16 0.27 v [] - Poison's ratio
17 Stress Limits:
18 Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit
19 1*1*1*17100 = 17,100
20 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit
21 1.5*1*1*1*17100 = 25,650
22 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit
23 1.5*1*1*1*17100 = 25,650
24 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity
25 MAX(3*1*1*17100,2*1*1*0) = 51,300
26 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit
27 Comments:
28 (1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it.
29 (2) Refer to VIII-2 Table AD-150.1 for k values
30 (3) The thermal expansion coeficient is only required for studies including thermal stresses
31 (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits
32 (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits
33 (6) Use IID tables 2A and 2B for Sm for VIII-2 studies
34 (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies
35 (8) Use B31.1 Table A for Sm values for B31.1 studies
36 (9) Use B31.3 Table A for Sm values for B31.3 studies
Model Information ver 4.00 Page 7 of 21

Summary:

The model used in this report represents the full hydraulic manifold block with added pipes. The mesh
size has been refined to reduce the reported error to less than 5%.

Contents:

Model
The model of the hydraulic manifold as used in the FEA is shown. The model was made in SolidWorks.
It accurately represents the dimensions of the hydraulic block with the connection threads removed.
Pipes are included to simulate the full loads they would apply to the manifold in operation. Refer to
Drawing PVE-1343a for details.

Note: the attached pipes are not shown in the results section. Refer to
http://www.pveng.com/documents/content_80.pdf for more information on the modeling and analysis of
NPT pipe fittings.

Mesh
A second order tetrahedral mesh was created in Cosmos Designer. A mesh size of 1/8" was used. The
pipes were bonded to the block. Refer to http://www.pveng.com/documents/content_151.pdf for more
information on the use of 2nd Order Integration Elements.

Refer to the "Material Stress Limits" section for each materials Modulus of Elasticity and Poison's Ratio.

Error Plot
The Error plot is shown based on the Cosmos Designer built in error plot estimation function. The error is
less than 5% as per ABSA guidelines except at sharp features higher error values are expected. These
localized areas of higher error do not reduce the validity of the overall results.

The error plot justifies the 1/8" second order mesh selected.
1 Model Ver 4.06 Page 8 of 21
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24 Exploded view of the "Hydraulic Manifold Block" model.

25 A complete solid model matching the "Hydraulic Manifold Block" geometry was used in the analysis.
26 The scope of the analysis is limited to the "Hydraulic Manifold Block" only.
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50 Assembled view of above with the pipes attached to the block.

51 Pipe & Pipe Caps are included to provide realistic results, these components resulting stresses will not be
52 analyzed in this report. Refer to PVE-1343a for details.
1 Mesh Ver 4.07 Page 9 of 21
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24 View of Mesh applied to model.

25 A global mesh size of 0.125" is used.
26 Mesh is Solid, 2nd Order, Tetrahedral.
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50 Close-up of above view.

51 Coincident components are treated as "Bonded" and meshed as a single body as can be seen above.
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1 Error Ver 4.06 Page 10 of 21
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24 View of Error plot, scale set to 5% Error.

25 Areas of error greater than 5% are limited to locations of discontinuity within (1) element of change.
26 Error results are Acceptable, Mesh size is appropriate.
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50 Close-up of "Manifold Line In" area.

51 Note that Error in excess of 5% is limited to locations of discontinuity within (1) element of change.
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Restraints & Loads ver 4.00 Page 11 of 21

Summary:

One pipe has been fixed to prevent motion. All interior cavities and attached pipes are pressurized. All
measured reaction forces are as expected when calculated theoretically. The model is in balance and
can be used for displacement and stress analysis.

Contents:

Restraints
All components are bonded. One open ended pipe has been fixed to prevent free body translation or
rotation of the entire model.

Loads
All components are internally pressurized. No other forces are required.

Reaction Area
The reaction area of the fixed pipe has been calculated. The reaction force is equal to the pipes inside
area x the pressure.

Reaction Forces
The predicted reaction force closely matches the predicted reaction force in all directions. The model is in
balance and can be used to calculate expected displacements and stresses.
1 Restraints Ver 4.06 Page 12 of 21
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24 View of "Fixed" restraint applied to end face of "Line In" pipe.

25 Applying the restraint to the pipe end allows the "Hydraulic Manifold Block" to deform without any undue
26 restraints. This simulates reality and is a valid.
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Fixed Restraint
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No Translation or Rotation
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in X, Y, Z directions
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50 Close-up of above plot.

51 The fixed restraint prevents translation and rotation in the X, Y & Z directions. The model is now fully
52 restrained from rigid body motion in all directions.
1 Loads Ver 4.06 Page 13 of 21
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24 View of 300 psi applied to all internal surfaces.

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50 Section view of above.

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1 Reaction Area Ver 4.02 Page 14 of 21
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24 View showing Reaction Area.

25 This area is used to calculate the Reaction Force.
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50 Alternative view of above.

51 Reaction Area = 3.36 in^2 (in the "X" direction).
52 Reaction Force = (3.36 in^2) * (300 psi) = 1008 lb (in the "X" direction)
1 Reaction Forces ver 4.08 Page 15 of 21
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24 View showing Global Reaction Forces from analysis "X" = 1009.6 lb, "Y" = 0.09 lb, "Z" = 3.47 lb
25 Calculated Reaction Forces = Analysis Reaction Forces within 0.2%
26 Model is balanced, results are valid.
27 X Axis: reaction forces on the YZ plane caused by loads in the X direction
28 3.36 XArea [in2] - Pressurized area on YZ plane
29 300 P [psi] - Pressure
30 0 XForce [lbs] - Added force in the X direction
31 1,009.6 XReaction [lbs] - Reaction force in X direction reported by FEA program
32 TReactionX [lbs] = XArea*P+XForce ~~ Theoretical X reaction force 3*300+0 = 1,008
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34 Y Axis: reaction forces on the XZ plane caused by loads in the Y direction

35 0 YArea [in2] - Pressurized area on XZ plane
36 0 YForce [lbs] - Added force in the Y direction
37 0.09 YReaction [lbs] - Reaction force in Y direction reported by FEA program
38 TReactionY [lbs] = YArea*P+YForce ~~ Theoretical Y reaction force 0*300+0 = 0
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40 Z Axis: reaction forces on the XY plane caused by loads in the Z direction

41 0 ZArea [in2] - Pressurized area on XY plane
42 0 ZForce [lbs] - Added force in the Z direction
43 3.40 ZReaction [lbs] - Reaction force in Z direction reported by FEA program
44 TReactionZ [lbs] = ZArea*P+ZForce ~~ Theoretical Z reaction force 0*300+0 = 0
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46 Resultant of reaction forces in X, Y and Z:

47 TResultant [lbs] = sqrt(TReactionX^2+TReactionY^2+TReactionZ^2) ~~ Theoretical resultant
48 SQRT(1008^2+0^2+0^2) = 1,008
49 Resultant [lbs] = sqrt(XReaction^2+YReaction^2+ZReaction^2) ~~ Actual resultant
50 SQRT(1010^2+0^2+3^2) = 1,010
51 Error [%] = 100*(TResultant-Resultant)/Resultant 100*(1008-1010)/1010 = -0.2
52 CheckError = abs(Error)<2 ~~ Error should be less than 2% ABS(-0.2)<2 = Acceptable
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Results ver 4.00 Page 16 of 21

Summary:

The 0.0002" maximum displacement is acceptable. The 3,095 psi peak stress is below the 20,000 psi
allowable membrane stress. The predicted cycle life is infinite. The manifold block design and cycle life
are acceptable.

Contents:

Displacement Plots
The direction of the pressurized model displacement is as expected. The maximum calculated
displacement is 0.0002". This very small displacement is acceptable.

Stress Plots
The highest stress found in the model is 3095 psi - found at the juncture between a drilled hole and the
central manifold (as shown in the cycle life plot). This stress is much below the allowed 20,000 psi
general membrane stress. Stress results are acceptable and no further stress categorization or analysis
is required.

Cycle Life
The cycle life is calculated based on peak 3095 psi stress observed. The predicted cycle life is infinite.
1 Displacement Ver 4.06 Page 17 of 21
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24 View of Displacement Plot with superimposed original geometry. Results are magnified 5000X.
25 Displacement of the "Hydraulic Manifold Block" is radially outwards due to internal pressure.
26 The "Hydraulic Manifold Block" also elongates axially due to internal pressure.
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50 Reverse view of above. Maximum deformation is 0.0002".

51 Note radial outwards displacement at the end of the "Hydraulic Manifold Block".
52 Deformation is acceptable.
1 Stress Ver 4.06 Page 18 of 21
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24 View of Stress Plot (Intensity). Scale is capped at 3000 psi.

25 Maximum stresses are at the threads. This is due to the exit pressure acting on the attached piping.
26 Stresses are also greater at areas of greater deformation.
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50 Alternative view of above.

51 Peak Stress = 3095 psi, less than general membrane allowable of 20000 psi.
52 Stresses are Acceptable, linearization is not required.
1 Cycle Life ver 4.04 Page 19 of 21
2 ASME VIII-2 2004 Ed. 2006 Add, Appx. 5 For series 3XX high alloy steels, nickel-chromium-iron alloy,
3 nickel-iron-chromium alloy, and nickel-copper alloy for temperatures
4 Fig 5-110.2.2 Curve A graph - Select graph not exceeding 800ºF and Sa <= 28.2ksi, Curve A - Areas not heat
5 3,095 Str [psi] - Enter stress value affected (Pl+Pb+Q) range <= 27.2ksi
6 28,000,000 ET [psi] - Modulus of elasticity at operating temp
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View of peak stress location used in Cycle Life Analysis.

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A peak stress of 3095 psi results in an infinite Cycle Life. Results are Acceptable.
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31 Salt [psi] = 1/2 * Str 1/2 * 3095 = 1,548

32 EG [psi] = PVELookup("EgTable","Lookup","Eg","CL_Fig511022A") 28,300,000
33 Se [psi] = Salt*EG/ET 1548*28300000/28000000 = 1,564
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35 Stress vs. Cycles

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100,000
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Stress

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10,000

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48 1,000
1.0E+00

1.0E+01

1.0E+02

1.0E+03

1.0E+04

1.0E+05

1.0E+06

1.0E+07

1.0E+08

1.0E+09

1.0E+10

1.0E+11

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Cycles
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55 Cycles = PVELookup("CL_Fig511022A","CycleLifeLookup",Se) 100,000,000,000