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Design and Testing of FRP Pressure Vessel
Design and Testing of FRP Pressure Vessel
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Bv Subrahmanyam
SIRCRREDDY COLLEGE OF ENGINEERING
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B v Subramanyam3,Asst Professor,
Mechanical Engineering,
SIR CR REDDY Engineering College,
Eluru, India,
of FRP pressure vessels and boilers. This and further testing’s are carried out in
vessel was made because of less space in the laboratory. The Material properties are listed
machine area The step by step procedure for in below table.
the designing of each component ASME Exotherm
section-x has been followed. After S. Type of Viscosit Gel ic peak
successfully completing the design no resin y time temperatu
procedure the pressure vessel was re
manufactured and the further pressure
testing was carried out in the laboratory. POLYE 130
20
1 STER 280 DEGREE
MIN
II. BENEFITS OF COMPOSITE MATERIALS RESIN S
Composites are light weight as
compared to other materials. Due to its less
weight it is having good life time. As TENSILE MODULUS IN
72590.29
compared to other metals or materials 1 AXIAL DIRECTION(Eta
psi
composites having high strength. The metals or E1)
and metal alloys are equally strong in all TENSILE MODULUS IN
directions. But in composite structure design 72590.2
2 HOOP DIRECTION(Eth or
criteria the engineers can design the high psi
E2)
strength in specified direction. Composites
having high strength to weight ratio for FLEXURAL MODULUS
870226.4
example take some metals which is having 3 IN AXIAL
psi
high strength and also high weight. But in DIRECTION(Efa)
composites we can get the higher strength in TENSILE MODULUS IN 870226.4
less weight also. In design light weight 4
HOOP DIRECTION(Efh) psi
materials plays a vital role. Composite
structures having high strength to weight POISSIONS RATIO IN
5 0.3
ratio in now a days. Corrosion is the main AXIAL DIRECTION(x)
property to damage the metals. To resist the POISSIONS RATIO IN
corrosion extra chemical coatings are 6 0.3
HOOP DIRECTION(y)
required to protect in case of metals. Even if
we coat the metal surface with chemicals we
cannot get the good results and it will resist
IV. DESIGN OF FRP PRESSURE VESSEL
the surface only fewer days. But in case of
composites such extra coatings are not ASME SECTION-X provides the
required due to having better polymeric requirements for FRP pressure vessel,
structure. So these composite vessels are According to this the pressure vessels are
suitable to install in inner and outer side of three types, they are
the environment with maintenance free. 1. Class I
Even if any problem is raised due to some
conditions it is easy to repair. 2. Class II
Class III: The Pressure shall not exceed CYLINDRICAL SHELLS UNDER
15000 psi manufacture by filament winding. EXTERNAL PRESSURE:
B. Design Temperature: The maximum allowable external
pressure of the cylindrical shell can be
The design Temperature for Class I and
calculated by the given formula.
Class II vessels 250°F (120°C) for Class I
and Class II, and 185°F (85°C) for Class III.
Calculate γ
In this Present work the Class I type
of vessel was designed by Contact Molding 3 1
Method. 𝐸𝑓ℎ 4 𝐸𝑡𝑎 2 𝐿𝑐 2
Zp= (1-xy) ( 1/2
)
𝐸𝑓𝑎 2 ∅0
∗𝑡 𝑐
2
GENERAL:
Calculations Required Under RD-1150.
= 51.79 < 100.
L = Length of Cylinder = 7.87 in.
F = Design factor 5 for internal pressure on
cylinders, 10 for external pressure on Then =1-0.001 Z p =0.94821.
spheres and heads, and internal pressure on
reinforcements. Substitute the value in the given equation
3 1 5
rc = Inside radius of cylindrical shell 𝐾𝐷0.8531 𝐸𝑓ℎ 4 𝐸𝑡𝑎 4 𝑡 2
= 1.77 in. Pa= 3
∅0
3
(1−ϑx ϑy )4 𝐿 ( )2 𝐹
P = Design Pressure = 75 psi. 2
288586 .95
0.41( )0.46 2 REINFORCEMENT OF OPENINGS AND
10
= NOZZLE ATTACHMENTS:
√(1−(0.3)(0.3))(2∗8)2
A) Length of secondary overlay on Nozzle:
The Secondary bond length can be
= 24.82 psi
calculated by using the formula
The value of K0 can be taken by the 𝑃∗𝑟𝑛
following table. Lb = 𝜏
2( 𝑠 )
𝐹
75∗0.25
= 1000
2( )
10
𝑃∗𝑟𝑛
tb =
𝑆𝑎
NOZZLE CALCULATIONS:
According to RD-620.1 The
75∗0.25
minimum Nozzle thickness is 1 inch. When =
0.001∗725290 .29
we calculate the outside diameter the Flange
thickness was above 50% of the inside
diameter of the shell.So the 2 inch nozzle = 0.025 in < 0.25 in.
was selected and its dimensions are reduced
to 3 times of the original dimension. The Let tb = 0.25 in.
Given table shows the actual and reduced
value. C) Thickness of reinforcement pad on shell
or Head:
N The thickness of the reinforcement
V Out Bolt Bolt pad on shell or head can be computed by
o.
al Siz sid circl Hol N two methods which is the greater of one and
Of FT
u e in e e e T two.
Bo
es dia dia Dia In first method the thickness can be
lts
computed by given formula.
A
0. 𝑝∗𝑅𝑐
ct 3.87 0.62 tp =
2 5 4 0.5 25 (0.001𝐸2 )
u 5 5
al
75∗1.77
=
S 0. (0.001∗725290 .29)
1.2 0.15 0.96 0.1
ca 0.5 4 06
5 6 5 25
le 25 = 0.183 in.
𝜋∗0.5∗75
= 0.6205 = 1000
4( )
10
In Step 2
After finding the β value the stress = 0.29 in <0.5
concentration factor Kt can be determined by
the chart RD1174.3 from ASME SECTION-
= 1 in.
X.
In Step 3
JOINING OF VESSEL PARTS:
The maximum stress at opening can
By joining the vessel parts we should
be calculated by
follow two criteria’s:
1) The thickness of the overlay must be
𝑆𝑚𝑎𝑥 = 𝑆2 𝐾𝑡 stronger when the stresses are produced by
= (725.29x4.2) the stronger part.
= 3046.21 psi 2) The length of the overlay must be
produce secondary bond shear strength
whoch is equal to longitudinal tensile
In Step 4 modulus of the weak part.
The moment M can be calculated by
the following formula HEAD TO SHELL JOINT OVERLAY
SUBJECTED TO INTERNAL PRESSURE:
𝑆𝑚𝑎𝑥 𝑡 2 The thickness of the overlay t0 is
𝑀=
6 𝑃(𝑟𝑐 +𝑡 𝑐 )
𝑡0 =
(0.001𝐸2 )
3046 .2 (0.46)2
=
6
75(1.77+0.46)
=
(0.001∗725290 .29)
= 107.42 in - lb.
In Step 5
Thickness of reinforcement by = 0.23 in.
assuming equivalent moment M is M/2.
The length of the secondary overlay is
𝑀
6( )
2
𝑡𝑝 = − 𝑡𝑐 𝑃∗𝑟𝑐
𝑆𝑓 𝐿0 = 𝑆
2( 𝑠 )
𝐹
After completing of the all contact molded method. For this the mould
calculations the Pressure vessel values are preparation also very easy. We can easily
calculated and the flange and overlay manufacture the mould from clay, cement,
calculations are completed. The pressure wood and sheet metal etc. It requires simple
vessel was made by hand-layup method by brushes, rollers and plates for removing air
preparing the moulds for manufacturing traps. The part is manufactured by pouring
shell part and flange part. After completion an activated resin on the mould and with the
of manufacturing the parts are joined as per help of rollers the resin was evenly
ASME section-x. The drawing of the distributed on the surface of the mold. After
pressure vessel was shown below and it Some time the resin was cured and the part
gives all the dimensions of parts like shell, was ready.
head and overlay. For the ease of design the
flange values are also shown in the drawing PREPARATION OF MOULD:
This pressure vessel having three flanges With the help of mould calculations
two are for inlet and outlet one for pressure the mould was made by the materials of
gauge. The detailed dimension of nozzle and wood and Rubber sheets. In this project we
shell was shown in figure. prepare three moulds for shell, Ellipsoidal
head and flanges. And film was used for the
release purpose.
MANUFACTURING PROCESS:
After completion of making of mold
the ellipsoidal head, Shell and Flanges. IN
this project we are using GRP mats. The
given figures show the head and shell at the
time of manufacturing process.
ELLIPSOIDAL HEAD
References
[1] ASME SECTION-X FBER
REINFORCED PLASTIC PRESSURE
VESSELS 2015.