Horizontal Pressure Vessel Design with detail component description and analysis PDF

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this is a project that is worked on the design an analysis of pressure vessel. the project includes the components, application force and stress analysis detail design with 2d and 3d diagram if the pressure vessel. the project also includes the material that should be used to make this project...

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CONTANTE CHAPTER

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CHAPTER ONE 1.1 1.2 1.3 1.4 1.5 1.6 1.7

INTRDACTION----------------------------------------------------------------------------------Background of the project OBJECTIVE Scope of the project Applications of Horizontal Pressure vessel Types of pressure vessel The main components of the pressure

CHAPTER TWO 2.1 MATRIAL SELECTION---------------------------------------------------------------------------- 7 2.2 WELDING TYPE----------------------------------------------------------------------------------- 11 CHAPTER THREE 3.1 CALCULATING SHELL THICKNESS------------------------------------------------------------- 15 3.2 DIFFERENT TYPES OF CLOSURE HEAD------------------------------------------------------- 18 3.3 CALCULATING HEAD THICKNESS------------------------------------------------------------- 20 CHAPTER FOURE 4.1 HEAD TO SHELL TRANSITIONS---------------------------------------------------------------- 21 4.2 SELECTING OF STANDARED FLANGE-------------------------------------------------------- 22 4.3 FLANGE AND GASKAT DESIN------------------------------------------------------------------ 24 CHAPTER FIVE 5.1 CALCULATING THICKNESS OF THE NOZZLE------------------------------------------------37 5.2 REINFORCEMENT OF OPENINGS------------------------------------------------------------- 38 5.3 DESIGN OF MANHOLE OR INSPACTION---------------------------------------------------- 42 5.4 SUPPORT DESIGN AND CHECK OF PRESSURE VESSLE----------------------------------- 42 5.5 FABRICATION AND WELDING METHOD---------------------------------------------------- 54 REFERENCE BOOK’S-----------------------------------------------------------------------------------------------

Abstract This paper is indented to emphasize the possibilities to show the influence of present standards to improve pressure vessel which it’s head is hemispherical. Pressure vessels is the containers for fluids under high pressure. The pressure vessels (i.e. cylinders or tanks) are used to store fluids under pressure. The pressure vessels are designed with great care because rupture of a pressure vessel means an explosion which may cause loss of life and property. My project is design of pressure vessel with spherical head which is used to store Acidic solution. It is commonly used in industry to carry (store) acidic solution. For this purpose the material I select in order to doing this pressure vessel is different from part to part, which means I use different types of material like stainless steel, cast iron and different types of alloy steel for the purpose of the media(acidic solution)and also this pressure vessel in in order to stand with high load. Analyses were carried out on head, shell and nozzle. The input parameters are type of material, pressure, temperature, and diameter and corrosion allowance. Analysis performed the calculations of internal and external pressure, weight of the element, allowable stresses, vessel longitudinal stress check and nozzle check.

Acknowledgement First of all I would like to give glory to god, next I would like to dedicate My deepest gratitude to my instructor Ms.samrawit in commenting and directing me to accomplish this project. . Lastly, I have thanks for everyone who had helped me by commenting on the project especially senior students.

CHAPTER-ONE 1. DESGIN OF PRESSURE VESSEl

1.1 Introduction A pressure vessel is considered as any closed vessel that is capable of storing a pressurized fluid, either internal or external pressure, regardless of their shape and dimensions. The cylindrical vessels, to which I refer in this volume, are calculated on the principles of thinwalled cylinders. it is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. The fluid being stored may undergo a change of state inside the pressure vessel for example steam boilers . Due to the high pressures the vessel is made to withstand its design should be done carefully and patiently because the slightest fault in dimensioning (wall thickness) or stress miscalculation will cause rupture or failure of the vessel thus causing an explosion which may prove fatal and cause significant property damage.

The material of pressure vessels may be brittle such as cast iron, or ductile such as mild steel. Pressure vessel have wide applications in thermal and nuclear power plants, process chemical industries, in pharmaceutical industries, and in food beverage industries.

The failure of pressure vessel may result in loss of health hazard and damage of property Pressure vessels often have a combination of high pressure together with high temperatures, and in some case flammable fluids or highly radioactive materials. Because of such hazards it is imperative that the design be such that no leakage can occur. With increasing demands from industrial process for high operating pressures and higher temperature, new technologies have been developed to handle the present-day specialized requirements.

Various parameters of pressure vessel are designed and checked according to the principles specified in American society of Mechanical Engineers (ASME) sec VIII and according to IBR. Pressure vessels can be classified according to their intended service, temperature and pressure, materials and geometry. Different types of pressure vessels can be classified as follows:

Figure 1.1 types of pressure vessel

Finally, pressure vessel are refers to those reservoirs and apparatus which work under internal and external pressure and operate under the pressure.

1.2 Background of the project A pressure vessel is a container designed to hold gases or liquids at a pressure substantially different from the ambient pressure. Pressure vessels can be dangerous, and fatal accidents have occurred in the history of their development and operation. Design involves parameters such as maximum safe operating pressure and temperature, safety factor, corrosion allowance and minimum design temperature (for brittle fracture). Construction is tested using nondestructive testing such as ultrasonic testing, radiography, and pressure tests. Hydrostatic tests use water, but pneumatic tests use air or another gas. Hydrostatic testing is preferred, because it is a safer method, as much less energy is released if a fracture occurs during the test (water does not rapidly increase its volume when rapid

depressurization occurs, unlike gases , like air, which fail explosively). In fact, there is no industrial plant without pressure vessels, steam boilers, tanks, autoclaves, collectors, heat exchangers, pipes, etc. More specifically, pressure vessels represent fundamental components in sectors of paramount industrial importance, such as the nuclear, oil, petrochemical, and chemical sectors

1.3 OBJECTIVE 1.3.1 MAIN OBJECTIVES  To design, develop, and build cylindrical pressure vessel with horizontal orientation and with Bracket(lug) supporting system. And to design pressure vessels with internal pressure of 10Mpa and the service temperature 400

.

1.3.2 SPECIFIC OBJECTIVE The objective of this project is to create basic understanding of pressure vessel and its components and design pressure vessels which contains an acidic solution,and oriented horizontally .  Proper material selection for pressure vessels for application of acidic solution. To provide the basic and the major concepts design procedure of horizontal bracket support pressure vessel.  To calculate, analytic stress and strength in pressure vessel.  To do a proper welding type selection for pressure vessel.  To do a design of different pipings  To provide a proper design of support

1.4 Scope of the project This project focuses on design and analysis of horizontal Presssure Vessel which contains an acidic solution. The ASME Code is construction code for this pressure vessel design ; and guidance for pressure vessel materials, design, welding and testing.my project takes some of the important design considerations. There is analysis of maximum stress value for main components of pressure vessel load.also there is design of pipings and support,the support design is done on the basis of weight, wind and earth quake.

CHAPTER TW0 2.1 LITERATURE REVIEW David Heckman [3] tested three dimensional, symmetric and axisymmetric models; the preliminary conclusion is that finite element analysis is an extremely powerful tool when employed correctly. Depending on the desired solutions, there are different methods that offers faster run times and less error. The two recommended methods included symmetric models using shell elements and axisymmetric models using solid elements. Contact elements were tested to determine their usefulness in modeling the interaction between pressure vessel cylinder walls and end caps. Yogesh Borse and Avadesh K. Sharma [4] present the finite element modeling and Analysis of Pressure vessels with different end connections i.e. Hemispherical, Ellipsoidal & Toro spherical. They describes its basic structure, stress characteristics and the engineering finite element modeling for analyzing, testing and validation of pressure vessels under high stress zones. Their results with the used loads and boundary conditions which remain same for all the analysis with different end connections shows that the end connection with hemispherical shape results in the least stresses when compared to other models not only at weld zone but also at the far end of the end-connection. A. J. Dureli (1973) presented work on the stresses concentration in a ribbed cylindrical shell with a reinforced circular hole subjected to internal pressure, by several experimental methods and the results obtained were compared with those corresponding to a nonreinforced hole in a ribbed and un-ribbed shell and also to a reinforced hole in an un-ribbed shell. From the result it was found that the maximum value of hoop stress, and longitudinal stress, in shells always occurred at the points θ = 0° and θ = 90°, respectively, along the edge of the hole, θ being the angle measured clockwise from the longitudinal axis of the hole R. C. Gwaltney (1973) compared theoretical and experimental stresses for spherical shells having single non-radial

nozzles. The stress distributions for radial and non-radial nozzle geometry are analyzed. Stressdistributions for the non-radial and the radial nozzle attachments are quite similar but the non-radial nozzle configuration gave the maximum normalized stress, both theoretical and experimental, for internal pressure and for axial loads on the nozzleas well as for pure bending moment loading in the plane of obliquity. M.A. Guerrer, C. Betego´n, J. Belzunce [5] A finite element analysis (FEM) was used to calculate the behavior of a pressure vessel (PV) made of high strength steel (P500) subject to the design loads and assuming the existence of the „„worst case‟‟ crack allowed by the European standards in order to demonstrate the safe use of these steels and the too conservative design rules currently applied by the PV manufacture codes. analysis was checked by the simulation of a Wide Plate Test. A good agreement was obtained with the experimental values determined using strain gauges and with the analytical KI expression available for this specific geometry. It was demonstrated that the presence of cracks on pressure vessels made of P500 high strength steel non detected during non-destructive tests, do not endanger the safety of the vessel, from the fracture mechanics point of view, since the maximum values of the stress intensity factor along the crack tip is always much lower than the room temperature fracture toughness of the material (coarse grain heat affected zone). That is why, although high strength P500 steel is excluded by EN 13445 Part 2, Annex B for the manufacture of pressure vessels, because it has a yield strength higher than 460MPa, its application can be fully successful and safe even under the worst

2.2Applications of Horizontal Pressure vessel Horizontal Pressure vessels are used in a number of different industrial and manufacturing areas like:  Power generation industry for fossils.  Nuclear power.  thermal and nuclear power plants  process and chemical industries  pharmaceutical industries  Manufacturing process and beverage industries.  chemical Industry  Pressure vessel used in garage  High pressure chemical reactors  High pressure mixers  Super critical extraction system 

2.3Types and components of pressure vessel 2.3.1 types of pressure vessel 2.3.1.1. Based on the dimension a) Thin shell: - if the ratio of t/D is less than 1/10 is called thin shells. b) Thick shell:- if the ratio of t/D is equal or greater than 1/10 is called thick shell used in high pressure cylinders, gun, barrels and other equipment where as thin shell are used in boiler, tanks and pipes.

2.3.1.2. Based on the end construction a) Open end construction pressure vessels b) Closed end construction pressure vessels

2.3.1.3. Based on the geometrical shapes a) Cylindrical geometrical shapes b) Conical and c) Spherical vessel with one or two cones.

2.3.1.4. Based on the materials a) Brittle material pressures vessels b) Ductile material pressure vessels

2.3.1.5 Based on the direction of force acting on the wall of vessels a) Subjected to internal pressure (pi) b) Subjected to external pressure (p)

2.3.1.6 Based on the position arrangement A. Horizontal Pressure Vessel Horizontal vessel is normally used as storage, separation tank or settling drum which used to particulate settles to form a deposit on to the bottom of the liquid. Size of this vessel is depending on the usage and the volume required by the industry. Large vessel can be as large as 84 inches in diameter and length about 30 feet long. Commonly used elliptical ratio is 2:1.

B. Vertical Pressure Vessel Vertical vessel regularly used as a surge drum or a knock out drum. As a surge drum, it acts as an absorber that maintaining the flow rate of the liquid out of the vessel regardless of flow rate into it. The design of this vessel is regularly using elliptical ratio of 3:1.

C. Spherical Vessel Pressure A sphere is the optimal geometry and most efficient structural shape for a pressure vessel. This is because of this shape is easy to fabricate and transported

2.4. The main components of the pressure The main components of the pressure vessels are:  Shell  head  nozzle  support  flange  manhole

figure2.1: components of pressure vessel

2.4.1 Shell The shell is the primary component that contains the pressure. Pressure vessel shells are welded together to form a structure that has a common rotational axis. Most pressure vessel shells are either cylindrical, hemi spherical or conical in shape.

Figure 2.2: vessel shell

2.4.2 Head Heads are usually categorized by their shapes. Ellipsoidal, hemispherical, Teri spherical, conical, tore conical and flat are commonly type of heads. All pressure vessel shell must be closed at the end by heads. The ends of cylindrical vessel are closed by head various shapes.  All pressure vessel shells must be closed at the ends by heads.  Heads are typically curved rather than flat. Curved configurations are stronger and allow the heads to be thinner, lighter, and less expensive than are heads with a flat shape. This are: Flanged plates head  Hemispherical head  Ellipsoidal head  Tore spherical head  Conical head  Tore conical head Even though there are several types of head for pressure vessel, but as we supposed to design pressure vessel having hemispherical head; we select the below head.

2.4.3Hemispherical heads The cylindrical section and hemispherical head of a vessel the thickness of the head need only be half that of the cylinder. However, as the dilation of the two parts would then be

different, discontinuity stresses would be set up at the head and cylinder junction. For no difference in dilation between the two parts (equal diametrical strain) it can be shown that for steels (Poisson’s ratio D 0.3) the ratio of the hemispherical head thickness to cylinder thickness should be 7/17. However, the stress in the head would then be greater than that in the cylindrical section; and the optimum thickness ratio is normally taken as 0.6.

figure2.3: Hemispherical head

2.4.4Nozzle A nozzle is a cylindrical component that penetrates the shell and/or heads of a pressure vessel.  Nozzles may be used for the following applications:  Attaching piping systems that are used for flow into or out of the vessel.  Attaching instrument connections, such as level gauges, thermos wells, or pressure gauges.  Providing access to the vessel interior at many ways.  Providing for direct attachment of other equipment items, such as a heat exchanger.

Figure 2.4: Nozzle

2.4.5 Support Support is used to bear all the load of pressure vessel, earthquake, and wind loads. There are different types of supports which are used depending upon the size and orientation of the pressure vessel. It is considered to be the non-pressurized part of the vessel. Types of Supports:

 Saddle Support  Lug Support  Skirt Support  Leg Support For our design we use saddle support.

2.4.5.1Saddle Support Horizontal drums are typically supported at two locations by saddle support. It spreads over a large area of the shell to prevent an excessive local stress in the shell at support point. One saddle support is anchored whereas the other is free to permit unstrained longitudinal thermal expansion of the drum.

Figure 2.5: saddle support

2.4.5.2. Lug support:This is a common means of support for vertical vessels that are mounted on beams. If the vessel is made of carbon steel, the lugs may be directly welded to the vessel.

2.4.5.3. Support skirts:-Most vertical vessels are supported by skirts. These supports transfer the loads from the vessel by shear action. They also transfer the loads to the foundation through anchor bolts and bearing plates.

2.4.5.4. Bracket support -Brackets, or lugs, can be used to support vertical vessels. The bracket may rest on the building structural steel work, or the vessel may be supported on legs; The main load carried by the brackets will be the weight of the vessel and contents; in addition the bracket must be designed to resist the load due to any bending moment due to wind, or other loads. If the bending moment is likely to be significant skirt supports should be considered in preference to bracket supports.

2.4.6. FLANGE A flange is an external or internal rib, or tip which is used for strength, or for a glade or for attachment to another object. Types of flange, and selection several different types of flange are used for various applications. The principal types used in the process industries are:

Figure 2.6: flange

1. Welding-neck flanges. 2. Slip-on flanges hub and plate types. 3. Lap-joint flanges. 4. Screwed flanges. 5. Blank, or blind, flanges 6. A bolt and nut.

2.4.6.1. Welding-neck flanges: have a long tapered hub between the flange ring and the welded joint. This gradual transition of the section reduces the discontinuity stresses between the flange and branch, and increases the strength of the flange assembly. Welding-neck flanges are suitable for extreme service

conditions; where the flange is likely to be subjected to temperature, shear and vibration loads. They will normally be specified for the connections and nozzles on process vessels and process equipment.

Figure 2.7 welding-neck flange

2.4.6.2. Slip-on flanges: slip over the pipe or nozzle and are welded externally and usually also internally. The end of the pipe is set back from 0 to 2.0 mm. The strength of a slipon flange is from one-third to two-thirds that of the corresponding stan...