Bài giảng tính toán bồn áp lực PRESSURE VESSEL DESIGN BY LING

bài giảng cung cấp kiến thức cơ sở cho, và các bài toán tính toán bồn áp lực bao gồm:1.GeneralPressure vessel design codesTypes of pressure vessel.Pressure vessel major componentsDesign considerations2.Vertical Vessel 3.Horizontal Vessel4. Spherical Vessel 5. Fabrication Inspection Tests

2002 LECTURE SLIDES 1

Pressure Vessel Design Lecture

By Ling Kui Muk, P.Eng

Basic Theories

1.1 Statically Determinate Members

1.2 Free Body Diagram

1.3 Statically Indeterminate Members

1.4 Centre of Gravity

1.5 Moment of Inertia

1.6 Section Modulus

1.7 Radius of Gyration

Statically Determinate Members

2 equations 2 unknowns

Statically Indeterminate Members

I, Z & r

b

a

x x

A = cross sectional area

P = force

Compressive Stress

P

P

Sc = P/A Compressive Stress, Sc

A = cross sectional area

P = force

2002 LECTURE SLIDES 11

Tension

Compression

Balance Condition

2002 LECTURE SLIDES 13

Consequent of Unbalance

Shear Stress

Ss = P/A Shear Stress, Ss

A = cross sectional area

P = force

P

Ss

2002 LECTURE SLIDES 15

Bending Stress

Sb = M/Z Bending Stress, Sb

Z = Section Modulus

M = P * L

P L

+Sb

Tension

-Sb

Compression

Radius : R

Thickness : t

Pressure : P

Membrance Stress

Membrane stresses are average tension or compression

stresses over the thickness of the vessel wall.

2002 LECTURE SLIDES 17

Membrance Stress-Cylindrical Shell

Circumferential Stress (@ Longitudinal Seam)

P R S1 = -

t

Longitudinal Stress (@ Circumferential Seam)

P R S2 = -

2 t

Spherical Shell - LPG Storage

Diam : 20m Thk : 48mm

 /2

 /2

Elongation

 u

For steel, E=205 kN/mm 2



Slope, E =  / e

Beam Formulas

Shear-Moment Diagram

R R

P

l/2 l/2

Sb = M/Z

V

V Shear

Mmax

2002 LECTURE SLIDES 25

Codes & Standards

Structural Components

1 American Codes

-AISC -AWS

2 British Codes

-BS 449 -BS 5950

Companys’ Spec & Standards

Petroleum Refinery

Import & Export Fac.

Crude Storage Tanks Processing Units

Products Storage Tanks

Pump

Petrochemical Plant

Feed Stock

Gas Liquid

Solid

Processing Products

Gas Liquid Solid

Process Units - Examples

DeiC5 Tower

Temp : 133C Press : 4.5 kg/cm2

Non-process Units - Flow Chart

Liquid

Products

Liquid Products

2002 LECTURE SLIDES 39

Non-process Units -LPG Bottling Plant

LPG Bottling Plant

LPG Vessel

Client’s Standards

1 Petroleum Refinery

+ Shell’s DEPs + Mobil’s EGEs & EGSs + EXXON’s BPs & Ips

2002 LECTURE SLIDES 41

Client’s Standards

Engineering Contractor’s Std

2002 LECTURE SLIDES 43

Why do we need our own standards?

quality

3 To prolong the life of the plant.

suppliers/contractors the requirements.

5 To supplement the industrial codes

and standards.

Pressure Vessel Design Part 1

1.General

-Pressure vessel design codes

-Types of pressure vessel.

-Pressure vessel major components

-Design considerations

2.Vertical Vessel

-Pressure parts

Part 3

1 Spherical Vessel

- Pressure parts - ASME VIII, Div 2

- Column Support Design

- Localised Stress

2 Fabrication & Inspection & Tests

2002 LECTURE SLIDES 47

Part 1

Pressure Vessel Design Codes

1 ASME VIII, Div 1 & 2

2 BS 5500

3 others

2002 LECTURE SLIDES 49

Definition of pressure vessel

ASME VIII, Div 1

- Pressure vessels are containers for

containment of pressure, either internal

or external

Basis of Lecture - based on ASME

Types of Pressure Vessel

2002 LECTURE SLIDES 51

Pressure Vessels - Samples

Horizontal Drum Vertical Drum

Tower

Spherical Vessel

Non-Pressure Parts

- Skirt -Anchor Chair & Bolts

Pipe and platform

Support Clips

Skirt thick.

Head thick

shell thick

Design Considerations

1 Major Dimensions

-Inner Diameter -TL-TL

-Skirt Height

2 Design Conditions

-Pressure -Temperature -Material

Vertical Vessel

-cylindrical shell,head,flanges,etc

-supports, support clips, lifting lug, etc.

e.g wind or earthquake

P = 100 psig

S = 17500 psi (515-70@650F)

Apex Angle



D

Max 30 deg

2 Factor B determination Steps

Step 1 : Assume t, find L/Do & Do/t Step 2 : Enter Fig UGO-28.0

Step 3 : Move horizontally to line Do/t, reads Factor A Step 4 : Enter Factor A in Material Chart

Step 5 : Read the value B.

Factor A

Do/t Line assumed t

L/Do Value

Factor A

2002 LECTURE SLIDES 63

Factor B

Factor B

Factor A

2002 LECTURE SLIDES 65

Part 2

Pressure Vessel Major Components

2002 LECTURE SLIDES 69

Support Design

1 Skirt, Anchor chairs & bolts

-Thickness of skirt -No and size of Anchor Bolts -Thickness of anchor chairs

2 Column & Baseplate

-Size and thick Of column -Size and thick of baseplate

Vessel Supports

Column

Skirt

2002 LECTURE SLIDES 71

Vessel Skirt & Anchor Chair & Bolts

1 Loadings

- Dead weights : Wd -Product weights : Wp -Moment : M (due to wind and piping loads)

Vessel Skirt & Anchor Chair & Bolts

3 Allowable Stress

- Based on ASME VIII, Div 1 : UG-23

- min (Sa, Factor B) -usually Factor B governs

Steps

1 A = 0.125/(Ro/t)

2 Read Factor B from appropriate Chart

3 Falls to the left of the chart, B = AE/2

2002 LECTURE SLIDES 73

Max Allowable Comp Stress

Factor B Allowable Comp Stress

Factor A = 0.125/(Ro/t)

AE

S = 2 Max.

-Anchor Bolt & Base

4.1 Tensile Load in A.B.

4 M W

P = -

n * d n

- n : no of anchor bolts

- d : bolt circle diameter 4.2 Tensile Stress ;

St = P/Ar

Ar = Root area of anchor bolt

Worst case : empty condition

Moment : due to wind and piping

15,300 psi (API 620) {0.425*Sy}

15,000 psi (Mobil’s EGE)

6 Anchor Base

-various types -Standard types (defined in standard drawings)

Anchor Bolt & Base

Ac = Cross sectional area of column

Column & Base Plate

7.4 Size and Thickness

- limit bearing pressure on foundation to

Design of Base Plates (Dennis R Moss)

Base Plate Design

Support Clips

F1 F2

Vessel Wall Inside Diameter

2002 LECTURE SLIDES 81

Support Clips - Localised Stress

d e

Local Stress Analysis

- with or without pad.

2002 LECTURE SLIDES 83

Horizontal Vessel

Horizontal Vessel

L

Ls D

Two saddles

2002 LECTURE SLIDES 85

Horizontal Vessel

Part 3

Pressure Vessel Engineering

Provide basic data Client

Main Contractor

PV fabricator

1.Review Specification 2.Prepare Requisition & Spec 3.Technical Evaluation

4.Review Fabrication Dwgs 5.Review fabr & inspec spec 6.Carry out inspection

7.Monitoring progress 8.Supervise installation

1 Procure material

2 Design & fabrication

3 Inspection and testing

Joint inspection

2002 LECTURE SLIDES 89

Vertical Vessel- Shop Fabrication

Vertical Vessel- Transportation

30 m over-hanged

Additional Stiffener Rings

Self-propelled modular trailer

2002 LECTURE SLIDES 91

Vertical Vessel- Transportation

Lifting Lug Design

1 Establish method of erection

- With or w/o spreader bar

- Fully dressed or bare

2 Lug or trunnion or others

3 Design the Lifting lug

a Loading consideration

b Lugs member size, thickness

c Size of weldment

3 Tailing Lugs (1 or 2 nos.)

4 Nozzle as lifting point

Lifting Lug Design

Repad

2002 LECTURE SLIDES 95

Trunnion Design

Advantage of Trunnion

1 Thinner Plate than lifting lug

2 Heavy Lift (> 200 mton)

3 Local Stress need to be analyzed

P

Shell plate

Repad

Equipment Installation

* Trunnion

* Partially Dressed

* Main Crawler Crane

* Tailing Crawler Crane

* 260 mtons, 75 m

2002 LECTURE SLIDES 97

Lifting Lug Design

* Lifting Lug

* Main Crawler Crane

* Tailing Crawler Crane

* 300 mton, 70m

* 600 mtons, 105m

2002 LECTURE SLIDES 101

Horizontal Vessel - Two Saddles

Horizontal Vessel

M3 M4

D

Two saddles

2002 LECTURE SLIDES 103

Shell Thickness Calculation

1 Base on internal pressure determine

* shell thickness

* head thickness

2 Carry Stress Analysis

* based on L.P Zick’s Method

* two locations, at mid span and at the saddle region

3 BS 5500 provided worked examples.

* detailed calculation, Case 5500/53

Horizontal Vessel

Hemi-spherical Head Multi-saddle - 8 nos.

Temporary Bracing Installation

On Saddle

2002 LECTURE SLIDES 105

Horizontal Vessel

Stiffener Ring Dye Penetration Test

Rotator

Horizontal Vessel

Post Weld Heat Treatment - LPG Gas Firing

2002 LECTURE SLIDES 107

Horizontal Vessel

Mounded LPG Vessel

Spherical Vessel

Shell Thickness

-ASME VIII, Div 2

Stress at column support

2002 LECTURE SLIDES 109

Spherical Vessel Fabrication

Pressing of Equator Shell Plate-1000 mton hydraulic jack

Spherical Vessel Fabrication

Inspection on Tolerances

2002 LECTURE SLIDES 111

Spherical Vessel Filed Assembly

Crown Plate Equator Plate

Spherical Vessel - Field Erection

Equator Plate & Column

2002 LECTURE SLIDES 113

Spherical Vessel - PWHT

Insulation work prior

to PWHT

Spherical Vessel Erection

Painting

Section 5 - Fabrication & Construction

* Introduction to FEM Program

* Multiframe 4D

* Create a model, analysis of the results.

Section 1 : General

2002 LECTURE SLIDES 117

General

1 Containers for storing and loading of

granular materials are called Bins

2 Others terms such as “ hopper ”, “ silo

“, and “ bunker ” are commonly used.

3 Cylindrical or rectangular shapes.

Section 2 : Application

Lubricating and Fuel Additive plant (Singapore)

One unit of Silo

9m

21 m

Column supported

2002 LECTURE SLIDES 121

Chemical Plant (Singapore)

Lime Hopper Diam 2.5m

Bracket Supports

PTA Plant (Taiwan)

Circular Steel Column

Skirt Supported

Bin

2002 LECTURE SLIDES 123

Polypropylene Facilities (USA & Spain)

Granule Holding Bins

PTA Plant (Malaysia)

Concrete Column

2002 LECTURE SLIDES 125

Coal Handling Equipment, Australia Bulk Material Handling Facilities (Australia)

Section 3 : Design

2002 LECTURE SLIDES 127

Design

Design Codes & References

1 AWRA Technical Note 14

by the Australian Welding Research Association, Dec 1984

2 Codes such as ASME, AISC, API 620,

BS 5950, etc may be used.

2002 LECTURE SLIDES 129

Bins major Components

Bracket supported Column Supported

Hopper

H > h



Filling Peak

 =(90+)/2

2002 LECTURE SLIDES 131

Design

1 Liquid Filled Tank or Bin

-API 620 or API 650 - Shell, Roof & Bottom

2 Shallow Bin

-Lambert - Cylindrical Shell -Ketchumm - Conical or Spherical bottom -Wozniak - Ring Compression

3 Deep Bin

-Lambert - Cylindrical Shell -Ketchumm - Conical or Spherical bottom -Wozniak - Ring Compression

-Boardman - Allowable compressive stress

4 Bins with Small Internal Pressure

-API 620

Section 4 : Fabrication

2002 LECTURE SLIDES 135

Fabrication

1 Shop Assembled Bin

- small diameters where can be transported from shop to the site.

2 Shop fabrication & field assembly

- large bins where transportation is non-economical or viable.

3 Field fabrication and Assembly

- large bins where transportation is non-economical or viable.

Shop Assembled Bin

Lime Hopper

2.5m

Field Fabrication & Field Assembly

Welding

Pre-assembly & Fit-up

Field Fabrication & Field Assembly

Cylindrical Shell

Conical Roof

Operation Room

2002 LECTURE SLIDES 141

Field Fabrication & Field Assembly

Insulation Work

Completed

Shop Fabrication & Field Assembly

Column Support

Upper Section Lower Section

2002 LECTURE SLIDES 143

Shop Fabrication & Field Assembly

Erection Section by Section

Top Section

Shop Fabrication & Field Assembly

Completely Assembled

2002 LECTURE SLIDES 145

Introduction to FEM

Introduction to FEM

1 General

* Matrix Method, solving simultaneous equations

* 1950s, originated from Aerospace Industry

* 1975, international conference on FEM

* today, PC based FEM are available

2 Analysis Methods

a) Analytical Procedure +Differential Equation’s Theory b) Weighted Residual Procedure +Galerkin Method (Rayleigh-Ritz) c) Variation Principle

2002 LECTURE SLIDES 147

Comparison of Analysis Methods

Method

Analytical Procedure

Weighte Residuce

Procedure

Variation Principle

Representaive

Method

Differential Equation's Theory

Galerkin Method (Rayleigh-Ritz)

Finite Element Method

Applicable Range Highly Limited Moderately Limited Hardly Limited

Basic Function

Differential Equation Exponent Series

Small Degree Polynominal

PC, Mini Comp, Main Frame Class

Finite Element Method at Present

Pre-Processing

FEM Analysis FEM

Analysis

Processing Post-

Post-Processing Evaluation

2002 LECTURE SLIDES 149

Introduction to

Multiframe

World Wide Application

Roof Structure Lifting

Span-3x30m

length-11x15m

-Turkey

Portal Crane Span-80m Heigth-40m Lift-15 mton @ mid-span -Turkey

2002 LECTURE SLIDES 155

Demo Items

3 examples will be shown

-Dome Roof Structure -Equipment support -Portal Frame for building

-Dome Roof Structure

2002 LECTURE SLIDES 157

-Equipment Structure & Portal Frame

Demo Items

2 Steps

a) Model generation b) Assigning of structural section c) Apply appropriate joint restraints d) Apply appropriate loads

e) Perform FEM analysis d) View the graphical output f) View the output data

g) Optimizing the design (Steel Designer)

2002 LECTURE SLIDES 159

The End.