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FE Analysis : Pressure Vessel

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INDEX

1. INTRODUCTION
2. OBJECTIVE
3. ASSUMPTIONS
4. CAD MODEL
5. MESHED MODEL
6. FE MODEL INFORMATION
7. MATERIAL PROPERTIES
8. LOADS AND BOUNDARY CONDITIONS
9. PROCEDURE
10. RESULTS DEFLECTIONS AND STRESSES
11. RESULTS SUMMARY
12. OBSERVATIONS AND CONCLUSION

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1. INTRODUCTION

This Report consists of Results and Conclusions for FE Structural Stress Analysis of
Vessel carried out to evaluate the Design adequacy for various loads like Design
Pressure, Hydro Test Pressure & Nozzles External Loads.

Based on the Inputs, Vessel dish end from flange with 9 Nos. Nozzles, 2 Stiffener
Rings and 2 Sliding Saddles are considered for the Analysis.

Analysis is carried out for 3 Load Cases :

Load Case-1 - First is for Internal Pressure, Temperature and Nozzles Loads; Load
Case-2 Second is for Nozzle Loads NO Internal Pressure;
Load Case-3 - Third is for Hydro Test for the Pressure of 7.2 Bars.

2.0 OBJECTIVE
To evaluate the design of Vessel Nozzles, Saddles and Stiffeners under various Loads.

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 3.0 ASSUMPTIONS

1. Material Properties are correct as per ASME Sec-II D.

2. Linear Material of Steel are taken for the Analysis Purpose.

3. Loads and Boundary Conditions applied as per the Supplied Inputs.

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 4. CAD MODEL : Assembly considered for FEA
Nozzles S3, S4, S5, S8, S9, S1A , S6A, S2A are areas of interest.

STIFFNER RING-2 STIFFNER RING-1

S2A
S6A S5

S4

S9
S1A S8
S3

FIXED
SLIDING
SADDLE SADDLE

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5. MESHED MODEL : Assembly considered for FEA

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 6. FE MODEL INFORMATION :
The Vessel with nozzles is meshed with 2nd Order Tetrahedral Elements.

No. of Nodes in the Model = 3,73,787 No. of Elements in the Model =

1,98,188

The quality of elements is qualifying following criteria:-

From all the components in the FE Model Assembly, 99% of elements

Qualify for :-

Achieved

Tetra Collapse > 0.1 (0% failed)

Skew < 60 (0% failed)
Jacobian > 0.5 (0% failed)
Vol. Aspect Ratio < 9.75 (0% failed)
Min. Angle Tria Faces > 15 (0% failed)
Max. Angle Tria Faces < 130 (0% failed)

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 7. MATERIAL PROPERTIES :

MATERIAL Youngs Modulus Poisson's Yield Strength Tensile Strength

(MPA) Ratio (MPa) (MPa)

Steel 198,000 0.29 240 450

SA 516 Gr 65

Properties of SA 516 Gr 65, as per ASME Sec-II, Part-D, Table-5A

Thermal conductivity : 0.0479 W/mm/oC

Thermal Expansion : 12.4 E-6 / oC
Elongation : 19% min in 8 23% min in 2
Max. Allowable Stress (Sm) : 144 MPa

2010 ASME Boiler and pressure vessel code, Section II, Part D

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 8. Loads and Boundary Conditions

S2A inner surface of vessel and nozzles

Design
S5 pressure applied on all the
S6A

S4

S9 No external loads on S3 & S4

S1A S8
9
S3

Hydro Test Pressure = 7.2Bar,

Design Temp. 159Deg. C

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 9.0 PROCEDURE
2D drawing is converted to 3D model as per the drawings.

The model is imported into Hyper mesh and meshed using solid tetra elements.

These elements were imported to ANSYS and assigned the Material Properties to each
component as specified in drawings.

The boundary conditions are applied as per Section-8 in this report.

Design pressure of 5.5 Bars is applied over the inner surfaces of vessel and nozzles.

Nozzle loads were applied as per nozzle loads table.

For load cases, temperature of 159oC is applied over the inner surfaces of vessel.

Model is solved for 3 different load cases as specified in Introduction section in this report.

10

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 10. RESULTS
Load Case-1 : Internal pressure,
Temperature & nozzles loads

CONSTRAINTS ON SLIDING SADDLE

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 9.1 Stress Analysis Results : Load Case-1
Deflection Plot (mm) Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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 9.2 Stress Analysis Results : Load Case-1
Deflection Plot (mm) Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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 9.3 Stress Analysis Results : Load Case-1
Deflection Plot (mm) Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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 9.4 Stress Analysis Results : Load Case-1
Deflection Plot (mm) Internal pressure, temperature, nozzles loads

Max. Deflection = 18mm

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 9.5 Stress Analysis Results : Load Case-1
S6A S5
Stress Plot (MPa) : Von-Mises Stresses S2A

S4

S9
S3 S8 S1A
S2A Stress linearization

S5
Stress (Pl+Pb+Q) = 358 MPa

16
Stress (Pl+Pb+Q) = 50 MPa
Stress (Pl+Pb+Q) = 291 MPa
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 9.6 Stress Analysis Results : Load Case-1
S6A S5
Stress Plot (MPa) : Von-Mises Stresses S2A

S4

S9
Stress linearization
S3 S8 S1A
S8

Stress (Pl+Pb+Q) = 396 MPa S6A

Stress (Pl+Pb+Q) = 73 MPa 17

Stress (Pl+Pb+Q) = 302 MPa
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 9.7 Stress Analysis Results : Load Case-1
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4 S4

S9
Stress linearization
S3 S8 S1A

S9

Stress (Pl+Pb+Q) = 58 MPa Stress (Pl+Pb+Q) = 95 MPa

Stress (Pl+Pb+Q) = 31 MPa

Stress (Pl+Pb+Q) = 129 MPa

Stress (Pl+Pb+Q) = 101 MPa 18

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 9.8 Stress Analysis Results : Load Case-1
Stress Plot (MPa) : Von-Mises Stresses S6A S5 S2A

S3 S4

S9
S3 S8 S1A
Stress linearization

S1A

Stress (Pl+Pb+Q) = 345 MPa

Stress (Pl+Pb+Q) = 35 MPa

19
07/10/2011 Stress (Pl+Pb+Q) = 248 MPa
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 9.9 Stress Analysis Results : Load Case-1
S5 S2A
S6A
Stress Plot (MPa) : Von-Mises Stresses
S4 R1
R2

S9

S3 S1A
S8

R1
R2

Stress (Pl+Pb+Q) = 342 MPa Stress (Pl+Pb+Q) = 91 MPa 20

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 9.10 Stress Analysis Results : Load Case-1
Stress Plot (MPa) : von-Mises Stresses

Sliding Saddle Fixed Saddle

Stress (Pl+Pb+Q) = 1055 MPa Stress (Pl+Pb+Q) = 985 MPa

After masking localized stress areas

21

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10. RESULTS
Load Case-2 : Nozzles loads, NO
Internal Pressure & Temperature

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 10.1 Stress Analysis Results : Load Case-2
Deflection Plot (mm) Nozzles loads only

Max. Deflection = 3 mm

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 10.2 Stress Analysis Results : Load Case-2
Deflection Plot (mm) Nozzles loads only

Top View Bottom View

Max. Deflection = 0.87mm

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 10.3 Stress Analysis Results : Load Case-2
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4

S9
S3 S8 S1A
S2A
Stress linearization

S5
Stress (Pl+Pb+Q) = 227 MPa

Stress (Pl+Pb+Q) = 7 MPa

Stress (Pl+Pb+Q) = 154 MPa

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 10.4 Stress Analysis Results : Load Case-2
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4

S9
S3 S8 S1A
S8
Stress linearization

S6A
Stress (Pl+Pb+Q) = 321 MPa

Stress (Pl+Pb+Q) = 2.5 MPa

26
Stress (Pl+Pb+Q) = 227 MPa
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 10.5 Stress Analysis Results : Load Case-2
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4
S4

S9
S3 S8 S1A
Stress linearization

S9

Stress (Pl+Pb+Q) = 17 MPa

Stress (Pl+Pb+Q) = 4 MPa

Stress (Pl+Pb+Q) = 1 MPa

Stress (Pl+Pb+Q) = 14 MPa 27

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 10.6 Stress Analysis Results : Load Case-2
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4
S3

S9
Stress linearization
S3 S8 S1A

S1A
Stress (Pl+Pb+Q) = 209 MPa

Stress (Pl+Pb+Q) = 125 MPa

28
Stress (Pl+Pb+Q) = 12 MPa
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 10.7 Stress Analysis Results : Load Case-2
S5 S2A
S6A
Stress Plot (MPa) : Von-Mises Stresses
S4 R1
R2

S9

S3 S1A
S8

R1
R2

S1A

29
Stress (Pl+Pb+Q) = 72 MPa Stress (Pl+Pb+Q) = 32 MPa
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 10.8 Stress Analysis Results : Load Case-2
Stress Plot (MPa) : Von-Mises Stresses

R2 R1

S1A

Sliding Saddle Fixed Saddle

Stress (Pl+Pb+Q) = 15 MPa
Stress (Pl+Pb+Q) = 28 MPa
After masking localized stress areas

30

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 11. RESULTS
Load Case-3 : Hydro
Test

Hydro Pressure=7.2 bar

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 11.1 Deflection Analysis Results : Load Case-3
Deflection Plot (mm)

Max. Deflection = 19mm

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 11.2 Deflection Analysis Results : Load Case-3
Deflection Plot (mm)

Max. Deflection = 19mm

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 11.3 Deflection Analysis Results : Load Case-3
Deflection Plot (mm)

Max. Deflection = 19mm

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 11.4 Deflection Analysis Results : Load Case-3
Deflection Plot (mm)

Max. Deflection = 19mm

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 11.5 Stress Analysis Results : Load Case-3
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses

S4

S9
S3 S8 S1A
S2A
Stress linearization

S5

Stress (Pl+Pb+Q) = 335 MPa

Stress (Pl+Pb+Q) = 257 MPa

Stress (Pl+Pb+Q) = 106 MPa 36

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 11.6 Stress Analysis Results : Load Case-3
S6A S5
Stress Plot (MPa) : Von-Mises Stresses S2A

S4

Stress linearization S9
S3 S8 S1A
S8

S6A
Stress (Pl+Pb+Q) = 207 MPa

Stress (Pl+Pb+Q) = 76 MPa

37
Stress (Pl+Pb+Q) = 164 MPa
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 11.7 Stress Analysis Results : Load Case-3
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S4 S4

Stress linearization S9
S3 S8 S1A

S9

Stress (Pl+Pb+Q) = 137 MPa

Stress (Pl+Pb+Q) = 69 MPa

Stress (Pl+Pb+Q) = 137 MPa

Stress (Pl+Pb+Q) = 157 MPa 38

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 11.8 Stress Analysis Results : Load Case-3
S6A S5 S2A
Stress Plot (MPa) : Von-Mises Stresses
S3 S4

S9
Stress linearization
S3 S8 S1A

Stress (Pl+Pb+Q) = 254 MPa

S1A

Stress (Pl+Pb+Q) = 71 MPa

39
Stress (Pl+Pb+Q) = 271 MPa
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 11.9 Stress Analysis Results : Load Case-3
S5 S2A
S6A
Stress Plot (MPa) : Von-Mises Stresses
S4 R1
R2

S9

S3 S1A
S8

R1
R2

Stress (Pl+Pb+Q) = 342MPa Stress (Pl+Pb+Q) = 114 MPa

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 11.10 Stress Analysis Results : Load Case-3
Stress Plot (MPa) : Von-Mises Stresses

R2

Fixed Saddle
Sliding Saddle
Stress (Pl+Pb+Q) = 1104 MPa Stress (Pl+Pb+Q) = 861 MPa

After masking localized stress areas

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 12.0 Result Summary:-
Stress Categories

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 12.1 Stress Result Summary:-
Nozzle No. Stress Category Load Case No. Stresses Baseline
Iteration (MPa)

S3 Pl+Pb <1.5*Sm (207 MPa) LC-2 209

Pl+Pb+Q <3*Sm (414 MPa) LC-1 38
Pl+Pb+Q <3*Sm (414 MPa) LC-3 254
S4 Pl+Pb <1.5*Sm (207 MPa) LC-2 17
Pl+Pb+Q <3*Sm (414 MPa) LC-1 58
Pl+Pb+Q <3*Sm (414 MPa) LC-3 137
S5 Pl+Pb <1.5*Sm (207 MPa) LC-2 7
Pl+Pb+Q <3*Sm (414 MPa) LC-1 50
Pl+Pb+Q <3*Sm (414 MPa) LC-3 106
S8 Pl+Pb <1.5*Sm (207 MPa) LC-2 321
Pl+Pb+Q <3*Sm (414 MPa) LC-1 396

Pl+Pb+Q <3*Sm (414 MPa) LC-3 207

43
Stress Sm = 144 MPa
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 12.2 Stress Result Summary:-
Nozzle No. Stress Category Load Case No. Stresses Baseline
Iteration (MPa)

S6A Pl+Pb <1.5*Sm (207 MPa) LC-2 2.5

Pl+Pb+Q <3*Sm (414 MPa) LC-1 73
Pl+Pb+Q <3*Sm (414 MPa) LC-3 76
S9 Pl+Pb <1.5*Sm (207 MPa) LC-2 1
Pl+Pb+Q <3*Sm (414 MPa) LC-1 31
Pl+Pb+Q <3*Sm (414 MPa) LC-3 69
S1A Pl+Pb <1.5*Sm (207 MPa) LC-2 12
Pl+Pb+Q <3*Sm (414 MPa) LC-1 35
Pl+Pb+Q <3*Sm (414 MPa) LC-3 71
S2A Pl+Pb <1.5*Sm (207 MPa) LC-2 227
Pl+Pb+Q <3*Sm (414 MPa) LC-1 358
Pl+Pb+Q <3*Sm (414 MPa) LC-3 335

Stress Sm = 144 MPa

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 12.3 Stress Result Summary:-
Nozzle No. Stress Category Load Case No. Stresses Baseline
Iteration (MPa)

Sliding Pl+Pb <1.5*Sm (207 MPa) LC-2 28

Saddle
Pl+Pb+Q <3*Sm (414 MPa) LC-1 1055
Pl+Pb+Q <3*Sm (414 MPa) LC-3 1104
Fixed Pl+Pb <1.5*Sm (207 MPa) LC-2 15
Saddle
Pl+Pb+Q <3*Sm (414 MPa) LC-1 985
Pl+Pb+Q <3*Sm (414 MPa) LC-3 861
Stiffener Pl+Pb <1.5*Sm (207 MPa) LC-2 32
Ring R1
Pl+Pb+Q <3*Sm (414 MPa) LC-1 91
Pl+Pb+Q <3*Sm (414 MPa) LC-3 114
Stiffener Pl+Pb <1.5*Sm (207 MPa) LC-2 72
Ring R2
Pl+Pb+Q <3*Sm (414 MPa) LC-1 342
Pl+Pb+Q <3*Sm (414 MPa) LC-3 342

Stress Sm = 144 MPa

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 12.4 OBSERVATIONS AND CONCLUSION

1. Stresses in all the Nozzles are below respective Allowable Stresses as per the
Stress Categories of ASME Section-II D for all load cases, hence design is safe
to carry these loads.

2. Stresses in both Saddles exceeds respective Allowable Stresses, hence

Saddle Design needs the modification to carry various loads.

3. Stresses in both Stiffener Rings are below respective Allowable Stresses,

hence Stiffener Ring Design is safe to carry various loads.

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Contact Us

Scott Raitt
Chief Executive Officer
scott@connektllc.com

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Grass Valley, CA 95949

(530) 604-5821