Pressure Analysis of a Flange

File: PVE-3396, Last Updated: March 18, 2009, By: BV

This sample report illustrates how FEA is used to validate flange design. This report format
may be used to justify ASME code compliance, provide stress and displacement analysis,
provide cycle life estimates, complete thermal analysis, and perform design validation and
optimization studies. This format is fully CRN compliant and may be applied to many
applications. 

Download:
FEA Report

Linear Multi-Body Analysis

Connections such as flanges, tri-clamps and any other multi-body assemblies are
analyzed using FEA. This example shows a Tri-Clamp connection under internal
pressure and describes how FEA is used to provide insight into the interaction between
components.

LINK

Linear Multi-Body Analysis

File: File:PVE-4472, Last Updated: Aug 23, 2010, By: DRV
 A highly displaced view of a coupler joining two pipes
finished with sanitary ferrules

FEA may be used to analyze single as well as multiple body designs. For multiple body
analysis the interactions and restraints between bodies must be defined. The solver can then
provide the resulting displacement, stress and contact pressure plots. Utilizing multiple bodies
is typical of connection or joint analysis and allows the user to ensure proper preload and
observe that joint separation does not occur. A complete engineering report of a multi body
analysis typical of what is provided by Pressure Vessel Engineering is available for download
below.
Interaction between multiple bodies can be defined as bonded, no interaction, or no
penetration. A bonded condition forces the bodies to act as a single component. For example
a head bonded to a shell would simulate a welded condition and solve the analysis as if the
head and shell were a single component. A no interaction condition does not account for the
interaction between multiple bodies; it allows the bodies to displace individually without any
imposed restraints by the adjacent components. This condition could result in bodies
interfering or overlapping each other. A no penetration condition allows multiple bodies to
contact each other, but not to penetrate. This condition is useful when analyzing connections
such as flanges, tri-clamps or split rings. No penetration conditions also provide contact
pressure plots. These plots are useful to ensure joint separation does not occur.
 A contact pressure plot showing resulting contact pressure between bodies. This plot is
useful to ensure joint separation does not occur.  the length and color of the arrows shows
the contact pressure.

Restraints between multiple bodies such as bolts may also be simulated. Bolt connectors are
defined in place of solid model bolts, and their material properties and preload defined. The
solver creates beams to simulate bolting where bolt connectors have been defined, and
transfers the applied preload to the connection accordingly. The software can then output the
resulting forces acting on each connector which can then be used to calculate stresses.
Defining appropriate restraints and interactions between bodies is critical to obtain accurate
FEA results. Applying incorrect interaction conditions between components will result in
incorrect results. FEA results with the wrong interactions may be interpreted as acceptable
and allow for unsafe designs.

Downloads:
FEA Report
Drawing

Reversed Dished Head

This reverse dished head could not be fabricated thick enough to meet the ASME VIII-1
rules. The chosen solution was to reinforce the head with ribs to prevent snap through.
Various alternate methods of analysis are shown.

LINK

Reversed Dished Head

File: PVE-407, Last Updated: June 2, 2003, By: LB

The Problem:

The process in this vessel required a reverse dished head. The reverse dished head could not
be fabricated thick enough to meet the ASME VIII-1 rules. The chosen solution was to
reinforce the head with ribs to prevent snap through.
Various alternate methods of analysis are shown here. Only the plate analysis was used for
the actual job. However, the comparison of the various methods is educational.
The head diameter and thickness and design pressure of 75 psi is the same for all of the
examples bellow. The material has a yield strength of 30,000 psi and an allowed design stress
of 20,000 psi. The maximum allowed membrane (tensile) stress is 20,000 psi, 30,000 at
regions of discontinuities. The maximum allowed membrane + bending stress is 30,000 psi,
60,000 psi at discontinuities.

Analysis – 2D Axisymmetric with Linear Material Properties:

This is one of the simplest methods of analyzing this vessel. A cross section of the head
without reinforcement is analyzed. Algor assumes that the 2D drawing is symmetrical about
an axis (axisymmetric). The results show the stress distribution in the head if there is no
material yielding (linear material properties).

Cross section of the reverse dished head (from center to left

side). Stresses are shown for an interior pressure in this and the
following shots.
The peak stress is 54,000 psi in the knuckle region, well above the 30,000 psi yield point. This
head fails the ASME VIII-1 code calculations for exterior pressure, but the stresses in the
knuckle region are less than the discontinuity stress limit of 60,000 psi. Predicted deflection is
0.15 inches (not shown). Perhaps the head is safe? The ASME code calculations provide a
safe pressure of 57 psi for a regular dished head. Also, the use of regular dished head exterior
pressure calculations is not proven for a reverse dished head.

Analysis – 2D Axisymmetric with Non-Linear Material Properties:

This analysis allows for material yielding. The same cross section is analyzed, but for this
analysis, the pressure is applied in steps, and the material will be allowed to yield (Non-Linear).
Up to 64 psi, the head can be seen deflecting linearly under pressure. At 69 psi snap through is
beginning (and the deflection is greater than the material thickness). At this point the head
has started permanent deformation – it will not return to the original shape after the pressure
is removed. Pressures beyond 72 psi show rapid snap through. The second image shows the
fully snapped through shape at 72 psi. This shape is kept permanently after the pressure is
removed.

Defection of the center of the head vs pressure. Snap through

starts around 66 psi.

Original and final shape of head. Loaded to 75 psi and Pressure

released.

Analysis – 3D Plate Analysis:

Reinforcing ribs were put on the head to prevent snap through. 3D analysis is required to
calculate the stresses. A surface model was created in SolidWorks. The material thickness is
specified at time of analysis in the Algor FEA program.

Plate model – top view – created in SolidWorks.

Plate model – bottom view.

The FEA analysis of the head in Algor showed that the stresses were acceptable. The
maximum allowed membrane (tensile) stress is 20,000 psi, 30,000 at regions of
discontinuities. The maximum allowed membrane + bending stress is 30,000 psi, 60,000 psi
at discontinuities. Peak stresses around stress concentrations can be larger.
 Membrane Stress – limited to 20,000 psi except in areas of
discontinuities. At areas of discontinuities, membrane stress
can be 30,000 psi. This plot shows maximum membrane
stresses at 42,000 psi at a concentration which is acceptable.

Total Stress (Membrane + Bending) – limited to 30,000 psi

except in areas of discontinuities. At areas of discontinuities,
membrane stress can be 60,000 psi. The total stresses are
acceptable.

Analysis – 3D Solid Analysis:

A solid model was created in SolidWorks including the reinforcing ribs and all weld fillets. The
actual material thickness was modeled. This was not done for the original analysis, but is
included here for educational purposes.
 Solid model – bottom view

Solid model detail – meshed at 1/8″ mesh size

Top side stress

 Bottom side stress detail

The solid model maximum calculated stresses are found in the same location as for the plate
model, but are much lower. The solid model accounts better for the stresses at connections,
and allows the effect of weld fillets to be included.
The maximum stress is 28,000 psi, found in small peak areas. This value could be used with a
fatigue analysis if required. All of the general stresses are below the 20,000 tensile limit, so no
stress linearization is required to separate membrane and membrane + bending loads.

Snap through analysis results for the solid bottom

head. pressure at 1 sec is 75 psi. At 3.5x operating
press the head starts to yield.
 Displaced head at 5x operating pressure – displacement
magnified 2x.

The Solution:
The design with the reinforcing ribs was successfully used. A report interpreting the results
according to ASME VIII-2 rules allowed the vessel to be registered. A later modification to the
process allowed a less expensive double wall head to be used instead.

Comparison of Methods Shown:

The Solid and Plate analysis methods here produced almost identical stress results except at
attachments. The Solid model with the weld fillets gave more realistic and lower stress
results. The solid model was also easier to make than the plate model which required each
surface to be split at all intersections. If the stresses were higher in the solid model, stress
linearization would have been required to separate the membrane and membrane + bending
stresses. The solid model stress linearization is more difficult than reading the stresses off of
the plate model.

Credits:
This tank was built by Price Schonstrom Inc., 35 Elm Street, Walkerton, Ontario, Canada, N0G
2V0

Riveted Vessels
This digester has been in use since 1926. Vessels built in that time period were typically
constructed with riveted butt joints.

LINK

Riveted Vessels
File:PVE-4687, Last Updated: 5-Nov-10, By: CBM
Pressure Vessel Engineering was contacted to help re-certify a series of 17′ Diameter 56′ tall
digesters for Tembec Inc. which are currently in use for the pulp and paper industry. These
digesters are filled with wood chips and mixed with acid in order to convert the wood chips to
paper pulp.
This digester has been in use since 1926. Vessels built in that time period were typically
constructed with riveted butt joints.

A shell model of the entire digester was created and analyzed to

determine the stress distribution.
 The resulting stress profile from the design pressure and static
head. The highest stresses were observed at the bottom shell
segments.

The next step was to analyze a small segment encompassing the bottom shell and cone and
modeling in the actual butt straps with rivets. Rivets are installed in a hot state, so as they
cool, they contract and generate a preload force that compresses the butt straps and the shell
together. As the rivets cool, they plastically deform with preload stresses relaxing back to the
yield point. Bolt connectors with the corresponding preload equal to the yield stress have been
used to simulate the rivets.
A solid model was created, incorporating the butt straps and the
legs. Weight is applied to the model to generate stresses at the
leg attachments.

Bolt connectors are applied at each of the rivet locations with

the calculated axial preload. No penetration contact sets are
applied between all butt straps and shells.
 The plane of symmetry cuts through the cylindrical shell.
Symmetry is applied here. A seam is present at the conical shell
thus no symmetry is applied. This forces the rivets to restrain
the model.

The rivet head is bonded on the inside and the outside butt
straps. The rivet is restrained from moving through the hole in
the conical shell.
The digesters experience radial expansion along with a bending
load on the legs.

Although the riveted areas are perforated, the butt straps provide
additional restraint and actually reduce stresses at the seam.
Peak stresses are generated immediately around the holes due
to the high compressive preload stress.
Higher stresses occur around the rivet holes. This is caused by
the rivet preload being set to the yield strength. This causes a
high compressive stress at the joint.

An outer row of rivets with a larger pitch was used in this design.
Although this is still below the allowable stress, a concentration
of stresses build up in this region.
Our FEA was successfully used to prove the integrity of the digesters in their current state to
the local jurisdiction and the insurance company. Even though riveted boilers and pressure
vessels have not been manufactured for many years, there are a number of them that are still
in operation today. Although built to ASME code, many of these boilers were constructed at a
time when no CRN requirement was in place. As inspectors come across these vessels, we
expect to see more of this type of inspection and certification requirement.
We at Pressure Vessel Engineering Ltd are very grateful to Tembec for allowing us to post this
analysis. Tembec has been acquired by Rayonier Advanced Materials and can be contacted
through their website at www.rayonieram.com.

Thermal Analysis
FEA can calculate temperature profiles in single and multi-part models. From this,
displacements and stresses are obtained. Here FEA is used to determine heat time and
required power for an injection mold.

LINK

Thermal Analysis
File: File:PVE-4437, Last Updated: Aug 23 2010, By: BTV

Transient and Steady State Analyses

Heat entering a part in a mold cavity

Thermal analyses are used to study thermal loadings and their resulting temperatures, heat
transfer rates, displacements and stresses. These analyses are broken into two main types,
steady state and transient. Steady state analysis will determine the energy balanced state at
an infinite period in time without any detail on what happens while progressing to this point.
Transient thermal analysis is able to analyze the heat flow through a body on a step by step
basis allowing temperature effects to be observed over time.

Steady State Analysis

Steady state analysis is used to observe the effects of thermal loadings once the object in
question has reached a constant, or steady state. This is useful to determine sustained
temperatures, heat transfer rates, displacements and stresses. Steady state analysis is also
useful to determine thermal loads and material properties to obtain a final desired result. As a
steady state analysis only provides a final continuous result it only requires a single
computation making it a very efficient solver.

Transient Analysis

Temperature vs time for various locations in the cavity

A transient analysis is used to observe the effects of thermal loadings over time. It allows the
user to view the changing temperature gradient through a component from initial though to a
steady state condition. Transient thermal impacts are important to analyze as thermal
loadings may result in peak stresses prior to reaching a steady state. It is also useful to
answer questions such as how long will a component take to reach a desired temperature. As
a transient analysis provides solutions for a defined number of time steps many
computations are required resulting in a much more complex analysis.

Downloads
FEA Report
Drawing

Finite Element Analysis at PVEng

We use FEA to design and validate fittings and vessels that can not be designed by
rule-based codes like VIII-1 or B31.3. We are experts in the specialized field of
pressure equipment design by FEA to validated ASME VIII-2 methods.
 SolidWorks Simulation and Abacus software
Pressure and thermal stress analysis
Permissible service life (fatigue life)
Wind and seismic analysis
Leg, saddle and clip design
Frequency and vibration analysis
Computational Fluid Dynamics (CFD)

Pressure Vessel Engineering has used Finite Element Analysis (FEA) to design and
verify thousands of pressurized components. We have the knowledge and experience
to get the job done right.

Other Services
ASME Code Design – We work to many ASME standards to design and validate
pressure vessels, boiler, fittings and piping systems.

Pipe Stress Analysis – Pipe stress analysis is mandatory for British Columbia
registration and it is recommended practice for many other systems.
Canadian Registration Number (CRN) – We are Canada’s largest independent registrar of
fittings, vessels and piping under the CRN program registering for more than a
thousand customers.

About Us
Pressure Vessel Engineering has twenty years of successful experience in the
pressure vessel field working for more than a thousand customers.
Six Professional Engineers on staff licensed to stamp and sign off on designs for use in
all Canadian jurisdictions.
Fast and professional assistance from our team.

Need help? Our contact information is to the right.

Pressure Vessel Engineering Ltd.

120 Randall Drive, Suite B
Waterloo, Ontario, Canada
N2V 1C6
519-880-9808