7/7/2012

OPTECH ENGINEERING PRIVATE LIMITED

INTERNSHIP REPORT ON PRESSURE VESSELS

Vivek Rathor

Internship Report On Pressure Vessels 2012

Preface

This report documents the work done during the summer internship at Optech Engineering Private Limited, D- 151, Amargyan Industrial Estate, Khopat,Thane under the supervision of directors of the company, Siddharth Desai and Trisit Bhuiyan. The report first shall give an overview of the tasks completed during the period of internship with technical details. Then the results obtained shall be discussed and analyzed. I have tried my best to keep report simple yet technically correct. I hope I succeed in my attempt.

Vivek Rathor

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Acknowledgments

Simply put, I could not have done this work without the lots of help I received cheerfully from whole Optech. The work culture in Optech really motivates. Everybody is such a friendly and cheerful companion here that work stress is never comes in way. I would specially like to thank Kiran sir to always help me in every possible way and for proving the nice ideas to work upon. I am also highly indebted to my supervisors Siddharth Desai and Trisit Bhuiyan, who seemed to have solutions to all my problems.

Vivek Rathor

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Company Introduction:
Optech Engineering Private Limited is incorporated in 2005 & is
dedicated to create a benchmark in the Indian Hydrocarbon sector. Optech Engineering has its reputation in delivering high quality products and innovative technology for its customers. The company has four main wings1. 2. 3. 4. OPFEB The Fabrication Shop. OPCON The Project and Construction Division. OPSERVE 24X7 Onsite Services. OPTEST Non Destructive Testing and Certifications.

OPFEB

OPTEST

OPTECH ENGG. PVT. LTD

OPCON

OPSERVE

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OPFEB The Fabrication Shop

The companys certified Pressure Vessel Fabrication facility at their factory is a state of the art facility with the most modern equipments to handle a job of 8 meters height and 33 meters in length and 10 meters in width. This department has the following equipment: 15MT Demag OT crane Plate rolling Machine for 60mm X 3m wide plate Trolley Mounted Column & boom welding machine with rotators All In-House NDT facilities

The Standards according to which the company fabricates the pressure vessels are ASME sec VIII Division 1 ASME sec VIII Division 2 PD5500 IS 2825 etc.

Their products include: LPG / PROPANE Storage tanks AMMONIA Storage Vessels CO2, H2, N2 & other industrial gases pressure vessels Large capacity vaporizers and heat exchangers Stainless Steel storage tanks vessel

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OPCON The Project and Construction Division

With over two decades of experience, customers are assured of innovative and reliable designs, well coordinated project execution, Fast and Quality construction in all projects. There are over 100 projects to its credits in India and abroad. The company has expertise in this division mainly in following areas: 1. 2. 3. 4. 5. PROPANE / LPG storage and handling terminals. LNG storage terminals. Large Crude Oil terminals and Floating roof storage tanks. Auto LPG dispensing station. LPG boiling plant etc.

OPSERVE 24X7 Onsite services

It is an Optechs third division which operates and maintains Hydrocarbon Storage and handling facilities on 24X7 basis.

OPTEST Non Destructive Testing and Certifications

Optech has its fourth division which undertakes all the Non Destructive Testing procedures and statutory certifications for Hydrocarbon storage and handling facilities. The companys expertise in this division is as follows: Large diameter Horton spheres and Pressure Vessels. Floating roof storage tanks (API 650).
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Auto LPG Stations. Radiographic inspection (ASME sec. VIII Div 1 & Sec IX). Harness Test (ASTM-E-110-89). Hydro testing (ASME Sec VII Div 1) etc. Ultrasonic Thickness Measurement (ASTM-A-4525-89). Dye Penetration Test (ASTM-E-165-89).

Major Projects
1. Lake Gas, Tanzania 1X64 KL water capacity Propane or LPG storage tank for bottling plant. 2. Sugam gas, Nepal 4X 106 KL water capacity LPG storage & bottling plant. 3. TATA Motors, Jamshedpur 3X 350 KL water capacity LPG mounded storage tank installation. 4. Mahindra and Mahindra, Chakan 2 X 30 KL water capacity H.S.D (High Speed Diesel) storage tank installation. 5. Ashok Leyland John Deree 1 X 30 KL capacity mounded Propane storage tank installation. 6. Munjal Showa, Haridwar 2 X 36 KL water capacity Propane or LPG mounded storage tank. 7. ISPAT Industries 2 X 20 KL water capacity Ammonia storage tank installation.

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The Goals :
Following Goals were set as I proceeded in my work 1. Understanding of basic concepts of Pressure Vessels. 2. Understanding of Designing and Fabrication of pressure vessels according to different codes viz. IS-2825, PD5500 & ASME Sec VIII Div 1. 3. To make a master design calculation plan for all the design calculation for the manufacture of Pressure Vessels by the different types of codes as stated above. 4. To assist in the designing and design calculation for the ongoing project of 130KL LPG tank.

Basics of Pressure Vessels :

Some definitions:

A PRESSURE VESSEL is a closed container designed to hold

gases or liquids at a pressure (either internal or external) substantially different from the ambient pressure, and whose water capacity exceeds 1000 liters.

DESIGN includes drawing, calculation, specifications, model

codes and all other details necessary for the complete description of the Pressure Vessel and its construction.

DESIGN PRESSURE means the pressure used in the design

calculations of a vessel for the purpose of determining the minimum thickness of various component parts of the vessel.
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DESIGN TEMPERATURE is the minimum and maximum temperature range taken for the designing purpose.

CYLINDER or GAS CYLINDER means any closed metal

container intended for storage and transportation of compressed gas.

CORROSION means all form of wastage, & includes oxidation,

scaling, mechanical abrasion & corrosion.

BOTTLING PLANT means a premises where cylinders are filled

with compressed gas.

FILLING DENSITY means the ratio of weight of liquefiable gas

allowed in a pressure vessel to the weight of the water that the vessel will hold at 150 C.

FILL POINT means the point of the inlet pipe connection of a

vessel where hose is connected for filling the compressed gas into vessel. LIQUEFIABLE GAS means any gas that may be liquefied by pressure above -100 C, but will be completely vaporized when in equilibrium with normal atmospheric pressure (760 mm Hg) at 30 0 C. CRITICAL TEMPERATURE means the temperature above which gas cannot be liquefied by the application of pressure alone.

A DESIGN CODE is a document that sets rules for the design of a new development. It is a tool that can be used in the design and planning process, but goes further and is more regulatory than other forms of guidance. Eg. IS-2825, ASME Sec VIII Div 1, etc.

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SAFETY RELIEF DEVICE means an automatic pressure relieving device actuated by the pressure upstream of the valve and characterized by fully opened pop action, intended to prevent the rupture f a pressure vessel under certain conditions of exposure. WATER CAPACITY means capacity in liters of the pressure vessel when completely filled with water at 150 C.

Types of Pressure Vessels:

Following are the main types of pressure vessels:
A. B.

According to the end construction According to the dimensions

Pressure vessel according to the end construction:

According to the end construction, the pressure vessels are may be OPEN END or CLOSED END. A simple cylinder with a piston is an example of open-end vessel whereas a tank is an example of closed end vessel. Due to the fluid pressure circumferential or hoop stresses are include in case of open ended vessels whereas longitudinal stresses in addition to circumferential stresses are induced in case of closed ended vessels.

Pressure vessels according to dimensions:

According to the dimensions pressure vessels may be of THIN SHELL or THICK SHELL. The deciding factor among thin and thick shells is its wall thickness and shell diameter if the ratio t/d is less than 1/10 the vessel is said to be THIN SHELL and if the ratio is greater than 1/10 it is said to be a THICK SHELL. Thin shell are used in boilers, tanks and
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pipes whereas thick shells are used in high pressure cylinder, tanks gun barrels.

Uses of pressure vessels: The pressure vessels are used to store

fluid such as liquid vapors and gases under pressure. Major uses of pressure vessels are as follows:

Pressure vessels are used in steam boilers. Pressure vessels are also used in storage of chemical in chemical plants. Use in storage of petroleum products (petrol, diesel etc). It is also used in engine cylinders.

Vessel Orientation:
There are three types of vessel orientation:

1. Horizontal 2. Vertical 3. Horton sphere

1. Horizontal: A horizontal Pressure Vessel is as shown in fig.-

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Internship Report On Pressure Vessels 2012 8. Vertical Pressure Vessel:

The Vertical Pressure Vessel is as shown in the fig. :

9. Horonsphere:
The Horton Sphere Pressure Vessel is as shown in the fig. :

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Types of Dish Ends :

There are many types of Dish Ends but only four types of Dish Ends are broadly used in industries, which are: 1. 2. 3. 4. Torispherical Semi-Ellipsoidal (2:1) Hemispherical Flat

1. Torispherical:
Torispherical heads are the most common type of head used for the manufacture of pressure vessels and usually the most economical to form. Generally, the I.C.R (Inside Crown Radius) is equal to 85% of I.D (Internal Diameter) of the head or less. The I.K.R (Inside Knuckle Radius) needs to be around 18.85% of the I.D of the head. The S.F (Straight Face) is normally between 10mm and 30mm depending on the diameter and thickness of the head to be formed.

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Internship Report On Pressure Vessels 2012 2. Semi-Ellipsoidal(2:1) :

Semi-Ellipsoidal (2:1) heads are deeper than a Torispherical head and therefore stronger and able to resist greater pressures. These heads are more difficult to form owning to the greater depth required. As a result these are more expensive to form than a Torispherical head, but may allow a reduction in material thickness as the strength is greater. The I.C.R is 80% of the O.D (Outer Diameter) of the head. The I.K.R is 15.4% of the O.D of the head. The maximum diameter we can form a 2:1 Semi-Ellipsoidal head to is 2310mm I.D. The S.F is normally between 10mm and 30mm depending on the diameter and thickness of the head to be formed.

3. Hemispherical:
Hemispherical heads allow more pressure than any other head. However, the hemispherical head is the most expensive to form, as they consists of a number of petals. The number of which depends on the size of the head and the thickness of the plate to be used. The depth of the head is half of the diameter.

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4. Flat:
A flat end with a knuckled outer edge. Typically used as bases on vertical atmospheric tanks and lids for smaller tanks. The I.K.R for most flat ends is usually 25mm, 32mm and 51mm depending on the diameter, thickness and customer requirements. The S.F is normally between 10mm and 30mm depending on the diameter and thickness of the head.

Support for Pressure Vessel:

Type of support used depends on the orientation and pressure of the pressure vessel. Support from the pressure vessel must be capable of withstanding heavy loads from the pressure vessel, wind loads and
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seismic loads. Pressure on pressure vessel design is not a consideration in designing support. Temperature can be a consideration in designing the support from the standpoint of material selection for the different thermal expansion. Various types of support that used to support the pressure vessel are as follows: 1. 2. 3. 4. Saddle Support Leg Support Lug Support Skirt Support

1. Saddle Support: Horizontal pressure vessel (Fig. 1) is generally supported by two advocates of saddle support. Wide saddle supports the weight of the ultimate burden on a large area on the shell to prevent excessive local stresses on the shell above the supporting point. The width of the saddle between the detail designs is determined based on the specific size and condition of the pressure vessel design.

Fig 1 - Pressure Vessel Horizontal with Saddle Support

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2. Leg Support: Small vertical pressure vessel is generally supported by the a leg at the bottom of the shell. Comparison between the maximum lengths of the support leg with a diameter of vessel is usually 2:1. Ring reinforcement pad is used to provide additional reinforcement of local and load distribution, where the local stresses that occur shell can be overdone. The sum of the leg is needed depends on size and weight received vessel. Support leg is also commonly used in pressurized spherical storage vessels.

3. Lug Support: Lug Support in a pressure vessel can also be used to support the vertical pressure vessel. Lug Support is limited to a small vessel with a diameter of up to medium diameter (10-10 ft). With a ratio of height to vessel diameter is 2:1 to 5:1. Lug often used to support vessel located on top of steel structures. Lug usually bolted on the horizontal structure to provide stability against the loads; however, bolt holes are often given the gap to provide radial thermal expansion of freedom in the vessel.

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4. Skirt Support: Vertical cylindrical pressure vessels which are high are generally supported by the skirt. Skirt support is part of a cylindrical shell, one of them at the bottom of the body vessel or the bottom head (for the cylindrical vessel). Skirts for spherical vessel on the vessel are closer to the center of the shell.

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Welded Joint:
Welding joints are formed by welding two or more work pieces, made of metals or plastics, according to a particular geometry. The most common types are butt and lap joints; there are various lesser used welding joints including flange and corner joints.

Categories of Welded joints in a Pressure Vessel:

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a) Category A: Longitudinal welded joints within the main sheet, communicating chambers, nozzles and any welded joints within a formed or flat head. b) Category B: Circumferential welded joints within the main shell, communicating chambers, nozzles and transitions in diameter including joints between the translations and a cylinder at either the large of small end, circumferential welded joints connecting from heads to main shells to nozzles and to communicating chambers. c) Category C: Welded joints connecting flanges, tubes sheets and flat heads to main shells, to formed heads, to nozzles or to communicating chambers and any welded joints connecting one side plate to another side plate of a flat sided vessel. d) Category D: Welded joints connecting communicating chambers or nozzles to main shells, to heads and to flat sided vessels and those joints connecting nozzles to communicating chambers.

Loadings
Loadings or forces are the causes of stress in pressure vessels. Loadings may be applied over a large portion (general area) of the vessel or over a local area of the vessel. General and local loads can produce membrane and bending stresses. These stresses are additive and define the overall state of stress in the vessel or component.

Categories of Loading:
General loads Applied more or less continuously across a vessel section. a) Pressure loadsInternal or external pressure (design, operating, Hydrotest, and hydrostatic head of liquid.) b) Moment loadsDue to wind, seismic, erection, transportation. c) Compressive/tensile loadsDue to dead weight, installed equipment, ladders, platforms, piping and vessel contents. d) Thermal loadsHot box design of skirt-head attachment.
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Local loads Due to reactions from supports, internal, attached Piping, attached equipment, i.e., platforms, mixers, etc. a) Radial load Inward or Outward. b) Shear loadLongitudinal or circumferential. c) Torsion load. d) Tangential load. e) Moment loadLongitudinal or circumferential. f) Thermal load.

Types of Loadings:
1. Steady Loads 2. Non- Steady Loads

Steady loadsLong-term duration, continuous. a) Internal/external pressure. b) Dead weight. c) Vessel contents. d) Loading due to attached piping and equipment. e) Wind Loads Non-steady loads- Short-term duration, Variable. a) Shop and field hydro-test. b) Earthquake. c) Erection. d) Transportation. e) Upset, emergency. f) Thermal Loads. g) Startup, shut down

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FAILURE IN PRESSURE VESSELS

Categories of Failures:
Material - Improper Selection of materials; defects in material. DesignIncorrect design data; inaccurate or incorrect design methods; inadequate shop testing. Fabrication Poor quality control; improper or insufficient fabrication procedures including welding; heat treatment or forming methods.

TYPES OF FAILURES

Elastic deformationElastic instability or elastic buckling, vessel geometry, and stiffness as well as properties of materials are protecting against buckling. Brittle fractureCan occur at low or intermediate temperature. Brittle fractures have occurred in vessels made of low carbon steel in the 40-50 F range during hydrotest where minor flaws exist. Excessive plastic deformationThe primary and secondary stress limits as outlined in ASME Section VIII, Division 2, are intended to prevent excessive plastic deformation and incremental collapse. Stress ruptureCreep deformation as a result of fatigue or cyclic loading, i.e., progressive fracture. Creep is a time-dependent phenomenon, whereas fatigue is a cyclic-dependent phenomenon Plastic instabilityIncremental collapse; incremental collapse is cyclic strain accumulation or cumulative cyclic deformation. Cumulative damage leads to instability of vessel by plastic deformation. High StrainLow cyclic fatigue is strain-governed and occurs mainly in lower strength/high-ductile materials. Stress corrosionIt is well know that chlorides cause stress corrosion cracking in stainless steels; likewise caustic service can
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cause stress corrosion cracking in carbon steel. Materials selection is critical in these services. Corrosion fatigueOccurs when corrosive and fatigue effects occur simultaneously. Corrosion can reduce fatigue life by pitting the surface and propagating cracks. Material selection and fatigue properties are the major considerations.

CODES
What is a design code?
According to the formal definition provided by the Department of Communities and Local Government: A design code is a set of illustrated design rules and

requirements which instruct and may advise on the physical development of a site or area. The graphic and written components of the code are detailed and precise, and build upon a design vision such a masterplan or a design and development framework for a site or area.
This means that, for a set of rules to constitute a code, they must:

Combine written instructions and graphic illustration, Concern physical development within a defined area, Give prescriptive and precise instructions (at least in part), Distinguish clearly between mandatory and advisory elements, and Not constitute a plan in their own right but put into operation another plan or framework.

A design code is a technical delivery document, which serves as a quality benchmark for the whole development, but not a prescription. Design Codes should be read in conjunction with other documents,
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which set out a clear vision, principles and character for the development, such as the Design & Access Statement and Spatial Master plan document. Codes should develop the design vision, and provide a clear set of requirements (the codes) to achieve/deliver this vision. The Spatial Master plan or Vision provides the broader place based vision, whilst codes interpret and articulate this vision. Design codes should be a briefly and clearly expressed separate document, which is easy to understand and use by non-technical people.

What are the advantages of codes?

There are a number of positive benefits of design codes for all parties involved, including: Greater design quality, character and sense of place. Greater co-ordination of different aspects at an earlier stage (e.g. highways, landscape and architecture), which avoid changes later in the process. Greater certainty for developers. Potentially faster process.

Different types of design codes used in the field of Pressure Vessel manufacturing/fabrication:
The most commonly used standard in the manufacture of Pressure Vessels in India is ASME Section VIII Div 1 even though there is another Indian standard for unfired Pressure Vessels. The Standards that are commonly used are ASME Boiler and Pressure Vessel Code Section VIII: Rules for Construction of Pressure Vessels. IS 2825-1969 (RE1977) code unfired Pressure vessels.
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BS 5500: Former British Standard, replaced in the UK by BS EN 13445 but retained under the name PD 5500 for the design and construction of export equipment. EN 13445: The current European Standard, harmonized with the Pressure Equipment Directive (97/23/EC). Extensively used in Europe. BS 4994: Specification for design and construction of vessels and tanks in reinforced plastics. ASME PVHO: US standard for Pressure Vessels for Human Occupancy AIAA S-080-1998: AIAA Standard for Space Systems Metallic Pressure Vessels, Pressurized Structures, and Pressure Components. AIAA S-081A-2006: AIAA Standard for Space Systems Composite Overwrapped Pressure Vessels (COPVs) etc.

Manufacturing of Pressure vessels:

Machines used in the manufacturing of pressure vessels arePlate Rolling Machine Welding Machines End Cups Manufacturing Machine Post Weld Heat Treatment Machine Other Tools and consumables

Steps of manufacturing in brief are as follows:

Cut the plates to the desire sizes. Role the plates to the required radius. Bevel the sides prior welding.
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Prepare the welding procedure, qualify these procedures and then prequalify welders. Install weldolets for fixing the gauges, pressure, temperature gauges and so on. Order the vessel end caps or cups. Weld all elements. Apply post weld heat treatment. Paint the vessel, and install the instruments and gauges.

Quality Management System

Optech Engineering Private Limited follows the method of Quality Management System according to which they inspect each and every part of their Pressure Vessel to be manufactured in between the process of manufacture for quality purposes. For example, we take a part of the shell to be manufactured, the parts of the shell are inspected and approved and only after that, they are manufactured and after that they proceed further in manufacturing process. This process is adopted for each and every part of the Vessel to assure Quality. A Quality Management System (QMS) can be expressed as the organizational structure, procedures, processes and resources needed to implement quality management. Early systems emphasized predictable outcomes of an industrial product production line, using simple statistics and random sampling. By the 20th century, labor inputs were typically the most costly inputs in most industrialized societies, so focus shifted to team cooperation and dynamics, especially the early signaling of problems via a improvement cycle. In the 21st century, QMS has tended to converge with sustainability and transparency initiatives, as both investor and customer satisfaction and perceived quality is increasingly tied to these factors. Of all QMS regimes the ISO 9000 and ISO 14000 series are probably the most widely implemented worldwide -

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the ISO 19011 audit regime applies to both, and deals with quality and sustainability and their integration.

Elements of a Quality Management System:

1. Organizational structure 2. Responsibilities 3. Methods 4. Data Management 5. Processes - including purchasing 6. Resources - including natural resources and human capital 7. Customer Satisfaction 8. Continuous Improvement 9. Product Quality 10.Maintenance 11.Sustainability - including efficient resource use and responsible environmental operations 12.Transparency and independent audit

Concept of Quality Historical Background:

The concept of quality as we think of it now first emerged out of the Industrial Revolution. Previously goods had been made from start to finish by the same person or team of people, with handcrafting and tweaking the product to meet 'quality criteria'. Mass production brought huge teams of people together to work on specific stages of production where one person would not necessarily complete a product from start to finish. In the late 19th century pioneers such as industrialists recognized the limitations of the methods being used in mass production at the time and the subsequent varying quality of output. Birland established Quality Departments to oversee the quality of production and rectifying of errors, and Ford emphasized standardization of design and component standards to ensure a standard product was produced. Management of quality was the responsibility of the Quality department and was implemented by Inspection of product output to 'catch' defects. Applications of statistical control came later as a result of World War production methods, and were advanced by the work done of W.
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Edwards Deming, a statistician, after whom the Deming Prize for quality is named. Joseph M. Juran focused more on managing for quality. The first edition of Juran's Quality Control Handbook was published in 1951. He also developed the "Juran's trilogy," an approach to cross-functional management that is composed of three managerial processes: quality planning, quality control and quality improvement. These functions all play a vital role when evaluating quality. Quality, as a profession and the managerial process associated with the quality function, was introduced during the second-half of the 20th century, and has evolved since then. Over this period, few other disciplines have seen as many changes as the quality profession. The quality profession grew from simple control, to engineering, to systems engineering. Quality control activities were predominant in the 1940s, 1950s, and 1960s. The 1970s were an era of quality engineering and the 1990s saw quality systems as an emerging field. Like medicine, accounting, and engineering, quality has achieved status as a recognized profession.

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Result:
According to different types of code, we performed design calculations which are as follows:

Type of Code

Type of Vessel

Capacity

Design Pressure
14.5 Kg/cm2 21 Kg/cm2 21 Kg/cm2 22.09 Kg/cm2

Allowable Stress

Hydrotest Pressure
20.7 Kg/cm2 30.3 Kg/cm2 27.4 Kg/cm2 28.6 Kg/cm2

Internal Diameter

PD 5500 IS 2825 IS 2825 IS 2825

Above Ground Above Ground Mounded Underground

130 KL 20 KL 30 KL 10 KL

20.843 Kg/mm2 20.944 Kg/mm2 16.405 Kg/mm2 16.405 Kg/mm2

3400 mm 2050 mm 2500 mm 1720 mm

Type of Dish End

Volumetric Calculations Volume of Two Dish Ends Volume of Cylindrical Shell

109.42 m3 17.72 m3 21.82 m3 8.56 m3

Shell Thickness Overall length

15472 mm 6430 mm 6969 mm 4550 mm 14 mm 12 mm 18 mm 14 mm

Dish End Thickness

Hemi Spherical Hemi Spherical Hemi Spherical Torrispherical

20.57 m3 2.26 m3 8.18 m3 1.44 m3

10 mm 14 mm 12 mm 14 mm

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Conclusion:
This organization has a great work culture, great minds and very high quality of work. I learned a lot about Pressure Vessel manufacturing and designing. I have tried to develop as many designs as possible for Optech and even got very encouraging results with some of them. I hope my work on Optech helps it meet its goals. The whole experience of working at Optech was great.

Refrences:
Wikipedia. Practical guide to pressure vessel manufacturing, Sunil Pullarcot. ASME boiler and Pressure Vessel codes. SMPV (Unfired) rules, 1981.

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