Professional Documents
Culture Documents
Vivek Rathor
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
OPCON
OPSERVE
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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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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.
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.
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:
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9. Horonsphere:
The Horton Sphere Pressure Vessel is as shown in the fig. :
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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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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.
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.
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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.
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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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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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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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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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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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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
130 KL 20 KL 30 KL 10 KL
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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