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Chapter 1 : Types of Equipment and Facilities,
Design codes and Application
software
Chimney Horizontal
pressure
vessel
Vertical
pressure
vessel
Piping
Process
column
Above round
storage tank
Spherical
storage tank
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Storag API 650, API Cone roof tank ( Self supported and
e Tank 620 ,API630 Supported)
Dome roof tank TANK®
Flat roof tank
Floating roof tank (not in software yet)
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Chapter 2 : Pressure Vessel Design
There are two types of mechanical design methods for pressure vessel
, namely design by formula (DBF) and design by analysis (DBA).
The basic idea of design by rule is that once the leading scantlings are
fixed in this way the designer simply obeys the rules laid down in the
procedures for specified components such as nozzles, dish head,
shells, etc. The methodology or reasoning behind the rules will not
always be apparent as we shall see. However, this is the most
common approach used in all national design codes.
The design by rule approach has the great advantage of simplicity and
being backed up by the long experience of users in many cases. The
greatest disadvantage is that the approach cannot easily be extended
either to different geometries or additional loadings beyond the
normal pressure cases, elastic –plastic and plastic state. For example,
ASME VIII Div 1, the design rules and formulas consider mainly the
loadings due to static internal pressure and external pressure within
elastic limit.
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107 , PD5500 Annex B and etc), and tubesheet design (TEMA,
ASME UHX, BS5500, ASME appendix A) Secondly, PVElite
provides a good traceability for the calculation results where a
negative answer is alerted in “red warning “, that the designer
has the possibility to understand which are parameters to be
changed in order to get the checking. While, a positive answer
shows the result the degree of possible overdesign, in order to
give the designer the possibly of decreasing excess thickness
when they are not needed.
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Protection Against Failure From Cyclic Loading – these
requirements apply to all components where the thickness
and configuration of the component is established using
design-by-analysis rules and the applied loads are cyclic.
In addition, these requirements can also be used to qualify
a component for cyclic loading where the thickness and
size of the component are established using the design-
by-rule
Requirements. Part 4.
PVElite can only dealt with requirements that are directly addressed
by the code and for cases where limitations prevent you from
obtaining the necessary result, a viable alternative would be to turn to
FEA (finite element analysis). PVElite does have interfaces with an FEA
program termed Nozzle-Pro and this is beyond the scope of his
manual.
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Despite the availability of vacuum valve, the external pressure is
considered for pressure vessel design in vacuum condition where the outlet
nozzle is connected to pump. The atmosphere pressure is sufficient to
compressively deform a pressure vessel due to large volume vessel with
insufficient thickness and/or stiffener, furthermore metallic materials have
relatively low compressive strength compare to its tensile strength (ASME
Section VIII Division 1, Part UG28, 2007).
External load like wind and seismic load is more critical for process
vessels like process columns and reactor. The deflection and vibration
analysis of tall slender column (H/D>15) are commonly checked to ensure
Types of loading
the structural is not over deflected. In conjunction, the stresses induced by
wind and seismic loads are always combined with other stresses (i.e.
longitudinal, circumferential and shear stress) due to internal pressure,
external pressure, and hydro test pressure to ensure the possible combined
Steady load – long-term duration, continuous Non steady loads—short term duration, variable
stresses are not more than allowable stress (ASME Section VIII Division 1,
Part UG22-23, 2007).
Pressure loads – Internal or external pressure (design, operating, and hydrostatic head
Shop and field of liquid)
hydrotest
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Upset, emergency
Constant cyclic pressure or thermal load
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Shear loads- Longitudinal and circumferential shear at shell, dish head and conical section, where saddle and support
oads- Bending moment due to wind, seismic, erection, transportation and horizontal support.
10 Thermal loads- Thermal expansion restricted regions likes piping at nozzle connection
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Section VIII, Division 2, Appendix 5)
Thermal loads is only concerned for DBF likes ASME Division for tube
sheet design. ASME Division 2, part 5 – Design By Analysis Requirements
(2007) checks the stresses induced by cyclic thermal loads, and the
ratcheting for pressure vessel components.
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- General Primary Stress
- Secondary Stress
- Peak Stress
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Primary general bending stress, Pb. Primary bending stresses are due
to sustained loads and are capable of causing collapse of the vessel. There
are relatively few areas where primary bending occurs. For instance, bending
stress in the center of the flat head or crown of a dished head; bending
stress in a shallow conical head and bending stress in the ligaments of
closely spaced openings.
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5 Basic features and operation of PV Elite
Generally, there are five major input processors in PVElite. There are
i) Heading
ii) Design Constraint
iii) General Input
iv) Load Cases
v) Seismic Data
vi) Wind Data
Before the user start to enter the design parameters into the input
processors as stated above , it is important to configure the settings at the
start. The configuration is at the tools option control utility processor as
shown in figure 2.2.
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5.1 Configuration
It is important to configure the settings at the start. From the tools option
control utility processor, options are given to customize how PVElite behaves
when analyzing a vessel. The settings are related to the pre and post
processing of the design or analysis for pressure vessel. Pre-processing is the
settings of the design requirements before the analysis, likes alternative
rules in design of pressure vessel components (i.e. use ASME Code
case2260/2261, 2286, 2004-A06 Addenda for Division 2, pre-99 Addenda
(Division 1 only) , Eigen solver and use OD as the basis for shell radius for
Zick’s analysis) or the setting allowable value such as material database,
graph for determining MDMT and allowable tower deflection. In addition,
post –processing involves filter or keep certain results or details to be appear
in the report such as no MDMT, no MAWP calculation, print equation and
substitution. It is important for the user to be familiar to the design
standards, practice and client required specification before perform any
setting in the configuration section.
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The input screen is divided into two areas. They are design data and design
modification. The design data section is related to general design parameter
like internal and external pressure /temperature, hydrotest type and
position, projection from to/ bottom for UG99-C . This information is very
common seen and indicated in the design data of vessel GA drawing and this
core information for pressure vessel design. The user can specific their
client preferred MAWP, MAPnc and hydrotest pressure, where these values
will overwrite/ replace the calculated values. Others inputs like construction
type, special service, degree of radiography are just for information only, it is
reported in the report echo.
If the user check the box of “Use Higher Longitudinal Stresses ?”, PVElite will
use higher allowable longitudinal stress for combined stresses analysis . The
ASME Code Section VIII, Division 1, Paragraph UG-23(d) allow the allowable
stress for the combination of earthquake loading, or wind loading with other
loadings to be increased by a factor of 1.2.
If the user check the box of “Consider Vortex Shedding ?”, PVElite will
compute fatigue stresses based on loads generated by wind flutter. In
addition, the program will compute the number of hours of safe operation
remaining under the wind vibration conditions. This section is suitable for
high column design with h/d (overall high over the vessel diameter) equal or
more than 15. For low vertical vessel like drum, it is advisable not to check
the box because the program will generate extreme non logical high value
which will cause overdesign for the structure.
If the user check the box of ”Is This a Heat Exchanger ?”, PVElite will write
out an ASCII text file that contains the geometry and loading information for
this particular vessel design.
If user check the box of “Hydrotest allowable is 90% yield”, PVElite will
consider 90% of the material yield stress for the hydrostatic test allowable.
This will generate higher allowable stress for hydrotest than the normal
value which is 1.3 time the material minimum allowable stress. ( This applies
only for Division 1 vessel design).
If user is designing a cylindrical ASME stack steel stack and wish to have
PVElite analyze allowable and stress combinations per ASME STS-2003(a),
then check this box. (This applies for Division 1 vessel design).
The 2009 version do not allow any modification of design code in this input
screen, but it is shown at the column for information. The reason of this new
feature is to remind the designer to select the design code at the earlier
stage (Refer to figure 2.4).
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Figure 4.4: Selection of design code at “New” column and pull down menu
Any modification at design data will affect design of the whole pressure
vessel and it components. For example, the change of internal design
pressure and temperature at this section will generate global change for all
the components of the pressure vessel at general input processor. In
addition, the change of design code for whole vessel is done by reselecting
the required design code at pull down menu. However, the user needs to
reselect the material before running the analysis.
(Note: For most Advance users, the options included are usually not used.)
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5.5 Load Cases
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The difference between wind loads and hydrotest wind loads is simply
a ratio (percentage) defined by the user. This percentage is specified
in the Wind Data definition of Global Data - usually about 33% (thus
setting the hydrotest wind load at 33% of the operating wind load).
Likewise, the hydrotest earthquake load is a percentage of the
earthquake load; this percentage is defined in the Seismic Data
definition of Global Data. Some steps that are not applicable for
horizontal vessels, such as natural frequency, will not be printed. Also,
if a vessel has no supports, then there will be no calculations that
involve wind or seismic loads.
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deals with design pressure that is used to calculate the thickness
(nozzle or clip) base on MAWP+ Static head to Bottom Element,
Design Pressure + Static head, Overall MAWP + Static head
(governing Element), MAWP + Static head to Nozzle (note: user must
select either one for their vessel’s nozzle design). The least of the
boxes is optional for vessel design.
If the user check the box of “Modify Tr based on the Maximum Stress
Ratio”, PVElite will looks at all of the defined load cases (combined
stresses) and select the highest stress ratio (actual stress/ allowable
stress). It will then use this number as a multiplier on the shell
thickness. Thus the nozzle design is based on the precise loading at
the bottom of that shell course. The reason for the above work is to
comply with ASME Section VIII Division 1 paragraph UG-22 that deals
with supplemental loadings. One factor in ASME nozzle design is the
required thickness of the shell (tr). Usually internal pressure (hoop
stress) governs. In some cases, such as when a nozzle is located on a
shell course at the bottom of a tall tower, longitudinal stresses will
govern. In this case the shell required thickness must be based on
longitudinal stresses and not the hoop stress.
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ASME Div 1 is the most common use standard for pressure vessel
design, the following are some of the common consideration in
pressure vessel design.
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Tasks to be complete :
Learning Outcome:
After completion of this topic, student will be able to use PVelite for :
Input all the design parameters to the correct input cursor.
Run the analysis and correct the design error by adjusting the
design parameter accordingly.
Obtaining an cost optimize design for pressure vessel components
due to internal pressure, external pressure, nozzle reinforcement ,
external loadings and skirt support. (target :+-10% greater than
actual load/stress/deflection rate)
(Note: Indicate the results with yellow highlight for printed
copy and save a PVE. file in CD for further evaluation)
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Seismic Coefficient Av: 0.2
Seismic Coefficient Cc: 2
Performance Factor: 1
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Nozzle Detail
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Tasks to be complete :
Learning Outcome:
After completion of this topic, student will be able to use PVelite for :
Input all the design parameters to the correct input cursor.
Run the analysis and correct the design error by adjusting the design
parameter accordingly.
Obtaining an cost optimize design for pressure vessel components due to
internal pressure, external pressure, horizontal supported conditions,
nozzle reinforcement , nozzle loading, external loadings and saddle
support. (target :+-10% greater than actual load/stress/deflection
rate)
(Note: Indicate the results with yellow highlight for printed copy
and save a PVE. file in CD for further evaluation)
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8) MAWP / MAP(N &C) ( ) N/mm 2
9) Hydrotest pressure (shop/filed) UG99(c), Shop ( )
2
N/mm
10) Heat treatment ( Applicable/ Not Applicable0
11) Joint Efficiency Dome end : meridoinal seam (Full RT)
circumferential seam
( spot RT)
Cylindrical shell : meridoinal seam
(spot RT)
circumferential seam
( spot RT)
11) Corrosion Allowance 0
12) Material
- Cylindrical shell SA 240 SS304
- Dome end SA 240 SS304
- Nozzle SA 312 TP304
- Nozzle flange SA 182 F304
- Bolting SA320 B8 with SA-194 B
- Saddle SA283 GRC
13) Weights Fabrication : ( ) tones
Empty: ( ) tones
Operating: ( ) tones
Test: ( ) tones
14) Wind load Wind Design Code: ASCE-93
Wind for Hydrotest: 33%
Design Wind Speed: 120 km/hr
Base Elevation : 3 meters from sea
level
Important factor: 1, Roughness factor:
1
15) Seismic load Seismic Design Code: ASCE-93
Seismic for Hydrotest: 0%
Seismic Coefficient Av: 0.2
Seismic Coefficient Cc: 2
Performance Factor: 1
Tutorial (2) : Horizontal pressure vessel
Nozzle Detail
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3000L WNRF 150#
N1
18,000
3600 mm 4,200
500 mm
B1 User
estimated
12,000 the size,
thickness of
2:1 Semielliptical Head, the saddle
SF=50mm, min thk ( and its
) mm, N2 components.
Nominal thk ( )mm. The distance
from saddle
centre line to
Dead Weight
Sub-topic:
Dish head selection for high pressure operation.
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Code case – 2260 “Alternative design rules for Ellipsoidal and Torispherical
formed heads.
Saddle type nozzle/ insert plate for nozzle opening reinforcement, Support
lugs design.
Contents
1.0 Design of high wall thickness pressure vessel (t > 100 mm) ( Division 1 , 2 and
PD5500)
3.1 Dish head selection for high pressure operation - semi
ellipse, torispherical, hemispherical formed head.
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3) Operating Pressure & 125 bar (internal), 120oC /
Temperature NA(external)
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