Design of Pressure Vessels

251 Pages·2020·6.248 MB·English

by  Subhash Reddy Gaddam

Design of Pressure
Vessels

Design of
Pressure Vessels
Edited By
Subhash Reddy Gaddam
First edition published 2021
by CRC Press
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Library of Congress Cataloging-in-Publication Data
Names: Gaddam, Subhash Reddy, author.
Title: Design of pressure vessels / Subhash Reddy Gaddam.
Description: First edition. | Boca Raton, FL : CRC Press/Taylor & Francis
Group, LLC, 2021. | Includes bibliographical references and index.
Identifiers: LCCN 2020035117 (print) | LCCN 2020035118 (ebook) | ISBN
9780367550646 (hardback) | ISBN 9781003091806 (ebook)
Subjects: LCSH: Pressure vessels--Design and construction.
Classification: LCC TA660.T34 G34 2021 (print) | LCC TA660.T34 (ebook) |
DDC 681/.76041--dc23
LC record available at https://lccn.loc.gov/2020035117
LC ebook record available at https://lccn.loc.gov/2020035118
ISBN: 978-0-367-55064-6 (hbk)
ISBN: 978-1-003-09180-6 (ebk)
Typeset in Times
by SPi Global, India
Contents
Preface .....................................................................................................................xiii
Author ......................................................................................................................xv
Chapter 1 Introduction .........................................................................................1
Chapter 2 Material ...............................................................................................3
2.1 Metallurgical Fundamentals .....................................................3
2.2 Variety of Materials ..................................................................3
2.2.1 Carbon Steel (CS) .........................................................3
2.2.2 Low Alloy Steel (LAS) .................................................3
2.2.3 Stainless Steel (SS) .......................................................4
2.2.4 Nonferrous Alloys .........................................................4
2.2.5 Nonmetallic Materials ..................................................5
2.3 Material Selection .....................................................................5
2.3.1 Criteria for Selection of Materials ................................5
2.3.2 Ductile and Brittle Materials ........................................5
2.3.3 Chemical Effect of Fluid in Contact .............................6
2.3.4 Temperature ..................................................................6
2.3.5 Pressure and Allowable Stress ......................................6
2.4 Heat Treatment ..........................................................................8
2.4.1 Division of the Ferrous Material ...................................8
2.4.2 Post-fabrication Heat Treatment ...................................8
2.4.3 Post-weld Heat Treatment (PWHT) ..............................8
2.5 Non-destructive Testing (NDT) and Weld Efficiency ...............9
2.6 Impact Test and Minimum Design Metal Temperature
(MDMT) .................................................................................10
2.7 Hydraulic Test (HT) ................................................................12
Reference ..........................................................................................12
Chapter 3 Mechanical Design Basics ................................................................13
3.1 Basics ......................................................................................13
3.1.1 XYZ Coordinate Convention ......................................13
3.1.2 Degrees of Freedom ....................................................13
3.1.3 Boundary Conditions ..................................................13
3.1.4 Load Condition ...........................................................14
3.1.5 Transfer of Forces .......................................................14
3.1.6 Rotation of Axis ..........................................................15
3.1.7 Free Body Diagram .....................................................17
3.1.8 Poisson’s Ratio ............................................................17
3.1.9 Moment of Inertia .......................................................17
v
vi Contents
3.1.10 Polar Moment of Inertia ............................................18
3.1.11 Significant Figures in Numbers ................................19
3.2 D esign Theories ......................................................................19
3.2.1 Elasticity Theory and Hook’s Law ...........................19
3.2.2 Plastic Theory ...........................................................19
3.2.3 Beam Theory.............................................................22
3.3 F lexure or Beam Formulas .....................................................23
3.4 D eflection ................................................................................24
3.4.1 Macaulay’s Method of Integration ............................24
3.4.2 Moment Area Method ...............................................25
3.4.3 Strain Energy Method.. .............................................26
3.4.4 CastgLiano’s Theorem ..............................................26
3.5 L ong Shells with Three Supports............................................27
3.6 L oads .......................................................................................30
3.7 S tresses ...................................................................................30
3.7.1 Tensile .......................................................................31
3.7.2 Compression .............................................................31
3.7.3 Shear Stress ...............................................................31
3.7.3.1 Pure Shear ..................................................31
3.7.3.2 Transverse Shear Stress..............................31
3.7.3.3 Torsional Shear ..........................................33
3.7.4 Combined and Allowable Stress ...............................33
3.7.5 Compression Bending ...............................................34
3.7.6 Fatigue ......................................................................34
3.7.7 Brittle Fracture ..........................................................35
3.7.8 Stress Concentration .................................................35
3.8 A nalysis Methods ...................................................................35
3.8.1 Equilibrium Method ..................................................35
3.8.2 Integration Method ...................................................36
3.8.3 Theorem of Least Work ............................................36
3.8.4 Experimental Method ...............................................36
3.8.5 Steps in Mechanical Design of Equipment ...............36
3.9 E lastic Failure Theories ..........................................................36
3.9.1 Maximum Principal Stress Theory ...........................37
3.9.2 Maximum Strain Theory ...........................................37
3.9.3 Maximum Shear Stress Theory.................................37
3.9.4 Theory of Constant Energy of Distortion
(Von-Mises Theory) ................................................37
3.10 M atrix Equation of the Beam Element ...................................38
Reference ..........................................................................................38
Chapter 4 Pressure Vessel Design Basics ..........................................................39
4.1 G eneral ....................................................................................39
4.1.1 Shape of the Shell .....................................................39
4.1.2 Pressure and Static Head ..........................................39
Contents vii
4.2 Loads .......................................................................................40
4.3 Membrane Theory...................................................................41
4.3.1 Shells of Revolution ....................................................41
4.3.2 Membrane Equation ....................................................42
4.4 Stresses ...................................................................................44
4.4.1 Stress Categorization ...................................................45
4.4.1.1 Primary Stresses ..........................................45
4.4.1.2 Secondary Stresses ......................................45
4.4.1.3 Peak Stress F ................................................45
4.4.2 Shear Stress in a Cylindrical Shell ..............................46
4.4.3 Allowable Stresses ......................................................46
4.4.4 Thermal Stresses .........................................................48
Chapter 5 Internal Pressure ...............................................................................49
5.1 Cylindrical Parts .....................................................................49
5.1.1 Circumferential Stress .................................................49
5.1.2 Longitudinal Stress......................................................50
5.1.3 Radial Stress ................................................................50
5.2 Spherical Parts ........................................................................50
5.3 Conical Parts ...........................................................................51
5.4 Toroidal Shell and Tube Bend ................................................53
5.5 End Closures ...........................................................................54
5.5.1 Flat...............................................................................55
5.5.2 Hemispherical .............................................................55
5.5.3 Ellipsoidal ...................................................................55
5.5.4 Torispherical ................................................................58
5.5.5 Ellipsoidal and Torispherical Heads
with 0.0005 < t/L < 0.002 ...........................................60
5.6 Failure Analysis ......................................................................60
References .........................................................................................61
Chapter 6 External Pressure ..............................................................................63
6.1 Cylinder ..................................................................................63
6.1.1 Effects on Analysis for Variations in L/D and D/t
Ratios...........................................................................63
6.1.2 Critical Length ............................................................64
6.1.3 Critical Pressure ..........................................................64
6.1.4 Strain Coincident to P ................................................66
c
6.1.5 Comparison of the above Equations with Code
Equations .....................................................................66
6.1.6 Design of a Circumferential Stiffener Ring ................67
6.2 Hemispherical Head ................................................................69
6.3 Ellipsoidal and Torispherical Heads .......................................69
6.4 Conical Parts ...........................................................................70
References .........................................................................................71
viii Contents
Chapter 7 Discontinuity Stresses .......................................................................73
7.1 General ....................................................................................73
7.2 General Procedure ..................................................................74
7.3 Cylindrical to Hemispherical Head ........................................76
7.4 Cylinder to Other End Closures ..............................................77
7.4.1 Semiellipsoidal Head ..................................................77
7.4.2 Torispherical Head ......................................................77
7.4.3 Flat Plate......................................................................77
7.5 Cylinder to Cone .....................................................................78
7.6 Analysis in the Cylinder for Edge Forces at any
Distance from the Edge ..........................................................81
7.7 Design Tips .............................................................................81
References .........................................................................................81
Chapter 8 Local Stresses ...................................................................................83
8.1 Openings under Pressure ........................................................83
8.1.1 Analysis .......................................................................83
8.1.2 Small Openings ...........................................................84
8.1.3 Single Opening ............................................................84
8.1.3.1 Set through (Insert) Radial Nozzle ..............85
8.1.3.2 Set on Nozzle ...............................................87
8.1.3.3 Taper Nozzle ................................................88
8.1.3.4 Pad Type Nozzles ........................................89
8.1.3.5 Non-radial Nozzles ......................................90
8.1.4 Multiple Openings .......................................................92
8.1.5 Continuous Openings (Ligaments) .............................93
8.1.6 Large Bore ...................................................................95
8.1.7 Weld Strength ..............................................................97
8.1.8 Local Stresses due to Opening in Other
Shells and Heads .......................................................100
8.1.9 Opening in Shells Subjected to External
Pressure .....................................................................100
8.2 Local Stresses at the Junction in the Shell due to External
Forces through Attachments including Nozzles ...................100
8.2.1 Cylindrical Shell........................................................104
8.2.1.1 Cylindrical Attachment or Nozzle .............104
8.2.1.2 Square/Rectangular Attachment ................104
8.2.1.3 Limitations and Effects ..............................107
8.2.2 Spherical Shell ..........................................................107
8.2.2.1 Rigid Attachment .......................................108
8.2.2.2 Hollow Attachment ....................................108
8.3 Local Stresses in the Cylindrical in Shell and Nozzle at
their Juncture due to External Force Tensor on the Nozzle ....110
References .......................................................................................112
Contents ix
Chapter 9 Thermal Stresses and Piping Flexibility .........................................113
9.1 Differential Movement ..........................................................113
9.2 Basics of Thermal Stresses ...................................................114
9.3 Guided Cantilever .................................................................115
9.4 Simplified Analysis ...............................................................116
9.4.1 3D Piping with Elements in Orthogonal
Axes ........................................................................117
9.4.2 3D Piping with Elements in any of the Three
Axes ........................................................................117
9.4.3 Code Comparison ...................................................118
9.4.4 Allowable Stress .....................................................118
9.5 Analysis from Basics ............................................................119
9.5.1 One-dimensional System ........................................119
9.5.2 Two-dimensional System ........................................119
9.5.3 Three-dimensional System .....................................121
9.6 Formation of Flexibility Matrix of Shell (Pipe)
Elements ...............................................................................121
9.6.1 Single Element in Plane Forces ..............................123
9.6.2 3D System ...............................................................123
9.6.2.1 Beam Theory ............................................124
9.6.2.2 Castigliano’s First Theorem .....................125
9.7 Formation of Flexibility Matrix for Bend Elements .............127
Reference ........................................................................................131
Chapter 10 Flat-Plate Components ....................................................................133
10.1 Flat Plate Theory ...................................................................133
10.2 Circular Plates .......................................................................134
10.2.1 Simply Supported ...................................................135
10.2.2 Clamped (fixed) ......................................................136
10.3 Rectangular Plates ................................................................137
10.3.1 Edges SS .................................................................137
10.3.2 Fixed Edges.............................................................138
10.3.3 Equations for Maximum Stress for
Rectangular Plates ..................................................139
10.4 Circular Ring ........................................................................140
10.4.1 Flat Ring under Internal Pressure with Both
Edges Supported .....................................................141
10.4.2 Flat Ring under Internal Pressure with One
Edge (Outer) Supported ..........................................142
10.5 Stiffeners ...............................................................................143
10.6 Rectangular Vessels ..............................................................144
10.7 Tube Sheet ............................................................................145
10.7.1 General ....................................................................145
10.7.2 Attachment to Shells, Tubes, and Stays ..................147