International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

N 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME AND TECHNOLOGY (IJMET) ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 3, September - December (2012), pp. 682-689 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

THICKNESS OPTIMIZATION OF INCLINED PRESSURE VESSELE

USING NON LINEAR FINITE ELEMENT ANALYSIS USING DESIGN BY ANALYSIS APPROACH
I.M.Jamadar1, S.M.Patil2, S.S.Chavan3, G.B.Pawar4, G.N.Rakate5 1,2 Assistant Professor, Department of Automobile Engineering, Annasaheb Dange College of Engineering and Technology, Ashta-416301, Maharashtra, India. E-mail: imranjamadar2@gmail.com 3,4,5 Assistant Professor, Department of Mechanical Engineering, Annasaheb Dange College of Engineering and Technology, Ashta-416301, Maharashtra, India.

ABSTRACT Nitrous oxide (N2O) has been produced and distributed by the industrial, gas industries for many years. It is mainly used for medical purposes (anesthesia). It is also used in the food (whipped cream) and electronic industries. Severe accidents such as violent decomposition of N2O and rupture of N2O tanks have occurred at production, storage and distribution facilities. A major cause of N2O accidents has been insufficient attention to the specific properties of N2O when designing equipment and developing operating procedures. On this basis, the principles and relevant details of safe production, storage and distribution of N2O are considered. The Objective of the Inclined Pressure Vessel (IPV) is to have large scale production of Nitrous Oxide. The rate of the reaction and its temperature is controlled by the inclination of the vessel. This investigation primarily deals with the probable causes of in-service damage of IPV with approximate estimation of stresses using Finite element analysis (FEA). Keywords: IPV-Inclined Pressure Vessel.FEA-Finite element analysis. I. INTRODUCTION Specifically Nitrous Oxide is obtained by ammonium nitrate pyrolysis synthesis. It is exothermic reaction occurring at around 200 deg C. Ammonium nitrate is a moderately sensitive explosive and a very powerful oxidizer. Above 240 deg C, the nitrate can even detonate. Hence, it is imperative to maintain temp below 240 deg C .The rate of the reaction and its temperature is controlled by the inclination of the vessel .At lower inclinations (Closer
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME to horizontal) the reaction will progress rapidly, as the steam will spread more and expose to more surface area of ammonium nitrate. As the inclination will increase, the steam will rise rapidly and escape to top chamber, causing the rate of reaction to reduce, thus in effect the inclination will control the rate of reaction, which is an exothermic reaction. This in turn will control the temperature of the reaction. Hence the temperature will be mostly maintained around 200oC. This reduces the cost of control, plus rate of reaction can be controlled without hampering the process. II. CONSTRUCTION It consists of oblique elongated inclined reactor. The vessel is closed at both the ends by conventional heads. Lower end is provided with furnace to supply steam which is circulated around the ammonium nitrate through steam pipe. Ammonium Nitrate receives the heat from steam pipe and undergoes pyrolysis, forming water vapors and nitrous oxide gas which are collected and separated out from upper end. III. DESIGN CHALLENGES From a design point of view, we can categorize the challenges as temperatures are to be maintained at 200oC, can cause considerable thermal stresses and Inclined nature of vessel (ASME code enables design of Horizontal or a Vertical vessel .No provision for an inclined vessel in it.)In Horizontal Vessels, the key challenge is the bending that will occur at the center. In such a case the vessel, behaves more like a beam supported at two ends with central bending. In Vertical Vessels, the key challenges are the bending loads that will occur at base due to wind load. In such a case the vessel will behave more like a cantilever beam supported at the base. In inclined vessels both wind deflection and central deflection has to be considered, plus we need to account for the temperature based stresses. In addition the internal weights in the system will be a function of the angle of inclination which will have to be considered. IV. DESIGN BY ANALYSIS (DBA) Design by analysis uses stress analysis directly. The maximum allowable load for the design is determined by performing a detailed stress analysis and checking against specified design criteria. Design by analysis can also be used for calculating the component thicknesses for pressure vessel components [2]. In the early days of DBA, the analysis methods were focused on linear elastic stress analysis. This is mainly so because inelastic analysis required considerable computer resources which at the time were not present. However as computers became more powerful inelastic analysis has become more popular. The DBA procedures were developed with the assumption that shell discontinuity analysis would be used for the calculations. Today the Finite Element Method (FEM) is the most popular approach for using DBA. V. FINITE ELEMENT ANALYSIS FOR PRESSURE VESSEL DESIGN Design engineers must use their experience and the latest design tools to maintain reasonable safety levels while providing the most cost effective design. One tool being used on an ever increasing basis is Finite Element (FE) analysis software [1]. The current
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME capabilities of FE software on desktop computers provide pressure vessel design engineers
with the ability to employ FE analysis on a nearly routine basis. Pressure vessel design engineers must

have a reasonable understanding of FE fundamentals to adequately use this design tool. The engineer must determine the most appropriate modeling approach; select the proper elements and solution technique to assure a reasonable analysis. The engineer must also determine if the model is reacting correctly and presenting reasonable results. VI. STRESS ANALYSIS OF IPV In dealing with the various modes of failure, the designer must have at his disposal a picture of the state of stress in the various parts. It is against these failure modes that the designer must compare and interpret stress values. But setting allowable stresses is not enough! For elastic instability one must consider geometry, stiffness, and the properties of the material. Material selection is a major consideration when related to the type of service. Design details and fabrication methods are as important as allowable stress in design of vessels for cyclic service. The designer and all those persons who ultimately affect the design must have a clear picture of the conditions under which the vessel will operate. This investigation primarily deals with the probable causes of in-service damage of IPV with approximate estimation of stresses [11]. The design temperature and pressure of vessel are 148.880C and 1.38795Mpa, respectively. There were four numbers of openings, Viz.entry and exit of steam, Exit of Nitrous oxide and drain. The vessel thickness was around 9.6mm, length 1275mm; inner diameter304.8mm.Stress analysis was carried out by finite element method using ANSYS 13.0 code. Both the ASME (2007) code and the EN13445-3 (2002) code regulate that the safety coefficient is 2.4 and thus the design stress strength is Sm=min (460/2.4, 250/1.5)=166.66MPa. Material Selection: Usually material in pressure vessel technology are ductile, the plastic flow does not necessarily restricts the usability. Limited plastic flow in testing and in normal operating load cases is admissible, even if it may occur repeatedly; it is taken into account in constitutive laws of material models. Because of plastic flow DBA is restricted to sufficiently ductile materials at operating temperature below creep region.
Properties Density Isotropic Secant Coefficient of Thermal Expansion Specific Heat Tensile Yield Strength MPa Tensile Ultimate Strength MPa Reference Temperature C Design Temperature in C Young's Modulus MPa Poisson's Ratio Bulk Modulus MPa Design Pressure, MPa Allowable Stress, MPa 684
0

7.85e-006 kg mm^-3 1.2e-005 C^-1 4.34e+005 mJ kg^-1 C^-1 250 460 22 148.88 2.e+005 0.3 1.6667e+005 1.37895 166.67

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME Model Geometry: In evaluating the geometry, there are several prime considerations. In addition to the necessity to accurately represent the actual geometry of the vessel or component of the vessel, one must consider the loading and support (boundary) conditions and the mesh to be employed. The extent of the vessel or component modeled is also of prime concern when the decision is made to model only part of an overall system. Modeling of the pressure vessel was done using CATIA V5R17 software. Later on to model was imported to ANSYS 13 where symmetric model was prepared, and then accordingly vessel was tilted to required inclinations.

Figure.1 Full Model in CATIAV5R15

Figure.2 Mehing with higher order brick element

Element Selection and Meshing: Once the geometry of the object to be analyzed is defined, the first task is to select the type of element that is to be employed. For most pressure vessel analyses, the element selection is made from three categories of elements: axisymmetric solid elements, shell/plate elements and 3-D brick elements. Although nearly all problems can be solved using 3-D brick elements, the other two types offer significant reductions in the solution time and effort where they are applicable. Often, this reduction in solution effort is significant enough to make the use of FE analysis feasible where it might not be with 3-D bricks. The higher order hexahedron element was used for meshing. The element is defined by twenty nodes. Boundary Conditions: The whole vessel is supported on two saddle supports. One saddle is a fixed saddle while the other is a sliding type saddle. The upper saddle was fixed while to the lower saddle cylindrical support was provided. All degrees of freedoms of are constrained for fixed saddle while sliding saddle provides free sliding along axis of vessel. Loadings: The vessel was analyzed for internal pressure 1.38 MPa, plus Thermal loads from steam at 148.880C plus Self Weight.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME VII. RESULTS AND DISCUSSION Variation of stresses with respect to angle of inclination is given below: Equivalent VonAngle, Total Maximum Mises Stress, Nodes [Degree] Deformation, [mm] [MPa] 0 123.41 1.7265 371000 4 126.12 1.7268 365123 8 131.24 1.7238 364213 12 150.8 1.7465 374256 16 176.56 1.7524 375136 20 190.8 1.7892 375812 24 210.61 1.8093 371365 28 225.6 1.8564 370152 32 242.38 1.8916 375180 ANSYS Results Plot:

Elements 91103 90236 93125 94563 95145 95200 92428 90832 94471

Figure 3- Linearised Stress along Vessel Thickness

Figure 4- Linearised Stress V/s vessel Thickness

Figure 5- Linearised Stress along Nozzle Thickness

Figure 6 - Linearised Stress V/s Nozzle Thickness

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME

Figure 7 - Equivalent Stress Along Vessel-Nozzle Intersection with reinforcement pad Thickness optimization results Variation of stresses with respect to the thickness of vessel for maximum inclination angle of 320 are given below Stress at Total Membrane Bending Thickness, Membrane+Bending nozzleStress, Stress, Stress, [mm] Stress, [MPa] Vessel [MPa] [MPa] [MPa] Intersection 11.336 16.887 13.197 27.626 28.652 39.147 9.489 22.222 15.756 34.332 34.63 61.964 7.2875 30.759 16.856 42.41 42.061 10741 6.0275 38.001 15.648 48.049 47.743 139.4 5.4671 46.859 19.968 57.824 57.81 178.45 5.6 with 33.066 24.843 53.987 57.938 87.179 RF Pad VIII. EXPERIMENTAL TESTING 1) Ultrasonic testing: At Nozzle-vessel Intersection:Weld spot at nozzle vessel inteersection tested with an ultrasonic probe positioned on it and transmitting sound pulses into the weld metal, as well as the echo sequence generated on the screen display of the ultrasonic instrument.This sound pulse is transmitted from the probe into the weld spot and partially reflected from the interface between the probe and weld spot. This reflection appears as interface echo at sound entry (1st indication to the farthest left) on the screen display of the ultrasonic instrument. The continuous part of the pulse enters the weld spot and is only reflected from its rear boundary, provided there is no flaw. This reflection is displayed as 1st backwall echo to the right of the interface echo. The sound pulse can run several times back and forth between the front and rear end of the weld spot, and delivers a part of the sound pulse to the probe every time it hits the front end. This ever decreasing part of sound pulse is
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME displayed as 2nd, 3rd, 4th backwall echo at the same intervals on the screen. In this connection, the interval between the individual backwall echoes corresponds to twice the material thickness (round trip within the material). If there is a flaw in the weld spot, e.g. in the form of a gas pocket, a part of the sound pulse correspoding to the size of this flaw is additionally reflected from it. As the flaw is situated between the front and rear end of the weld spot, the corresponding flaw echoes also occur between the backwall echoes. In the case of major weld flaws, the flaw echoes are higher and possibly only recognizable. 2) Hydro-testing : Vessel was also tested for hydro-test pressure of 1.5 MPa and temperature 1500C which are slightly higher than the operating values. Also at the same time strain gauges (LC 4CI X- HBM ) are mounted at the saddle supports and at the nozzle-vessel intersection for measuring the deformations. IX. CONCLUSIONS As seen from the table, the stresses in the vessel thickness are increasing with reduction of thickness. Here, membrane and bending stresses are within allowable limits for all cases considered. But the equivalent Von-Mises stress at nozzle-vessel intersection is increasing abrouptly as thickness is reducing. Particularly at 5.65mm thickness the vessel will fail at interection because stress is higher than allowable limits. So slight modification is made in the original design i.e. provision of reinforcement pad at vessel-nozzle intersection. Providing the reinforcement pad has reduced stress which are below allowable limits. The results of the ANSYS were compared with experimental values which are in good agreement. ACKNOWLEDGEMENT We sincerely thank Mr.V.G.Patil for his continuous support in providing advances in Pressure Vessel analysis technology and for guidance to prepare this paper. We also thank his team of Vaftsy Engineering Services Ltd. Pune for providing testing facilities and inputs to complete the content of this research topic. X. REFERENCES [1] H. Darijani, M. H. Kargarnovin, R. Naghbadi (2009), Design of Spherical vessels under steady state thermal loading using Thermo elastic plastic concept, International Journal of Vessels and Piping, Electronic Publication: Digital Object Identifiers (DOIs), Pp 619-624. [2] Donald Mackenzie, Duncan Camilleri, Robert Hamilton (2008), Design by analysis of ductile failure and buckling in Toro spherical pressure vessel heads. International Journal of thick walled cylinders, Pp 963-974. [3] Thanh Ngoc Tran (2007), Calculation of load carrying capacity of shell structures with elasto plastic material by direct approach, International conference of material theory and non linear dynamics, Pp 24-26. [4] Josef L. Zeman (2006), Franz Rauscher and Sebastian Schindler, Pressure Vessel Design- The Direct Route, Elsevier Publications Ltd. [5] Rolf Sandstram, Peter Langenberg, Henrik Sieurin (2005), Analysis of the brittle fracture avoidance model for pressure vessels in European Standard, International Journal Of pressure Vessel and piping, Pp 872-881.

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 3, Sep- Dec (2012) IAEME [6] Ho-Sung Lee, Jong-Hoon Yoon, Jae-Sung Park, Yeong-Moo Yi (2005), A Study on Failure Characteristics of Spherical Pressure Vessel, Journal of Materials Processing Technology, Pp 882-888 [7] You-Hong Liu (2004), Limit pressure and design criterion of cylindrical pressure vessel with nozzles, International Journal of pressure Vessels and Piping, Pp 619-624. [8] A. Th. Diamantoudis, Th. Kermanidis. (2004), Design By Analysis versus Design by Formula Of High Strength Steel Pressure Vessels, A Comparative Study, International Journal of Vessels and Piping, Pp 143-152. [9] Yukio Tachibana,Shigeaki Nakagawa,Tatsuo Iyoku(2004), Reactor pressure Vessel design of the high temperature engineering reactor, International journal of Nuclear Engineering and design, Pp 103-112. [10] Imran M.Jamadar, Prof.R.M.Tayade, Mr.Vinay Patil (2012), Structural Analysis of Inclined Pressure vessel Using FEM, International Journal of Engineering Research & Technology (IJERT), ISSN: 2278-0181, Vol. 1 Issue 3, Pp. 1-5. [11] Dennis R. Moss (2004), Pressure Vessel Design Manual-Third Edition, Gulf Professional Publishing. [12] Clifford Matthews (2001), Engineers Guide to Pressure Equipment Professional Engineering Publishing Limited, London and Bury St Edmunds, UK. [13] James R.Farr,Maan H. Jawad, Guide Book For the design of ASME Section VIII Pressure Vessels Second Edition. [14] Matin Kagadi, Prof. Girish Tembhare1, Vinaay Patil, Sujay Shelke (2012), Optimization of Self Activating Bi-Metallic Valve using ThermoStructural Coupled FEA, transtech publication inc, publishers in science and engineering, Pp.147-151. [15] T.Vishnuvardhan and Dr.B.Durga Prasad, Finite Element Analysis and Experimental Investigations on Small Size Wind Turbine Blades International Journal of Mechanical Engineering & Technology (IJMET), Volume3, Issue3, 2012, pp. 493 - 503, Published by IAEME [16] Mane S.S and Prof. Wankhede P.A, The Design of Vertical Pressure Vessels Subjected To Applied Forces and Vibrational Conditions International Journal of Mechanical Engineering & Technology (IJMET), Volume3, Issue2, 2012, pp. 38 - 45, Published by IAEME [17] Manikandapirapu P.K, Srinivasa G.R, Sudhakar K.G and Madhu D., Comparative Analysis Of Pressure Measurements In Ducted Axial Fan International Journal of Mechanical Engineering & Technology (IJMET), Volume3, Issue2, 2012, pp. 85 - 91, Published by IAEME [18] Dr.R.Uday Kumar and Dr.P.Ravinder Reddy, Influence of Viscosity on Fluid Pressure in Hydroforming Deep Drawing Process International Journal of Mechanical Engineering & Technology (IJMET), Volume3, Issue2, 2012, pp. 604 - 609, Published by IAEME [19] Ayub A. Miraje and Dr. Sunil A. Patil, Infinite Fatigue Life Of Three Layer Shrink Fitted Compound Cylinder Under Fluctuating Internal Pressure International Journal of Mechanical Engineering & Technology (IJMET), Volume3, Issue1, 2012, pp. 288 - 299, Published by IAEME

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