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DESIGN OF 600 (103 BAR) 820MM SELF SEALING REPAIR CLAMP AND
VERIFICATION USING LIMIT-LOAD ANALYSIS METHOD
DECEMBER 2011
Table of Contents
1. DECLARATION OF AUTHENTICITY .................................................................................... 3
2. INTRODUCTION ........................................................................................................................ 3
3. REVIEW OF DESIGN SPECIFICATION ................................................................................. 4
3.1
3.2
3.3
3.4
3.5
1. DECLARATION OF AUTHENTICITY
I declare that this Technical Report represents an original piece of work by Antony
Nicholls and that the statements made herein are true to the best of my knowledge.
Signature:
----------------------------------------------
2. INTRODUCTION
I will demonstrate my knowledge and understanding of engineering principles to M
Eng. Level by undertaking the design process for a high pressure self sealing repair
clamp.
The clamp will be designed in accordance with API Specification 6H, which requires
design to be in accordance with the methodology set out in ASME Boiler and
Pressure Vessel Code design Based on Stress Analysis.
I will develop the basic design using formula calculations to determine basic
structural geometry (bolt sizes etc) and carry out stress analysis using finite element
analysis of a solid model of the clamp.
My role in the project will be as Design Engineer with responsibility for the product
design.
My project will use the same customer specification and drawing as the basis for a
design to ASME VIII Division 2.
3.1
The
customer
specification
details
are
recorded
using
Furmanite
Specification Sheet (see Appendix ii) which utilises drop down boxes to limit the
range of options and to guide the sales department. This information was used
to define the specification of the clamp designed.
3.2
Furmanite uses a Design Specification Review process (see Appendix iii) which
set out the design requirements in a standard tabular manner which aides the
review process and contributes to the design of a fit for purpose product.
Furmanites offers self seal clamps that conform to API 6H.
requirements for the project are:
Feature
Requirement
Design Pressure
Design
Temperature
Nominal Pipe
Dimensions
Defect Envelope
Materials
Corrosion
Allowance
Design
Calculations
Content
The key
Sections redacted.
4.
4.1
The determination of the shell thickness is derived from the basic formula for
hoop stress:
PD
2t
Where
I have calculated the minimum wall thickness in accordance with ASME VIII
Division 2, 2007 Part 4.
Main Shell thickness tD. min 33.729mm
Actual corroded shell thickness tDa 39.000mm
The final shell wall thickness of 42.5mm exceeds the minimum
requirements.
4.2
Requirements & General Membrane Stress Intensity Limits (at design &
test conditions) Based on Formula for Cylindrical Shells Given in ASME
VIII 2, Appendix 4-222. (see Appendix v, Section B).
7
4.4.1
Minimum Lug Height for Stress Limit - (see appendix v, Section D.1)
H L min 1
2 4
2
HL min 1 81.54mm
Sections redacted
4.4.4
The clamp will be tested in excess of the design pressure (a proof test)
and so the lug and bolt arrangement needs to be designed to prevent
excessive lug separation in the seal region at the test pressure.
The deflection due to bending and possible prising of the lugs should
be within the recommended allowable limit, YSa :
It can be seen from Appendix V section D.4 that the actial prising is
YSt 0.0898mm
5.
A 3D Computer Aided Design (CAD) package was used and I worked with the
Furmanite design engineer who developed the 2D design into a 3D solid model
which was then imported into the Finite Element Analysis (FEA) software.
The creation of a 3D model creates geometry that the FEA software can interpret
and use to mesh the structure (see Figure 1).
6.
Sections redacted
7.
I imported the de-featured 3D model (volume), which was now 1/8th of the final
product into ANSYS FEA software as Parasolid file (this is in binary format and can
communicate and migrate 3D solids which are understood by the FEA software)
which defines volumes, areas, lines and points.
Orientation of the clamp was important as Furmanite use standard macros in
ANSYS and manipulation and analysis are easier if conventional axis orientation is
observed. For a straight clamp the X axis lies across the half joint plane, Y axis is
normal to the half joint face and Z axis along the main centreline.
10
8.
The meshing process required the volume to be divided into shell and lug
components in order to develop regular elements with minimum distortion to make
the analysis as accurate as possible. In the meshing process, I utilised 20 node
bricks for the shell and 10 node tetrahedrons for the lugs. The shell/lug interface
was meshed using 13 node pyramids, which provide a good transition between the
20 node bricks and 10 node tetrahedrons (see Figure 5).
11
Once the meshing was completed, I used a macro to define the bolting constraints
using real constant sets (see table 1), the key steps being:- create lines representing
the bolt centres (red line in Figure 5), create pre tension sections at the mid-length
point of the bolt line (green point in Figure 5) and link bolts to clamp volumes using
constraint equations which defined a rigid region.
Table 1 Real Constant Set
Real
Constant
Set
Area Moment of
Inertia
IYY and IZZ
mm4
3.9479E+05
A contact surface was then defined at the half joint faces (where opposing lugs
contact one another). As only one lug was being modelled, the contact surface was
defined as being rigid and fully constrained.
12
It was necessary to ensure that the model had sufficient constraints to prevent rigid
body motion, whilst at the same time not over constraining the model and inducing
unrealistic stresses and strains. As the clamp has three planes of symmetry, there
was no requirement for additional constraints.
freedom, that is, the model was fixed from moving in the X, Y and Z axis and rotating
(ROT) in the X, Y and Z axis. The model was then saved to the database.
The following material properties were used for the analyses; Yield Stress, Tangent
Modulus, Youngs modulus and poisons ratio(yield stress only applies to the elasticplastic (limit) analysis).
13
Material ID1
205000
(Solid Structure)
Poissons Ratio
0.3
207
Plasticity Model
Bilinear Kinematic
Hardening
Material ID2
205000
(Bolts)
Poissons Ratio
0.3
723
Plasticity Model
Bilinear Kinematic
Hardening
Coefficient of Friction
Material ID3
(Joint Contact)
9.
SOLVE ANALYSIS
ASME VIII, Division 2, Part 5 design-by-analysis, requires that four potential failure
modes be considered:
a. Protection against plastic collapse
b. Protection against local failure
c. Protection against collapse from buckling
d. Protection against failure from cyclic loading
Failure modes a), b) and d), are all applicable to the clamp and conditions being
analysed, as the material thickness and configuration are established through
14
design-by-analysis rules. The clamp will not be subjected to loads that will induce a
compressive stress field and so mode c) is not applicable in this case.
Each of the analysis runs were performed on an ANSYS model. The primary
pressure loading was applied to a set of areas called AP_1 which represents the
pressure area of the sectioned clamp (see Figure 6).
Figure 6 - Areas on which internal pressure was imposed
9.1
Sections redacted
9.3
Sections redacted
15
10.6 Conclusion
The design was shown to meet the requirements of the referenced standards
for gross plastic deformation, progressive plastic deformation, bolt areas and
service stresses.
16
The results of the analysis were compiled into a standard design validation report
(see appendix IX) that sets out the design specification and performance of the
clamp.
17