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CHAPTER-2 Introduction 10
2.21 Shell 12
2.22 Head 12
2.23 Nozzle 13
2.24 Support 13
2.4.5 Types 20
2.5.1 Stress 23
1
2.5.3 Primary general stress 25
Materials of constructions 30
Materials of constructions 31
construction
1 Q235-A 34
2 20g 35
3 16MnR 35
2
4.3 Design data of vessel 40
vessel
5.3 Pressure 44
5.5 Calculation 49
5.7.1 Rule 52
3
5.8.1 Thickness of cylinder 53
Advantages 55
Conclusion 56
Reference 57
4
Figure No Figure Name Page No
Materials of constructions 30
Case-2 31
Material of constructions
5
DESIGN AND FABRICATION OF STEAM POWER PLANT
ABSTRACT
multilayered high pressure vessels, their advantages over mono block vessel
A boiler is a closed vessel in which water or other fluid is heated. The fluid
does not necessarily boil. ("furnace" is normally used if the purpose is not
actually to boil the fluid.) The heated or vaporized fluid exits the boiler for
6
CHAPTER:1
LITERATURE REVIEW
supercritical fluid extractors, etc., are widely used in chemical, oil refining,
energy industries, and so on. Such vessels are key equipments in various
processes industries and have potential hazards. Much attention has been
paid to using them safely and to lowering their costs, with great progress
being made in the last century. For example, Analysis of Pressure Vessel
Sivaramakrishna Iyer not only tells the use of method to solve such high
tension zone problems but also gives a way to predict results for stresses and
tells the use of computer programs instead of hand calculations for analyzing
economical and common use which can be seen in India and other
are validated for different end connections and for cylinder shell itself. As
burst pressure. The optimization of pressure vessels show that the stacking
Adali’s results were not compared with experimental testing and the stiffness
filament wound pipes which were exposed to open ended internal pressure.
8
[6] Mirza etal. (2001) investigated
the moisture concentration and the hydro thermal internal stress fields for
stiffness-degradation model
vessels
9
CHAPTER: 2
INTRODUCTION
2. INTRODUCTION
have recognized the limitations involved for confining large volumes of high
thickness of the vessel intended to hold that fluid is an automatic choice. The
fabrication difficulties but also demands stronger material for the vessel
changes to the physical properties of the vessel material during service. One
of these that is often encountered is hydrogen, which under the action of high
pressure and / or high temperature produces two effects: (1) A diffusion into
form within the metal, thereby creating extremely high pressures with
10
effect on sulfides or oxides present in the steel creating a brittleness and
to internal or external pressures. The pressure vessels are used to store fluids
under pressure. The fluid being stored may undergo a change of state inside
the pressure vessels as in case of steam boilers or it may combine with other
thermal and nuclear power plants, process and chemical industries, in space
and ocean depths, and in water, steam, gas and air supply system in
industries. The material of a pressure vessel may be brittle such as cast iron,
11
2.1 INTRODUCTION TO PRESSURE VESELS
(internal or external) more than the atmospheric pressure used for channeling
2.2.1 SHELL
Pressure vessel shells are welded together to form a structure that has a
common rotational axis. Most pressure vessel shells are cylindrical, spherical
2.2.2 HEAD
All pressure vessel shells must be closed at the ends by heads (or
another shell section). Heads are typically curved rather than flat. Curved
configurations are stronger and allow the heads to be thinner, lighter, and
less expensive than flat heads. Heads can also be used inside a vessel.
12
2.2.3 NOZZLE
pressure vessel. The nozzle ends are usually flanged to allow for the
pressure gauges).
2.2.4 SUPPORT
The type of support that is used depends primarily on the size and
orientation of the pressure vessel. In all cases, the pressure vessel support
must be adequate for the applied weight, wind, and earthquake loads.
Calculated base loads are used to design of anchorage and foundation for the
pressure vessels.
13
2.3 MOUNDED STORAGE VESSEL
horizontal cylindrical vessels placed near ground level and covered with
suitable backfill. Several vessels may be located side by side in one mound.
The decision for the earth covered type of installation is mainly justified by
the safety advantages in respect to external influence on the vessel; such has
Division II .The various stresses (due to pressure, seismic, mound and dead
storage vessel is done with the help of the FEA (Finite element analysis)
14
2.4 HISTORY OF PRESSURE VESSELS:
Pressurized Tanks
Heat Exchangers
Process Heaters
all stages of processing oil. At the beginning of cycle, they are used to store
15
crude oil. Much different types of these pressure vessels, process the crude
oil into oil and gasoline for the customer. The use of pressure vessels in
Pressure vessels are made in all sizes and shapes. The smaller one may
vessels may be of dia 150ft. or more in India .Some are buried in ground or
as size and shape. The usual range of pressure for mono block construction is
about15 psi to 5000 psi. Although there are many vessels designed
for pressure below and above that range .The ASME boiler and pressure
vessel code section VIII Div.II, specify a range of internal pressure from 15
psi.
16
2.4.1 CLASSIFICATION OF BOILERS
1969)
b) Class 2: Vessels which do not fall in the scope of clas1 and class 3
is limited to 38 mm.
c) Class 3: There are vessels for relatively light duties having plate
thickness not in
temperatures not
for services at
17
2.4.2 TYPES OF HIGH PRESSURE VESSELS
exchangers. They are vessel with an integral bottom and a removable top
head, and are generally provided with an inlet, heating and cooling system
and also an agitator system. High Pressure vessels are used for a pressure
thick walled cylindrical vessels, ranging in size from small tubes to several
meters diameter. Both the size of the vessel and the pressure involved will
ends. Due to high internal pressure and large thickness the shell is considered
ratio of diameter to wall thickness and the shell is designed as thick cylinder,
if its wall thickness exceeds one-tenth of the inside diameter. A solid wall
18
2.4.3 TYPES OF FAILURES
against buckling.
fractures have occurred in vessels made of low carbon steel in the 40-
19
Stress corrosion—it is well know that chlorides cause stress corrosion
these services.
2.4.4 TYPES
are applied. Each layer is vented (except the core) and welded
about the same thickness are successive “shrunk fit” over the core. This
20
creates compressive stress in the core, which is relaxed during
frottage from the French word meaning self hooping.” Multilayer auto-
frettage Begins with a core about ½ in. thick. Bands or forged rings are
The core is stressed into plastic range but below ultimate strength. The
outer rings are maintained at a margin below yield strength. The elastic
Begin with inner core of thickness less than required for pressure. Core
is wrapped with steel cables in tension until the desired auto frottage is
achieved.
or coiled with a thin steel sheet until the desired thickness is obtained.
Only two longitudinal welds are used, one attaching the sheet to the
21
2.4.5 THERMAL STRESS
restrain.
limiting. Thermal stresses will not cause failure by rupture. They can
they must deflect and rotate together. The stresses in the respective
22
2.5 FATIGUE ANALYSIS
loadings.
2.5.1 STRESS
23
2.5.2 TYPES OF STRESSES
Radial
9. Normal
24
2.5.3 PRIMARY GENERAL STRESS:
These stress act over a full cross section of the vessel. Primary stresses
external forces and moments. Primary general stress are divided into
the saddles.
25
2.5.4 PRESSURE STRESS:
forces act. The vessel walls are at a uniform temperature and are
Axial stress at the juncture of a flange and the hub of the flange
Thermal stresses.
26
Bending stress at the gross structural discontinuity: nozzle, lugs,
thick-walled vessels.
temperature.
Categories of Failures:
forming methods.
27
Service—Change of service condition by the user;
Temperature
4. Hydrogen 9. Ammonia
5. Compressed air
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CHAPTER: 3
specified:
IS: 2825
ASME SEC. VIII DIV.2 For Pressure vessels (Selectively for high
ASME SEC. VIII DIV.3 For Pressure vessels (Selectively for high
29
CASE 1: MATERIALS OF CONSTRUCTION
YP (Min)
UTS (Min)
Description Material Type of Steel N/mm2
N/mm2
SA 515 GR 267.6
Shell Liner Austenitic 492.9
70
-
Shell Layers SA 212 GR B Carbon Steel 490.0
SA 515 GR 267.6
Dished Ends Austenitic 492.9
70
30
MATERIAL PROPERTY SUMMERY
strength(Mpa) Modulus(Mpa)
31
3.1 MATERIAL SELECTION FOR PRESSURE VESSEL
CONSTRUCTION
Materials are generally selected by the user for whole of the plant and
criteria.
Design life and fatigue affected events during the plant life
32
3.2 GENERAL MATERIAL SELECTION PROCESS
data sources such as experience in pilot units, corrosion coupon tests in pilot
giving special attention to all factors that may influence corrosion. Since
33
these factors would be peculiar to a particular system, it is impractical to
attempt to offer a set of hard and fast rules that would cover all situations.
The materials from which the system is to be fabricated are the second
steel. The manufacturing materials are varied, and the commonly used
1. Q235-A
better quality. The limited range of application: the design pressure is less
and the thickness of steel plate cannot be more than 16mm when Q235-A
the pressure vessel which is filled with liquefied petroleum gas and the
medium with its extreme toxicity degree and high harm, and is heated
directly by flame.
34
2. 20g
steel. Compared with Q235-A, 20g boiler steel plate has lower sulfur
content and higher strength, and the range of its service temperature is
3. 16MnR
medium, low pressure vessels, which can reduce the weight of the vessel
35
4. THE MATERIAL FOR LOW TEMPERATURE VESSELS (LESS
THAN -20℃)
prevent the brittle rupture at low temperature. Generally the steel for low
When the temperature is less than 400℃, the common carbon steel
is between 500 to 600℃, 15CrMo and 12Cr2Mol are adopted; when the
36
CHAPTER 4
core tube. The construction involves the use of several layers of material,
usually for the purpose of quality control and optimum properties. Multi
applications the inner liner is made of special material and is not considered
for strength criteria. The outer load bearing shells can be made of high
37
4.1 DESIGN OBJECTIVES
shell, which is the indication for most effective use of the material in
the shell.
and remaining layers for reducing the cost of the construction of the
vessel.
at outside surface of the shell and to ascertain that the stresses do not
38
4.2 DESIGN CONSIDERATIONS
I.
the design of the multi layer shell only. For other parts the Factor of
taken.
WA/PVP-6.)
39
4.3 DESIGN DATA OF THE VESSEL:
40
4.4 DESIGN CRITERIA
a) For carbon and low alloy steel vessels- 6mm (Including corrosion
allowance not exceeding 3.0mm), but not less than that calculated as per
following:
b) For stainless steel vessel and high alloy vessels -3 mm, but not less than
41
c) Tangent to Tangent height (H) to Diameter (D) ratio (H/D) greater than 5
d) For carbon and low alloy steel columns / towers -8mm (including
42
CHAPTER: 5
Ellipsoidal Dished
process licensor.
43
3. Hemispherical Ends shall be considered when the thickness of shell
exceeds 70mm.
5. Pipe Caps may be used for vessels diameter < 600mm having no
internals.
5.3 PRESSURE
Maximum pressure likely to occur any time during the lifetime of the
vessel
44
5.3.2 DESIGN PRESSURE
all the three cases, Allowable Stress values: Shell Liner & Layers ; 164
1.5 /1.3/ 1.25 (depending on design code) times the design pressure corrected
for temperature.
site testing of the vessel at a pressure of 1.5/ 1.3 / 1.25 (depending on design
code) times the design pressure measured at the top with the vessel in the
45
vertical position and completely filled with water. The design shall be based
c) Vessels open to atmosphere shall be tested by filling with water to the top.
separate vessels i.e. each chamber shall be tested without pressure in the
adjacent chamber.
during hydro testing tension shall not exceed 90% of yield point.
46
5.3.4 CORROSION ALLOWANCE:
base metal. The cladding or lining material (in no case less than 1.5 mm
47
5.5.5 CALCULATION
Let,
l = length of cylinder,
48
Total force on a longitudinal section of the shell = Intensity of pressure
× projected Area
= px d × l ………….….. (1)
and the total resisting force acting on the cylinder walls=σ t1× 2t ×
l...…(2)
σ× 2t × l = p × d × l or
section.
Let
In this case,
sectional Area
49
From equation (i) and (ii), we have
σ t2×πd.t = p ×4 π (d) ²
Where
D= mean diameter
D=Di + t
5.7.2 RULE:
where as the test pressure is taken as 30% more than internal pressure.
η ×σ =Pi×(Di+t)/2t
η ×σ x2t =Pi×(Di+t)
50
5.7.3 DESIGN OF ELLIPTICAL HEAD:
Elliptical heads are suitable for cylinders subjected to pressures over 1.5
MPa. The shallow forming reduces manufacturing cost. It’s thickness can be
t = pi di W/2σ J
Where,
W= 1/6 (2+K2)
Where
51
5.8 DESIGN CALCULATION:
Given data
= 1.066
∴ t = 1.066mm
52
5.8.2 DESIGN OF MANHOLE:
GIVEN DATA:
CA = NIL
d = d i + CA = 254.51 mm.
tm=P i D i /2 σ η –Pi
t m=1.66mm
53
5.8.3 DESIGN CALCULATION SUMMARY:
DIAMETER
(DI)
THICKNESS 6mm
(T)
(T)
THICKNESS 9.27mm
OF NOZZLE
(TN)
54
ADVANTAGES
Home application.
Industrial application.
55
CONCLUSION
planning, purchasing, assembling and machining while doing this project work. We
feel that the project work is a good solution to bridge the gates between institution and
industries.
We are proud that we have completed the work with the limited time
successfully.
difficulties in maintaining the tolerances and also quality. We have done to our ability
In conclusion remarks of our project work, let us add a few more lines about our
By using more techniques, they can be modified and developed according to the
applications.
56
REFERENCES
Press, 2005.
International, 1999.
Construction of Pressure Vessels (Sec. VIII, Division 1). ASME Boiler and
Pressure Vessel Code. New York: ASME (The American Society of Mechanical
Engineers), 2007.
Vessels: The ASME Code Simplified. 8th Edition. s.l.: McGraw-Hill, 2004.
57
6. Bringas, John E. The Metals Black Book. Edmonton, Alberta: CASTI
10. Bednar, Henry H. Pressure Vessel Design Handbook. 2nd Edition. Malabar,
56
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