More FEA Samples - Pressure Vessel Engineering

More FEA Samples – Pressure Vessel Engineering https://pveng.
com/home/fea-stress-analysis/more-fea-samples/
This basic sample illustrates how FEA is used to validate a flange design that cannot be
calculated with standard VIII-1 Appendix 2 code rules due to the shape of its hub.
Standard Appendix 2 loads are applied and assessed against the rules of ASME VIII-2 for
full code compliance.
LINK
File: PVE-3396, Last Updated: March 18, 2009, By: BV
This sample report illustrates how FEA is used to validate flange design. This report format may
be used to justify ASME code compliance, provide stress and displacement analysis, provide
cycle life estimates, complete thermal analysis, and perform design validation and optimization
studies. This format is fully CRN compliant and may be applied to many applications.
Download:
FEA Report
Connections such as flanges, tri-clamps and any other multi-body assemblies are
analyzed using FEA. This example shows a Tri-Clamp connection under internal pressure
and describes how FEA is used to provide insight into the interaction between
components.
LINK
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More FEA Samples – Pressure Vessel Engineering https://pveng.com/home/fea-stress-analysis/more-fea-samples/
File: File:PVE-4472, Last Updated: Aug 23, 2010, By: DRV
A highly displaced view of a coupler joining two pipes

finished with sanitary ferrules
FEA may be used to analyze single as well as multiple body designs. For multiple body analysis
the interactions and restraints between bodies must be defined. The solver can then provide the
resulting displacement, stress and contact pressure plots. Utilizing multiple bodies is typical of
connection or joint analysis and allows the user to ensure proper preload and observe that joint
separation does not occur. A complete engineering report of a multi body analysis typical of
what is provided by Pressure Vessel Engineering is available for download below.
Interaction between multiple bodies can be defined as bonded, no interaction, or no

penetration. A bonded condition forces the bodies to act as a single component. For example a
head bonded to a shell would simulate a welded condition and solve the analysis as if the head
and shell were a single component. A no interaction condition does not account for the
interaction between multiple bodies; it allows the bodies to displace individually without any
imposed restraints by the adjacent components. This condition could result in bodies interfering
or overlapping each other. A no penetration condition allows multiple bodies to contact each
other, but not to penetrate. This condition is useful when analyzing connections such as
flanges, tri-clamps or split rings. No penetration conditions also provide contact pressure plots.
These plots are useful to ensure joint separation does not occur.
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A contact pressure plot showing resulting contact pressure between bodies. This plot is
useful to ensure joint separation does not occur. the length and color of the arrows shows
the contact pressure.
Restraints between multiple bodies such as bolts may also be simulated. Bolt connectors are
defined in place of solid model bolts, and their material properties and preload defined. The
solver creates beams to simulate bolting where bolt connectors have been defined, and
transfers the applied preload to the connection accordingly. The software can then output the
resulting forces acting on each connector which can then be used to calculate stresses.
Defining appropriate restraints and interactions between bodies is critical to obtain accurate
FEA results. Applying incorrect interaction conditions between components will result in
incorrect results. FEA results with the wrong interactions may be interpreted as acceptable and
allow for unsafe designs.
FEA Report
Drawing
This reverse dished head could not be fabricated thick enough to meet the ASME VIII-1 rules. The chosen
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solution was to reinforce the head with ribs to prevent snap through. Various alternate
methods of analysis are shown.
LINK
File: PVE-407, Last Updated: June 2, 2003, By: LB
The process in this vessel required a reverse dished head. The reverse dished head could not
be fabricated thick enough to meet the ASME VIII-1 rules. The chosen solution was to reinforce
the head with ribs to prevent snap through.
Various alternate methods of analysis are shown here. Only the plate analysis was used for the
actual job. However, the comparison of the various methods is educational.
The head diameter and thickness and design pressure of 75 psi is the same for all of the
examples bellow. The material has a yield strength of 30,000 psi and an allowed design stress
of 20,000 psi. The maximum allowed membrane (tensile) stress is 20,000 psi, 30,000 at regions
of discontinuities. The maximum allowed membrane + bending stress is 30,000 psi, 60,000 psi
at discontinuities.
This is one of the simplest methods of analyzing this vessel. A cross section of the head without
reinforcement is analyzed. Algor assumes that the 2D drawing is symmetrical about an axis
(axisymmetric). The results show the stress distribution in the head if there is no material
yielding (linear material properties).
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Cross section of the reverse dished head (from center to left

side). Stresses are shown for an interior pressure in this and
the following shots.
The peak stress is 54,000 psi in the knuckle region, well above the 30,000 psi yield point. This
head fails the ASME VIII-1 code calculations for exterior pressure, but the stresses in the
knuckle region are less than the discontinuity stress limit of 60,000 psi. Predicted deflection is
0.15 inches (not shown). Perhaps the head is safe? The ASME code calculations provide a
safe pressure of 57 psi for a regular dished head. Also, the use of regular dished head exterior
pressure calculations is not proven for a reverse dished head.
This analysis allows for material yielding. The same cross section is analyzed, but for this
analysis, the pressure is applied in steps, and the material will be allowed to yield (Non-Linear).
Up to 64 psi, the head can be seen deflecting linearly under pressure. At 69 psi snap through is
beginning (and the deflection is greater than the material thickness). At this point the head has
started permanent deformation – it will not return to the original shape after the pressure is
removed. Pressures beyond 72 psi show rapid snap through. The second image shows the fully
snapped through shape at 72 psi. This shape is kept permanently after the pressure is
removed.
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Defection of the center of the head vs pressure. Snap

through starts around 66 psi.
Original and final shape of head. Loaded to 75 psi and

Pressure released.
Reinforcing ribs were put on the head to prevent snap through. 3D analysis is required to
calculate the stresses. A surface model was created in SolidWorks. The material thickness is
specified at time of analysis in the Algor FEA program.
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Plate model – top view – created in SolidWorks.
Plate model – bottom view.
The FEA analysis of the head in Algor showed that the stresses were acceptable. The
maximum allowed membrane (tensile) stress is 20,000 psi, 30,000 at regions of discontinuities.
The maximum allowed membrane + bending stress is 30,000 psi, 60,000 psi at discontinuities.
Peak stresses around stress concentrations can be larger.
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Membrane Stress – limited to 20,000 psi except in areas of

discontinuities. At areas of discontinuities, membrane stress
can be 30,000 psi. This plot shows maximum membrane
stresses at 42,000 psi at a concentration which is acceptable.
Total Stress (Membrane + Bending) – limited to 30,000 psi

except in areas of discontinuities. At areas of discontinuities,
membrane stress can be 60,000 psi. The total stresses are
acceptable.
A solid model was created in SolidWorks including the reinforcing ribs and all weld fillets. The
actual material thickness was modeled. This was not done for the original analysis, but is
included here for educational purposes.
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Solid model – bottom view
Solid model detail – meshed at 1/8″ mesh size
Top side stress
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Bottom side stress detail
The solid model maximum calculated stresses are found in the same location as for the plate
model, but are much lower. The solid model accounts better for the stresses at connections,
and allows the effect of weld fillets to be included.
The maximum stress is 28,000 psi, found in small peak areas. This value could be used with a
fatigue analysis if required. All of the general stresses are below the 20,000 tensile limit, so no
stress linearization is required to separate membrane and membrane + bending loads.
Snap through analysis results for the solid bottom

head. pressure at 1 sec is 75 psi. At 3.5x operating
press the head starts to yield.
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Displaced head at 5x operating pressure – displacement

magnified 2x.
The design with the reinforcing ribs was successfully used. A report interpreting the results
according to ASME VIII-2 rules allowed the vessel to be registered. A later modification to the
process allowed a less expensive double wall head to be used instead.
The Solid and Plate analysis methods here produced almost identical stress results except at
attachments. The Solid model with the weld fillets gave more realistic and lower stress results.
The solid model was also easier to make than the plate model which required each surface to
be split at all intersections. If the stresses were higher in the solid model, stress linearization
would have been required to separate the membrane and membrane + bending stresses. The
solid model stress linearization is more difficult than reading the stresses off of the plate model.
This tank was built by Price Schonstrom Inc., 35 Elm Street, Walkerton, Ontario, Canada, N0G
2V0
File:PVE-4687, Last Updated: 5-Nov-10, By: CBM
Pressure Vessel Engineering was contacted to help re-certify a series of 17′ Diameter 56′ tall
digesters for Tembec Inc. which are currently in use for the pulp and paper industry. These
digesters are filled with wood chips and mixed with acid in order to convert the wood chips to
paper pulp.
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This digester has been in use since 1926. Vessels built in that time period were typically
constructed with riveted butt joints.
A shell model of the entire digester was created and analyzed

to determine the stress distribution.
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The resulting stress profile from the design pressure and

static head. The highest stresses were observed at the
bottom shell segments.
The next step was to analyze a small segment encompassing the bottom shell and cone and
modeling in the actual butt straps with rivets. Rivets are installed in a hot state, so as they cool,
they contract and generate a preload force that compresses the butt straps and the shell
together. As the rivets cool, they plastically deform with preload stresses relaxing back to the
yield point. Bolt connectors with the corresponding preload equal to the yield stress have been
used to simulate the rivets.
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A solid model was created, incorporating the butt straps and

the legs. Weight is applied to the model to generate stresses
at the leg attachments.
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Bolt connectors are applied at each of the rivet locations with

the calculated axial preload. No penetration contact sets are
applied between all butt straps and shells.
The plane of symmetry cuts through the cylindrical shell.

Symmetry is applied here. A seam is present at the conical
shell thus no symmetry is applied. This forces the rivets to
restrain the model.
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The rivet head is bonded on the inside and the outside butt
straps. The rivet is restrained from moving through the hole in
the conical shell.
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The digesters experience radial expansion along with a

bending load on the legs.
Although the riveted areas are perforated, the butt straps

provide additional restraint and actually reduce stresses at
the seam. Peak stresses are generated immediately around
the holes due to the high compressive preload stress.
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Higher stresses occur around the rivet holes. This is caused

by the rivet preload being set to the yield strength. This
causes a high compressive stress at the joint.
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An outer row of rivets with a larger pitch was used in this

design. Although this is still below the allowable stress, a
concentration of stresses build up in this region.
Our FEA was successfully used to prove the integrity of the digesters in their current state to
the local jurisdiction and the insurance company. Even though riveted boilers and pressure
vessels have not been manufactured for many years, there are a number of them that are still in
operation today. Although built to ASME code, many of these boilers were constructed at a time
when no CRN requirement was in place. As inspectors come across these vessels, we expect
to see more of this type of inspection and certification requirement.
We at Pressure Vessel Engineering Ltd are very grateful to Tembec for allowing us to post this
analysis. Tembec has been acquired by Rayonier Advanced Materials and can be contacted
through their website at www.rayonieram.com.
FEA can calculate temperature profiles in single and multi-part models. From this,
displacements and stresses are obtained. Here FEA is used to determine heat time and
required power for an injection mold.
LINK
File: File:PVE-4437, Last Updated: Aug 23 2010, By: BTV
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Heat entering a part in a mold cavity
Thermal analyses are used to study thermal loadings and their resulting temperatures, heat
transfer rates, displacements and stresses. These analyses are broken into two main types,
steady state and transient. Steady state analysis will determine the energy balanced state at an
infinite period in time without any detail on what happens while progressing to this point.
Transient thermal analysis is able to analyze the heat flow through a body on a step by step
basis allowing temperature effects to be observed over time.
Steady state analysis is used to observe the effects of thermal loadings once the object in
question has reached a constant, or steady state. This is useful to determine sustained
temperatures, heat transfer rates, displacements and stresses. Steady state analysis is also
useful to determine thermal loads and material properties to obtain a final desired result. As a
steady state analysis only provides a final continuous result it only requires a single
computation making it a very efficient solver.
Temperature vs time for various locations in the cavity
A transient analysis is used to observe the effects of thermal loadings over time. It allows the
user to view the changing temperature gradient through a component from initial though to a
steady state condition. Transient thermal impacts are important to analyze as thermal loadings
may result in peak stresses prior to reaching a steady state. It is also useful to answer
questions such as how long will a component take to reach a desired temperature. As a
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transient analysis provides solutions for a defined number of time steps many computations are
required resulting in a much more complex analysis.
FEA Report
Drawing
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We use FEA to design and validate fittings and vessels that can not be designed by
rule-based codes like VIII-1 or B31.3. We are experts in the specialized field of
pressure equipment design by FEA to validated ASME VIII-2 methods.
SolidWorks Simulation and Abacus software

Pressure and thermal stress analysis
Permissible service life (fatigue life)
Wind and seismic analysis
Leg, saddle and clip design
Frequency and vibration analysis
Computational Fluid Dynamics (CFD)
Pressure Vessel Engineering has used Finite Element Analysis (FEA) to design and
verify thousands of pressurized components. We have the knowledge and experience
to get the job done right.
ASME Code Design – We work to many ASME standards to design and validate
pressure vessels, boiler, fittings and piping systems.
Pipe Stress Analysis – Pipe stress analysis is mandatory for British Columbia registration
and it is recommended practice for many other systems.
Canadian Registration Number (CRN) – We are Canada’s largest independent registrar of

fittings, vessels and piping under the CRN program registering for more than a
thousand customers.
Pressure Vessel Engineering has twenty years of successful experience in the pressure
vessel field working for more than a thousand customers.
Six Professional Engineers on staff licensed to stamp and sign off on designs for use in all
Canadian jurisdictions.
Fast and professional assistance from our team.
Pressure is
Need help? Our contact information Vessel
to theEngineering
right. Ltd.
120 Randall Drive, Suite B
Waterloo, Ontario, Canada
N2V 1C6
519-880-9808
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More FEA Samples – Pressure Vessel Engineering https://pveng.

File: PVE-3396, Last Updated: March 18, 2009, By: BV

File: File:PVE-4472, Last Updated: Aug 23, 2010, By: DRV

A highly displaced view of a coupler joining two pipes

Interaction between multiple bodies can be defined as bonded, no interaction, or no

File: PVE-407, Last Updated: June 2, 2003, By: LB

Cross section of the reverse dished head (from center to left

Defection of the center of the head vs pressure. Snap

Original and final shape of head. Loaded to 75 psi and

Plate model – top view – created in SolidWorks.

Plate model – bottom view.

Membrane Stress – limited to 20,000 psi except in areas of

Total Stress (Membrane + Bending) – limited to 30,000 psi

Solid model – bottom view

Solid model detail – meshed at 1/8″ mesh size

Top side stress

Bottom side stress detail

Snap through analysis results for the solid bottom

Displaced head at 5x operating pressure – displacement

File:PVE-4687, Last Updated: 5-Nov-10, By: CBM

A shell model of the entire digester was created and analyzed

The resulting stress profile from the design pressure and

A solid model was created, incorporating the butt straps and

Bolt connectors are applied at each of the rivet locations with

The plane of symmetry cuts through the cylindrical shell.

The digesters experience radial expansion along with a

Although the riveted areas are perforated, the butt straps

Higher stresses occur around the rivet holes. This is caused

An outer row of rivets with a larger pitch was used in this

File: File:PVE-4437, Last Updated: Aug 23 2010, By: BTV

Heat entering a part in a mold cavity

Temperature vs time for various locations in the cavity

SolidWorks Simulation and Abacus software

Canadian Registration Number (CRN) – We are Canada’s largest independent registrar of

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