Pressure Vessel Design The Direct Route Else_PVD-ZEMAN_Prelims.qxd 5/3/2006 11:42 AM Page i i Elsevier Internet Homepage - http://www.elsevier.com Consult the Elsevier homepage for full catalogue information on all books, journals and electronic products and services. Elsevier Titles of Related Interest Pressure Vessel Design Manual Moss 2003, 0-7506-7740-6 Plastic Limit Analysis of Plates, Shells and Disks Massonet ISBN: 0-444-89479-9 Related Journals: The following titles can all be found at: http://www.sciencedirect.com: International Journal of Pressure Vessels and Piping International Journal of Engineering Sciences International Journal of Solids and Structures International Journal of Fatigue Engineering Structures To Contact the Publisher Elsevier welcomes enquiries concerning publishing proposals: books, journal special issues, confer- ence proceedings, etc. All formats and media can be considered. Should you have a publishing pro- posal you wish to discuss, please contact, without obligation, the publisher responsible for Elsevier’s Energy Publishing programme: Henri van Dorssen Publisher, Energy Elsevier Ltd The Boulevard, Langford Lane Phone: +44 1865 843931 Kidlington, Oxford Fax: +44 1865 843920 OX5 1GB, UK E-mail: h.dorssen@elsevier.com General enquiries including placing orders, should be directed to Elsevier’s Regional Sales Offices – please access the Elsevier internet homepage for full contact details. Else_PVD-ZEMAN_Prelims.qxd 5/3/2006 11:42 AM Page ii ii Pressure Vessel Design The Direct Route Josef L. Zeman In cooperation with Franz Rauscher • Sebastian Schindler Amsterdam - Boston - Heidelberg - London - New York - Oxford Paris - San Diego - San Francisco - Singapore - Sydney - Tokyo Else_PVD-ZEMAN_Prelims.qxd 5/3/2006 11:42 AM Page iii iii ELSEVIER B.V. ELSEVIER Inc. 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Because of rapid advances in the medical sciences, in particular, independent verification of diagnoses and drug dosages should be made. First edition 2006 ISBN-13: 978-0-08044-950-0 ISBN-10: 0-080-44950-6 Printed in Great Britain. 06 07 08 09 10 10 9 8 7 6 5 4 3 2 1 Else_PVD-ZEMAN_Prelims.qxd 5/3/2006 11:42 AM Page iv iv Contents Foreword ix Acknowledgement xiii On the Use of this Book xv Chapter 1. Introduction 1 Chapter 2. General 3 2.1. General on the Direct Route in Design by Analysis 3 2.2. General Terms and Definitions 6 2.2.1. Failure-Related Terms 6 2.2.2. Action-Related Terms 10 2.2.3. Model-Related Terms 15 2.2.4. Thickness-Related Terms 18 2.2.5. Response-Related Terms 19 2.2.6. Design Check-Related Terms 21 2.3. General on Characteristic Values and Characteristic Functions of Actions 26 2.3.1. Requirements in the Pressure Equipment Directive 26 2.3.2. Consequences from the PED Requirements 28 2.4. General on Design Models and Constitutive Laws 30 2.4.1. General on Design Models 30 2.4.2. General on Constitutive Laws 33 Chapter 3. Design Checks and Load Cases 43 3.1. Design Checks 43 3.2. Load Cases 45 3.3. Procedure 50 3.3.1. Step 1: Setting Up of Load Case Specifications List 50 3.3.2. Step 2: Setting Up of Design Check Table 50 3.3.3. Step 3: Setting Up of Design Models 52 3.3.4. Step 4: Execution of Design Checks 52 3.3.5. Step 5: Final Conclusion 53 3.4. Example 53 Else_PVD-ZEMAN_Contents.qxd 4/6/2006 9:58 PM Page v v Chapter 4. Gross Plastic Deformation Design Check (GPD-DC) 55 4.1. Introduction 55 4.2. Procedure 58 4.3. Design Models 59 4.4. Design Values of Actions 63 4.5. The Principle 65 4.6. Application Rule 67 4.7. Examples 67 Chapter 5. Progressive Plastic Deformation Design Check (PD-DC) 69 5.1. Introduction 69 5.2. Procedure 76 5.3. Design Models 77 5.4. Design Functions of Actions 79 5.5. The Principle 80 5.6. Application Rules 80 5.7. Examples 82 Chapter 6. Stability Design Check (S-DC) 83 6.1. Introduction 83 6.2. Procedure 95 6.3. Design Models 95 6.4. Design Values and Functions of Actions 98 6.5. The Principle 98 6.6. Application Rules 99 6.7. Examples 99 Chapter 7. Cyclic Fatigue Design Check (F-DC) 101 7.1. Introduction 101 7.1.1. General Remarks to the F-DC 101 7.1.2. General Remarks to the F-DC of Unwelded Region 104 7.1.3. General Remarks to the F-DC of Welded Regions 110 7.2. Procedure 116 7.3. Design Models 117 7.3.1. Requirements with Regard to Welded Regions 117 7.3.2. Requirements with Regard to Unwelded Regions 118 7.3.3. General Requirements with Regard to Welded and Unwelded Regions 118 7.4. Design Values and Design Functions of Actions 120 7.5. The Principle 120 7.6. Correction Factors for Unwelded Regions 121 7.6.1. Plasticity Correction Factor 121 7.6.2. Effective Stress Concentration Factor 124 vi Contents Else_PVD-ZEMAN_Contents.qxd 4/6/2006 9:58 PM Page vi 7.6.3. Surface Finish Correction Factor 125 7.6.4. Thickness Correction Factor 125 7.6.5. Mean Stress Correction Factor 126 7.6.6. Temperature Correction Factor 127 7.7. Correction Factors for Welded Regions 128 7.7.1. Plasticity Correction Factor 128 7.7.2. Thickness Correction Factor 128 7.7.3. Temperature Correction Factor 129 7.8. Design Fatigue Curves 129 7.8.1. Design Fatigue Curves for Welded Regions 129 7.8.2. Design Fatigue Curves for Unwelded Regions 130 7.9. Cycle Counting 131 7.9.1. General 131 7.9.2. The Reservoir Cycle Counting Method 133 7.10. Fatigue Damage Accumulation 134 7.11. General Remarks to the Methodology 135 7.12. Methodology for Welded Regions and Surface Hot Spots 136 7.13. Methodology for Welded Regions and Internal Hot Spots 137 7.14. Methodology for Unwelded Regions 138 7.15. Examples 143 Chapter 8. Static Equilibrium Design Check (SE-DC) 145 8.1. Introduction 145 8.2. Procedure 146 8.3. Design Models 146 8.4. Design Values of Actions 147 8.5. The Principle 148 8.6. Examples 149 Epilogue 151 References 153 Annex A: Useful Shakedown Theorems 161 Annex E: Examples 165 Annex E.3: Example of a Design Check Table 165 E.3.1: Design Check Table of a Jacketed Autoclave 165 Annex E.4: Examples of Gross Plastic Deformation Design Checks 169 E.4.1: GPD-DC of a Hydrocracking Reactor 170 E.4.2: Detailed Investigation of the Transition of a Cylindrical to a Hemispherical Shell 177 E.4.3: GPD-DC of an Air Cooler Header 189 E.4.4: GPD-DC of a Nozzle in Hemispherical End 201 Contents vii Else_PVD-ZEMAN_Contents.qxd 4/6/2006 9:58 PM Page vii Annex E.5: Examples of Progressive Plastic Deformation Design Checks 211 E.5.1: PD-DC of a Hydrocracking Reactor 211 E.5.2: PD-DC of an Air Cooler Header 219 E.5.3: PD-DC of a Nozzle in Hemispherical End 226 Annex E.6: Examples of Stability Design Checks 232 E.6.1: First S-DC of a Jacketed Stirring Vessel 232 E.6.2: Second S-DC of a Jacketed Stirring Vessel 237 Annex E.7: Examples of Cyclic Fatigue Design Checks 240 E.7.1: F-DC of a Cylindrical to Hemispherical Shell Transition 240 E.7.2: F-DC of an Air Cooler Header 243 Annex E.8: Examples of Static Equilibrium Design Checks 248 E.8.1: SE-DC of a Skirt Supported Heavy Reactor Column 248 E.8.2: SE-DC of a Skirt Supported Light Pressure Vessel 254 E.8.3: SE-DC of a Leg Supported Vertical Storage Tank 262 Annex L: Input Listings 271 L.4.1: GPD-DC of a Hydrocracking Reactor 271 L.4.2: GPD-DC of Details of Cylindrical Shell to Hemispherical End 274 L.4.3: GPD-DC of an Air Cooler Header 275 L.4.4: GPD-DC of a Nozzle in Hemispherical End 282 L.5.1: PD-DC of a Hydrocracking Reactor 283 L.5.2: PD-DC of an Air Cooler Header 283 L.5.3: PD-DC of a Nozzle in Hemispherical End 289 L.6.1: First S-DC of a Jacketed Autoclave 289 L.6.2: Second S-DC of a Jacketed Autoclave 292 Subject Index 295 viii Contents Else_PVD-ZEMAN_Contents.qxd 4/6/2006 9:58 PM Page viii It is the mark of an instructed mind to rest assured with that degree of precision that the nature of the subject admits, and not seek exactness when only an approximation of the truth is possible. Aristotle Foreword Twelve years after the first draft on the new approach in Design by Analysis was published by CEN TC 54 WG C, seven years after the adoption of the legal basis for its usage in the design of pressure vessels, the so-called Pressure Equipment Directive (PED) [1], five years after the issue of the Design-by-Analysis Manual [3], a handbook based on the draft of this new approach, five years after the com- ing into force of the PED and the approval of the harmonized standard EN 13445 Parts 1 through 5 [2] on unfired pressure vessels, seems to be the right time for a comprehensive, consolidated compendium related to this new approach, which is now called Direct Route in Design by Analysis, and which is laid down in the nor- mative Annex B of EN 13445: Unfired Pressure Vessels, Part 3: Design. This book had already been planned long ago, as a continuation of my basic textbook on the fundamental principles of the structural design of pressure vessels [4], in German. Discussions at international conferences, experience in interna- tional research groups, and the numerous publications on this topic [5–22], have convinced me that a publication in English is the best vehicle to achieve the de- sired objective – the promotion of this new and promising approach in the design of pressure vessel components. Most admissibility checks of the structural design of pressure vessels are based on the concept of Design by Formulae (DBF), which involves relatively simple calculations to arrive at required thicknesses of components, or cross-sectional di- mensions, via more or less simple formulae or diagrams, and by usage of the con- cept of the nominal design stress, also called allowable stress, allowable working stress, or design stress intensity. Most of the space of design codes is devoted to this concept, and this concept is still part of the culture and state of the art in pres- sure vessel structural design. The great benefit of the DBF approach is still its sim- plicity, only in the recent past the formulae and calculations in DBF have become more and more elaborate, pretending accuracy that is often not there. Else_PVD-ZEMAN_FOREWORD.qxd 4/21/2006 4:39 PM Page ix ix [...]... include pressure transients that result in opening of safety valves and where the momentary pressure surge is limited to a value below 110% of the maximum allowable pressure Pressure (in bar or in MPa): Pressure means pressure relative to atmospheric pressure, i.e gauge pressure As a consequence, vacuum is designated by a negative value (PED) Calculation pressure (PC or pc in MPa): The calculation pressure. .. Direct Route in Design by Analysis as laid down in Annex B of EN 13445-3 [2], the scope of this book is limited to that of the standard: Design, construction, inspection, and testing of unfired pressure vessels made of sufficiently ductile steels and steel castings The definition of pressure vessels is the one of the PED [1], encompassing vessels designed and built to contain fluids under pressure with... MPa): The design pressure is the pressure at the top of each chamber of the pressure equipment chosen for the derivation of the calculation pressure of each component (EN 764-1, EN 13445-3) Design temperature (TD or td in °C): The design temperature is the temperature chosen for the derivation of the calculation temperature of each component (EN 764-1, EN 13445-3) Design mechanical loads: Design mechanical... conjunction with design pressure and design temperature Operating pressure (Po or po in bar or MPa): The operating pressure is the fluid pressure, which occurs under specified operating conditions (EN 764-1) Operating temperature (To or to in °C): The operating temperature is the fluid temperature, which occurs under specified operating conditions (EN 764-1) Maximum permissible pressure or rating pressure. .. (PR or pr in bar or MPa): The maximum permissible pressure is the pressure obtained with the analysis thickness at the calculation temperature for a given component from the DBF (EN 13445-3) Else_PVD-ZEMAN_ch002.qxd 14 4/26/2006 5:29 PM Page 14 Pressure Vessel Design: The Direct Route Test pressure (PT or pt in bar or MPa): The test pressure is the pressure the equipment is subjected to for test purposes... constitutive laws of design models used, and in the plasticity correction within the check against cyclic fatigue damage Because of the importance of the possibility of plastic deformation in efficient pressure vessel design, and because DBA-DR is especially dedicated to “standard” pressure vessels materials, this approach is, in the standard and in this work, for the time being restricted to vessels made... extension to vessels made of other sufficiently ductile materials and operating temperatures below the creep regime is straightforward, and the extension to vessels operating in the creep regime is under discussion The DBA-DR deals with pressure vessel failure modes directly, in the so-called design checks These design checks are named after the main failure mode they deal with, but some design checks... in such cases As a modern, efficient method for designing reliable pressure vessels for longer service, the DBA-DR takes into account that the “usual” materials in pressure vessel technology are ductile, that plastic flow does not necessarily limit the usability, and 3 Else_PVD-ZEMAN_ch002.qxd 4 4/26/2006 5:29 PM Page 4 Pressure Vessel Design: The Direct Route that onset of plastic flow is not a failure... Temperature TS2+ TS1+ TS3+ TS1– TS3– PS3– Figure 2.1: Design domain 2.2.3 Model-Related Terms Vessels: Vessel means a housing designed and built to contain fluids under pressure including its direct attachments up to the coupling point connecting it to other equipment A vessel may be composed of more than one chamber (PED) Components: A component is a part of pressure equipment or assembly, which can be considered... Route in Design by Analysis: This Direct Route is new, very general, with very wide application range; terms and concepts are used in a very general context; new ideas, new terms, and definitions have been introduced, old and familiar designations used in a new, unfamiliar sense, with more general definitions – a guidebook in this new territory of design of pressure vessels is considered essential Design . and promising approach in the design of pressure vessel components. Most admissibility checks of the structural design of pressure vessels are based on the concept of Design by Formulae (DBF), which. Unfired Pressure Vessels, Part 3: Design. This book had already been planned long ago, as a continuation of my basic textbook on the fundamental principles of the structural design of pressure vessels [4],. to design, ● fair knowledge of manufacturing and testing procedures, and especially ● extreme carefulness in each step, from the design specification to the design report. 2 Pressure Vessel Design: