Pressure Vessel Design for HPgTPC - indico.fnal.gov

Prashant Kumar, Vikas Teotia, Sanjay Malhotra

Bhabha Atomic Research Centre Trombay, India

26.07.2019

Pressure Vessel Design for HPgTPC

DUNE Pressure Vessel Meeting 26.07.2019


Pressure Vessel Shell thickness calculation for AL 5083

Design and Analysis for Torispherical Head

Design and Analysis for Elliptical Head

Comparison b/w Elliptical Heads based on ratio of Major to Minor axis

Analysis of Support for Pressure Vessel

Topics discussed in previous Meeting

Note: Material Properties for AL 5083 (71 MPa) were taken from literature survey

Outline

• Allowable stress (ASME, D) for PV Materials and corresponding thickness

• Maximum Allowable stress for AL 5083 Series

• Appendix 1 / Ellipsoidal Head Design

• 2D Axisymmetric Analysis & Results Discussion

• Assessment of failure criteria and limitation of Div 1

• Design by Analysis (Div 2 ) Requirements

• Stress Classification for HPgTPC P. Vessel

• Elastic stress analysis to avoid Plastic Collapse

• Limit verification to avoid Plastic Collapse

• 3D FEM Analysis for HPgTPC Pressure Vessel with distributed mass (300 Ton)

Initiated

• Summary and Conclusion

• Future Work


Allowable S for PV Materials & corresponding Thickness

S.

No

Categori

es

ASME

Materials

(Plate, sheet),

II, D

Allowabl

e stress

(MPa)

Shell

(t mm)

(Div 1, UG-27)

Elliptical

Head (t, mm)

Appendix 1

Nozzle wall

(t, mm)

Opening

1000 mm

1 Aluminu

m

SB20

9

A95083,

H321

86.9 33.2 = 34 23 6

2 Carbon

Steel

SA 283 118 24.3 = 25 17 5

SA 516 128 22.4 = 23 16 4

SA 537 138 20.8 = 21 14 4

SA 738 158 18.1 = 19 13 4

3 Stainless

Steels

SA-240 S301 138 20.8 = 21 14 4

SA-666 S21904 177 16.2 = 17 11 3

SA-240 S30815 172 16.7 = 17 12 3

SA-240 S32202 185 15.5 = 16 11 3

4 Nickel SB-409 177 16.2 = 17 11 3

SB-424 161 17.8 = 18 12 4

*** Corrosion allowance, mill tolerance to be added further


Maximum Allowable stress for AL 5083 Series


Appendix 1 / Ellipsoidal Head Design

D / 2h = 5725 / (2*2000) = 1.43

K = 0.67

t = 23 mm

Crown radius = K * D

= 0.67 * 5725

= 3836 mm

S. N Description Value

1 Internal pressure (P) 10 bar (1 MPa)

2 D 5725 mm

3 K 0.66

4 S (AL 5083) 86.9 MPa

5 E 1.00


2D Axisymmetric Analysis & Results Discussion

500 mm

Nozzle to Head Junction Head to Shell Transition Shell


Assessment of Failure criteria and limitation of Div 1

Failure Criteria

Justification for higher allowable stresses (Div 2)

• Experienced obtained from other PV Codes

• More stringent material requirements

• Higher material toughness requirements

• Increased NDE

Assessment

(Particular to

HPgTPC)

Div 1 Div 2

TOF MPST Tresca (earlier) /

Distortion Energy

Criteria (Now)

FOS 3.5 3.0 (Higher S)

Load

classification

Not

considered

in Design

Detail consideration

in Design

Fabrication and

Inspection

norms

Easy

compared to

Div 2

Stringent

Requirement


Design by Analysis (Div 2 ) Requirements

Design by Analysis: It is organised based on protection against the failure modes.

1. Protection against Plastic Collapse

2. Protection against Local Failure

3. Protection against collapse from buckling

4. Protection against failure from cyclic loading

3 Analysis method are provided for evaluating protection against plastic collapse

1. Elastic stress analysis method

2. Limit – Load Method

3. Elastic – Plastic Stress Analysis Method (Ratcheting analysis)


Stress Classification for HPgTPC P. Vessel (Div 2)

S. N Vessel

Component

Location Origin of Stress Type of Stress Classification

1 Shell Remote from

Discontinuities

Internal Pressure General Membrane

Gradient through shell

thickness

Pm

Pb

PL

Q

Junction with head or

flange

Internal Pressure

2 Dished head

(Elliptical Head)

Crown Internal Pressure Membrane

Bending

Knuckle or Junction to

shell

Internal Pressure Membrane

Bending

Peak

3 Nozzle

(In one of the Elliptical

Head)

Outside the limits

of reinforcement

Pressure General Membrane Pm

Pb

PL

Q

Pressure and all external

loads and moments

(Load attributed by dead

weight of nozzle closure,

weight of Person)

Membrane

Bending

Peak

Nozzle wall Gross structural

discontinuities

Membrane

Bending

Peak

Differential Expansion

4 Nozzle Closure

(Flat head)

Center region Internal pressure Membrane

Bending

Pm

Pb

Junction to shell Internal pressure Membrane

Bending

PL

Q


Elastic stress analysis to avoid Plastic Collapse

S.N AL 5083 (SB209)

1 Density 2657 Kg/m3

2 Isotropic elasticity 71 GPa

3 Tensile yield strength 125 MPa

4 Tensile ultimate strength 275 MPa


Limit Verification

Load Combination

(MPa)

Limit SCL 1 SCL 2 SCL 3 SCL 4 SCL5 SCL 6 SCL

7/8

SCL 9 SCL 10

Pm (S) 86.9 21.768 13.12 4.35 20.05 27.36 37.662 40.59 87.4 76.95

Pb (1.5 SPL) 130.35 28.593 145.01 62.48 45.673 36.05 30.19 18.12 1.24 34.44

Pm + Pb (1.5 SPL) 124.05 30.687 124.93 54.34 65.72 63.09 67.851 58.70 87.96 84.06

Peak Stress 29.58 9.64 23.53 16.29 1.43 0.9 0.004 73.97

Max Total 55.68 56.163 67.93 58.83 87.96 120.95

Remarks Pass …… Pass Pass Pass Pass Pass …… …….


3D FE Analysis of HPgTPC Pressure Vessel

Solid Model Load Consideration

Mesh

S.

N

Particulars Values

1 Internal Pressure 10 bar (1 MPa)

2 ID of Shell 5725 mm

3 Head Type Ellipsoidal (D/2h = 1.43)

4 Manhole ID 1000 mm

5 Distributed Mass 300 Ton

6 Shell Thickness 40 mm

7 Nozzle Height 300 mm


Summary and Conclusion

• Shell Thickness calculation done for different PV materials including

Al 5083

• 2D Analysis and stress classification

• Design by Analysis as per Div 2 initiated (Preliminary)

• 3D Analysis with distributed mass (300 Ton) initiated


Future Work

• Thickness calculation as per Div 2

• Rigorous analysis for Ellipsoidal Head and Shell to be carried out

(As per Div 2)

• Support System

• BOLT Design

• Flange Design for Pressure Vessel and Heads

• Support Locations to avoid excessive sagging and hogging


Thank You

For

Your Kind Attention


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Pressure Vessel Design for HPgTPC - indico.fnal.gov

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