10
III
https://doi.org/10.22214/ijraset.2022.41116
March 2022
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue III Mar 2022- Available at www.ijraset.com
Design of Pressure Vessel Using Computational Techniques
Bhavik Chavda1, Rupak Shukla2, Harshit Tiwari3, Ashutosh Pandey4, Yusuf Rehman5
1, 2, 3, 4
5
Mechanical Department, Mumbai University,
Assistant Professor, Mechanical Engineering Theem College of Engineering Boisar.
Abstract: This paper discusses some of the recent advances in determining the stress concentration factor in pressure vessels at
openings, stress analysis of various types of end connections, and stress minimization by optimizing the location and angle of the
nozzle on the shell and head. The area of stress concentration analysis in pressure vessels is gaining popularity, according to the
literature. The goal of this study is to look at the stress concentrations that occur at the openings of pressure vessels and how to
mitigate their effects. The ASME pressure vessel code governs the design of pressure vessels. The code specifies the thickness
and stress of fundamental components; it is up to the designer to determine stress due to other loadings using an appropriate
analytical approach. Recent and previous developments, theories for stress concentration estimate, and the possibilities for
future investigations are all discussed in this study. We'll also use data analysis software like Solidworks to computationally
assess our design. Also, technologies like Excel were considered for creating our design's data sheet, and they were coupled with
Solidworks software for a speedy outcome. This strategy will not only save time but will also save money if used on a large basis.
The project's main goals and objectives are as follows: Design the pressure vessel following the ASME (American Society of
Mechanical Engineers) code. Create a Solidworks 3D model of a pressure vessel. Using Solidworks software, analyze the
stiffness and strength of pressure vessel material and design. To improve the facility, staff, and public safety. To use simulation
tools to check the design's accuracy. To ensure computation repeatability by using EXCEL as the design calculation method. To
make all design methods more efficient in terms of time. To enhance public and personal security.
Keywords: Pressure Vessel, Solidworks, Design, Excel, Etc.
I. INTRODUCTION
A process in engineering is a collection of interconnected actions that, when combined, change inputs into a certain output. These
jobs can be performed by humans, nature, or robots using a variety of resources; an engineering process must be examined in the
context of the agents doing the tasks as well as the resource properties. Systems engineering normative papers, as well as those
related to Maturity Models, are often built on processes, engineering procedures and the Capability Maturity Model Integration
(CMMI) institutionalization and improvement approach. Constraints placed on the tasks and resources needed to complete the
project and are required to complete the tasks listed. Process manufacturing is a branch of manufacturing that deals with formulas
and production recipes, as opposed to discrete manufacturing, which deals with discrete units, bills of materials, and component
assembly. Food, beverage, chemical, pharmaceutical, nutraceutical, consumer packaged products, cannabis, and biotechnology
businesses all use process manufacturing. Ingredients, not parts, formulas, not bills of materials, and bulk materials, not individual
units, are important in process manufacturing. Despite the fact that there is inevitably cross-over between the two manufacturing
branches, the major contents of the end product are the same. Manufacturing systems can generally be classed as one or the other
based on the product and the majority of the resource intensity of the production process. A bottle of juice, for example, is a discrete
thing, although juice is processed made. Although the plastic used in injection moulding is process produced, the components it
shapes are typically separate and require additional assembly.
A. Types of Process Equipment used in industries
1) Pumps
2) Filters
3) Valves
4) Vessel and Tanks
5) Heat Exchangers
Based on the reliability and feasibility, we chose to design Pressure Vessel (Vessel and Tanks) and perform the analysis of our
project using ASME codes, PV Elite, Solidworks and Ansys computational software.
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B. Pressure Vessel
A pressure vessel is a container that is designed to hold gases or liquids at a pressure higher than atmospheric pressure. The size of
the vessel, the contents, the operating pressure, mass limits, and the number of items required will all influence the construction
methods and materials used. Maximum safe operating pressure and temperature, safety factor, corrosion allowance, and minimum
design temperature are all factors to consider when designing (for brittle fracture). Nondestructive testing, such as ultrasonic testing,
radiography, and pressure tests, are used to evaluate the construction. Water is commonly used in hydrostatic pressure tests, whereas
air or another gas is used in pneumatic pressure tests. Hydrostatic testing is favored since it is a safer procedure because if a fracture
occurs during the test, substantially less energy is produced (water does not greatly increase its volume when rapid depressurization
occurs, unlike gases, which expand explosively). Representatives are frequently seen in mass or batch production products. If the
system's overall safety is sufficiently improved, pressure relief devices may be installed. Most countries require vessels of a given
size and pressure to be built according to a set of rules. The ASME Boiler and Pressure Vessel Code is the code used in the United
States (BPVC). The Pressure Equipment Directive is the code in Europe. The majority of the information on this page is only valid
in ASME. Each vessel has a nameplate with pertinent information about the vessel, such as maximum allowable working pressure,
maximum temperature, minimum design metal temperature, what company manufactured it, the date, its registration number
(through the National Board), and American Society of Mechanical Engineers.
II. LITERATURE REVIEW
In thus section research papers are discussed related to the present work.
Henry H. Bednar (1986), has explained that when the forces applied to a vessel or its structural attachments are referred to as loads
and in any mechanical design, the first requirement in vessel design is determine the actual values of the loads and the condition to
which the vessel will be subjected in operation. These are also determined on the past experience, design codes, calculations, or
testing. They also explained that a design engineer should determine conditions and all pertaining data as thoroughly and accurately
and be conservative. The author also studied that Finite Element Analysis (FEA) is the most important numerical method. The
reason is that FEA has gaining predominance in the computer process because the method can be formalized in a standard procedure
that does not require any engineering decisions and is eminently suitable for computer programming.
Eugene F. Megyesy (2001), has explained about the stresses and different types of pressure under pressure vessels when pressure
vessels are subjected to various loadings, which exerts stresses of different intensities in the vessel components. The category and
intensity of stresses are the function of the nature of loadings, geometry and construction of the vessel components. When a vessel
under external pressure, when other forces are not factors, designed must be resist the circumferential buckling. The code will help
to provide the method of design to meet the required outcomes. The author also explained that the code symbol should be applied
and vessel shall be designed and stamped with maximum allowable external working pressure. They recommended that a suitable
margin is provided when establishing the maximum allowable external pressure to allow for pressure variation in service.
David Heckman (1998), tested contact elements to determine their usefulness in modelling the interaction between pressure vessel
cylinder walls and end caps. When they modeled correctly, contact elements proved to be useful, but in this case the operator also to
be able to interpret the results properly. Problems such as local stress risers, unrealistic displacements such data become extremely
important in this kind of analysis. This highlights the importance of finite element analysis (FEA). The Professor also highlighted
that the analyst should also able to approximate the solution using hand calculation in order to verify the solution.
B. S. Thakkar and S. A. Thakkar, did a case study and put efforts to design the pressure vessel using ASME code & standards to
legalize the design. The performance of a pressure vessel under pressure can be determined by conducting a series of tests to the
relevant ASME standard. Pressure vessel components are selected on the basis of available ASME standard and the manufactures
also follow the ASME standard while manufacturing the components so that leaves designer free from designing the components.
This aspect of design greatly reduces the development time of new pressure vessel, it also allows the designer to keep free from
multiple prototypes for pressure vessel before finalizing the design, here standard part is used so it reduces time for replacement so
less overall cost.
Somnath Chattopadhyay, has explained that pressure vessels often have a combination of high pressure together with high
temperature, and in some cases flammable fluids or highly radioactive materials. This can occur to an hazards situation, so author
explained that the rules for design, fabrication and inspection of pressure vessels are provided by codes that have been developed by
industry and government. In various codes all have established rules of safety governing design, fabrication and inspection of
boilers, pressure vessels and nuclear components. These codes are intended to provide reasonable protection of life and property and
also provide for margin for deterioration in service.
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In addition, there is a continuous attempt to understand all failure modes, and provide rational margins of safety against each type of
failure. The author also concluded about pressure vessel by using computational techniques. In 1960s the use of components began
to make an impact on design and analysis of pressure vessels. The rapid development of finite element software has remarkably
impacted the detailed design of pressure vessel components. These developments along continuing increase in computing speed and
storage capacity of the computer have really made the design process extremely quick and at the same time have led to very
accurate design assessment. Initially the early to mid-1970s, detailed finite element analysis were generally performed for
confirmatory analysis. The three-dimensional finite element analysis programs using solid elements are rapidly replacing plate,
shell, and two-dimensional programs for routine structural design analysis of pressure vessels. In additions the concepts of
computer-aided design (CAD) and computer-aided manufacturing (CAM) are being integrated.
S.J Niranjana, designed and explained that a pressure vessel is a device which has a pressure difference inside it by atmospheric
pressure. As high operating pressures are a danger, utmost care should be taken while designing the pressure vessels. Any
mechanical structure fails if there are stresses induced in them. The pressure vessel life under cyclic load is related to the number of
cycles it is exposed to and to the intensity of the stress. The pressure vessel is assumed to be a thin cylinder, and therefore the
analysis follows the thin cylinder formulae. The modeling was done on a modeling software, and a finite element analysis was
carried out to highlight the various points of stress concentration. The finite element analysis-based workbench is used for analyzing
pressure vessel components. It discusses modeling methods for various parameters in a cracked pressure vessel. It also gives few
rules for performing analysis using fem like starting with a simple design and using, closed-form solutions for analysis.
R. Rustam, studied the effectiveness of FEA in the design and analysis of horizontal pressure vessels with and without expansion
joints. It was concluded that the FEA tool was useful to design and analyze such components. The FEA results were also found to be
in good agreement with mathematical model results. After doing an extensive literature survey it is found that vessels of different
shapes and dimensions were designed and analyzed using a dedicated analysis software’s. Thermal and structural loads were
considered as the boundary conditions for the same. Materials used in the actual pressure vessel are considered as input parameter.
From the available literature it is evident that comparative study of structural performance of pressure vessel of different
engineering materials has not been studied extensively.
Literature also suggests that stress analysis in thin-walled pressure vessels has not been validated. Such designs are light weight and
compact and useful for small scale industrial plants. Very few studies have focused on the failure study of pressure vessel structures
and it is an important factor for the selection of material in the fabrication of such critical components. This study focusses on the
failure analysis of different engineering alloys such as stainless steel, carbon steel and titanium alloy used in structural, high strength
applications involving dynamic pressure situations. The modelled pressure vessel is subjected to varying pressures keeping in mind
the dynamic pressure variations expected in such vessels and their structural performance when subjected to different internal
pressure values.
Abdolreza Toudehdehghan And Tan Wai Hong, explained that the design of a vessel needs to achieve a balance between the safety
as well as economics. It was concluded that to accomplish this task, it requires the understanding of parameters affecting the
pressure vessel due to varying loads, pressure and thickness. ASME code requires the pressure vessel to be designed based on the
most severe conditions that the vessel is subjected to, including during the start-up, normal operation, possible deviations, and shut
down.
M. A. Khattak, A. Mukhtar, A. F. Rafique and N. Zareen, explained that the design of pressure vessels safety, is the primary
consideration, especially for nuclear reactor pressure vessels, due the potential impact of a possible severe accident. In general,
however, the design is a compromise between consideration of economics and safety. The design factor used in the ASME Boiler
and Pressure Vessel Code is intended to account for unknown factors associated with the design and construction of the equipment.
The design formulas and the stress analysis methods are generally approximate and have built-in assumptions. Typically, it is
assumed that the material is homogeneous and isotropic.
Matt Weber, explained the simulation and impacts on an object due to real-world loading circumstances were investigated.
Computer simulation is a sort of simulation in which Cad Models are used to represent real objects, and varied load conditions are
applied to the model to examine real-world impacts. We apply loads to a restricted model under predetermined environmental
conditions in Solidworks Simulation and examine the results. Static analysis, in which loads are given to a body, the body deforms,
and the effects of the loads are transferred throughout the body, was also discussed by the author. The body generates internal forces
and reactions at the supports to balance the applied external loads in order to absorb the effect of loads. Internal forces and reactions
produce strain and stress in the body.
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Radostina V. Petrova, the principle of the FEM was explained, as well as the meshing of the solid model. The goal of the FEM is to
slice the solid body into many small, simple-shaped cells that precisely mimic the body's form. Finite elements (FEs) or simply
elements are the names given to these microscopic cells. They communicate with one another at nodes. Meshing is the process of
converting a solid body model into a FE model, and it is a crucial stage in the FE workflow. It allows a complex engineering
challenge to be replaced by a series of smaller bonded problems that must all be solved at the same time. The software generates a
set of algebraic equations on its own, then connects them to construct a single sparse matrix equation.
A.
B.
C.
D.
E.
F.
G.
H.
III. AIMS AND OBJECTIVES
Whatever dimensions of the Pressure Vessel they have been computed using ASME codes have there been utilized to form
visual understanding.
This 3D model is designed for safe working of the Pressure Vessel.
It will increase Repeatability.
It will increase Reproducibility.
This method will be Time Efficient.
It can be used for slightly different configuration of vessels for different components.
Also, we will use data sheet in solid works which will give the quick calculative results.
Use of excel data sheet in industries will save time and also save cost of the worker which will be used in design of vessels in
conventional way.
IV. METHODOLOGY
A. Research Methodology
This project is conducted accordingly till the completion of the project in which desired results are obtained as shown below.
1) Start
2) Select and define research topic
3) Prepare and evaluate research plan
4) Literature review
5) Identify the design parameters for pressure vessel design
6) Study and list down the equations involved for design from ASME
7) Implement the algorithm based on the design parameters and equations accordingly
8) Designing in Solidworks
9) Report writing
10) End
B. Tools
This project will require the following tools to carry out the project:
1) Microsoft Excel: MS Excel is used to calculate the given parameters of the pressure vessel and also with editable format.
2) Solidworks 2021: Solidworks is used specifically to design support system for the pressure vessel design based on the suitable
algorithm along with equations for pressure vessel design.
V. DESIGN AND CALCULATION
A. Design Of Shell
Material:
SA 516 GR 70 N
DESIGN CONDITIONS
Design Code
PARAMETER
VALUE
UNITS
ABREVATION
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Internal Design Pressure
Design Temperature
kg /cm2(g)
3.5
95
Min. Design Metal Temperature
12.5
Max. Allowable Working Pressure
Allowable stress
Corrosion Allowance
Under Tolerance Allowance
Joint efficiency
Shell Diameter (Internal)
Shell Radius (Internal)
Length of the shell
Specific gravity of shell material
o
C
o
C
P
T
MDMT
2
3.5
485
kg / cm (g)
3
mm
0.85
2100
1050
6000
7.85
mm
mm
mm
MAWP
S
Mpa
C. A
UTP
E
id
Ri
L
sp.gr.
CALCULATING REQUIRED THICKNESS FOR DESIGN PRESSURE
Along circumferential
P x Ri
tb =
S x E - 0.6 x P
tb=
12
+
C. A
+
C. A
mm
DISH END
P x Di
2SE - 0.2P
tb=
tb=
12
mm
B. Weight Calculations
Shell:
Ws = π * D * L * t * sp.gr.
in kg
where,
D: Mean shell diameter
L: Length of the shell
t: Thickness of the shell
sp.gr.: Specific gravity of shell material
hence,
Ws =
2.112
m
6
m
0.012
m
7850
kg/m3
3735.70
kg
Dished ends:
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Wd = 1.084 * D2 * t * sp.gr. * 2
hence,
in kg
Wd =
907.90
kg
Manhole & cover:
205.00
kg
Nozzles:
150.00
kg
Internals:
200.00
kg
Externals:
100.00
kg
Saddles:
500.00
kg
Volume: (Full)
49.50
m3
Volume: (Operating - max. liquid level 1.8m from
bottom)
45.60
m3
Specific gravity of process fluid
0.980
Insulation:
Wi = π * D * L * t * sp.gr. + 1.084 * D2 * t * sp.gr. * 2 in kg
were,
D: Mean shell diameter Including insulation
2.137
m
6
m
t: Thickness of the insulation
0.025
m
sp.gr.: Specific gravity of shell material
7850
kg/m3
9719.70
kg
Fabricated weight:
5798.60
kg
after adding 10% extra
6378.46
kg
say after rounding off
1400
kg
Site erected weight :
16098.16
kg
say after rounding off
1400
kg
Operating weight (max.)
46088
kg
say after rounding off
46500
kg
Weight full of water:
50900
kg
say after rounding off
50900
kg
Maximum Weight:
50900
kg
L: Length of the shell
hence,
Wi =
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C. 3D Model of Pressure Vessel
In 3D computer graphics, 3D modelling is the process of developing a mathematical coordinate-based representation of any surface
of an object (inanimate or living) in three dimensions via specialized software by manipulating edges, vertices, and polygons in a
simulated 3D space.
Three-dimensional (3D) models represent a physical body using a collection of points in 3D space, connected by various geometric
entities such as triangles, lines, curved surfaces, etc. Being a collection of data (points and other information), 3D models can be
created manually, algorithmically (procedural modelling), or by scanning. Their surfaces may be further defined with texture
mapping.
Almost all 3D models can be divided into two categories:
1) Solid: These models define the volume of the object they represent (like a rock). Solid models are mostly used for engineering
and medical simulations, and are usually built with constructive solid geometry.
2) Shell or boundary: These models represent the surface, i.e. the boundary of the object, not its volume (like an infinitesimally
thin eggshell). Almost all visual models used in games and film are shell models.
Figure 1 Final Model of Pressure Vessel
D. Introduction To Design Table
A design table allows you to build multiple configurations of parts or assemblies by specifying parameters in an embedded
Microsoft Excel worksheet. The design table is saved in the model document and is not linked to the original Excel file.
Inserting a Design Table
1) You can select create in the Design Table Property Manager to insert a design table.
2) To have the SOLIDWORKS software insert a design table.
3) In a part or assembly document, click Design Table (Tools toolbar) or Insert > Tables > Design Table.
4) In the Property Manager, under Source, select Auto-create.
5) Set the Edit Control settings and Options, as desired.
6) Click Depending on the settings you selected, a dialog box may appear that asks which dimensions or parameters you want to
add.
7) An embedded worksheet appears in the window, and the SOLIDWORKS toolbars are replaced with Excel toolbars.
8) Cell A1 identifies the worksheet as Design Table for: model name.
9) Click anywhere outside of the worksheet (but in the graphics area) to close the design table.
Figure 2 Model of Shell Through Design Table
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Figure 3 Model of Dished End Through Design Table
VI. ANALYSIS AND RESULT
This are the results of the model after analysis
A. Stress Analysis
Figure 4 stress analysis
The above figure shows the result of stress analysis performed on Soliworks Simulation.
The value is less than the maximum value. i.e., 5.095 x 107 (N/m2) < 2.5 x 108 (N/m2
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B. Displacement Analysis
As a result, using the List Result Force option, the force required to produce the prescribed displacement can be backed out, and the
resulting stresses may be calculated.
If you ever need to apply both a translation and a rotation, you can use the Remote Load/Mass option found under the External
Loads pulldown.
Figure 5 displacement analysis
C. Strian Analysis
Figure 6 strain analysis
The above figure shows the result of strain analysis performed on solidworks simulation.
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D. Result Obtained
Test
Displacement
Stress
Max. Design value
2mm
2.500 x 108 N/m2
Obtain value
0.477mm
5.095 x 107 N/m2
Remarks
Safe
Safe
The following values are true and considerably under limit as analysis is concerned.
Therefore, we conclude that the overall design of our SA 516 Gr. 70 N Pressure Vessel is Safe.
VII. CONCLUSION
1) In this topic the analysis of pressure vessel is done using ASME codes and Solidworks simulation software.
2) Whatever dimensions have been obtained is useful to design and compute a horizontal pressure vessel.
3) This topic is introduced for small to medium scaled industry which will result in saving capital.
M oney VS M ont h
30000
25000
20000
15000
10000
5000
0
April
M ay
June
July
4) In the above given graph, we can see that how the slope increases. The x-axis is represented by month and y-axis is represented
by amount in rupees which is to be spent for designing a pressure vessel.
5) In today’s scenario, we assumed the daily wage of the draftsman to be 250 rupees. If we multiply the amount by 26 working
days, we would get an amount of rupees 6,500. Which will save 78,000 rupees of the industry yearly.
6) Thus, by introducing this idea in the industry, not only we can save the capital but also can have a good interchangeability,
good repeatability, feasibility of the project.
7) This project is looking forward to help industry with user friendly software.
A.
B.
C.
D.
E.
F.
G.
VIII.
FUTURE SCOPE
This can be used with Structured Query Language (SQL).
It can be used with web development software like java, python, etc.
It can be used in FEA software like Ansys, Matlab.
Further verification of pressure vessel can be done using PV Elite software.
It can also be used for the fluid which is in dynamics.
This technique can be introduced in academic syllabus.
It can be used using smartphones or tablet pc.
IX. ACKNOWLEDGMENT
This work was supported by Department of Mechanical Engineering of Theem College of Engineering, Boisar, Maharashtra. And
we are also thankful to S. Tech. Consultancy Services, Mumbai for Providing an opportunity and availability of an on-going
Industrial Project on Pressure Vessel as a Final Year Project.
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Heckman, D. (1998). Finite Element Analysis of Pressure Vessel. 1-7.
Hong, A. T. (2019). A Critical Review and Analysis of Pressure Vessel Structures. International Postgraduate Conference on Mechanical enginering, 7-8.
M. A. Khattak, A. M. (2016). Reactor Pressure Vessel Design and Fabrication . Journal of Advanced Research in Applied Mechanics, 1-6.
Megyesy, E. F. (1972). Pressure Vessel Handbook. Pressure Vessel Publising,inc.
Moss, D. R. (2004). Pressure Vessel Design Manual. USA: Gulf Proffesional.
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S.J.Niranjana. (2018). Design and Analysis of Vertical Pressure Vessel using ASME Code and FEA TEchnique. IOP Conference Series: Materials Science and
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Weber, M. (2017). Solidworks Simulation . USA: CAD/CAM/CAE Works.
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