2022年压力容器疲劳计算算例终稿 .pdf

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1、2 Table of Contents1. Summary. 3 2. Design Condition3 3. Loads Analysis . 5 3.1 The determination of the required load for fatigue analysis.5 3.2 Working conditions of fatigue analysis . 5 4. Fatigue analysis. 6 4.1 Model simplification6 4.2 Mesh division. .7 4.3 Constraint and loading. .8 4.4 Calcu

2、lation results.12 4.5 Fatigue analysis18 5. Conclusion . 20 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 1 页，共 21 页 - - - - - - - - - 3 1. Summary The product undertaken by our company (x): DN850X1550(WL-WL)Dehydrator （DWG NO. ：x）. the design standard is ASME- -201

3、5ED & PED 2014/65/EU，the design conditions provided by customers are as follows：Design pressure is 2.5MPa ，Design temperature is -60oC300 oC，operating pressure is 0MPa2.1MPa ，operating temperature is -40oC275 oC，Temperature & pressure fluctuation time is 11000. Due to the design pressure, design tem

4、perature, weight loads of equipment, insulation and attachments are not alternating load properties, and belong to the Static load category, which can be calculated according to ASME -2015 as per 17E.104 /105.00-CAL. The Cyclic load in design conditions, which beyond the standard range of ASME VIII

5、- I because of too many number of cycles for operating pressure and operating temperature. An additional calculation is needed. The fatigue analysis and checking calculation of the equipment are based on ASME -standard article 5 section 5.5Prevent failure caused by cyclic loading .2. Design Conditio

6、n The structure of the equipment as per below Fig.1 O.D.85014252530026.310002210150060 5nn10.520.58.550 5nR3200270B.C.D.1101B.C.D.126150014(min11.7)14(min11.7)100030030020307526549002名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 2 页，共 21 页 - - - - - - - - - 4 The ov

7、erall design parameters of the equipment are shown in table 1 Table 1 Design pressureMPa 2.5 Operating pressureMPa 02.1 Test pressure MPa3.83 Design of temperature oC-60/300 Design of temperature oC-40250 设计寿命Y 10 Operating pressure cycle times 11000 Operating temperature cycle times 11000 Start and

8、 shutdown times (set)20 Intermediate maintenance times 5 Corrosion allowance mm 0 Joint efficiency1 Insulation thickness mm 80 MaterialShell/Head SA-240 304(1.4307) N1/N2/N3/M1 Pipe, Flange SA-182 F304L(1.4307) Insulation material Mineral wool Material properties are shown in table 2 Table 2 Materia

9、lMediumelastic modulusMPa Poissonrateheat conductivity coefficient Heat transfer coefficientcoefficient of thermal expansion-50oC20oC 275oCW/mm.oKW/mm2.oK mm/mm/ o KSA-240 304L 199.5 X103 195.5X103 179 X1030.31 16.28X10-3 16.24 X10-3SA-182 F304L Mineral wool 4.9X10-6 Air 1X10-5 Temperature & pressur

10、e cyclic curve as below Fig.2 Fig.2 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 3 页，共 21 页 - - - - - - - - - 5 3. Loads Analysis 3.1 The determination of the required load for fatigue analysisAccording to table，The material of dehydrator: SA-240 304L for Shell& He

11、ad, SA-182 F304L for Pipe and Flange，Tensile strength Rm552MPa, cycle time of operating pressure is 11000 ， which more than 1000 times， pressure fluctuation range P=2.1-0=2.1MPa ，which is equal to 84 % of design pressure (2.5MPa) and exceed 20% of design pressure. According to ASME -section 5.5.2.3,

12、 and table 5.9,the equipment need to be analyzed by fatigue analysis. Due to the combinative cycle loads from pressure and temperature, cumulative fatigue damage for shell need to be considered.3.2 Working conditions of fatigue analysis Due to the operating temperature of cyclic loading is between40

13、oC275oC, the operating pressure is between02.1MPa (shown in Fig.2). We need to analyze four extreme conditions as below: Condition 1：Pressure 2.1MPa 、Temperature 10 oC Condition 2：Pressure 0MPa 、Temperature 275 oC 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 4 页，共

14、21 页 - - - - - - - - - 6 Condition 3：Pressure 0MPa 、Temperature -50 oC Condition 4：Pressure 2.1MPa 、Temperature -50oC The stresses generated by such four conditions can be combined into six cases, and we chose the maximum stress fluctuation to check the fatigue of the equipment, and such four condit

15、ions need to be checked as shown in below Table 3 Table 3 Condition 1 Condition 2 Condition 3 Condition 4 Calculated Tem. oC 10 275 50 50 Calculated Pre. MPa2.1 0 0 2.1 Considering the influence of the Start and Shutdown, we chose operating condition 1, and operating condition 5 (test pressure 3.83M

16、Pa, test temperature 20oC) for hydrostatic test after maintenance. The general design condition of the equipment such as design pressure, design temperature, equipment weight and so on, which belong to the static load, no need to be considered in the fatigue calculation. 4. Fatigue analysis Calculat

17、ion Basis ：ASME -2015 Chapter 5.5 Calculation tool：Ansys 17. 4.1 Model simplification The equipment is consisted of heads, shell, nozzles, legs, insulation and other attachments. The heads, shell, pad flange and insulation can be treated as axisymmetric structure. Manhole and other nozzles located o

18、n the plane symmetry of shell, which will have no influence on the result of fatigue analysis. Due to the weight of equipment and supports belong to static loads, which no need to be considered for fatigue calculation. In order to simplify the model, change the location of manhole as follow figure.

19、The jacket of insulation is 0.6mm aluminum sheet and ignore the temperature influence of this jacket will generate a more conservative result. The simplified model as per follow Fig. 3. The minimum actual thickness of head is 11.7 and the thickness of shell is 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - -

20、- - - - - - - - - 名师精心整理 - - - - - - - 第 5 页，共 21 页 - - - - - - - - - 7 13.7mm. Fig.3 4.2 Mesh division When the mesh is divided for conduction of heat calculation, we use the 3-D 20-nodes hexahedron solid element SOLID90, which has one temperature translational degrees of freedom, The finite elemen

21、t model after the mesh is shown in figure 4 Figure 6. In order to calculate the structure stress, we use the 3-D solid element SOLID186, which is tetrahedron solid with 20 nodes unit, each node has X, Y, Z three direction translational degrees of freedom,The finite element model contains 254437 elem

22、ents and 985408 nodes, the grid unit quality factor is 0.855256 on average, the aspect ratio of the average value is 2.9628, Jacobi averaged 6.12, warping factor averaged 3.8204e-002, parallel deviation of the average value is 10.482.名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 -

23、- - - - - - 第 6 页，共 21 页 - - - - - - - - - 8 Fig.4 Fig.5 Fig.64.3 Constraint and loadingWe should consider four conditions as follows while calculating the heat conduction for this equipment：Condition 1：The inside temperature of shell is 10 oC, The outside cross-ventilation coefficient of insulation

24、 is 1X10-5W/mm2.K, the temperature of environment is 20 o C, see Fig.7. 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 7 页，共 21 页 - - - - - - - - - 9 图 7Condition 2：The inside temperature of shell is 275 oC, The outside cross-ventilation coefficient of insulation is

25、1X10-5W/mm2.K, the temperature of environment is 20 o C, see Fig.8. 图 8Condition 3、Condition 4：名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 8 页，共 21 页 - - - - - - - - - 10 The inside temperature of shell is -50 oC, The outside cross-ventilation coefficient of insul

26、ation is 1X10-5W/mm2.K, the temperature of environment is 20 o C, see Fig.9. 图 9 For structure stress, loading symmetry constraint on plane of symmetry ，We set a constraint that only allows to move along the radial direction and circumferential & axial constraint of shell is 0. See Fig. 10 Fig. 10Co

27、ndition 1：Loading the distribution of temperature generated by heat-transfer calculation as thermal load, see Fig. 11. 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 9 页，共 21 页 - - - - - - - - - 11 Loading pressure 2.1MPa inside of shell ，Loading on the surfaces of f

28、lange ：N2 FlangeMPadddPFioiN4875.01022351021.22222222=-=-=N3 MPadddPFioiN7514.01543001541. 22222223=-=-=M1 MPadddPFioiM4651.14847554841. 22222221=-=-=，See Fig.12 。Fig.11 Fig.12 Condition 2：Loading the distribution of temperature generated by heat-transfer calculation as thermal load , see Fig.13 。Th

29、e pressure inside of shell is 0MPa. Condition 3：Loading the distribution of temperature generated by heat-transfer calculation as thermal load，see Fig.14 The pressure inside of shell is 0MPa. Condition 4：Loading the distribution of temperature generated by heat-transfer calculation as thermal load，s

30、ee Fig.14 。The pressure inside of shell is 2.1MPa ，Loading on the surfaces of flange ：名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 10 页，共 21 页 - - - - - - - - - 12 N2 FlangeMPadddPFioiN4875.01022351021.22222222=-=-=N3 MPadddPFioiN7514.01543001541. 22222223=-=-=M1 M

31、PadddPFioiM4651.14847554841. 22222221=-=-=，See Fig 12. Fig. 13 Fig. 14Condition 5：Loading 3.83MPa to inside of shell, Loading on the surfaces of flange：N2 凸缘MPadddPFioiN8891.010223510283.32222222=-=-=N3 MPadddPFioiN3704. 115430015483. 32222223=-=-=M1 MPadddPFioiM672.248475548483.32222221=-=-=，见图 15。

32、名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 11 页，共 21 页 - - - - - - - - - 13 Fig. 154.4 Calculation results The result of heat transfer temperature distribution for condition 1 as per Fig.16, the maximum temperature located at the outside of insulation, which is 1

33、9.567 oC. the minimum temperature located at the inside of shell , which is 10 oC. The result of heat transfer temperature distribution for condition 2 as per Fig.17, the maximum temperature located at the inside of shell , which is 275 oC. the minimum temperature located at the outside of insulatio

34、n, which is 31.039 oC. The result of heat transfer temperature distribution for condition 3&4 as per Fig.18, the maximum temperature located at the outside of insulation, which is 16.97 oC. the minimum temperature located at the inside of shell , which is -50 oC.。Fig. 16 Fig. 17 名师资料总结 - - -精品资料欢迎下载

35、 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 12 页，共 21 页 - - - - - - - - - 14 Fig. 18 The result of structure stress For condition 1, the maximum stress located at the inside point between shell and manhole pipe, which is 213.29MPa, see Fig. 19. For condition 2, the maximum stress loc

36、ated at the inside surface of manhole flange, which is 119.97MPa, see Fig. 20. For condition 3, the maximum stress located at the inside surface of manhole flange, which is 26.5MPa, see Fig. 21. For condition 4, the maximum stress located at the inside point between shell and manhole pipe, which is

37、213.57MPa, see Fig. 22. For condition 5, the maximum stress located at the inside point between shell and manhole pipe, which is 404.3MPa, see Fig. 23. Fig. 19 Fig. 20 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 13 页，共 21 页 - - - - - - - - - 15 Fig. 21 Fig. 22 Fig

38、. 234.4.1 Maximum stress amplitude The maximum stress amplitude for shell calculated by condition 1 minus condition 2 which located at the inside point between shell and manhole pipe, and the result is 214.5398MPa, see Fig. 24. The maximum stress amplitude for shell calculated by condition 1 minus c

39、ondition 3 which located at the inside point between shell and manhole pipe, and the result is 213.01MPa, see Fig. 25. The maximum stress amplitude for shell calculated by condition 1 minus condition 4 which located at the inside surface of manhole flange, and the result is 22.6847MPa, see Fig. 26.

40、The maximum stress amplitude for shell calculated by condition 2 minus condition 3 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 14 页，共 21 页 - - - - - - - - - 16 which located at the inside surface of manhole flange, and the result is 146.432MPa, see Fig. 27. The ma

41、ximum stress amplitude for shell calculated by condition 2 minus condition 4 which located at the inside point between shell and manhole pipe, and the result is 214.776MPa, see Fig. 28. The maximum stress amplitude for shell calculated by condition 3 minus condition 4 which located at the inside poi

42、nt between shell and manhole pipe, and the result is 213.248MPa, see Fig. 29. All these showed that the maximum stress fluctuation on shell located between condition 2 and condition 4, which is 214.776MPa. For condition 5, the maximum stress amplitude is 404.3MPa. Fig. 24 名师资料总结 - - -精品资料欢迎下载 - - -

43、- - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 15 页，共 21 页 - - - - - - - - - 17 Fig. 25 Fig. 26 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 16 页，共 21 页 - - - - - - - - - 18 Fig. 27 Fig. 28 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - -

44、 - - - - 第 17 页，共 21 页 - - - - - - - - - 19 Fig. 29 4.4.2 Maximum effective equivalent stress amplitudeFor condition 1 condition4 (operating condition), maximum effective equivalent stress amplitude is:MPaSKKSkefalt56.1822776.21417.12,=?=For condition 1(Start and shutdown condition), maximum effecti

45、ve equivalent stress amplitude is:AS per Fig 19, maximum effective equivalent stress amplitude is 213.29MPa MPaSKKSkefalt3.181229.21317.12,=?=For condition 5(pressure test condition), maximum effective equivalent stress amplitude is:MPaSKKSkefalt655.34323.40417.12,=?=名师资料总结 - - -精品资料欢迎下载 - - - - - -

46、 - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 18 页，共 21 页 - - - - - - - - - 20 -tK Fatigue strength weakened coefficient 疲劳损失系数-keK,Fatigue loss coefficient 最大有效当量应力幅-altSMaximum effective equivalent stress amplitude4.5 Fatigue analysis The material of shell and head is SA-240 304L The material of

47、 flange for N1N3 /M1 is SA-182 F304L The minimum tensile strength is 485MPa，which is less than 552MPa 4.5.1 Operating condition MPaSEESaltTFCalt88.19856.1821079.11095.155=量确定疲劳曲线用弹性模-FCEcurvefatigueDeterminetoused moduluselastic弹性模量平均温度下被评定材料-TEetemperaturaverageinassessed were materialstheof modulu

48、selastic，The elastic modulus for shell, pipe and flange is same according to table 2, the average temperature is different for various conditions and we chose the minimum elastic modulus at 275 for safety. According to ASME VIII-Div. 2(2015ED) Appendix 3 Section 3.F.1, the Design cycles N can be cal

49、culated by the following formula:XN10=413.41483624249372531=+=YCYCYCYCYCYCYCYCCX8947576.Cus=, 85.28,=usaltTFCuskaltCSEECSYParameter987654321C,C,C,C,C,C,C,C,Ccan be found in ASME SEC. VIII DIV22015ED Table 3.F.4 .The design cycles N is:258821=N名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - -

50、名师精心整理 - - - - - - - 第 19 页，共 21 页 - - - - - - - - - 21 The fatigue damage is:425.0258821100011=NnD4.5.2 Start，shutdown and intermediate maintenance condition：According to Fig.19 ,the maximum stress amplitude is 213.29MPaSEESaltTFCalt75.21229.21310955.11095.155=量确定疲劳曲线用弹性模-FCEcurvefatigueDetermineto