Pressure Vessel Design: The Direct Route

319 Pages·2006·5.558 MB·English

by  Josef L Zeman, Franz Rauscher, Sebastian Schindler

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Pressure Vessel Design
The Direct Route
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Pressure Vessel Design Manual
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2003,0-7506-7740-6
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International Journal of Engineering Sciences
International Journal of Solids and Structures
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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
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First edition 2006
ISBN-13: 978-0-08044-950-0
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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
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vi Contents
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
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Contents vii
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
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viii Contents
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
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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.
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