FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME is Based on the finite element method. Design by analysis has an established history in Pressure Vessel Design Procedures are specified in national and international codes of practice.
FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME is Based on the finite element method. Design by analysis has an established history in Pressure Vessel Design Procedures are specified in national and international codes of practice.
FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME is Based on the finite element method. Design by analysis has an established history in Pressure Vessel Design Procedures are specified in national and international codes of practice.
FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME is Based on the finite element method. Design by analysis has an established history in Pressure Vessel Design Procedures are specified in national and international codes of practice.
(GROWTH) PROGRAMME Donald Mackenzie University of Strathclyde Glasgow, Scotland, UK The Finite Element Method The Finite Element Method in Pressure Vessel Design By Analysis in Pressure Vessel Design By Analysis FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Introduction Introduction Design by Analysis has an established history in Pressure Vessel Design Procedures are specified in national and international codes of practice UK: PD5500 Unfired Fusion Welded Pressure Vessels EU: EN13445: Unfired Pressure Vessels USA: ASME Boiler & Pressure Vessel Code Sections III & VIII FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Design by Formula Design by Formula Prior to 1963 all Code vessels were designed according to a systematic Design by Formula approach Based on experience and simple mechanics Keep hoop stress low with respect to yield Use ductile material to accommodate local peak stress In DBF, the vessel geometry and major dimensions such as radius, length etc. are specified The required thickness is then calculated for a given load using Closed-form equations Graphical data FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Improved Design Improved Design The development of nuclear technology in the 1950s led to a reappraisal of pressure vessel design requirements In the USA, ASME established a Special Committee to Review Code Stress Basis ... to investigate what changes in Code design philosophy might permit use of higher allowable stresses without reduction in safety. Advances in mechanics theory and analysis methods allowed a new, more scientific basis for PVD FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME ASME Design Philosophy ASME Design Philosophy In 1963 ASME published the B&PV Code Section III: Nuclear Vessels Based on the principles of Limit Analysis Shakedown Analysis Fatigue Analysis Stress analysis was used to determine Higher allowable loads More consistent margins of safety FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME ASME III ASME III The new Code permitted two approaches to design Improved Design by Formula More accurate formulae for sizing common components Higher allowable stresses Intended for standard configurations Design by Analysis Designer performs stress analysis and evaluates results against Code limits Intended for configurations not covered by DBF FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME DBA Today DBA Today The ASME III approach has influenced all other Codes ASME VIII Division 2: Alternative Rules for Pressure Vessels BS5500 Annex A EN 13445 Annex C Design by Analysis - Method based on stress categories. Annex B Design by Analysis Direct Route is a novel approach introduced in the Euro Code FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Scope and Purpose of DBA Scope and Purpose of DBA PD5500 Annex A gives design criteria for stress systems resulting from the application of loads and/or the use of components or types of component not covered explicitly by Section 3 .. The intention is to ensure the design basis is consistent [with DBF]Formal analysis is only required in the case of significant additional loadings or loadings from components significantly different to those covered in Section 3. Suggests DBA is specifically for vessels outside the DBF remit Does not explicitly state the procedures cannot be applied to vessels covered by DBF FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Scope and Purpose of DBA Scope and Purpose of DBA EN 13445 Annex B.1 Design by analysis provides rules for the design of any component under any action. It may be used as an alternative to design by formulas as a compliment to design-by-formulas Annex C.1 may be used as an alternative to design by formulas as a compliment to design-by-formulas as an alternative to the design-by- analysis direct route FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Scope and Purpose of DBA Scope and Purpose of DBA ASME VIII DBA applies to non-standard configurations The thickness of elements of the vessel covered by DBF rules e.g. Cylindrical shell Flat head must meet DBF minimum thickness requirements FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME DBA Design Objectives DBA Design Objectives The main guidelines prevent Gross plastic deformation or ductile burst under static load Incremental plastic collapse under repeated or cyclic load Fatigue under cyclic load Other mechanisms considered as required: Elastic buckling, creep, brittle fracture, stress corrosion, etc. FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Gross Plastic Deformation Gross Plastic Deformation Plastic hinge Associated with ductile failure of the vessel under static mechanical load Mechanisms Ductile rupture or collapse when the entire volume of the material experiences plastic deformation Plastic collapse through formation of local areas of plasticity that form plastic hinge mechanisms FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Incremental Plastic Collapse Incremental Plastic Collapse Pressure vessels are frequently subject to repeated mechanical and thermal loads If the maximum load lies between yield load and plastic collapse load The vessel deforms plastically during the first cycle of load What happens next depends on the load and geometry FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Elastic Shakedown Elastic Shakedown
y Elastic Shakedown
r Elastic-perfectly plastic material If yielding does not occur during unloading subsequent re-loading is wholly elastic The structure is said to exhibit Elastic Shakedown FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Plastic Shakedown Plastic Shakedown Elastic-perfectly plastic material
Loading Unloading Alternating Plasticity
+ p
p p (a) (b) Unloading plastic strain equal and opposite to loading plastic strain Causes local damage and local failure mechanism Low cycle fatigue associated with plastic strain range, p FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Ratchetting Ratchetting
Loading Unloading + p
p (a)
Ratchetting d p d p (b) (c) Net plastic strain increment d p for each cycle Accumulates dp to form global failure mechanism Ratchetting or Incremental plastic collapse Ratchetting is not permitted in pressure vessel design FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Analysis Methods Analysis Methods The Codes do not specify use of specific analysis methods in design In practice the terminology used suggests that the expected method is shell discontinuity analysis State of the art in the 1960s Finite Element Analysis now predominates The analysis capability has greatly outgrown PVD Code requirements Problems can arise in interpreting code guidelines FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Elastic & Plastic Analysis Elastic & Plastic Analysis Most Code guidelines are for elastic analysis Problematic as gross plastic deformation and incremental Plastic collapse are inelastic failure mechanisms The Codes give limited guidelines for plastic analysis Mostly limit analysis FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Elastic Analysis & Stress Categorisation Elastic Analysis & Stress Categorisation Elastic stress is categorised into three classes: Primary stress Associated with gross plastic deformation Secondary stress (plus primary stress) Associated with incremental plastic collapse Peak stress (plus Primary plus secondary) Associated with fatigue failure Each type of stresses is limited to different allowable values Specified in terms of a design stress FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Stress Classification Stress Classification Difficult and often subjective Limited guidelines for specific configurations given in Codes Categories defined in terms of membrane and bending distributions Stress Classification (PD5500) Allowable Stress Intensity (wrt Design Stress f) Allowable Stress Intensity (wrt Yield Stress y ) General primary membrane f m f 2/3 y Local primary membrane f L 1.5 f y Primary membrane plus bending (f m + f b ) or (f L + f b ) 1.5 f y Primary plus secondary (f m + f B +f q Q) or (f L + f b +f q ) 3 f 2 y FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Stress Limits Stress Limits Primary stress Yield limited to prevent gross plastic deformation Primary plus secondary Limited to twice yield to assure shakedown Primary plus secondary plus peak Determines fatigue design life FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Shell FEA Shell FEA Can be used to model thin-shell vessels Results given as membrane and bending stress Compatible with Code categories Cannot be used for Configurations with significant non-linear variation in through-thickness stress (thick vessels) Complex 2-D or 3-D geometry FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Solid FEA Solid FEA Can be used to model any 2-D or 3-D configuration The total elastic stress at a point is defined by six elementary stresses ij Not compatible with Code membrane and bending stress categories A methodology is required to relate the distribution of to
ij the code categories Most widely used method is through-thickness Stress Linearisation Extracts pseudo membrane and bending stress from elastic distribution FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Linearising Linearising Membrane Stress Membrane Stress 0 h 2 -h 2 X 3
ij 0 h 2 -h 2 X 3
ij w
ij ( ) m Nonlinear Stress Equivalent Membrane Stress w FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Linearising Linearising Bending Stress Bending Stress 0 h 2 -h 2 X 3
ij 0 h 2 -h 2 X 3
ij w
ij ( ) b Nonlinear Stress Equivalent Bending Stress
ij X3 x3
ij ( ) b w FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Linearisation Linearisation Example Example Cl ass Li ne A Cl ass Li ne B x x y y
Axisymmetric cylindrical shell with flat head Class Line A axial stress Reasonable linearisation?
Y local system (N/mm 2 ) Distance through section (mm) FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Linearisation Linearisation Example Example Cl ass Li ne A Cl ass Li ne B x x y y
Class Line B axial stress Reasonable linearisation? How should the difference between total and mem+bend stress be treated? Is it a peak stress? If so, where is the associated SCF?
Y l ocal system (N/mm 2 ) Distance through secti on (mm) FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Limitations of Elastic Analysis Limitations of Elastic Analysis The major problem is stress categorisation Stress distribution must be defined in terms of membrane, bending and peak stress. There is no theoretical justification for linearising certain regions of a vessel Many papers have been published on the subject, more or less concluding that: It is appropriate to place a class line anywhere in a vessel except where you would actually like to place one i.e. where the stress distribution is complex In practice, designers usually regard linearisation as valid throughout the vessel, for both 2-D and 3-D models FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Barriers to Elastic FEA Barriers to Elastic FEA The major problem is stress categorisation 1997 survey of the European pressure vessel industry (as part of the JRC/EPERC Design by Analysis project) identified interpretation of finite element analysis results as the major problem in design by analysis. The designer is required to: Obtain linearised membrane and bending stresses Assign these to the appropriate category Primary yield limited, possible over-conservative Secondary twice yield limited, possible not conservative Code guidance is limited FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Inelastic Analysis Inelastic Analysis Inelastic analysis removes the stress categorisation problem The analysis is related directly to inelastic failure mechanisms Gross plastic deformation Ratchetting Routine inelastic FEA capabilities have now overtaken DBA guidelines Different types of inelastic analysis are included in the different Codes FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME PD5500 Inelastic DBA PD5500 Inelastic DBA Considers Limit Analysis for gross plastic deformation check Elastic-perfectly plastic material model Small deformation (linear geometry) theory Analysis evaluates the Limit Load The allowable load is 2/3 the limit load Relatively simple to perform Requires only Code material data May be applied to non-standard configurations FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME EN13445 EN13445 Inelastic DBA Inelastic DBA Considers Limit analysis but Annex B Design by Analysis Direct Route [2] states: In checks on structures where deformation has an unfavorable (weakening) effect, geometrically non-linear effects shall be taken into account in gross plastic deformation checks. Accounts for geometric weakening No rules or procedures given for including material strain hardening Enhances load carrying capacity May be applied to any configuration FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME ASME VIII Inelastic DBA ASME VIII Inelastic DBA Limit analysis procedures similar to PD5500 Geometric non-linearity and strain hardening effects may be incorporated in a Plastic Analysis Defines the plastic load by application of a criterion of plastic collapse The allowable load is 2/3 the plastic load Plastic criterion dependent ASME Twice Elastic Slope criterion has been shown to be inconsistent Often results in plastic load similar to limit load FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Shakedown Shakedown Shakedown analysis procedures are limited and not generally well understood Inelastic shakedown analysis is permissible but not widely used Incremental and bounding theorem approaches FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Education & Training Requirements Education & Training Requirements PD5500 and ASME VIII do not stipulate any particular education or training requirements for the designer EN13445 B and EN13445 C both stipulate that when using advanced analysis techniques: Due to the advanced methods applied, until sufficient in-house experience can be demonstrated, the involvement of an independent body, appropriately qualified in the field of DBA, is required in the assessment of the design (calculations) and the potential definition of particular NDT requirements. FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Education & Training Requirements Education & Training Requirements The Design by Analysis Manual (European Commission, DG- JRC/IAM, Petten, The Netherlands, 1999) Contains an extensive account of PV DBA An e-version is available on-line and free at: http://ped.eurodyn.com/jrc/design_by_analysis FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Use of DBA in Industry Use of DBA in Industry DBA tends to be used only when DBF is not possible Non-standard configurations Problem designs that do not satisfy DBF Tends to be restricted to organisations manufacturing advanced, high capitol cost designs Wider use limited by Cost of computer hardware, software and in-house expertise or Cost of qualified external consultancy FENET THEMATIC NETWORK COMPETITIVE AND SUSTAINABLE GROWTH (GROWTH) PROGRAMME Conclusion Conclusion FE based DBA is long established in PVD Procedures were innovative when implemented but now lag routine analysis capabilities Advanced analysis methods simplify the design process Code guidelines need to be improved for Inelastic analysis including large deformation and strain hardening effects Shakedown analysis Adopting advanced analysis methods has implications for Education & Training of designers
