Fatigue Analysis Seminar

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The document discusses fatigue analysis procedures for pressure vessels under cyclic loading conditions.

Cyclic service refers to when a vessel is subjected to repeated loading that could cause failure by the development of a progressive fracture.

Fatigue failure can occur with little warning and damage is cumulative and normally unrecoverable.

PRESSURE VESSELS

PRESENTED BY DUG-GYU PARK.


Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
TABLE OF CONTENTS
1. DEFINITION OF CYCLIC SERVICE
2. ALTERNATING STRESS
3. FATIGUE FAILURE
4. ASSUMPTIONS ON AD-160.2
5. AD 160.2 OF DIV. 2
6. USER’S DESIGN SPECIFICATION
7. FATIGUE ANALYSIS PROCEDURE
8. FATIGUE ANALYSIS BY FE/PIPE
9. FINITE ELEMENT ANALYSIS BY ANSYS
10. SAMPLE OF FATIGUE ANALYSIS
11. SPECIAL CONSIDERRATIONS

Pressure Vessel Technical Forum


Mechanical Discipline of Bantrel
1. DEFINITION OF
CYCLIC SERVICE
When a vessel is subjected to repeated
loading that could cause failure by the
development of a progressive fracture, the
vessel is in cyclic service.
Fatigue analysis is not necessary if the
operating conditions of the vessel during its
life time can satisfy either condition A or
condition B of ASME Section VIII, Division
2, paragraph AD-160.2.

Pressure Vessel Technical Forum


Mechanical Discipline of Bantrel
1. DEFINITION OF
CYCLIC SERVICE
ASME Code, Section VIII, Division 1,
does not specifically require the design of
vessels in cyclic service.
ASME Code, Section VIII, Division 2 is
to be used to determine whether a service
is “cyclic”, even though the vessel may be
designed and constructed to ASME
Section VIII, Division 1 or another code.

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1.1 STRESS CATEGORIES AND
LIMITS OF STRESS INTENSITY

S12= 1 - 2
S23= 2 - 3
S31= 3 - 1

S= Max (|S12|, |S23|, |S31|)

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2. ALTERNATING STRESS

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Mechanical Discipline of Bantrel
3. FATIGUE FAILURE
Failure due to fatigue
may occur with little or
no warning.
Periods of rest with the
fatigue stress removed
will not lead to any
healing or recovery.
Damage once done
during the fatigue
process is cumulative
and normally
unrecoverable.

Pressure Vessel Technical Forum


Mechanical Discipline of Bantrel
ASSUMPTIONS ON AD-160.2

The worst geometrical stress


concentration factor to be considered is 2.
The concentration factor of 2 occurs at a
point where the nominal stress is 3Sm,
the highest allowable value of primary-
plus-secondary stress.
All significant pressure cycles and
thermal cycles have the same stress
ranges as the most severe cycle.
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
ASSUMPTIONS ON AD-160.2

The highest stress produced by a pressure


cycle does not coincide with the highest
stress produced by a thermal cycle.
The calculated stress produced by a
temperature difference δT between two
points does not exceed 2 EαδT, but the
peak stress is raised to 4EαδT.

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Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2
Annual shutdown and unplanned shutdown
(Consider 1 shutdown in a year. Therefore
Minimum tensile total cycles for 40 years of plant will be 40)
strength not exceeding Unplanned shutdown requiring full
80,000 psi depressurization, during first year of
Number of cycles of types operation do not exceed 24 @ 2 per month.
of a)+ b)+ c)+ d) does not Unplanned shutdown requiring full
exceed 1000 depressurization, after the first year of
operation do not exceed 1 per year. (Total-
39)
a) The expected Unplanned shutdown requiring full automatic
depressurization after the first year of
(design) number operation. Allowing 1 cycle for 2 cases (Fire
of full-range case and Emergency Shutdown). 2 per year
(Total-78)
pressure cycle.
Total type (a) pressure cycles are therefore
40+24+39+78=181
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2

b) The expected number of


Based on normal operating
operating pressure condition, operates at a certain
cycles in which the pressure and variation does not
range of pressure exceed 20% of design pressure.
variation exceeds 20% Hence cycle due to operating
of design pressure. condition is 0.

Pressure Vessel Technical Forum


Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2
c)The effective number of
changes in metal
temperature between any
two adjacent points.

Adjacent points are


defined as follows: Cooldown during planned and
Shells and Dished unplanned shutdown.
Heads, (For example Metal
L=2.5*SQRT (Rt) Temperature Differential 151
Flat Plates to 250, Factor
FACTOR 4.
L= 3.5*a (a=radius Total type (C) cycles therefore
of hot spot) are estimated to be 181*4=724

Pressure Vessel Technical Forum


Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2

d) The number of temperature


cycles for components involving
welds between materials having
different coefficients of
expansion.
Type of material.

For cycles to type (a), plus Type (b), plus Type (c),
plus type (d) does not exceed 1000, as follows:
181+0+724+0=905 < 1000
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2

CODE CASE 2306

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Mechanical Discipline of Bantrel
5. AD 160.2 OF DIV.2
c) Checking that the
temperature difference
between adjacent two
points is below Sa/(2E)

Adjacent points are defined


as follows: d) Checking that the
Shells and Dished Heads, temperature variation zone
L=2.5*SQRT (Rt) of the portion made of
Flat Plates materials having different
elastic coefficients and
L= 3.5*a (a=radius of expansion coefficients is
hot spot) below
Sa/2(E1-E2)
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
6. USER’S DESIGN
SPECIFICATION

ASME CODE SEC. VIII, DIV.2


SPECIFY THE OBLIGATION OF
THE USER TO SUBMIT USER’S
DESIGN SPECIFICATION
CERTIFIED BY A REGISTERED
PROFESSIONAL ENGINEER.

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6. USER’S DESIGN
SPECIFICATION
The specification consists of the following.
Operating condition (temperature and
pressure)
Necessity of fatigue analysis
External loading conditions
Other detailed data necessary for
designing the pressure vessels

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SAMPLE FOR USER’S
DESIGN SPECIFICATION

User’s Design Specification

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7. FATIGUE ANALYSIS
Start PROCEDURE 1
Alternating Stress
Sizing Calculation for
Intensity
Each Component Salt ij=0.5 S ij

Detailed Calculation for Allowable Number of


Each Transient Cycles

Stress Intensity
Usage Factor
Calculation
Principal Stress
Intensity Calculation NO
S ij=i - j Design Change U<1.0
YES
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1 Stop
Mechanical Discipline of Bantrel
7. FATIGUE ANALYSIS
PROCEDURE
The stress calculation for the fatigue evaluation
is done based on the elasticity.
For the local discontinuity in a structure, the
evaluation is made by using the stress
concentration factor theoretically obtained.
Under Div.2, the stress indexes for calculation
of the maximum stress value when the internal
pressure is applied on the nozzle are given in
Article 4-6 and AD 560.7.
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
7. FATIGUE ANALYSIS
PROCEDURE
The stress calculation is made for each
transient against the pressure, bending
moment, shear force, thermal loading
and other loadings.
These transients include those during
operating period, namely at the testing,
start-up, normal operation and shut-
down.
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
7. FATIGUE ANALYSIS
PROCEDURE
The stress intensity when the stress carries periodically
because of cyclic operations is called “alternating stress
intensity”.
 To obtain the principal stresses from the stress value
obtained for each transient.
 To obtain the stress differences for each transient from
thus obtain principal stress.
 To select the values of each extreme the variation range
from the stress differences at all transient in the cycle.
 The magnitude of variation is expressed as a half of
stress difference.

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7. FATIGUE ANALYSIS
PROCEDURE
 To obtain the corresponding allowable
number of repetition N1, N2, N3…from
the designed fatigue curve for each major
variation cycle.
 To divide the specified number of
repetition to obtain the usage factor
Ui=ni/Ni (i=1,2,…)
 The cumulative usage factor U being the
total of the usage factor shall be below 1.
Pressure Vessel Technical Forum
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7. FATIGUE ANALYSIS
PROCEDURE

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7. FATIGUE ANALYSIS
PROCEDURE

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8. FE ANALYSIS FOR
NOZZLE BY FE/PIPE
FE/PIPE
INPUT

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8. FE ANALYSIS FOR
NOZZLE BY FE/PIPE
Pl+Pb+Q+F Sa
FE/PIPE OUTPUT Primary+Secondary+Peak (Inner)
Load Case 4 18,665 psi < Sa 41,425 psi
Stress Concentration Factor = 1.350
Strain Concentration Factor = 1.000
Cycles Allowed for this Stress =
113520.1 45%
"B31" Fatigue Stress Allowable =
50000.0
Markl Fatigue Stress Allowable =
41701.0
Plot Reference: 12) Pl+Pb+Q+F < Sa
(EXP,Inside) Case 4
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
8. FE ANALYSIS FOR
NOZZLE BY FE/PIPE
FE/PIPE OUTPUT Nozzle 1 Next to Shell Pl+Pb+Q+F
Primary+Secondary+Peak (Inner) Load
Case 4 15,045 psi < Sa 41,425 psi
Stress Concentration Factor = 1.350 Strain
Concentration Factor = 1.000
Cycles Allowed for this Stress = 261131.4
36%
"B31" Fatigue Stress Allowable = 42750.0
Markl Fatigue Stress Allowable = 41701.0
Plot Reference: 12) Pl+Pb+Q+F < Sa
(EXP,Inside) Case 4

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9. FINITE ELEMENTANALYSIS
BY ANSYS

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9. FINITE ELEMENTANALYSIS
BY ANSYS
INPUT OUTPUT

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10. SAMPLE OF FATIGUE
ANALYSIS
Design Data

Shell inside diameter: 3.2 m


Shell overall length: 13.4 m
Support skirt height: 4.65 m
Material: SA 516 grade 70

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10. SAMPLE OF FATIGUE
ANALYSIS
Load Condition
Pressure Temperature Cycles
(Kg/mm2) (deg. C)
Shop test 0.105 21.11 5
Field test 0.0975 21.11 30
Emergency 0.04 145 1000
Shutdown 0.047 208
Operation F.V. 105 30000
0.048 125
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10. SAMPLE OF FATIGUE
ANALYSIS

Nozzle load for operating cycles


P=-4082 Kg
M=2661453 Kg-mm

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10. SAMPLE OF FATIGUE
ANALYSIS

Wind Load
P1=0.00176 Kg/mm2 0~9.1 m
P2=0.00234 Kg/mm2 9.1~12.25 m
Seismic Load
Seismic load by ANSI A 58.1

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10. SAMPLE OF FATIGUE
ANALYSIS
The analysis is performed using Finite Element Analysis
computer program ANSYS.
In summary, the following five regions are found to be
most dangerous regions.
Region I: bottom of nozzle (Max. Stress Amplitude under
operation)
Region II: neck region (Max. Stress under Shutdown,
Operation & Seismic Load)
Region III: top shell region (Max. Stress under Shop &
Field Tests)
Region IV: vessel-skirt joint region (Joint Part)
Region V: bottom of skirt (Max. Stress under Pure Wind)

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10. SAMPLE OF FATIGUE
ANALYSIS

Stress Intensity, Stress Amplitude and


Fatigue Life
Shop Test (P=0~0.105 Kg/mm2, T=21.11 C)
SI Sr Sa Sa’ N
Region I 21.4 21.4 10.7 11.5 205630
Region II 21.2 21.2 10.6 11.4 216257
Region III 41.3 41.3 20.7 22.2 18736

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CALCULATION OF USAGE
FACTOR, REGION I
N n n/N(Ui)
Shop Test 205630 5 0.0000243
Field Test 282335 30 0.000106
Shutdown 106 1000 0.001
Operation w/o 165166 3000 0.182
Wind & Seismic
Operation with 167191 3000 0.185
Wind Load
Operation with 96932 3000 0.311
Seismic load
Total Usage factor: U=SUM(Ui)
Operation with Seismic Load U=0.183
Operation with Wind Load U=0.186
Operation with Seismic Load U=0.312

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CALCULATION OF USAGE
FACTOR, REGION II
N n n/N(Ui)
Shop Test 216257 5 0.0000231
Field Test 299818 30 0.0001
Shutdown 106 1000 0.001
Operation w/o 3884420 3000 0.078
Wind & Seismic
Operation with 374751 3000 0.08005
Wind Load
Operation with 374751 3000 0.08005
Seismic load
Total Usage factor: U=SUM(Ui)
Operation with Seismic Load U=0.0791
Operation with Wind Load U=0.0812
Operation with Seismic Load U=0.0812

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CALCULATION OF USAGE
FACTOR, REGION III
N n n/N(Ui)
Shop Test 18736 5 0.0000267
Field Test 23533 30 0.00127
Shutdown 106 1000 0.001
Operation w/o 106 3000 0.03
Wind & Seismic
Operation with 106 3000 0.03
Wind Load
Operation with 106 3000 0.03
Seismic load
Total Usage factor: U=SUM(Ui)
Operation with Seismic Load U=0.0325
Operation with Wind load U=0.0325
Operation with Seismic Load U=0.0325
Pressure Vessel Technical Forum
Mechanical Discipline of Bantrel
11. SPECIAL CONSIDERRATIONS FOR
PRESSURE VESSELS IN CYCLIC SERVICE

Threaded connections are not permitted.


Pad type nozzle reinforcement is not
allowed.
All nozzles in Division 1 vessels shall have
reinforcement calculations and strength-of-
attachment welding calculations performed,
regardless of size.
Small diameter nozzles shall be long-weld-
neck flanges where possible.
Pressure Vessel Technical Forum
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11. SPECIAL CONSIDERRATIONS FOR
PRESSURE VESSELS IN CYCLIC SERVICE

All welds shall be free of undercuts.


All attachment welds shall be full
penetration welds.
All fillet welds shall be contoured into the
pressure part material.
Vertical unit shall be supported on skirts.
The center-lines of the skirt and corroded
shell plate (bottom course) shall be
approximately coincident.
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QUESTIONS

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