Abstract: This work describes an investigation on the effect of filler metals diameter to weld joint, and low alloy carbon steel A516 Grade 70 is the base metal. Commercially SA516 Grade70 is frequently used for the manufacturing of pressure vessels, boilers and storage tank, etc. In fabrication industry, the hardness of the weld joint is between the important parameters to check, after heat treatment of the weld. Submerged arc welding (SAW) is used with two filler metal diameters, and this solid wire electrode is used for SAW non-alloy and for fine grain steels (SFA 5.17). The different diameters were selected (Ø = 2.4 mm and Ø = 4 mm) to weld two specimens. Both specimens were subjected to the same preparation conditions, heat treatment, macrograph, metallurgy micrograph, and micro-hardness test. Samples show almost similar structure with highest hardness. It is important to indicate that the thickness used in the base metal is 22 mm, and all specifications, preparation and controls were according to the ASME section IX. It was observed that two different filler metal diameters performed on two similar specimens demonstrated that the mechanical property (hardness) increases with decreasing diameter. It means that even the heat treatment has the same effect with the same conditions, the filler metal diameter insures a depth weld penetration and better homogenization. Hence, the SAW welding technique mentioned in the present study is favorable to implicate for the industry using the small filler metal diameter.
Abstract: In order to respond the policy decision of non-nuclear homes, Tai Power Company (TPC) will provide the decommissioning project of Kuosheng Nuclear power plant (KSNPP) to meet the regulatory requirement in near future. In this study, the computational fluid dynamics (CFD) methodology has been employed to develop a flow prediction model for boiling water reactor (BWR) with upper pool under decommissioning stage. The model can be utilized to investigate the flow behavior as the vessel combined with upper pool and continuity cooling system. At normal operating condition, different parameters are obtained for the full fluid area, including velocity, mass flow, and mixing phenomenon in the reactor pressure vessel (RPV) and upper pool. Through the efforts of the study, an integrated simulation model will be developed for flow field analysis of decommissioning KSNPP under normal operating condition. It can be expected that a basis result for future analysis application of TPC can be provide from this study.
Abstract: Commercially SA 516 Grade 70 is frequently used for the manufacturing of pressure vessels, boilers and storage tanks etc. in fabrication industry. Heat input is the major parameter during welding that may bring significant changes in the microstructure as well as the mechanical properties. Different welding technique has different heat input rate per unit surface area. Materials with large thickness are dealt with different combination of welding techniques to achieve required mechanical properties. In the present research two schemes: Scheme 1: SMAW (Shielded Metal Arc Welding) & GTAW (Gas Tungsten Arc Welding) and Scheme 2: SMAW & SAW (Submerged Arc Welding) of hybrid welding techniques have been studied. The purpose of these schemes was to study hybrid welding effect on the microstructure and mechanical properties of the weldment, heat affected zone and base metal area. It is significant to note that the thickness of base plate was 12 mm, also welding conditions and parameters were set according to ASME Section IX. It was observed that two different hybrid welding techniques performed on two different plates demonstrated that the mechanical properties of both schemes are more or less similar. It means that the heat input, welding techniques and varying welding operating conditions & temperatures did not make any detrimental effect on the mechanical properties. Hence, the hybrid welding techniques mentioned in the present study are favorable to implicate for the industry using the plate thickness around 12 mm thick.
Abstract: The present study focused on carrying out the creep analysis in an isotropic thick-walled composite cylindrical pressure vessel composed of aluminum matrix reinforced with silicon-carbide in particulate form. The creep behavior of the composite material has been described by the threshold stress based creep law. The values of stress exponent appearing in the creep law were selected as 3, 5 and 8. The constitutive equations were developed using well known von-Mises yield criteria. Models were developed to find out the distributions of creep stress and strain rate in thick-walled composite cylindrical pressure vessels under internal pressure. In order to obtain the stress distributions in the cylinder, the equilibrium equation of the continuum mechanics and the constitutive equations are solved together. It was observed that the radial stress, tangential stress and axial stress increases along with the radial distance. The cross-over was also obtained almost at the middle region of cylindrical vessel for tangential and axial stress for different values of stress exponent. The strain rates were also decreasing in nature along the entire radius.
Abstract: Polymeric composites are being increasingly used as
repair material for repairing critical infrastructures such as building,
bridge, pressure vessel, piping and pipeline. Technique in repairing
damaged pipes is one of the major concerns of pipeline owners.
Considerable researches have been carried out on the repair of
corroded pipes using composite materials. This article attempts a
short review of the subject matter to provide insight into various
techniques used in repairing corroded pipes, focusing on a wide range
of composite repair systems. These systems including pre-cured
layered, flexible wet lay-up, pre-impregnated, split composite sleeve
and flexible tape systems. Both advantages and limitations of these
repair systems were highlighted. Critical technical aspects have been
discussed through the current standards and practices. Research gaps
and future study scopes in achieving more effective design
philosophy are also presented.
Abstract: A Multi-dimensional computational fluid dynamics
(CFD) two-phase model was developed with the aim to simulate
the in-core coolant circuit of a pressurized heavy water reactor
(PHWR) of a commercial nuclear power plant (NPP). Due to the
fact that this PHWR is a Reactor Pressure Vessel type (RPV),
three-dimensional (3D) detailed modelling of the large reservoirs of
the RPV (the upper and lower plenums and the downcomer) were
coupled with an in-house finite volume one-dimensional (1D) code
in order to model the 451 coolant channels housing the nuclear fuel.
Regarding the 1D code, suitable empirical correlations for taking into
account the in-channel distributed (friction losses) and concentrated
(spacer grids, inlet and outlet throttles) pressure losses were used.
A local power distribution at each one of the coolant channels
was also taken into account. The heat transfer between the coolant
and the surrounding moderator was accurately calculated using a
two-dimensional theoretical model. The implementation of subcooled
boiling and condensation models in the 1D code along with the use
of functions for representing the thermal and dynamic properties of
the coolant and moderator (heavy water) allow to have estimations
of the in-core steam generation under nominal flow conditions for a
generic fission power distribution. The in-core mass flow distribution
results for steady state nominal conditions are in agreement with the
expected from design, thus getting a first assessment of the coupled
1/3D model. Results for nominal condition were compared with
those obtained with a previous 1/3D single-phase model getting more
realistic temperature patterns, also allowing visualize low values of
void fraction inside the upper plenum. It must be mentioned that the
current results were obtained by imposing prescribed fission power
functions from literature. Therefore, results are showed with the aim
of point out the potentiality of the developed model.
Abstract: The design, manufacture, and operation of thin-walled
pressure vessels must be based on maximum safe operating pressure
and an adequate factor of safety (FoS). This research paper first
reports experimental evaluation of longitudinal and hoops stresses
based on working pressure as well as maximum pressure; and then
includes a critical study of factor of safety (FoS) in the design of a
glass fiber pressure vessel. Experimental work involved the use of
measuring instruments and the readings from pressure gauges.
Design calculations involved the computations of design stress and
FoS; the latter was based on breaking strength of 55 MPa for the
glass fiber (pressure-vessel material). The experimentally determined
FoS value has been critically compared with the general FoS allowed
in the design of glass fiber pressure vessels.
Abstract: This paper presents the design analysis of saddle
support of a horizontal pressure vessel. Since saddle have the vital
role to support the pressure vessel and to maintain its stability, it
should be designed in such a way that it can afford the vessel load
and internal pressure of the vessel due to liquid contained in the
vessel. A model of horizontal pressure vessel and saddle support is
created in ANSYS. Stresses are calculated using mathematical
approach and ANSYS software. The analysis reveals the zone of high
localized stress at the junction part of the pressure vessel and saddle
support due to operating conditions. The results obtained by both the
methods are compared with allowable stress value for safe designing.
Abstract: In this paper, thick walled Cylindrical tanks or tubes
made of functionally graded material under internal pressure and
temperature gradient are studied. Material parameters have been
considered as power functions. They play important role in the
elastoplastic behavior of these materials. To clarify their role,
different materials with different parameters have been used under
temperature gradient. Finally, their effect and loading effect have
been determined in first yield point. Also, the important role of
temperature gradient was also shown. At the end the study has been
results obtained from changes in the elastic modulus and yield stress.
Also special attention is also given to the effects of this internal
pressure and temperature gradient in the creation of tensile and
compressive stresses.
Abstract: Flow forming is widely used in many industries, especially in defence technology industries. Pressure vessels requirements are high precision, light weight, seamless and optimum strength. For large pressure vessels, flow forming by 3 rollers machine were used. In case of long range rocket motor case flow forming and welding of pressure vessels have been used for manufacturing. Due to complication of welding process, researchers had developed 4 meters length pressure vessels without weldment by 4 rollers flow forming machine. Design and preparation of preform work pieces are performed. The optimization of flow forming parameter such as feed rate, spindle speed and depth of cut will be discussed. The experimental result shown relation of flow forming parameters to quality of flow formed tube and prototype pressure vessels have been made.
Abstract: In the article, the wire winding process for the reinforcement of a pressure vessel frame has been studied. Firstly, the importance of the wire winding method has been explained. The main step in the design process is the methodology axial force control and wire winding process. The hot isostatic press and wire winding process introduce. With use the equilibrium term in the pressure vessel and frame, stresses in the frame wires analyzed. A case study frame was studied to control axial force in the hot isostatic press. Frame and them wires simulated then friction effect and wires effect in elastic yoke in the simulation model considered. Then theoretical and simulate resulted compare and vessel pressure import to frame because we assurance wire wounded not received to yielding point.
Abstract: In the article, the wire winding process for the reinforcement of a pressure vessel frame has been studied. Firstly, the importance of the wire winding method has been explained and literature was reviewed. The main step in the design process is the methodology axial force control. The frame consists of two columns and two semi-cylinders with circumstantial wires. A computational algorithm has been presented based on the governing equations and relations on stress-strain behavior of the whole system of the frame. Then a case study was studied to calculate the frame dimensions and wire winding procedure.
Abstract: The effect of autofrettage process in strain hardened
thick-walled pressure vessels has been investigated theoretically by
finite element modeling. Equivalent von Mises stress is used as yield
criterion to evaluate the optimum autofrettage pressure and the
optimum radius of elastic-plastic junction. It has been observed that
the optimum autofrettage pressure increases along with the working
pressure. For two different working pressures, the effect of the ratio
of outer to inner radius (b/a=k) value on the optimum autofrettage
pressure is also noticed. The Optimum autofrettage pressure solely
depends on K value rather than on the inner or outer radius.
Furthermore, percentage reduction of von Mises stresses is compared
for different working pressures and different k values. Maximum von
Mises stress developed at different autofrettage pressure is equated
for elastic perfectly plastic and elastic-plastic material with different
slope of strain hardening segment. Cylinder material having higher
slope of strain hardening segment provides better benedictions in the
autofrettage process.
Abstract: Carbon steel is used in boilers, pressure vessels, heat
exchangers, piping, structural elements and other moderatetemperature
service systems in which good strength and ductility are
desired. ASME Boiler and Pressure Vessel Code, Section II Part A
(2004) provides specifications of ferrous materials for construction of
pressure equipment, covering wide range of mechanical properties
including high strength materials for power plants application.
However, increased level of springback is one of the major problems
in fabricating components of high strength steel using bending.
Presented work discuss the springback simulations for five different
steels (i.e. SA-36, SA-299, SA-515 grade 70, SA-612 and SA-724
grade B) using finite element analysis of air V-bending. Analytical
springback simulations of hypothetical layered materials are
presented. Result shows that; (i) combination of the material property
parameters controls the springback, (ii) layer of the high ductility
steel on the high strength steel greatly suppresses the springback.
Abstract: An accurate optimal design of laminated composite
structures may present considerable difficulties due to the complexity
and multi-modality of the functional design space. The Big Bang
– Big Crunch (BB-BC) optimization method is a relatively new
technique and has already proved to be a valuable tool for structural
optimization. In the present study the exceptional efficiency of the
method is demonstrated by an example of the lay-up optimization
of multilayered anisotropic cylinders based on a three-dimensional
elasticity solution. It is shown that, due to its simplicity and speed,
the BB-BC is much more efficient for this class of problems when
compared to the genetic algorithms.
Abstract: Pressure vessels are usually operating at temperatures
where the conditions of linear elastic fracture mechanics are no
longer met because massive plasticity precedes crack propagation. In
this work the development of a surface crack in a pressure vessel
subject to bending and tension under elastic-plastic fracture
mechanics conditions was investigated. Finite element analysis was
used to evaluate the hydrostatic stress, the J-integral and crack
growth for semi-elliptical surface-breaking cracks. The results
showed non-uniform stress triaxiality and crack driving force around
the crack front at large deformation levels. Different ductile crack
extensions were observed which emphasis the dependent of ductile
tearing on crack geometry and type of loading. In bending the crack
grew only beneath the surface, and growth was suppressed at the
deepest segment. This contrasts to tension where the crack breaks
through the thickness with uniform growth along the entire crack
front except at the free surface. Current investigations showed that
the crack growth developed under linear elastic fracture mechanics
conditions will no longer be applicable under ductile tearing
scenarios.
Abstract: The development of shape and size of a crack in a
pressure vessel under uniaxial and biaxial loadings is important in
fitness-for-service evaluations such as leak-before-break. In this
work finite element modelling was used to evaluate the mean stress
and the J-integral around a front of a surface-breaking crack. A
procedure on the basis of ductile tearing resistance curves of high and
low constrained fracture mechanics geometries was developed to
estimate the amount of ductile crack extension for surface-breaking
cracks and to show the evolution of the initial crack shape. The
results showed non-uniform constraint levels and crack driving forces
around the crack front at large deformation levels. It was also shown
that initially semi-elliptical surface cracks under biaxial load
developed higher constraint levels around the crack front than in
uniaxial tension. However similar crack shapes were observed with
more extensions associated with cracks under biaxial loading.
Abstract: In pressure vessels contain hydrogen, the role of
hydrogen will be important because of hydrogen cracking problem. It
is difficult to predict what is happened in metallurgical field spite of a
lot of studies have been searched. The main role in controlling the
mass diffusion as driving force is related to stress. In this study, finite
element analysis is implemented to estimate material-s behavior
associated with hydrogen embrittlement. For this purpose, one model
of a pressure vessel is introduced that it has definite boundary and
initial conditions. In fact, finite element is employed to solve the
sequentially coupled mass diffusion with stress near a crack front in a
pressure vessel. Modeling simulation intergrarnular fracture of AISI
4135 steel due to hydrogen is investigated. So, distribution of
hydrogen and stress are obtained and they indicate that their
maximum amounts occur near the crack front. This phenomenon is
happened exactly the region between elastic and plastic field.
Therefore, hydrogen is highly mobile and can diffuse through crystal
lattice so that this zone is potential to trap high volume of hydrogen.
Consequently, crack growth and fast fracture will be happened.