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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

CONTENTS

1 INTRODUCTION

2 FATIGUE LIFE CALCULATION

2.1 DESIGN DATA FOR FATIGUE ANALYSIS

2.2 FEM MODEL & BOUNDARY CONDITION FOR THERMAL ANALYSIS AROUND TOP DISHED
END

2.3 RESULTS FROM THERMAL ANALYSIS AROUND TOP DISHED END

2.4 FEM MODEL AND BOUNDARY CONDITION FOR FATIGUE STRESS ANALYSIS AROUND TOP
DISHED END

2.5 RESULTS FROM FATIGUE STRESS ANALYSIS AROUND TOP DISHED END AND FATIGUE
LIFE CALCULATION

2.6 FEM MODEL & BOUNDARY CONDITION FOR THERMAL ANALYSIS AROUND BOTTOM
DISHED END

2.7 RESULTS FROM THERMAL ANALYSIS AROUND BOTTOM DISHED END

2.8 FEM MODEL AND BOUNDARY CONDITION FOR FATIGUE STRESS ANALYSIS AROUND
BOTTOM DISHED END

2.9 RESULTS FROM FATIGUE STRESS ANALYSIS AROUND BOTTOM DISHED END AND
FATIGUE LIFE CALCULATION

2.10 CONCLUSIONS FROM FATIGUE LIFE CALCULATION

3 STRESS CHECK FOR NOZZLES N1/A1 AND N2

3.1 DESIGN DATA FOR STRESS ANALYSIS

3.2 FEM MODEL AND BOUNDARY CONDITIONS FOR STRESS ANALYSIS AROUND NOZZLE
A1/N1

3.3 RESULTS FROM STRESS ANALYSIS FOR NOZZLE A1/N1

3.4 FEM MODEL AND BOUNDARY CONDITIONS FOR STRESS ANALYSIS AROUND NOZZLE N2

3.5 RESULTS FROM STRESS ANALYSIS FOR NOZZLE N2

3.6 STRESSES IN OTHER NOZZLES

3.7 FATIGUE LIFE CALCULATION FOR FLANGE AND FLANGE BOLTING

3.8 FATIGUE ANALYSIS FOR INTERNAL DIS TRIBUTOR PIPE FOR NOZZLE N1 & N2

3.9 FATIGUE CALCULATION FOR ATTACHMENTS

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

3.10 FATIGUE CALCULATION FOR BED SUPPORT COMPONENTS

3.11 STRESSES AROUND WELDS

4 CONCLUSIONS

5 REFERENCES

LIST OF TABLES

TABLE 1. MATERIAL DATA

LIST OF FIGURES

FIGURE 1. FEA MODEL FOR TOP DISHED END

FIGURE 2.TEMPERATURE DISTRIBUTION AROUND TOP DISHED END

FIGURE 3.DISPLACEMENT PROFILE FOR TOP DISHED END (THERMAL AND PRESSURE LOAD )

FIGURE 4.MAXIMUM SHEAR STRESS CONTOUR FOR TOP DISHED END (THERMAL AND PRESSURE
LOAD)

FIGURE 5.FEA MODEL FOR BOTTOM DISHED END

FIGURE 6.TEMPERATURE DISTRIBUTION AROUND BOTTOM DISHED END

FIGURE 7.DISPLACEMENT PROFILE FOR BOTTOM DISHED END (THERMAL AND PRESSURE LOAD
)

FIGURE 8.MAXIMUM SHEAR STRESS CONTOUR FOR BOTTOM DISHED END (THERMAL AND
PRESSURE LOAD)

FIGURE 9.DISPLACEMENT PROFILE FOR TOP DISHED END (THERMAL, PRESSURE AND NOZZLE
LOAD)

FIGURE 10.MAXIMUM SHEAR STRESS CONTOUR FOR TOP DISHED END (THERMAL , PRESSURE
AND NOZZLE LOAD)

FIGURE 11.DISPLACEMENT PROFILE FOR BOTTOM DISHED END (THERMAL , PRESSURE AND
NOZZLE LOAD)

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FIGURE 12.MAXIMUM SHEAR STRESS CONTOUR FOR BOTTOM DISHED END (THERMAL ,
PRESSURE AND NOZZLE LOAD)

FIGURE 13.MAXIMUM SHEAR STRESS CONTOUR FOR SKIRT TO BOTTOM DISHED END JOINT

(THERMAL, PRESSURE AND NOZZLE LOAD)

FIGURE 14 MAXIMUM SHEAR STRESS N1 NOZZLE (NOZZLE LOCAL LOADS)

FIGURE 15 MAX. SHEAR STRESS ON N2 NOZZLE ( NOZZLE LOCAL LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

1 INTRODUCTION

Three number of Adsorbers (4C-1301 A/B/C) are manufactured for WOODSIDE ENERGY

LIMITED, AUSTRALIA as per AS1210 -1997. Each of the equipment is vertical with inside

diameter of 4000 mm, shell thickness of 109 mm and top / bottom dished end thickness of 58 mm.

Each Adsorber undergoes 1350 minute operating cycle consisting of temperature ramp-up/ramp-

down in the range of 21°C to 320°C, and corresponding internal pressure variation from 5780 kPaa

to 5370 kPaa .The temperature fluctuation take place in not less than 20 minutes time. Adsorbers

are externally insulated.

Mechanical design of vessel, nozzles is required to consider the effects of above mentioned

thermally induced cyclic stresses. Design life of vessel is required to be 20 years.

The present report covers following calculations –

• Fatigue life calculations for vessel shell, dished ends, nozzles N1/A1 (36”)&N2 (24”) for above

thermal, pressure cycle using FEA module of NISA version 9.0 software.

• Stress check for nozzles N1/A1 & N2 for thermal, internal pressure and nozzle local loads

using NISA software.

2 FATIGUE LIFE CALCULATION

This analysis is done in following two steps:

• Transient thermal analysis to arrive at time step corresponding to severest temperature gradient

across thickness of various components.

• Peak stress and fatigue life calculation for above time step.

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2.1 DESIGN DATA FOR FATIGUE ANALYSIS

Adsorber is undergoing the following 1350 min. operating cycle

Adsorption Duration 900 min.

Regeneration heating Duration 200 min.(including 20 min. ramp-up)

Regeneration cooling Duration 100 min.(including 10 min. ramp-down)

Standby Duration 150 min.

The maximum temperature ramp up at the regeneration gas heater outlet is from 21°c to 320°c

in not less than 0.33hr and vice versa for maximum temperature ramp down. The internal

pressure varies from 5780 kPaa to 5370 kPaa.

Nozzle local loads are varying as per the following. These loads are assumed to include the

thermal movement of piping attached & as a result no additional constraint are required.

Nozzle Forces in KN Moments in KNm

mark
FL FA FC MC MT ML
A1(36”) +/-24 +/-43 +/-23 +/-76 +/-66 +/-43
N2(24”) +/-20 +/-34 +/-145 +/-56 +/-41 +/-185

The design life of vessel is required to be 20 years, subject to above cycle s.

The material data is as given in table 1.

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2.2 FEM MODEL & BOUNDARY CONDITION FOR THERMAL ANALYSIS AROUND TOP DISHED

END

Top section of the vessel including nozzle N1/A1, dished end and shell portion is modeled as shown

in Fig.1. All dimensions are taken in corroded condition. The model is having 1000 second order,

quadrilateral axisymmetric solid elements and 3357 nodes.

The model is subjected to following boundary conditions and loading

• For all external insulated surfaces, heat flux (q) =0.

• Temperature frames as follows –

Heating case: inside gas temperature of 320°C and initial vessel temperature of 21°C.

Cooling case: inside gas temperature of 21°C and initial vessel temperature of 320°C.

• Convective film heat transfer coefficients on inside surfaces is assumed as follows. These are

estimated based on KJV data sheet no. LNG1304/20/001 Rev.0.

Shell and dished end = 70 Kcal/hr m² °C (81.34 W/m²°K)

Nozzle = 125 Kcal/hr m² °C (145.25 W/m²°K)

• The temperature distribution is calculated at time steps as shown in following diagram

Heating Cooling Standby Adsorption

TEMP. 10s 100s 10s 100s

Timestep size

320°C

21°C

20m 33m 200m 233m 300m 450m 1350m -8-

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2.3 RESULTS FROM THERMAL ANALYSIS AROUND TOP DISHED END

Fig.2 Shows temperature distribution around top dished end at time step of 1300 seconds from

beginning of thermal ramp-down, as it gives maximum temperature gradient across thickness of

vessel.

2.4 FEM MODEL AND BOUNDARY CONDITION FOR FATIGUE STRESS ANALYSIS AROUND TOP

DISHED END

Same FEA model as that used for thermal analysis is used for stress analysis. The boundary

conditions used for stress analysis are as follows

• Displacement at bottom edge of model is restrained in axial direction.

• Separate runs are taken with temperature distribution at time steps of

10,1300,6600,13310,15600 seconds as obtained from thermal analysis is applied on nodes.

• Separate runs are taken with internal pressure of 5780 kPaa and 5370 kPaa is applied at 1300

and 10,6600,13310,15600 seconds respectively.

2.5 RESULTS FROM FATIGUE STRESS ANALYSIS AROUND TOP DISHED END AND FATIGUE

LIFE CALCULATION

Fig.3 shows typical deformation profile of the model under given loading at 1300 seconds. Fig. 4

shows typical maximum shear stress contours for the model at 1300 seconds.

Since the principle stress direction are varying with time, as per [3], clause SC2.2.2, following table

lists stress ranges at various time steps and at various locations. The stress ranges are calculated

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based on stress output at 1300 seconds as base case, as this gives highest combination for stress

ranges.

Stress range based on time step combination Maximum stress range

Location 10 s & 1300s 6600 s & 1300s 13310 s & 1300s 15600 s & 1300s
Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa
Noz.crotch
Node no. 94 12.53 122.9 7.03 69.0 25.07 245.9 22.48 220.5 25.07 245.9
Noz. Neck
Node no.106 5.02 49.2 4.01 39.3 9.62 94.4 7.32 71.8 9.62 94.4
Edge of pad
Node no.83 2.9 28.4 1.55 15.2 4.94 48.5 6.07 59.5 6.07 59.5
D’end to shell joint
Node no.48 3.49 34.2 2.11 20.7 6.02 59.1 6.68 65.5 6.68 65.5
Shell
Node no.31 4.82 47.3 2.96 29.0 9.76 95.7 8.27 81.1 9.76 95.7

As shown in above table, the maximum peak stress range in the model due to loading cycle is 25.07

Kg/mm² (245.9 MPa) around inner corner of nozzle A1/N1 & 3.88 Kg/mm² (38.09 MPa) at outer

corner to top dished end junction. To these stresses the fluctuating stress range due to noz. Local

loads (calculated separately) are added. The max. shear stresses due to nozzle local loads are

shown in figure 14.

The fatigue life calculations at critical locations are as follows –

Symbol Unit Inner corner Outer corner

Alternating stress range due to Srij1 Kg/mm²(MPa) 25.07(245.9) 3.88 (38.09)

pressure and temperature

Alt. Stress range due to nozzle Srij2 Kg/mm²(MPa) 0.47 (4.61) 2.66 (26.09)

loads

Total stress range Srij1+Srij2 Kg/mm²(MPa) 25.54 (250.54) 6.54 (64.15)

Alternating stress amplitude Salt=0.5x Srij Kg/mm²(MPa) 12.77 (125.27) 3.27 (32.09)

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Modulus of elasticity E Kg/mm²(MPa) 18249 (179022.7) 18249 (179022.7)

Modulus of elasticity on fatigue Egraph Kg/mm²(MPa) 21101 (207000) 21101 (207000)

curve

Corrected alternating stress Salt’ = Salt x Egraph Kg/mm²(MPa) 14.76 (144.85) 3.78 (37.09)

amplitude /E

Minimum tensile strength Rm Kg/mm²(MPa) 49.22 (482.8) 49.22 (482.8)

Fatigue life from fig.SC1.2.1 N Cycles 60,000 Infinite

Required fatigue life Nr Cycles 7,787 7,787

2.6 FEM MODEL & BOUNDARY CONDITION FOR THERMAL ANALYSIS AROUND BOTTOM

DISHED END

Bottom section of the vessel including nozzle N2, dished end, shell portion and skirt is modeled as

shown in Fig.5. All dimensions are taken in corroded condition .The model is having 2124 second

order, quadrilateral axisymmetric solid elements and 7393 nodes.

The model is subjected to following boundary conditions and loading

• For all external insulated surfaces, heat flux (q) =0.

• Temperature frames as follows –

Heating case: inside gas temperature of 320°C and initial vessel temperature of 21°C.

Cooling case: inside gas temperature of 21°C and initial vessel temperature of 320°C.

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• Convective film heat transfer coefficients on inside surfaces is assumed as follows. These are

estimated based on KBR data sheet no. LNG1304/20/001 Rev.0.

Shell and dished end = 70 Kcal/hr m² °C (81.34 W/m²°K)

Nozzle = 250 Kcal/hr m² °C (290.5W/m²°K)

Around skirt = 10 Kcal/hr m² °C (11.62W/m²°K)

• The temperature distribution is calculated at time steps as explained in section 2.2

2.7 RESULTS FROM THERMAL ANALYSIS AROUND BOTTOM DISHED END

Fig.6 Shows temperature distribution around bottom dished end at time step of 1220 seconds from

beginning of thermal ramp-up, as it gives maximum temperature gradient across thickness of

vessel.

2.8 FEM MODEL AND BOUNDARY CONDITION FOR FATIGUE STRESS ANALYSIS AROUND

BOTTOM DISHED END

Same FEA model as that used for thermal analysis is used for stress analysis. The boundary

conditions used for stress analysis are as follows

• Displacement at bottom edge of model is restrained in all directions.

• Separate runs are taken with temperature distribution at time steps of

10,1220,6600,13200,15600 seconds from beginning of thermal ramp-up as obtained from

thermal analysis is applied on nodes.

• Separate runs are taken with internal pressure of 5780 kPaa and 5370 kPaa is applied at 1220

and 10,6600,13200,15600 seconds respectively

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2.9 RESULTS FROM FATIGUE STRESS ANALYSIS AROUND BOTTOM DISHED END AND

FATIGUE LIFE CALCULATION

Fig.7 shows typical deformation profile of the model under given loading at 1220 seconds. Fig.8

shows typical maximum shear stress contours for the model at 1220 seconds.

Since the principle stress direction are varying with time, as per [3], clause SC2.2.2, following table

lists stress ranges at various time steps and at various locations. The stress ranges are calculated

based on stress output at 1220 seconds as base case, as this gives highest combination for stress

ranges.

Stress range based on time step combination Maximum stress range

Location 10 s & 1220 s 6600 s & 1220 s 13220 s & 1220 s 15600 s & 1220 s 10 s & 6600 s
Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa
noz. Crotch *
node no.145 19.97 195.9057 10.99 107.8119 39.08 383.3748 36.68 359.8308 8.04 78.8724 39.08 383.3748
noz.neck
node no.154 5.68 55.7208 4.65 45.6165 10.93 107.2233 7.85 77.0085 1.31 12.8511 10.93 107.2233
pad end
node no.8 2.39 23.4459 1.26 12.3606 4.04 39.6324 5.13 50.3253 2.35 23.0535 5.13 50.3253
d'end to skirt junction
node no.25 2.93 28.7433 8.17 80.1477 4.38 42.9678 7.12 69.8472 9.06 88.8786 9.06 88.8786
shell to d'end junction
node no.122 2.92 28.6452 3.03 29.7243 6.46 63.3726 3.44 33.7464 2.51 24.6231 6.46 63.3726
shell to d'end junction
node no.105 4.92 48.2652 2.96 29.0376 8.344 81.85464 7.61 74.6541 2.74 26.8794 8.344 81.85464
skirt to d'end junction
node no.169 12.95 127.0395 21.08 206.7948 13.29 130.3749 14.02 137.5362 34.19 335.4039 34.19 335.4039

* since peak stress range is exceeding 3 Sm, membrane + bending stress range excluding peak

stress range is calculated & checked as follows

Membrane + bending stress

Location
range (Mpa)

Nozzle crotch 313.988

Allowable stress range (3*Sm) 3*119.68 = 359.04

As shown in above table the maximum peak stress range due to loading cycle is 39.08 Kg/mm²

(383.37 MPa) around inner corner of nozzle N2 & 14.52 Kg/mm² (142.44 MPa) about outer

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

corner and bottom dished end junction. To these stresses the fluctuating stress range due to nozzle

local loads (calculated separately) are added. The max. shear stress due to nozzle local loads are

shown in figure 15.

The fatigue life calculations at critical locations are as follows –

Symbol Unit Inner corner Outer corner

Alternating stress range due to Srij1 Kg/mm²(MPa) 39.08 (383.37) 14.52 (142.44)

pressure and temperature loads

Alt. Stress range due to nozzle Srij2 Kg/mm²(MPa) 1.68 (16.48) 13.6 (133.41)

loads

Total stress range Srij1+Srij2 Kg/mm²(MPa) 40.76 (399.85) 28.12 (275.85)

Alternating stress amplitude Salt=0.5x Srij Kg/mm²(MPa) 20.38 (199.92) 14.06 (137.92)

Modulus of elasticity E Kg/mm²(MPa) 18249 (179022.7) 18249 (179022.7)

Modulus of elasticity on fatigue Egraph Kg/mm²(MPa) 21101 (207000) 21101 (207000)

curve

Corrected alternating stress Salt’=SaltxEgrap Kg/mm²(MPa) 23.565 (231.17) 16.257 (159.48)

amplitude h/E

Minimum tensile strength Rm Kg/mm²(MPa) 49.22 (482.8) 49.22 (482.8)

Fatigue life from fig.SC1.2.1 N Cycles 10,300 40,500

Required fatigue life Nr Cycles 7,787 7,787

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2.10 CONCLUSIONS FROM FATIGUE LIFE CALCULATION

As seen from section 2.5 and 2.9 the fatigue life of vessel subjected to thermal cycle as per section

2.1 is observed to be 10,300 cycles, which is more than required 7,787 cycles.

3 STRESS CHECK FOR NOZZLES N1/A1 AND N2

The stresses around nozzles N1/A1 and N2 are checked for thermal, internal pressure and nozzle

local load using FEA. Special axisymmetric elements are used for this analysis, which allow for

application of non-axisymmetric loading. This is used to simulate axial force and circumferential

/longitudinal moments nozzle local loads. The stresses due to shear loads (i.e. longitudinal

/circumferential forces and torsional moment) are calculated separately using classical method.

These two stresses are superimposed algebraically to arrive at maximum stress intensity, which is

checked against code allowable limit.

3.1 DESIGN DATA FOR STRESS ANALYSIS

• Design pressure = 0.6728 Kg/mm² (6.6 MPa)

• Nozzle local loads as follows -

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

Nozzle Forces in KN Moments in KNm

mark
FL FA FC MC MT ML
A1(36”) +/-24 +/-43 +/-23 +/-76 +/-66 +/-43
N2(24”) +/-20 +/-34 +/-145 +/-56 +/-41 +/-185

• The material data is as given in table 1.

3.2 FEM MODEL AND BOUNDARY CONDITIONS FOR STRESS ANALYSIS AROUND NOZZLE

A1/N1

Same FEA model as that used for fatigue life calculations is used. The element type used allows

for application of non-axisymmetric loads as described in 3.1 earlier. The boundary conditions used

are as follows-

• Displacement at bottom edge of model is restrained in axial direction.

• Temperature distribution at time step of 1300 seconds as obtained from thermal analysis is

applied on nodes.

• Internal pressure of 0.6728 Kg/mm² (6.6 MPa)

• Nozzle longitudinal stress = 5.67 Kg/mm² (55.62 MPa)

• Loads due to FA, ML & MC are applied as equivalent pressure load on nozzle free face.

3.3 RESULTS FROM STRESS ANALYSIS FOR NOZZLE A1/N1

Fig.9 shows deformation profile of model under given loading.Fig.10 shows maximum shear stress

contour for model. The maximum stress is located at nozzle to dished end junction.

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

Calculations for stresses due to nozzle local loads FL, FC and MT on nozzle A1/N1 are as follows-

Description Symbol Value Unit

Mean radius at nozzle-head junction r 469.45 mm
Thickness (corroded) at nozzle-head junction t 76.1 mm
Longitudinal force FL 24 KN
Circumferential force FC 23 KN
Torsional Moment MT 66 KN-m
Nozzle Cross sectional Area = 2πrt A 224467.7 mm²
Nozzle sectional shear modulus = 4πr²t J 2.1075E+8 mm3
Shear stress due to FL = FL/A t1 0.0109 (0.107) Kg/mm² (MPa)
Shear stress due to FC = FC/A t2 0.0105 (0.103) Kg/mm² (MPa)
Shear stress due to MT = MT/J t3 0.0319 (0.313) Kg/mm² (MPa)
Max. shear stress = sqrt[(t1+t3)² + t2²] S 0.0441 (0.433) Kg/mm² (MPa)
Max. stress intensity = 2S SI 0.0882 (0.865) Kg/mm² (MPa)

The comparison of stresses with allowable limits at various locations is as follows –

Membrane + bending S.I.

Noz. Crotch Noz.neck Edge of pad D'end to shell junction Shell
Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa
Due to thermal, pressure and
28.66 281.15 7.36 72.20 13.67 134.10 19.47 191.00 17.31 169.81
nozzle loads
Due to nozzle local shear
0.09 0.87 0.09 0.87 0.09 0.87 0.09 0.87 0.09 0.87
loads
Total stress intensity 28.75 282.02 7.45 73.07 13.76 134.97 19.56 191.87 17.40 170.68
Allowable stress intensity 3xS=36.6 Kg/mm² (359.05 MPa)

3.4 FEM MODEL AND BOUNDARY CONDITIONS FOR STRESS ANALYSIS AROUND NOZZLE N2

Same FEA model as that used for fatigue life calculations is used. The element type used allows

for application of non-axisymmetric loads as described in 3.1 earlier. The boundary conditions used

are as follows-

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

• Displacement at bottom edge of model is restrained in all direction.

• Temperature distribution at time step of 1200 seconds from the beginning of thermal ramp-

down as obtained from thermal analysis is applied on nodes.

• Internal pressure of 0.6728 Kg/mm² (6.6 MPa)

• Longitudinal stress for nozzle = 4.41 Kg/mm² (43.26 MPa)

• Longitudinal stress for shell = 6.36 Kg/mm² (62.35 MPa)

• Loads due to FA, ML & MC are applied as equivalent pressure load on nozzle free face.

3.5 RESULTS FROM STRESS ANALYSIS FOR NOZZLE N2

Fig.11 shows deformation profile of model under given loading.Fig.12 shows maximum shear stress

contour for model. The maximum stress is located at nozzle to dished end junction.

Calculations for stresses due to nozzle local loads FL, FC and MT on nozzle N2 are as follows-

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

Description Symbol Value Unit

Mean radius at nozzle-head junction r 314.35 mm
Thickness (corroded) at nozzle-head junction t 62.3 mm
Longitudinal force FL 20 KN
Circumferential force FC 145 KN
Torsional Moment MT 41 KN-m
Nozzle Cross sectional Area = 2πrt A 123050 mm²
Nozzle sectional shear modulus = 4πr²t J 7.7362E+7 mm3
Shear stress due to FL = FL/A t1 0.0166 (0.163) Kg/mm² (MPa)
Shear stress due to FC = FC/A t2 0.120 (1.177) Kg/mm² (MPa)
Shear stress due to MT = MT/J t3 0.054 (0.530) Kg/mm² (MPa)
Max. shear stress = sqrt[(t2+t3)² + t1²] S 0.175 (1.717) Kg/mm² (MPa)
Max. stress intensity = 2S SI 0.35 (3.43) Kg/mm² (MPa)

The comparison of stresses with allowable limits at various locations is as follows –

Membrane + bending S.I.

Shell to d'end
Noz. Crotch Noz.neck Pad end D'end to skirt junction Shell to d'end junction skirt to d'end junction *
junction
Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa Kg/mm² MPa
Due to thermal, pressure
29.70 291.36 5.30 51.99 13.08 128.31 19.73 193.55 15.00 147.15 14.09 138.22 33.58 329.42
and nozzle loads
Due to nozzle local shear
0.35 3.43 0.35 3.43 0.35 3.43 0.35 3.43 0.35 3.43 0.35 3.43 0.35 3.43
loads
Total stress intensity 30.05 294.79 5.65 55.43 13.43 131.75 20.08 196.98 15.35 150.58 14.44 141.66 33.93 332.85
Allowable stress intensity 3xS=36.6 Kg/mm² ( 359.05 MPa)

(* Stresses taken at 6600 seconds from start of temperature ramp-up)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

3.6 STRESSES IN OTHER NOZZLES :

The other nozzle stresses are calculated by stress index method given in (article 4-6 of ASME sect.

VIII div.2) as shown below.

Induced stress range

*Max. stress Sa'
near non-integral Sa Fatigue Required
range Time **Stress index attachments (S (Sa x 207E3 /
Sr. no. Nozzle Location (S induced life life
(S range) combinition (SCF) 179.02E3)
induced=S range x /2) (Mpa) (Cycles) (Cycles)
(Mpa) SCF) (Mpa) (Mpa)
1 N3A/B shell 48.85 13220 & 1220 5.75 280.91 140.45 162.41 4.20E+04 7,787
2 N4 shell 48.85 13220 & 1220 3.3 161.22 80.61 93.21 5.00E+05 7,787
4 K1 shell 48.85 13220 & 1220 3.3 161.22 80.61 93.21 5.00E+05 7,787
5 K2/3 shell 48.85 13220 & 1220 3.3 161.22 80.61 93.21 5.00E+05 7,787

* From FEA results

** Form stress in opening for fatigue evaluation of ASME sec VIII Div. 2 article 4-6

3.7 FATIGUE LIFE CALCULATION FOR FLANGE AND FLANGE BOLTING:

fatigue life calculation for flange and flange bolting due to internal pressure cycle is as given in table

below.

PRESSURE Bolt area *Flange stress *Bolt stress

Max.load (N) M (N-mm)
(KPaa) (mm²) (MPa) (MPa)
5780 4853825.154 47907 862243379 94.84308 101.316699
5370 4507711.971 47907 800759694 88.04475 94.092615

Flange stress range 6.79833 Bolt stress range 7.224084

stress concentration factor 3 stress concentration factor 3
Flange stress amplitude 10.197495 Bolt stress amplitude 10.836126
Fatigue life infinite Fatigue life infinite

* Based on method from 4P-1104-MDR Part1

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

3.8 FATIGUE ANALYSIS FOR INTERNAL DISTRIBUTOR PIPE FOR NOZZLE N1

& N2 :

The construction of this internal distributor pipe (N1&N2) isolates it from the stresses arising from

vessel temperature variation. As a result no fatigue analysis is required.

3.9 FATIGUE CALCULATIONS FOR ATTCHMENTS

the fatigue life calculations for welded attachments are calculated based on cyclic stress range

obtained from FEA results for plain shell. The calculations are given as follows

Induced stress range

*Max. stress Stress near non-integral Sa'
Sa Fatigue Required
Non-integral range Time concentration attachments (S (Sa x 207E3 /
Sr. no. Location (S induced life life
attachement (S range) combinition factor (assumed) 179.02E3)
induced=S range x /2) (Mpa) (Cycles) (Cycles)
(Mpa) (SCF) SCF) (Mpa) (Mpa)
1 Lifting trunion shell 48.85 13220 & 1220 3 146.56 73.28 84.73 1.00E+06 7,787
2 Platform cleat pad shell 48.85 13220 & 1220 3 146.56 73.28 84.73 1.00E+06 7,787
3 Platform cleat pad Dished end 19.33 13220 & 1220 3 57.98 28.99 33.52 infinite 7,787
4 Insulation cleat shell 48.85 13220 & 1220 3 146.56 73.28 84.73 1.00E+06 7,787
5 ladder cleat shell 48.85 13220 & 1220 3 146.56 73.28 84.73 1.00E+06 7,787
6 Pipe support cleat pad shell 48.85 13220 & 1220 3 146.56 73.28 84.73 1.00E+06 7,787

* from FEA results

As given in above table, calculated fatigue life is more than required fatigue life for attachments.

3.10 FATIGUE CALCULATION FOR BED SUPPORT COMPONENTS

The bed support components are subjected to reversing loading depending on direction of

regeneration cycle. The calculation of stresses for these components is as per method described in
Induced stress range
*Max. stress Stress near non-integral Sa'
Sa Fatigue Required
range concentration (Sa x 207E3 /
4P-1105-
Sr. no. BedMDR Part4. Following table shows fatigue life calculation
component (S induced for these components.
attachments (S
(S range) factor (assumed) induced=S range x
179.02E3)
life life
/2) (Mpa) (Cycles) (Cycles)
(Mpa) (SCF) (Mpa)
SCF) (Mpa)
1 Bed support cleat 115.17 3 345.51 172.75 199.75 12,000 7,787
2 Bed support beam 168.71 1 168.71 84.36 97.54 410,000 7,787

* BASED ON METHOD FROM 4P-1104-MDR PART4

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

3.11 STRESSES AROUND WELDS

Stresses around butt welds in vessel are calculated based on FEA result for plain shell, the stress

range obtained from FEA in plain shell is multiplied by assumed stress concentration factor of 3

(the actual stress concentration factor will be less than 3, however 3 is a conservative assumption)

to arrive at peak stress range around welds. The calculations are shown as below.

*Max. Induced stress range

near non-integral Sa'
stress Stress Sa Fatigue Required
Weld attachments (S (Sa x 207E3 /
Sr. no. range concentration (S induced life life
location induced=S range x 179.02E3)
(S range) factor (SCF) /2) (Mpa) (Cycles) (Cycles)
SCF) (Mpa) (Mpa)
(Mpa)
1 Shell 48.85 3 146.56 73.28 84.73 1.00E+06 7,787
2 Dished end 19.33 3 57.99 29.00 33.53 infinite 7,787
3 Insert plate 52.49 3 157.46 78.73 91.03 5.70E+05 7,787

*From FEA results

As shown in above table these welds can be used in “as welded" condition, without smooth

dressing.

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4 CONCLUSIONS

In the present analysis, vessel shell, dished ends and nozzle A1/N1 and N2 are checked for cyclic

loading using FEA, for calculating fatigue life. Also the two nozzles A1/N1,N2 and skirt are

checked for combined thermal, pressure and nozzle local loads. The stresses from FEA results are

used to derive fatigue life for other nozzles and attachments. The flange and bolting are also

checked for fatigue life.

• The maximum peak stress range is found to be around inner corner of nozzle N2 to bottom

dished end junction.

• Fatigue life of the vessel is calculated to be 10,300 cycles, which is more than required 7,787

cycles.

• The stresses around nozzle A1/N1,N2 and skirt for combined pressure, thermal and nozzle local

loads are found to be within code allowable limits.

• The fatigue life for other nozzles, attachments, flanges and bolting is found to be satisfactory.

• The fatigue life for bed support components is found to be satisfactory.

5 REFERENCES

1. WOODSIDE / KELLOGG specification numbers LNG1304/20/001 Rev.0.

2. General assembly of Adsorber 1P-1105 R0

3. Australian standard for pressure vessels AS1210-1997

4. ASME section II, part D, edition 2001

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

TABLE 1. MATERIAL DATA

Materials unit SA 350 LF2 AS1548-5-490

NL20
Minimum UTS Kg/mm² (MPa) 49.21 (482.81) 49.21 (482.81)
Allowable stress (s) Kg/mm² (MPa) 12.2 (119.73) 13.25 (130)
Design temperature °C 350 350
Modulus of elasticity Kg/mm² (MPa) 18249.31 18249.31
(179025.7)
(179025.7)
Coefficient of thermal expansion m/m/°K 13.563E-6 13.563E-6
Thermal conductivity W/m°K 46.924 46.924
Specific heat J/Kg°k 566.473 566.473
Density Kg/m3 7850 7850

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 1. FEA MODEL FOR TOP DISHED END

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 2. TEMPERATURE DISTRIBUTION AROUND TOP DISHED END

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 3. DISPLACEMENT PROFILE FOR TOP DISHED END (THERMAL AND PRESSURE

LOAD )

FIGURE 4.

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FIGURE 4 MAXIMUM SHEAR STRESS CONTOUR FOR TOP DISHED END (THERMAL AND

PRESSURE LOAD)

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FIGURE 5. FEA MODEL FOR BOTTOM DISHED END

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 6. TEMPERATURE DISTRIBUTION AROUND BOTTOM DISHED END

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FIGURE 7. DISPLACEMENT PROFILE FOR BOTTOM DISHED END

(THERMAL AND PRESSURE LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 8. MAXIMUM SHEAR STRESS CONTOUR FOR BOTTOM DISHED END (THERMAL

AND PRESSURE LOAD)

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FIGURE 9. DISPLACEMENT PROFILE FOR TOP DISHED END (THERMAL, PRESSURE AND

NOZZLE LOAD)

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FIGURE 10. MAXIMUM SHEAR STRESS CONTOUR FOR TOP DISHED END (THERMAL,

PRESSURE AND NOZZLE LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 11. DISPLACEMENT PROFILE FOR BOTTOM DISHED END (THERMAL, PRESSURE AND

NOZZLE LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 12. MAXIMUM SHEAR STRESS CONTOUR FOR BOTTOM DISHED END (THERMAL,

PRESSURE AND NOZZLE LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 13. MAXIMUM SHEAR STRESS CONTOUR FOR SKIRT TO BOTTOM DISHED END

JOINT (THERMAL, PRESSURE AND NOZZLE LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 14 MAXIMUM SHEAR STRESS N1 NOZZLE(NOZZLE LOCAL LOADS)

FIGURE 15 MAX. SHEAR STRESS ON N2 NOZZLE ( NOZZLE LOCAL LOAD)

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FATIGUE ANALYSIS REPORT FOR ADSOBER 4P-1105-MDR PART5

FIGURE 15 MAXIMUM SHEAR STRESS N1 NOZZLE(NOZZLE LOCAL LOADS)

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