IRJET - Effect of Change in Location of Essential Elements of Saddle Supports
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This document summarizes the analysis and optimization of saddle supports for a pressure vessel. Three iterations of saddle design were analyzed using finite element analysis in ANSYS. The initial design had two vertical ribs and a center web, which resulted in the lowest stress of 31 MPa but highest factor of safety of 8.39. Subsequent designs removed structural elements to reduce weight, with the final design having only two side webs achieving a stress of 40 MPa but lower factor of safety of 6.38. While weight increased with each iteration, the optimizations reduced the over-design of the initial structure. Further modifications are recommended to reduce weight, such as adding patterns or holes to lower-stressed areas of the saddle.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 570
“EFFECT OF CHANGE IN LOCATION OF ESSENTIAL ELEMENTS OF
SADDLE SUPPORTS”
Akash Gawde1, Mrugank Divekar 2, Tanveersingh Dhanjal3, Umesh Tendulkar4, Preethakumari5
1,2,3,4Student, Department of Mechanical Engineering, Lokmanya Tilak College of Engineering, Maharashtra, India.
5Professor, Department of Mechanical Engineering, Lokmanya Tilak College of Engineering, Maharashtra, India.
---------------------------------------------------------------------***----------------------------------------------------------------------
Abstract – Pressure vessels are subjected to various types of
loadings viz. internal / externalpressure, operatingconditions
thermal loadings, nozzle loadings, hydro test pressure, wind
and seismic loadings, etc. These loads are transferred to the
foundation through saddle supports. Thus, in addition to
pressure boundary, one of the important elements in the
construction is saddle supports. The structural analysis of
supports is being carried out for two configurations and
results compared.
Key Words: Pressure vessel, saddle supports, ANSYS,
FEA, stress analysis, design of saddle
1. INTRODUCTION
Pressure vessel is an enclosed container in which a fluid, in
the form of liquid or gas, is stored under the desired
pressure. In addition to theinternal pressure,external forces
due to wind, seismic, piping, dead loads, etc. are to be
considered for design. Furthermore, hydrostatic tests are to
be performed at higher pressure to ensure that the pressure
vessel could withstand the desired loads. Pressure vessels
are supported on support systems, which must withstand
the above-mentioned loads. Therefore, stress analysis must
be performed on the supports to check the safety of the
design. Finite Element Analysis (FEM) enables simulation of
the theoretical loads acting on the pressure vessel and thus
helps to optimize and validate the design. In the present
work, supports were modelled on SOLIDWORKS and the
analysis were performed on ANSYS 18.1 simulation
software.
2. LITERATURE REVIEW
L. P. Zick (1951)[1] presented a study in which he discussed
various stresses acting in cylindrical vessels. Using these
stresses, it is possible to determine which pressure vessels
must be designed only based on internal pressure. It also
helps to develop stiffening rings for those requiring it.
Shen Naijie (1995)[2] found out the stresses in the saddle
supports of pressurevesselsbyexperimental andtheoretical
analysis, using electric strain gauge and double Fourier
series expansion method. Also, a trial and error method has
been proposed to determine the contact pressure
distribution pattern.
N.EL-Abbasi(2001)[3] In this research, a three-dimensional
finite-element analysis of the pressure vessel resting on a
flexible saddle framework was created. It evaluates and
addresses the effects of saddle length, saddle width, plate
extension, and support overhang on the resulting stress
fields in the vessel and the support.
Shafique M. A. Khan (2010)[4] The stress distribution was
discovered in various parts of the saddle, such as wear,
network, flange and base plate, using 3D finite element
analysis. Based on the optimum values of the support
distance ratio from the end of the vessel, the effects of load
shift and various geometric parameters were studied, and
recommendations were made.
3. DESIGN OFPRESSUREVESSELANDSADDLESUPPORTS
The design of pressure vessel were carried out on
Solidworks and analyzed on ANSYS.
3.1 Design of Pressure Vessel
The pressure vessel considered in our analysis is meant to
carry LPG as its working fluid, with the following general
dimensions-
Table -1
Dimensions of pressure vessel
Shell outside diameter, D 2133.6 mm
Shell length L 5000 mm
Spherical head outside diameter 2133.6 mm
Corrosion allowance 1.28 mm
Thickness 91.8 mm
The material used for pressure vessel and saddle is SA-516
GR. 70 with the following properties –
Table -2
Properties of Saddle Material
Material SA-516 GR.70
Density 7750 kg/m3
Modulus of Elasticity 1.92E+11 N/m2
Poisson ratio 0.3
Yield Strength 260 MPa
Operating pressure 1.69 MPa
Design Pressure 6.8 MPa
Operating temperature 297 K](https://image.slidesharecdn.com/irjet-v7i399-201202091332/85/IRJET-Effect-of-Change-in-Location-of-Essential-Elements-of-Saddle-Supports-1-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 571
The design, cross section and model of the pressure vessel
are as shown below -
Fig -1: Dimensions of CAD model of pressure vessel
Fig -2: CAD model of pressure vessel
3.2 Design of Saddle
The dimensions for saddle were taken fromtheDennisMoss
book (2013)[5].
Fig -3: Saddle Dimensions
Fig -4: Typical Saddle Dimensions
Based on the above table, we have selected84-inchdiameter
pressure vessel and designed the saddle according to the
dimensions given. In order to have further clarity, the table
given below has been prepared-
Table -3
Typical Saddle Dimensions
Vessel O.D. 84 inches
Maximum Operating
Weight
57525 pounds
A 74 inches
B 51 inches
C 12 inches
D 0.75 inches
E 33 inches
F 8 inches
G 0.375 inches
H 30.2 inches
Bolt Diameter 1.25 inches
Saddle Angle (ϴ) 121°
Approximate Weight /
Set
810 pounds
The saddle modeled in Solidworks is as shown below.
Fig -5: Dimensions of saddle in CAD
3.3 Forces and Boundary Conditions
The forces considered for analyzing the saddle are as
follows-](https://image.slidesharecdn.com/irjet-v7i399-201202091332/85/IRJET-Effect-of-Change-in-Location-of-Essential-Elements-of-Saddle-Supports-2-320.jpg)
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 574
Fig -18: CAD model of saddle (Iteration 3)
Fig -19: Section CAD model of saddle (Iteration 3)
The maximum Von Mises stress was found to be 40 MPa in
the saddle.
Fig -20: Von Mises Stresses of Iteration 3
5. CONCLUSION
The following are the observations from the ANSYS analysis
of different saddles.
Table -4
Saddle Optimization Results
Iterations Weight (kg) Factor of Safety
1 (Baseline) 237 8.39
2 289 7.20
3 279 6.38
As the initial design was over-designedwitha factorofsafety
greater than 8, the design was modified. Although we could
reduce the factor of safety to considerable levels, the weight
of the saddle increased in subsequent iterations. Therefore,
further modifications are necessary in the design for
reducing the weight of the saddle. The modifications can be
in the form of providing patterned gaps or holes in the low
stressed areas.
ACKNOWLEDGEMENT
We are extremely grateful to Mr. Punit Ravani (Manager-
Design & Engg., L&T) for his continued support and for
providing invaluable guidance to us.
REFERENCES
[1] Zick, L. P. "Stresses in large horizontal cylindrical
pressure vessels on two saddle supports." Welding Journal
Research Supplement 30, no. 9 (1951): 435-445
[2]Shen Naijie Zhu Jitao, Lu Wenge “Stressstateinthesaddle
zone of pressure vessels and piping”,International Journal of
Pressure Vessels and Piping
Volume 63, Issue 2, 1995, Pages 155-164
[3]N El-Abbasi SA Meguid, A Czekanski “Three-dimensional
finite element analysis of saddle supported pressure
vessels”, International Journal Of Mechanical Sciences. - 5 :
Vol. 43.
[4] Khan, Shafique. "Stress distributions in a horizontal
pressure vessel and the saddle supports." International
Journal of Pressure Vessels and Piping 87, no. 5(2010):239-
244
[5] Dennis R. Moss, Michael Basi, Pressure Vessel Design
Manual fourth edition, 2013.
[6] ASME Boiler and Pressure Vessel Code. Section VIII.
Pressure Vessels Division, 2. New York: ASME; (1989)
BIOGRAPHIES
Akash Gawde, pursuing B.E. in
Mechanical Engineering from
Lokmanya Tilak College of
Engineering affiliated to Mumbai
University.](https://image.slidesharecdn.com/irjet-v7i399-201202091332/85/IRJET-Effect-of-Change-in-Location-of-Essential-Elements-of-Saddle-Supports-5-320.jpg)
IRJET - Effect of Change in Location of Essential Elements of Saddle Supports
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 570 “EFFECT OF CHANGE IN LOCATION OF ESSENTIAL ELEMENTS OF SADDLE SUPPORTS” Akash Gawde1, Mrugank Divekar 2, Tanveersingh Dhanjal3, Umesh Tendulkar4, Preethakumari5 1,2,3,4Student, Department of Mechanical Engineering, Lokmanya Tilak College of Engineering, Maharashtra, India. 5Professor, Department of Mechanical Engineering, Lokmanya Tilak College of Engineering, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------- Abstract – Pressure vessels are subjected to various types of loadings viz. internal / externalpressure, operatingconditions thermal loadings, nozzle loadings, hydro test pressure, wind and seismic loadings, etc. These loads are transferred to the foundation through saddle supports. Thus, in addition to pressure boundary, one of the important elements in the construction is saddle supports. The structural analysis of supports is being carried out for two configurations and results compared. Key Words: Pressure vessel, saddle supports, ANSYS, FEA, stress analysis, design of saddle 1. INTRODUCTION Pressure vessel is an enclosed container in which a fluid, in the form of liquid or gas, is stored under the desired pressure. In addition to theinternal pressure,external forces due to wind, seismic, piping, dead loads, etc. are to be considered for design. Furthermore, hydrostatic tests are to be performed at higher pressure to ensure that the pressure vessel could withstand the desired loads. Pressure vessels are supported on support systems, which must withstand the above-mentioned loads. Therefore, stress analysis must be performed on the supports to check the safety of the design. Finite Element Analysis (FEM) enables simulation of the theoretical loads acting on the pressure vessel and thus helps to optimize and validate the design. In the present work, supports were modelled on SOLIDWORKS and the analysis were performed on ANSYS 18.1 simulation software. 2. LITERATURE REVIEW L. P. Zick (1951)[1] presented a study in which he discussed various stresses acting in cylindrical vessels. Using these stresses, it is possible to determine which pressure vessels must be designed only based on internal pressure. It also helps to develop stiffening rings for those requiring it. Shen Naijie (1995)[2] found out the stresses in the saddle supports of pressurevesselsbyexperimental andtheoretical analysis, using electric strain gauge and double Fourier series expansion method. Also, a trial and error method has been proposed to determine the contact pressure distribution pattern. N.EL-Abbasi(2001)[3] In this research, a three-dimensional finite-element analysis of the pressure vessel resting on a flexible saddle framework was created. It evaluates and addresses the effects of saddle length, saddle width, plate extension, and support overhang on the resulting stress fields in the vessel and the support. Shafique M. A. Khan (2010)[4] The stress distribution was discovered in various parts of the saddle, such as wear, network, flange and base plate, using 3D finite element analysis. Based on the optimum values of the support distance ratio from the end of the vessel, the effects of load shift and various geometric parameters were studied, and recommendations were made. 3. DESIGN OFPRESSUREVESSELANDSADDLESUPPORTS The design of pressure vessel were carried out on Solidworks and analyzed on ANSYS. 3.1 Design of Pressure Vessel The pressure vessel considered in our analysis is meant to carry LPG as its working fluid, with the following general dimensions- Table -1 Dimensions of pressure vessel Shell outside diameter, D 2133.6 mm Shell length L 5000 mm Spherical head outside diameter 2133.6 mm Corrosion allowance 1.28 mm Thickness 91.8 mm The material used for pressure vessel and saddle is SA-516 GR. 70 with the following properties – Table -2 Properties of Saddle Material Material SA-516 GR.70 Density 7750 kg/m3 Modulus of Elasticity 1.92E+11 N/m2 Poisson ratio 0.3 Yield Strength 260 MPa Operating pressure 1.69 MPa Design Pressure 6.8 MPa Operating temperature 297 K
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 571 The design, cross section and model of the pressure vessel are as shown below - Fig -1: Dimensions of CAD model of pressure vessel Fig -2: CAD model of pressure vessel 3.2 Design of Saddle The dimensions for saddle were taken fromtheDennisMoss book (2013)[5]. Fig -3: Saddle Dimensions Fig -4: Typical Saddle Dimensions Based on the above table, we have selected84-inchdiameter pressure vessel and designed the saddle according to the dimensions given. In order to have further clarity, the table given below has been prepared- Table -3 Typical Saddle Dimensions Vessel O.D. 84 inches Maximum Operating Weight 57525 pounds A 74 inches B 51 inches C 12 inches D 0.75 inches E 33 inches F 8 inches G 0.375 inches H 30.2 inches Bolt Diameter 1.25 inches Saddle Angle (ϴ) 121° Approximate Weight / Set 810 pounds The saddle modeled in Solidworks is as shown below. Fig -5: Dimensions of saddle in CAD 3.3 Forces and Boundary Conditions The forces considered for analyzing the saddle are as follows-
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 572 i) Gravitational Force The primary force that a saddle has to bear is the force due to its own weight. The mass of the saddle came out to be 237 kg. Fig -6: Gravitational force ii) Pressure Force The pressure vessel was designed for operating at 1.69 MPa pressure. The force due to the expansion of the vessel due to the internal pressure acts on the saddle. Fig -7: Pressure Force iii) Wind Loads Wind load was calculated for the Zone-4 structure in India, which came out to be 20 kN in longitudinal direction and 5 kN in lateral direction. Fig -8: Wind load in lateral direction Fig -9: Wind load in longitudinal direction iv) Constraints Both of the saddles were fixed at their base to simulate no movement in the saddles. Fig -10: Fixed Support (Saddle 1) Fig -11: Fixed Support (Saddle 2) 4. ANALYSIS AND ITERATIONS I) Iteration 1 As the first iteration, the saddle was designed with two vertical ribs on the sides and one web at the centre, which is considered as the baseline design. The saddle and its cross section are shown below.
- 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 573 Fig -12: CAD model of saddle (Iteration 1) Fig -13: Section CAD model of saddle (Iteration 1) Analysis of the structure using ANSYS indicated maximum Von Mises stress of 31 MPa in the saddle. Fig -14: Von Mises Stresses of Iteration 1 II) Iteration 2 In the second iteration, the saddle was designed with two side webs without the inner centre web. The two centre ribs were retained the saddle and its cut section are shown below. Fig -15: CAD model of saddle (Iteration 2) Fig -16: Section CAD model of saddle (Iteration 2) Analysis of this structure indicated maximum Von Mises stress of 36 MPa in the saddle. Fig -17: Von Mises Stresses of Iteration 2 III) Iteration 3 In the third iteration, the saddle was designed with two side webs only, without any ribs. This was like a box type structure. The saddle and its cut section are shown below.
- 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 574 Fig -18: CAD model of saddle (Iteration 3) Fig -19: Section CAD model of saddle (Iteration 3) The maximum Von Mises stress was found to be 40 MPa in the saddle. Fig -20: Von Mises Stresses of Iteration 3 5. CONCLUSION The following are the observations from the ANSYS analysis of different saddles. Table -4 Saddle Optimization Results Iterations Weight (kg) Factor of Safety 1 (Baseline) 237 8.39 2 289 7.20 3 279 6.38 As the initial design was over-designedwitha factorofsafety greater than 8, the design was modified. Although we could reduce the factor of safety to considerable levels, the weight of the saddle increased in subsequent iterations. Therefore, further modifications are necessary in the design for reducing the weight of the saddle. The modifications can be in the form of providing patterned gaps or holes in the low stressed areas. ACKNOWLEDGEMENT We are extremely grateful to Mr. Punit Ravani (Manager- Design & Engg., L&T) for his continued support and for providing invaluable guidance to us. REFERENCES [1] Zick, L. P. "Stresses in large horizontal cylindrical pressure vessels on two saddle supports." Welding Journal Research Supplement 30, no. 9 (1951): 435-445 [2]Shen Naijie Zhu Jitao, Lu Wenge “Stressstateinthesaddle zone of pressure vessels and piping”,International Journal of Pressure Vessels and Piping Volume 63, Issue 2, 1995, Pages 155-164 [3]N El-Abbasi SA Meguid, A Czekanski “Three-dimensional finite element analysis of saddle supported pressure vessels”, International Journal Of Mechanical Sciences. - 5 : Vol. 43. [4] Khan, Shafique. "Stress distributions in a horizontal pressure vessel and the saddle supports." International Journal of Pressure Vessels and Piping 87, no. 5(2010):239- 244 [5] Dennis R. Moss, Michael Basi, Pressure Vessel Design Manual fourth edition, 2013. [6] ASME Boiler and Pressure Vessel Code. Section VIII. Pressure Vessels Division, 2. New York: ASME; (1989) BIOGRAPHIES Akash Gawde, pursuing B.E. in Mechanical Engineering from Lokmanya Tilak College of Engineering affiliated to Mumbai University.
- 6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072 © 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 575 Umesh Tendulkar, pursuing B.E. in Mechanical Engineering from Lokmanya Tilak College Of Engineering affiliated to Mumbai University. Mrugank Divekar, pursuing B.E. in Mechanical Engineering from Lokmanya Tilak College of Engineering affiliated to Mumbai University. Tanveersingh Dhanjal, pursuing B.E. in Mechanical Engineering from Lokmanya Tilak College of Engineering affiliated to Mumbai University. Preethakumari, Professor, Department of Mechanical Engineering,Lokmanya Tilak College of Engineering.