FINITE ELEMENT ANALYSIS OF COMPOSITE WATER BUFFER DRUM

Abstract

Composite materials offer many advantages for oil and gas developments based on their low density, corrosion resistance, and excellent fatigue performance.  In addition, the use of composites allows for greater design flexibility for tailoring the properties to meet specific design requirements, thus promoting better system oriented and cost-effective solutions. However, on a performance equated basis, the economic incentive to use composite components can often be demonstrated based on their capability to reduce system and life cycle costs.

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Water buffer drum which is a pressure vessel holds a specified volume of fluid with desired temperature and pressure. Its function is to provide water with certain temperature to equipment facility. For smooth working large number of piping is attached to this. These conditions create critical nozzle loading on the pressure vessel. This paper gives an idea about comparative study between carbon steel and combination of carbon steel and composites. Composites such as Glass fibered reinforced are used for the study. Pressure vessel with a combination of different boundary conditions such as Pressure, Nozzle loading, Wind, Seismic is analyzed for carbon steel and the combination of carbon steel and composites. Various thickness combinations of composite and carbon steel are used for design study. While analyzing water buffer drum components stress induced in various components are compared. By replacing some thickness of carbon steel there will be % reduction in weight which will save many costs related to the weight of water buffer drum.

Table of Contents

Acknowledgement

Abstract

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List of Illustrations

List of Tables

Chapter 1 Introduction

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1.1 What is water buffer drum

1.2 Research Objective

1.3 Composites

Chapter 2 Geometry

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Chapter 3 Design Parameters

3.1 Design conditions

3.2 Material Properties

Chapter 4 Design Calculations & Loading Conditions

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4.1 Weight

4.2 Pressure & Static Head

4.3 Nozzle Loads

4.4 Seismic Loading

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4.5 Wind Loading

4.6 Loading Combinations

Chapter 5 Carbon Steel Results

5.1 Load Case 1

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5.2 Load Case 2

5.3 Load Case 3

5.4 Load Case 4

5.5 Comparison of Load cases

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Chapter 6 Composites

6.1 E-glass properties

6.2 Simulation

Chapter 7 Composite Results

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7.1 Results for shell

7.2 Results for Support Leg

7.3 Results for RF Pad

7.4 Results for E-glass

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7.5 Weight Difference

Chapter 8 Conclusion

Future Work

References

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Biographical Information

List of Illustrations

Figure 1‑1 Chilled water buffer drum

Figure 1‑2 Hot water buffer drum

Figure 1‑3 Composites

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Figure 2‑1 Overall Dimensions

Figure 2‑2 Overall Geometry

Figure 2‑3 Nozzle orientation

Figure 2‑4 Water buffer drum with nozzles

Figure 2‑5 Leg support with reinforcement pad

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Figure 2‑6 Leg cross section

Figure 2‑7 Baseplate cross section

Figure 4‑1 Direction of applied nozzle Loads

Figure 4‑2 Seismic Loads & Reactions for a vessel with unbraced legs

Figure 4‑3 Coefficient Rw

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Figure 4‑4 Coefficients Ca & Cv

Figure 4‑5 Structure Category & Exposure Categories from Moss

Figure 4‑6 (a) Case 1 (b) Case 2 (c) Case 3 (d) Case 4

Figure 5‑1 Case 1 Results (a) Total Deformation (b) Overall Stress
(c) Legs (d) RF Pad

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Figure 5‑2 Case 2 Results (a) Total Deformation (b) Overall Stress
(c) Legs (d) RF Pad

Figure 5‑3 Case 3 Results (a) Total Deformation (b) Overall Stress
(c) Legs (d) RF Pad

Figure 5‑4 Case 4 Results (a) Total Deformation (b) Overall Stress
(c) Legs (d) RF Pad

Figure 5‑5 Stress comparison chart

Figure 6‑1 0° Fiber direction

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Figure 6‑2 Lay up direction

Figure 7‑1 Stress generated in shell for combination 4+2

Figure 7‑2 Stress generated in shell for combination 4+4

Figure 7‑3 Stress generated in shell for combination 6+2

Figure 7‑4 Stress comparison for shell

Figure 7‑5 Stress generated in leg for combination 4+2

Figure 7‑6 Stress generated in leg for combination 4+4

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Figure 7‑7 Stress generated in leg for combination 6+2

Figure 7‑8 Stress comparison for Leg

Figure 7‑9 Stress generated in RF Pad for combination 4+2

Figure 7‑10 Stress generated in RF Pad for combination 4+4

Figure 7‑11 Stress generated in RF Pad for combination 6+2

Figure 7‑12 Stress comparison for RF Pad

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Figure 7‑13 Stress & MOS in solid composite for combination 4+2

Figure 7‑14 Stress & MOS in solid composite for combination 4+4

Figure 7‑15 Stress & MOS in solid composite for combination 6+2

Figure 7‑16 Comparison of MOS for ply sequence

Figure 7‑17 Weight Comparison with a different combination

List of Tables

Table 2‑1 Nozzle properties

Table 3‑1 Design Parameters

Table 3‑2 Material List

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Table 3‑3 Material Properties

Table 4‑1 Empty weight distribution

Table 4‑2 Static head

Table 4‑3 Nozzle Loads

Table 4‑4 Wind calculation coefficient from Moss

Table 5‑1 Comparison of stress-induced for all load cases

Table 6‑1 E-glass Properties

Table 7‑1 Comparison of stress generated in shell

Table 7‑2 Comparison of stress generated in Leg

Table 7‑3 Comparison of stress generated in Leg

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Table 7‑4 Margin of safety for Ply sequence

Table 7‑5 Weight Comparison

Chapter 1  Introduction

The pressure vessel is one most important equipment for the smooth functioning of many industries such as oil and gas, pharmaceutical, healthcare, HVAC. The pressure vessel is nothing but equipment to hold the desired volume of gas or liquid at required temperature and pressure. The pressure vessel is generally made of carbon steel, stainless steel or metals. There are very few cases where non-metal is used for manufacturing of pressure vessel. Pressure vessel construction is very costly for its service time considered. Corrosion is one of a factor that cost many lots in construction. But there are ways to reduce the overall cost of the pressure vessel.

To reduce pressure vessel cost, the weight of pressure vessel should decrease, and lifespan should increase. The decrease in weight will affect vessel transportation, operation, and maintenance cost. Reducing weight is very tedious job due to complexity in pressure vessel operation. For this new material with low density and high strength and stiffness can be used.

In recent years, composite materials with these properties are evolved. Also, extensive research on various materials and improvising their properties are going on.

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Many materials with such properties are easily available in the market.

1.1 What is water buffer drum

Water buffer drum is pressure vessel used for water flow circulation to increase system efficiency in chillers, reactors, boilers. Depending upon application temperature range of fluid in water buffer drum is decided. As per process requirement capacity of the drum, more factors are taken into consideration for design. It is used in fluid circulation vessel so the major piping system is attached to this.

Chilled water buffer drums are designed for use of chilled water system with insufficient water volume capacity, in relation to chiller capacity. Chilled water buffer drum increases system volume and reduces the rate of temperature change in return water, resulting in improved temperature control, consistent system operation and controlled compressor cycling.

Figure 1‑1 Chilled water buffer drum

Hot water buffer drum is designed for use of high temperature, a high-efficiency system that incorporates small, modular low mass boiler. It adds necessary thermal mass to the system to dampen fast transitions and minimize boiler cycling that occurs during zero or low domestic load conditions.

Figure 1‑2 Hot water buffer drum[1]

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1.2 Research Objective

The objective of this study is to analyze water buffer drum which is used in industry for storing water with desired temperature and pressure. For smooth functioning of the drum, piping is attached to it. For most of the cases, piping loads are affecting design thickness of drum. In this study, we are analyzing buffer drum with various thickness combination of composite and carbon steel. We will be keeping same design conditions for the composite model as that of original carbon steel model to withstand combined loads like internal pressure, nozzle load, wind load, seismic load.

We aim to show stress generated due to loading condition various parts with variation in a combination of thickness with carbon steel and composite. As using composite will be beneficial for weight reduction of whole geometry.

1.3 Composites

A composite material is made by combining two or more materials – often ones that have very different properties. The two materials work together to give the composite unique properties. However, within the composite, you can easily tell the different materials apart as they do not dissolve or blend into each other. Most composites are made of just two materials. One is the matrix or binder. It surrounds and binds together fibers or fragments of the other material, which is called the reinforcement. Composite materials are high in strength to weight ratio[2]. Composites are a combination of two or more constituent materials with significantly different physical and chemical properties. When two or more materials combine it give other material which is completely different from individual materials.

Figure 1‑3 Composites[3]

In this study we considering E-glass fiber. E-glass fiber is having some distinct properties to be considered, those properties are listed below:

• High stiffness
• Low cost
• Corrosion resistant
• Thermal resistance
• Low density
• Design flexibility
• Low manufacturing constraints

Also, while analyzing composite some factors should consider:

• Delamination in ply
• In Plane shear due to deflection
• Shear due to out of plane deformation

Chapter 2  Geometry

In this chapter, we will discuss about water buffer drum geometry used for analysis. Overall length of 7150 mm with TL to TL length 4100 mm and internal diameter of 1450 mm. 8 mm thickness is used for geometry for shell and head. For this study, carbon steel material is used for preliminary analysis.

Figure 2‑1 Overall Dimensions

Figure 2‑2 Overall Geometry

For working of water buffer drum various nozzles are attached to water buffer drum. Nozzle orientation with nozzle properties is mentioned below.

Figure 2‑3 Nozzle orientation

Figure 2‑4 Water buffer drum with nozzles

Form nozzle table other details for nozzles like nozzle projection, nozzle size, nozzle thickness, reinforcement pad can be obtained. Nozzle thickness is nothing but nozzle schedule. Nozzle is a pipe, so thickness of nozzle varies with schedule, but the outer diameter remains the same for every size. Nozzle table is mentioned below.