"DESIGN ANALYSIS OF LIFTING TRUNNION FOR A

HORIZONTAL PRESSURE VESSEL USING CAE TOOLS"

A dissertation submitted
in the partialfulfilment of the requirement for the award of the degree of

MASTER OF TECHNOLOGY

IN

MACHINE DESIGN
(MECHANICAL ENGINEERING)

BY

PRASHANTYADAV

211319
(Session 2011-2013)

UNDER THE GUIDANCE OF

JAIDEEP GUPTA

DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY, KURUKSHETRA
HARYANA-136119
 •'^'.A

.0 .
 CERTIFICATE

This is to certify that the dissertation entitled DESIGN ANALYSIS OF LIFTING

TRUNNION FOR A HORIZONTAL PRESSURE VESSEL USING CAE TOOLS",
being submitted by Prashant Yadav (Roll number-211319) to the Department of Mechanical
Engineering, National Institute of Technology, Kurukshetra, for the award of degree of
Master of Technology in Mechanical Engineering (Machine Design), is a bonafide research
work carried out by him under my supervision and guidance. His dissertation has reached the
standard of fulfilling the requirements of the regulations relating to the award of Master in
Technology degree of this university.
The results presented have not been submitted in part or in full to any other
University/Institute for the award of any degree or diploma.

(Mr. Jaideep Gupta)

Associate Professor
Mechanical Engineering Dept.
National Institute of Technology
Kurukshetra-136119

>^l^ i ::•
 ACKNOWLEDGEMENT

This project has been possible by mercy and grace of God. It is my great pleasure to
express my thanks to all the magnanimous persons who rendered their full support to my
work directly or indirectly.
I would like to express my special thanks and indebtedness to my guide Mr. Jaideep
Gupta, Associate Professor, Mechanical Engineering Department, National Institute of
Technology, Kurukshetra for their deep involvement, invaluable and continuous
motivation throughout this work.
I would like to express my sincere gratitude to Dr. Sudhir Saxena, H.O.D. Mechanical
Engineering Department, N.I.T. Kurukshetra for all his possible support to let me use
various facilities of the Department for this work.
Finally, I would like to dedicate this project work to my friends who are great source of
support & encouragement, especially in all of our academic endeavours.
Above all, without the blessings of the Almighty God, this endeavour would not have
borne fruit.

(Prashant Yadav)
 ABSTRACT
The designer of pressure vessels and similar equipment will ultimately become involved
in the movement, transportation, and erection of that equipment. After designing a
pressure vessel there is seldom a problem when the equipment gets to its final
destination. There is also an economic benefit in including the lifting attachments in the
basic vessel design. These lifting attachments are relatively inexpensive in comparison
to the overall cost of the vessel and minuscule compared to the cost of the erection of the
equipment. The erection alone for a major vessel can run into millions of dollars. Thus
for a pressure vessel designing lifting attachment are the essential part of designing to
take care of loads during lifting and transportation.

There are many different methods and techniques for the erection of vessels and the
related costs of each that a coordinated effort between the designer and erector is
mandatory.The conventional method and FEM method has been described in detail in
this report with sample calculations. This project presents analysis results of stress
distributions in a pressure vessel having lifting trunnions on either side of vessel.

In this project an attempt has been made to analyse lifting trunnions with four triangular
shaped stiffeners and applying loads at different lifting angles using finite element
method. For every case stress categorization line is taken where maximum stress are
produced, and the resuhs of finite element method have been compared with the yield
strength of the respective used material.
Further, two different material has been taken for analysis and the stress values has been
compared for the same.
 LIST OF CONTENTS

Topic Page No.

Certificate i
Acknowledgement ii
Abstract iii
List of contents iv
List of figures v
List of tables vii
Chapter 1, Introduction 1

1.1 Pressure vessels

1.2 Components of pressure vessel

Chapter 2, Literature review 10

Chapter 3, Problem selection 11

Chapter 4, F.E.A. of lifting trurmion for pressure vessel using ANSYS 12

Chapter 5, FEM solution of lifting trunnion 22

5.1 FEM solution for material SA516Gr60

5.2 FEM solution for material A36

Chapter 6, Results and discussion 42

Chapter 7, Conclusion and Future scope 45

7.1 Conclusion

7.2 Future scope

References 46
 List of figures and graphs

No, Title Page no.

1.1 Lifting of horizontal pressure vessel using trunnion and lug with two cranes 5

1.2 Various lifting attachment of pressure vessel 8

4.1 Element, Solid 185 14

4.2 Typical model for analysis 15
4.3 Meshed model of the Trunnion 16
4.4 Boundary conditions 17

4.5 Diagram for load calculation at different lifting angle 18

4.6 Load direction on trunnion at 0 degree lift angle 19

4.7 Load direction on trunnion at 30 degree lift angle 20

4.8 Load direction on truimion at 45 degree lift angle 20

4.9 Load direction on trunnion at 60 degree lift angle 21

4.10 Load direction on trunnion at 75 degree lift angle 21

4.11 Load direction on trunnion at 90 degree lift angle 22

5.1 Nodal Solution of Von Mises Stress for case 1 23

5.2 Nodal Solution of Von Mises Stress for case 2 24

5.3 Nodal Solution of Von Mises Stress for case 3 24

5.4 Nodal Solution of Von Mises Stress for case 4 25

5.5 Nodal Solution of Von Mises Stress for case 5 25

5.6 Nodal Solution of Von Mises Stress for case 6 26

5.7 SCL for case 1 27

5.8 SCL for case 2 28

5.9 SCL for case 3 29

5.10 SCL for case 4 30

5.11 SCL for case 5 31

5.12 SCL for case 6 32

5.13 Nodal Solution of Von Mises Stress for A36 case 1 33

5.14 Nodal Solution of Von Mises Stress for A36 case 2 33

5.15 Nodal Solution of Von Mises Stress for A36 case 3 34

5.16 Nodal Solution of Von Mises Stress for A36 case 4 34

5.17 Nodal Solution of Von Mises Stress for A36 case 5 35

5.18 Nodal Solution of Von Mises Stress for A36 case 6 35

5.19 SCL for A36 easel 36

5.20 SCL for A36 case 2 37

5.21 SCL for A36 case 3 38

5.22 SCL for A36 case 4 39

5.23 SCL for A36 case 5 40

5.24 SCL for A36 case 6 41

6.1 Comparing the SCL results of SA516Gr60 and A36 43

6.2 Comparison of maximum von mises stresses with allowable stress of 43
the respective material

VI
 List of Tables

No. Title Page no.

4.1 Model dimensions 13

4.2 Load acting on trunnion at different angle 19

5.1 SCL for SA516gr60 case 1 27

5.2 SCL for SA516gr60 case 2 28

5.3 SCL for SA516gr60 case 3 29

5.4 SCL for SA516gr60 case 4 30

5.5 SCL for SA516gr60 case 5 31

5.6 SCL for SA516gr60 case 6 32

5.7 SCL for A36 easel 36

5.8 SCL for A36 case 2 37

5.9 SCL for A36 case 3 38

5.10SCLforA36case4 39

5.11 SCL for A36 case 5 40

5.12 SCL for A36 case 6 41

VII
 CHAPTER 1

INTRODUCTION

1.1 Pressure vessels

The continued and prolonged use of pressure vessels for power generation, nuclear or
chemical reactions, industrial processing, and storage requires them to withstand
severe conditions of pressure, temperature, and other environments. Such
environmental conditions include corrosion, neutron irradiation, hydrogen
embrittlement, and so on. Pressure vessels are required to operate at a temperature
range from as high as 600 °C to as low as -20 C, with design pressures as high as
140 MPa. Some vessels are designed to carry noncorrosive fluids; while others are
designed to withstand harsh corrosive and highly radioactive environments. The type
of service, whether steady or cyclic, may also vary considerably. For each set of
operating parameters, the pressure vessel material may be required to have certain
properties. For example, operation at very low temperatures would require the use of
materials with high notch toughness, while operation at high temperatures would
require materials with high creep strength. Apart from the mechanical properties,
considerations on manufacturability, commercial availability, as well as cost, has to
be accounted for in the selection process. The materials that are used in pressure
vessel construction are:

• Steels
• Nonferrous materials such as aluminium and copper
• Specialty metals such as titanium and zirconium
• Non-metallic materials, such as, plastic, composites and concrete
• Metallic and non-metallic protective coatings

The mechanical properties that generally are of interest are:

• Yield strength
• Ultimate strength
• Reduction of area (a measure of ductility)
• Fracture toughness

The failures that the pressure vessels are to be designed against are generally stress
dependent. For this reason it becomes necessary to obtain the stress distribution in the
pressure vessels. There is a need to evaluate the operating stresses due to the imposed
conditions by analytical methods and sometimes by experimental means. Furthermore
we also need to understand the significance of these stresses on the structural integrity
of the pressure vessel by considering the material properties of the vessel.
Developments in aerospace, nuclear, chemical, and petrochemical industries have put
demands on pressure vessel materials to sustain thermal shock, dynamics, and cyclic
operation (fatigue). Knowledge of the material behaviour is necessary not only to
ensure that the vessel can withstand theloading but also to make sure that the material
has been chosen and utilized in an optimum maimer. The requirements that are
imposed on the design of a pressure vessel by the mode of operation specified for the
overall plant are divided into two groups. The first group includes those resulting
from the operation at maintained loading either under maximum or normal conditions.
For this group the operating pressure (internal and external) existing during the
normal operation is required. The second group includes the transient conditions that
exist during start-up or shutdown or during a general change in loading. For this
group it is necessary to know the maximum maintained pressure that may be
anticipated. The fluid temperature is another fundamental requirement. The maximum
and minimum values as well as the history of temperature variation need to be knovra.
The material selection is dictated to some extent by this requirement. Further
requirements might involve enviroimiental characteristics such as corrosion, erosion,
and irradiation.

Mechanical loads on the pressure vessel include those due to:

• Pressure
• Dead weight
• Seismic factors
• Piping

In addition, snow and wind loadings should be considered wherever appUcable. Other
loads due to various postulated accidents must also be considered. Pressure vessels
are designed for a postulated or expected design life. In addition the possibility of
periodic inspections is of importance. Thus it is required to provide inspection ports in
terms of hand holes or manholes as necessary. The detailed description of the mode of
operation, the definition of the rate of change of fluid temperatures as well as the
number of occurrences of various transient events need to be specified. The vessels
need to be designed according to the severity of operation. For example, pressure
vessels for nuclear applications have to be designed according to postulated accidents
and associated possible risks of failure, including the release of radioactive materials.
This is also the case for vessels with corrosive fluids at high pressure. The energy
released in the event of a catastrophic failure is an important consideration in the
design of vessels. These considerations lead to a classification of vessels varying from
nuclear reactor vessels at one end of the scale to underground water tanks at the other.
The designer uses his or her own discretion as to the position of the particular design
in the scale of the severity. The stress level is maintained below the allowable level,
which is basedon consideration of many failures; for example, plastic collapse.
fatigue,brittle fracture, or buckling. Stress analysis involves determining the
relationship between theapplied loads on the vessel and the associated response in
terms ofdeflections, stresses, and strains.

If we exert a tensile load on a specimen made of mild carbon steel, and we transfer on
the X-axis the values of the elongation per unit of length between the references (s)
(called strain) and on the y-axis the values of the stress (a) that equals the load applied
to the specimen divided by its original crosssectionalarea, we obtain a diagram
qualitatively similar to the one shown inFig. 3.1

Fig 1.1

We notice that there is proportionality between stress and strain in the first portion of
the curve, i.e., the steel follows Hooke's law that constitutes the basis of classic
calculation in the elastic field. In fact, the steel behaves in an elastic fashion, i.e., the
deformations completely disappear after removal of the load, and the specimen
returns to its original shape. The angular coefficient E of the straight portion given by
the relationship o/e is called modulus of elasticity, or Young's modulus. The point on
the curve at the end of the linear section identifies a value of a which is called
proportional limit.

Steel behaves in an elastic fashion even beyond the proportional limit, as long as
another characteristic point corresponding to stress called elastic limit is not exceeded.
Note that the two points mentioned above are near, and the second one is not easy to
determine. In practice, we typically equate the proportional limit to the elastic limit.

By increasing the load applied to the specimen, we reach a point on the curve
corresponding to a stressCT,called upper yield strength that represents the maximum
value of a taking place at the onset of the yielding phenomenon. In fact, after reaching
the upper yield strength the load decreases, and we reach a relative minimum of the
curve that identifies the stress called lower yield strength.
The yielding phenomenon is characterized by large deformations (when compared to
those typical of the elasticity field) under practically constant load.

This portion of the curve is then followed by a portion characterized by progressive

increase in stress with large deformations. This is the well-known phenomenon of
steel hardening, which persists until the stress reaches a maxi- mum value called
ultimate strength. After that a decreases (again with regard to the original cross-
sectional area of the specimen), and we reach rupture.

Conversely, if we consider the actual cross-sectional area of the specimen in the

different stages, the highest value of c is reached in correspondence with the rupture
point. In fact, substantial elongations in correspondence with yielding and hardening
areas happen together with a significant reduction of the cross-sectional area.

The lower value of the yield strength (simply known as "yield strength", Os) and the
maximum value of o that precedes the rupture are the most significant parameters of
the steel's mechanical properties, and are therefore indicated in test certificates and
represent the basis of resistance calculus. The yield strength basically shows the
condition under which the material starts yielding. At this point, the yielded fiber is
not able to absorb growing stresses, and thus to contribute to the equilibriimi of forces
applied to the vessel. This is because we rule out the possibility that under safety
conditions the deformations become so large that one is forced to consider the
hardening phenomenon. The fiber can be plastic deformed and, as we shall see, this
has an important impact on the behaviour of neighbouring fibers, if we start from the
assumption that they have not yet reached the yield strength. This leads to a different
kind of calculation, somewhat different firom the classic one based on the elasticity
behaviour of the entire component.

1.2 Components of Pressure Vessels

The main pressure vessel components are as follow:
1. Shell
2. Head
3. Nozzle
4. Support
5. Lifting attachments
1) Shell: The shell is the primary component that contains the pressure. Pressure
vessel shells are welded together to form a structure that has a common rotational
axis. Most pressure vessel shells are cylindrical, spherical and conical in shape.
 Fig 1.1 Lifting of horizontal pressure vessel using trunnion and lug with two cranes

2) Head: All pressure vessel shells must be closed at the ends by heads (or another
shell section). Heads are typically curved rather than flat. Curved configurations
are stronger and allow the heads to be thinner, lighter, and less expensive than flat
heads. Heads can also be used inside a vessel. These "intermediate heads"
separate sections of the pressure vessel to permit different design conditions in
each section. Heads are usually categorized by their shapes. Ellipsoidal,
hemispherical, torispherical, conical, toriconical and flat are the common types of
heads.

3) Nozzle: A nozzle is a cylindrical component that penetrates the shell or heads of a

pressure vessel. The nozzle ends are usually flanged to allow for the necessary
connections and to permit easy disassembly for maintenance or access. Nozzles
are used for the following applications:

a) Attach piping for flow into or out of the vessel.

b) Attach instrument connections, (e.g., level gauges, thermowells, or pressure
gauges).
c) Provide access to the vessel interior at manways.
 d) Provide for direct attachment of other equipment items, (e.g., a heat exchanger
or mixer).
4) Support: The type of support that is used depends primarily on the size and
orientation of the pressure vessel. In all cases, the pressure vessel support must be
adequate for the applied weight, wind, and earthquake loads. Calculated base
loads are used to design of anchorage and foundation for the pressure vessels.
Typical kinds of supports are as follow:

a) Skirt: Tall, vertical, cylindrical pressure vessels are typically skirt supported.
A support skirt is a cylindrical shell section that is welded either to the lower
portion of the vessel shell or to the bottom head (for cylindrical vessels). Skirts
for spherical vessels are welded to the vessel near the mid-plane of the shell.
The skirt is normally long enough to provide enough flexibility so that radial
thermal expansion of the shell does not cause high thermal stresses at its
junction with the skirt.

b) Leg: Small vertical drums are typically supported on legs that are welded to
the lower portion of the shell. The maximimi ratio of support leg length to
drum diameter is typically 2:1. The number of legs needed depends on the
drum size and the loads to be carried. Support legs are also typically used for
spherical pressurized storage vessels. The support legs for small vertical
drums and spherical pressurized storage vessels may be madefi"omstructural
steel columns or pipe sections, whichever provides a more efficient design.
Cross bracing between the legs, is typically used to help absorb wind or earth-
quake loads.

c) Saddle: Horizontal drums are typically supported at two locations by saddle

supports. A saddle support spreads the weight load over a large area of the
shell to prevent an excessive local stress in the shell at the support points. The
width of the saddle, among other design details, is determined by the specific
size and design conditions of the pressure vessel. One saddle support is
normally fixed or anchored to its foundation. The other support is normally
free to permit unrestrained longitudinal thermal expansion of the drum. A
typical scheme of saddle support is shown on Figure 1.2.
 d) Lugs: Lugs that are welded to the pressure vessel shell, which are shown on
Figure L6, may also be used to support vertical pressure vessels. The use of
lugs is typically limited to vessels of small to medium diameter (1 to 10 ft.)
and moderate height-to-diameter ratios in the range of 2:1 to 5:1. Lug supports
are often used for vessels of this size that are located above grade within
structural steel. The lugs are typically bolted to horizontal structural members
to provide stability against overturning loads; however, the bolt holes are often
slotted to permit free radial thermal expansion of the drum.

5) Lifting attachments: These are welded to the pressure vessel for the purpose of
lifting and transportation of pressure vessel without affecting the integrity of
vessel. Various attachments being used are

a) Head lug: Usually the simplest and most economical, and produces the least
stress.

b) Cone lug: Similar to a head lug but located at a conical transition section of
the vessel.

c) Topflangelug: The choice for high pressure vessels where the topflangesand
head are very rigid. This method is uneconomical for average applications.

d) Side flange lug: Rarely used because it requires a very heavy nozzle and shell
reinforcement.

e) Truimions: Simple and economical. Used on a wide variety of vessels.

 C^O. flU C©lM!l»1 •

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Fig. 1.2 Various lifting attachment of pressure vessel

The terminologies in the abovefigureare

1. Shellflangelug

2. Top head lug

3. Topflangelug

4. Truimion

5. Side lug

6. Cone lug

7. Tail beam
8. Tail lug

9. Choker (sling)

10. Base ring stiffener

 CHAPTER 2

LITERATURE REVIEW

1. Y.S. Choo, C.K. Quah, N.E. Shanmugam, J.Y.R. Liew [2], show the results
of an experimental study on the behaviour of plate trunnions subjected to shear
loads. The computational study and design considerations for plate trunnions
are described in a companion paper.The experimental results show that thexe is
a significant strength contribution from the side braces to the overall plate
trunnion strength, which the industry practice ignores. With due consideration
of the strength contribution of the side braces, the shear plate thickness may be
rationalised with corresponding reduction in the welding requirements at the
shear plate to main plate connection.

2. Y.S. Choo, C.K. Quah, N.E. Shanmugam, J.Y.R. Liew [3], The FE
modelling and analysis of plate trunnions subjected to shear loads have been
presented. Three-dimensional solid elements are used to model the
components of the plate trunnion, with specification of material and geometric
nonlinearities in the analysis. Results from a computational study on the
behaviour of plate trunnions subjected to shear loads are presented in this
paper. The experimental study on nine large-scale plate trunnion specimens is
described in a companion paper. The reference shear yield strengths of the
shear plate and side braces are foimd to provide consistent lower-bound
reference strength for plate trunnions. With appropriate design factors, the
reference shear yield strength will provide a direct indication of the trunnion
shear strength. Proper evaluation of sling load distribution, dimensioning of
trunnion components and associated fabrication aspects are important
considerations for the design of plate trunnions.

3. S. Rajasekaran, D. Annet and Y. Sang Choo [1], the optimum location of

offshore platform lift points are determined considering moment and
frequency as objective fiinctions. In this study, the analytical formulation of
the minimum support stiffness is developed for different types of beam-end
conditions based on connectivity conditions at the support point.

4. IS 816-1998 Indian Standard, [4], Section 7. PERMISSIBLE STRESSES IN

WELDS. Fillet welds throat length permissible stress i.e., bending stress, shear
stress, and combination of stresses and their formulas.

IS 800-2007 Indian Standard, [5], SECTION 11. working stress design,

members subjected to bending- bending stresses, shear stresses, and combined
stresses, their formulas and allowable limit for checking strength

10
6. T. Nguyen, M, Romios, O. S, Es-said, [6], this case study is to determine the
cause of failure of a conveyor trunnion shaft from a solid bowl centrifuge. The
trurmion shaft fractured at the weld joint, which joins a flange to the end of the
shaft. Fracture occurred through the walls of the shaft. It was determined that
the failure was caused by defects related to the welding procedures. These
defects included cracks in the weld joint, unfused welds, slags, and porosity.
The causes of these defects were due to boor welding techniques prior to and
during the welding procedure. The weld joint was an area of high stress
concentration, in addition the flange was inaccurately machined, which may
have caused high bending stresses during operation and contributed to the
failure. The flange should also be more accurately machined to prevent
misalignment with the shaft.

7. Dennis R Moss, [7], Pressure vessel design manual Chapter 7. Transportation

and Erection of Pressure Vessels: procedure 7-8: Design of trunnion,
PROCEDURE 7-9: local loads in shell due to erection forces

8. Guidelines for lifting points and heavy lift criteria, document no. EM/039
Rev:3, [8], This manual describes the guidelines on the design fabrication and
inspection of lifting points for light and medium lift weight. These criteria are
mainly intended for lifting points on packages for offshore lifting.

9. Choo YS, Padmanaban K, Shanmugam NE, Liew JYR. Behaviour of plate

truimions subjected to shear loads. In: 5th International Offshore & Polar
Engineering Conference, The Hague, 1995;IV: 29-36. This paper represents
the results of a parametric study, with systematic variation of relevant
geometric parameters, on the elasto-plastic responses of plate trunnions
subjected to shear loads from the sling eyes. It was observed that the plate
trurmion possesses significant reserve strength beyond its limit load and that
the current industry practices, which considers the shear plate only to transfer
the total sling load into the main plate.

11
 CHAPTER 3

PROBLEM SELECTION

Every pressure vessel does not need to be designed for erection or have lifting
attachments, but the larger the size of vessel, the more complex and expensive the
vessel, and the more care is to be taken into account when designing the attachments
lift. The following listing may provide some guidelines for the designing of special
lifting attachments that the lifting attachments are either required or not and thus a
lifting analysis to be done. In general, lifting attachments are employed for the
following cases:
1. Vessels over 50,000 lb (25 tons).
2. Vessels with L/D ratios greater than 5.
3. Vertical vessels greater than 8 ft in diameter or 50 ft in length.
4. Vessels located in a structure or supported by a structure.
5. High-alloy or heat-treated vessels (since it would not be advisable for the field
to be doing welding on these vessels after they arrive on site, and wire rope
slings could contaminate the vessel material)
At the initial lift, when the vessel is horizontal, the load is shared by two trunnions
and a tail lug, during each degree of rotation, the load on truimions and the shell are
continuously varying until the vessel is completely erected vertically to groimd.
In this project trurmion with stiffeners and the loading at various lift angles are done
using FEM method and the analysis is carried out for two different material to study
the effect on stresses when the material is changed.

12
 CHAPTER 4

F.E.A. OF LIFTING TRUNNION FOR PRESSURE VESSEL

A Finite Element stress analysis of lifting trunnion is carried out as per the dimensions
given in Table 4.1. The model consists of trunnions, pad & Cylindrical Shell. ANSYS
Version 10.0 software is used for finite element analysis.

DIMENSIONS
Sr. no. Parameter Symbol Units Valu
e
1. Pressure vessel Outside diameter Do mm 2836
Inside diameter Di mm 2800
Vessel Thickness ts mm 18
Length Ls mm 5000
2. Pad Outside diameter Pod mm 1230
Inside diameter Pid mm 630
Width Pw mm 18
3. Trunnion Pipe outside diameter Tod mm 630
Pipe inside diameter Tid mm 566
Pipe length T, nmi 290
Number of trurmions n 2
4. Front cover plate Diameter Fd mm 830
thickness Ft mm 24
5. Central ring Outside diameter Cod mm 830
Inside diameter Cjd mm 566
Thickness c, mm 24
6. Right angle Length Ri mm 300
triangular shaped Width Rw mm 24
stiffeners
Height Rh mm 124
Number of ribs Rn 4

Table 4.1 Model Dimensions

13
4.1 Procedure for doing the analysis in ANSYS 10.0 consist of

4,1.1) Element Type

SOLID 185 is used for 3-D modelling of solid structures. It is defined by eight nodes
having three degrees of freedom at each node: translations in the nodal x, y, and z
directions. The element has plasticity, hyper elasticity, stress stiffening, creep, large
deflection, and large strain capabilities. It also has mixed formulation capability for
simulating deformations of nearly incompressible elastoplastic materials, and fully
incompressible hyper elastic materials. It allows for prism and tetrahedral
degenerations when used in irregular regions. Various element technologies such as
B-bar, uniformly reduced integration, and enhanced strains are supported. The
geometry and node locations for this element are shown in Fig 6.1.

M.N,0,P

.0 not reKXTnended

Fig4.I Element, Solid 185

4.1.2) Materials used and its Properties

4.1.2.1) Material 1
> Material used is SA516 GRADE 60 having minimiun tensile yield strength of
220 MPa
> Structural, linear, elastic, isotropic material with following properties is taken.
o Modulus of Elasticity: 2.023 5e5 N/mm2
o Poison Ratio: 0.3

14
4.1.2.1) Material 2
> Material used is A36 having tensile yield strength of 250MPa
> Structural, linear, elastic, isotropic material with following properties is taken.
o Modulus of Elasticity: 1.3476e5N/nim2
o Poison Ratio: 0.26

4.1.3) ModelUng
Following model shown in Fig 6.2 with dimensions given in Table 6.1 is made using
ANSYS 10.0

Fig 4.2 Typical model for analysis

4.1.4) Meshing
Meshing is an integral part of the computer-aided engineering simulation process. The
mesh influences the accuracy, convergence and speed of the solution. In this report
sweep meshing is used to mesh the solid model. Using voliraie sweeping, we can fill
an existing unmeshed volume with elements by sweeping the mesh from a bounding

15
area (called the source area) throughout the volume. If the source area mesh consists
of quadrilateral elements, the volume is filled with hexahedral elements. If the area
consists of triangles, the volume is filled with wedges. If the area consists of a
combination of quadrilateral and triangular elements, the volume is filled with a
combination of hexahedral and wedge elements. The swept mesh is fiilly associated
with the volume.

ANSYSI

Fig.4.3 Meshed Model Of A Trunnion

4.1.5) Boundary conditions
Structural displacement constrained is applied in all directions at the side faces of
shell as shown in the fig.

16
 Fig .4.4 Boundary condition (zero degree of freedom at side faces)

4.1.6) Loads
Gravitational acceleration is applied in the global Y-direction, when the vessel is in
horizontal position. The load acting on two trunnions is equal to 148723 kg acting in
global X-Y plane. When the starts the vessel is in horizontal position making angle of
90 with lifting cables, as the lifting starts the angle changes to zero degree. The load
case taken are case 1 at 0 degree, case 2 at 30 degree, case 3 at 45 degree, case 4 at 60
degree, case 5 degree at 75 degree, case 6 at 90 degree. With the variation of lifting
angle load on the trunnions also changes respectively.
The lifting cables are attached with trunnion at the locations on trunnion pipe
between face plate and middle plate. The cable width taken is 25mm, and the contact
angle is taken 120 degree. In this report six load cases are analysed starting fi'om
horizontal position of the vessel to the vertical erection position with ground
While erecting a vessel tail lug is also attached at one end of vessel and at another
end two lifting trunnions. The terminology for load calculation is as follows:

17
LI = Sm, length of vessel,

L2 = 2.5m, distance between tail lug and center of gravity of vessel,

L3 = Im, distance between trunnion and center of gravity of vessel,

L4 = 1.42m, diameter of vessel,

W= 148723 kg, weight of pressure vessel,

F = Load on tail lug,

T= Load on two trunnions.

L4saiA L2cosA_ L3cosA

LlcosA

Diagram for load calculation at diflferent lifting angles

Fig 4.5
Load on lug is found by the formula

L = (W X L3 X cos A)/(L4 sin A + (L2 + L3) x cos A)

And for the trunnions, the load is

T = W-F

18
Sr. No. Angle between Force on tail lug Force on trunnions Force per trunnion
vessel axis and F (in kg) T(inkg) T/2(inkg)
horizonal axis
1 0° 42492.28 106230 53115

2 30° 34427.91 114295 57147.5

3 45° 30228.25 118494.75 59247.375

4 60" 24955.5 123767.5 61883.75

5 75° 16901.28 131821 65910.5

6 90° 0 148723 74361

TABLE 4.2 Load acting on trunnion at different ang e

The various load cases are shown in figure

Casel: when vessel in horizontal position

VCLDKES AN
tivt mjK

CASE 1 design a n a l y s i s of l i f t i n g tr'jnnicn

Fig.4.6 Load direction on trunnion at 0 degree lift angle

19
Case2: when lift angle is30 degree

AN
lYEE NTO

: nil r.. .iJL

CASS 2 deaagn analysis of lifting trunnion

Fig. 4.7 Load direction on trunnion at 30 degree lift angle

Case3: when lift angle is 45 degree

VOLUMES AN
TYPE ITUy.

X 1 f ^'

^ /

CASE 3 d e s i g n a n a l y s i s of l i f t i n g trunnion

Fig. 4.8 Load direction on trunnion at 45 degree lift angle

20
Case4: when lift angle is 60 degree

TCLOKES AN
I^PE HUM

CASE 4 d e s i g n a n a l y s i s cf l i f t i n g tr-onnicn

Fig. 4.9 Load direction on trunnion at 60 degree lift angle

Case 5: when lift angle is 75 degree

VCLDKES AN
TYPE 17D«

X I P
Hj j

CASE 5 design analyais cf lifting tr-jnnion

Fig. 4.10 Load direction on trunnion at 75 degree lift angle

21
Case6: when lift angle is 90 degree

TCIDHS AN

CASE 6 deaigri analysis of l i f t i n g tr-jnnicn

Fig. 4.11 Load direction on trunnion at 90 degree lift angle

22
 CHAPTER 5

FEM SOLUTION FOR MATERIAL SA516Gr60 USING ANSYS

5.1 Using ANSYS the nodal solution of von mises stress distribution for the different
cases are shown below:

Case 1: When pressure vessel is in horizontal position i.e. 0 degree angle,

IT:OAL SOLUTION AN

15.9

23. S
I
31.7

39.S

47.5
I
55.4

63.3

71.2 I
design analysis of lifting trunnion

Fig. 5.1 Nodal Solution of Von Mises Stress for case 1

23
Case 2: LIFTING ANGLE IS 30 DEGREE

HODAL SCLUIICH AN
SIEF-l
StTB =.1
IIKE»l
SE2V IAVC-!

I
DKX - . 6
SKli = . 1
SKX = - S .5
3MXE-144 . 1

26.3

::::!
52 .6

61.3

70

design analysis of lifting trunnion

Fig. 5.2 Nodal Solution of Von Mises Stress for case 2

Case 3: LIFTING ANGLE IS 45 DEGREE

HCOW. 301DTI0N AN
SICP«1
SUB - 1
IIKE-1
SEJV (AVS)
DKX « . 4
srai -0
SKX -lOS s
SKXB=143 3
24.2 I

36.3

•3S.4 1

60.4!

"2.5

24.6

96.7

mam^^wmm^ lOS.S I
design a n a l y s i s of l i f t i n g tr-onnicn

Fig. 5.3 Nodal Solution of Von Mises Stress for case 3

24
Case 4: LIFTING ANGLE IS 60 DEGREE

HODAL SCtrmOH AN
SIEP-l
3DB =1
IIKE-1
SEQV (ATC-)

I
OKU. - . 2
SKW •=.!
SKX - 1 1 0 . 9
SKXB-153.3

56.3

35.6

110. 9 I
design analysis cf lifting tiunnicn

Fig. 5.4 Nodal Solution of Von Mises Stress for case 4

Case 5: LIFTING ANGLE IS 75 DEGREE

MC3S1 SCLOTi:H AN
SIEE=1
SOB - 1
IIKE-1
SE2V (A'/S)
DM; - . 9
3MK - . 1
SHX - 1 4 6 1
SKXB-133 7
32.5

45.

65

I
129.9

146.1 I
desian analysis cf lifting trunnion

Fig. 5.5 Nodal Solution of Von Mises Stress for case 5

25
Case 6: LIFTING ANGLE IS 90 DEGREE

n:C'AL sc LIJII 3 AN
SIEP-l
srj3 =1
TIKE-: _K«>-^ ^«4HM3n
SEQV
2yx = 1 .
SMI - . 1
SKX -=16:
2XX3=231

design analysis cf lifting trunnion

Fig. 5.6 Nodal Solution of Von Mises Stress for case 6

For a pressure vessel it is necessary to calculate the membrane stresses value, thus
stress categorization factor is calculated near the maximum stress locations.

a) In the finite element method, when continuum elements are used in an analysis, the
total stress distribution is obtained. Therefore, to produce membrane and bending
stresses, the total stress distribution shall be linearized on a stress component basis
and used to calculate the equivalent stresses. If shell elements (shell theory) are used,
then the membrane and bending stresses shall be obtained directly from shell stress
resultants.

b) Membrane and bending stresses are developed on cross sections through the
thickness of a component. These sections are called stress classification planes
(SCPs). In a planar geometry, a Stress Classification Line (SCL) is obtained by
reducing two opposite sides of a SCP to an infinitesimal length. SCPs are flat planes
that cut through a section of a component and SCLs are straight lines that cut through
a section of a component. SCLs are surfaces when viewed in an axisymmetric or
planar geometry.

26
Case 1: Stress categorization factor when lifting angle is 0 degree

FOSTl AN
3IEF-1
SOB -1
iiyx-i
SECIIOH FLOI
1ICO1-5603S
HOD2-555I.0 71.235
scav
MEM+EEH;- _., , , j ^
i:iAL
70.374

70.037

s=2^ 59. a

€3.513

€9.22e

€3.333

cS 3ga
0 4.8 3.5 14.4 13. 2 24
2-4 7.2 12 ie.3 21-6
DIS7

design analysis cf l i f t i n g trunnion

Fig 5.7 SCL for case 1

PRINT LINEnniZED STREeS THROUCM A SECTION DEFINED BV PATH- CAGEl
<»»>«»• POSTl LINEARIZED STRESS LISTING
INSIDE NODE - 56090 OUTSIDE NODE - sssia
LOAD STEP 1 SUBSTEP- 1
TIME- i . a c i e a LOAD C A S E - B

THE FOLLOWING X . y . Z STRESSES A R E I N THE GLOBAL COORDINATE SVSTEM.

•" n E N B R A N E ••
sx SV SZ SKV SVZ SXZ
11.3B 59 .05 5.864 26 . 7 0 0 .3087 -0.5706E-01
ei S2 B3 S I NT SEQU
71.00 5.863 - 0.5970 71.59 68-59
• " • B E N D I N G -^• I - I N S I D E C-CENTER 0-OUTSIDE
SY SZ SVZ SXZ
I - 0 . 1sx
883E-ei -0.9261E-ei 0.3Z35E-ei e .sxy
3253E -01 -10.41 1 .690
C 0.000 0.000 O-O00 0.000 0-000 0-0OO
O 0.ia83E-01 a-9261E-01 - 0-323SE-B1 -a.32S3E -01 10.41 -1 .690
SI S2 S3 S I NT SEQU
I 10.52 -0-1044E-01 -10-S8 21.10 18 -27
C 0-000 0.000 0-000 O-O0O 0-OO0
O 10.58 0.1044E-01 -10.52 21 . 1 0 IB . 2 7
>»> MEMBRANE PLUS BENDING ••" I - I N S I D E C-CENTER O-OUTSIDE
8X SV SZ SKV SVZ SXZ
I 11 . 3 3 58 . 9 6 5.896 -26.66 -10.10 1.633
c 11 11 .. 3a 7s 59 . 0 5 5 .864 26.70 0.3087 -B-S7a6E-01
O 59 . 1 4 5 .831 -26.73 10.72 - 1 . 7 4 7
81 S2 S3 S I NT SEQU
I 72.37 5 -534 -1-714 74-0B 70-73
c 71 - 0 0 5 -863 -0-5970 71 -59 68 .59
O 72-75 5.438 -1.847 74.60 71 . 2 4
»»** P E A K *M« I - I N S I D E C-CENTER O-OUTSIDE
SX SV SZ SKV SVZ SXZ
I - 2 . 1 6 4 -1.145 1.097 1 .744 -0.3616 -0.2650
G 1 .521 -0.1959 -0.4225 -0.6327 - 0 . 7 3 4 6 E - 02 - 0 . 20O2 E-02
O - 2 , 1 6 2 - 1 . 1 3 7 1.102 1.746 0.3766 0.2678
SI S2 S3 6 I NT SEQU
I 1 .277 -0.1836E-01 -3.471 4-748 4.251
c 1.729 -a.4011 -0.4252 2.154 2.142
O 1.292 -0.1961E-01 -3.469 4.761 4.260
p»» T O T A L • « » I-INSIDE C-CENTER O-OUTS IDE
SX SV SZ SXV SVZ SXZ
I 9 ,169 57.81 6-993 -24-92 -10.47 1 .368
c 12-87 58 -85 5-441 -27.33 0-3014 -0.59B6E-01
o 9 .209 58.00 6.933 -24.98 11 . 1 0 —1.480
SI S2 S3 S I NT SEQU TEMP
1 69.96 6 .345 -2.331 72.29 68.36 0.0O0
c 71.58 5.441 0.1499 71.43 68.93
O 70.37 6 .212 -2.434 72.80 68.89 0.000

Table 5.1

27
Case2: Stress categorization factor when lifting angle is 30 degree

ECSH AN
SIEF-l
SOB - 1
IIME-1
SE"I1CH ELCT
NODl-52535
N002-52636 *""''
SEaV «_,i:

XEy+3Ei]; tc.sos
ICIAl
eo.ase /
ss.aei
^—-•""""^^'y^
siQv „„,
SD.e-rr-
y"^^^ /
^ /
ae.3-
---^
5"".B«3

S7.3S€

se.e^s
0 4.e 9-« 14.4 IS- ; S4
3-4 •'.2 IS 1€,S Sl-f

Disr

d e s i g n a n a l y s i s of l i f t i n g trunnion

Fig. 5.8 SCL for case2

PRINT L.INEnRIZED STRESS THROUGH R SECTION DEFINED BV P A T H ' CaSE3

" ™ ~ - P08I1 LINEARIZED STRESS LISTING - » » ~ ~
INSIDE N O D E - S2535 OUTSIDE NODE - 52G8e
L O R D STEP SUBSTEP" 1
TIHE- 1.
LORD C R S E ~ O
THE FOLLOWING K.V.Z STRESSES ARE IN THE GLOBAL COORDINATE SVSTEM.
•»> MEnBRRNE « «
SX SV SZ SKV SVZ SXZ
42 .48 34.40 5.613 27.60 0.4836 -2 .119
SI 82 S3 S I NT SEQU
66.39 10.V5 S.3S3 61.04 58.53
* BENDING «>» I-INS -CENTER O-OUTSIDE
SK sy SZ SKV SVZ S»Z
1 0.3513 0.2388 0.1336 0.3539 -7.545 4.Va9
C 0.000 0.000 8.000 0 . 0 0 0 0 . 0 0 0 0.000
0 0.3513 0 . 2 3 8 8 - 8 . 1 3 3 6 - B - 3 5 3 9 7 . 5 4 5 -4.?29
SI S2 83 SINT SEQU
1 8.686 -0.1050E-e2 -9.142 17.83 15.44
C 0.000 0.000 0.000 0.000 0.000
O 9.142 0.10G0E-02 -8.686 17.83 15.44
>» NEMBRRNE PUIS BENDING »» I=1NSIDE C=CENTER O-OUTSIDE
SK sy SZ SKV SYZ SKZ
I 42.13 34.16 S.V47 2V.24 V.0G2 2.610
c 42.48 34.40 5.613 -27.60 0.4836 -2.119
O 42.84 34.64 5.480 -27.9S 8.029 -6.847
SI S2 S3 SINT SEQU
I 66.40 12.39 3.255 63.14 59.11
c 66.39 IB.VS S.3S3 61.04 58.53
o 6 8 . VI 10.84 3.408 65.30 61.92
» PERK •« I<°INSIDE C=CENTER 0=0UTSIDE
SK SZ SXV SVZ SXZ
-2.314 sy -0.4526 1.147 -0.2546 -0.5S99E-01
1.063 -0.8869 -0.7106E-01 -0.5441 -0.5800E-01 0.3109E-01
-2.311 0.2612 -B-4HS9 1.147 0.4550 -0.7418E-ai
SI -0-8547 S3 SINT SEQU
-0.8062E-O1 S2 -2.954 2.873 2.645
1.340 -0.6189 02 -0.9143E-01 1.431 1.386
0.6953E-01 0.4569E- -2.974 3.043 2.750
-0.6676
SX » TOTRl. * I-INSIDE C=CENTER O-OUTSIDE
SZ SXV syz SXZ
I 39.82 sy 5.294 -26.09 -7.316 2.554
C 43.55 33.27 5.542 -28.14 0.4256
O 40.52 34.66 -2.087
SI 5.074 -26.80 8-484 -6.921
63.63 33 .78 S3 SINT SEQU TEMP
I S2
C 67.65 12.11 |-§2S *9-" 56.85 0.000
66.08 10.82
o 10.56 5.287 62.36 59.79 0.000
2.744 63.34 59.82

Table 5.2

28
Case 3: Stress categorization factor when lifting angle is 45 degree

FOSTl AN
STEP-1
SUB - 1
TIKE-1
SECTION FL"T
NODl-5-259
NOD2-5166e
3EQV lo-.QOs

KEM+BEtir 105.2ze
TCTAL
103.443

101.««
SEQV 35_5„

Se.C94

S4.311

34.528

S2.-45

fiC.S<3
0 J.2 2.4 3-« 4.8 e.ccx
.€ 1-5 3 4.2 S.4

DIST

d e s i g n a n a l y s i s cf l i f t i n g t;ruTinicn

Fig. 5.9 SCL for case 3

PRINT LINEARIZED STRESS THROUGH A SECTION D E F I N E D BV PATH== CASES
"»«*"• P O S T l L I N E A R I Z E D S T R E S S L I S T I N G ~ » —
INSIDE NODE > 57259 OUTSIDE NODE " 51668
LOAD STEP 1 SUBSTEP<° 1
TINE- i . e e a e LOAD CASE- e
THE FOLLOUING X , y , Z STRESSES ARE I N THE GLOBAL COORDINATE SVSTEII.
«» MENBRANE »»
SX sy sz sxy syz SXZ
5.001 -71.57 -12.51 1.863
SI S2 S3 -11.15 -37.81
12.45 -0.6236 -90.90 8 INT SEQU
103.3 97.47
>» B E N D I N G •H* I-INSIDE C-CENTER O-OUTSIDE
SX sy SZ sxy syz SXZ
I -0.61V3 -2.119 12.43 0.9242E-02
0.000 0.000 0.6330 10.95 0.000
c a.eee 2.119 -12.43 0.000 -10.95 -0.9242E-02
0 0.6173 S2 S3 -0.6330 SEQU
SI -0.5809 -8 . 0 2 9 SI N T 23.51
1 18.30 0.000 0.000 26.33 0.000
C 0.000 0.5809 -18.30 0.000 23.51
O S.029 26.33
» MEMBRANE P L U S B E N D I N G •w I-INSIDE C-CENTER O-OUTSIDE
SX sy SZ sxy syz sxz
I 4.383 -73.69 -0.82 37E-01 -10.52 -26.86 1.872
C 5.001 -7M.57 -12.51 -11.15 -37.81 1.863
0 5.618 -69.45 -24.94 -11.79 -48.75 1.854
SI S2 S3 SINT SEQU
1 12.31 1.762 -83.47 95.78 90.96
C 12.4S -0.6236 -90.90 103.3 97.47
O 14.29 -1.524 -101.5 115.8 108.8
» PEAK • I^INSIDE C-GENTER O-OUTSIDE
SX SV SZ sxy SVZ SXZ
I -0.2680E-03 -0.9200E-03 0.5396E-02 0.4753E-02 0.4013E-05
C 0.4796E-13 0.3144E-12 0.2748E-03 0.4334E-12 0.1910E-13
0.2680E-03 -0.5684E-13 0 . 3 5 5 3 E - 1 3
O 0.9200E-03 -0.5396E-02 -0.2748E-03 -0.4753E-02 -0.4013E-05
SI S2 S3 SI N T SEQU
I 0.7947E-02 -0.2522E-O3 -0.3486E-02 0.1143E-01 0.1021E-01
c 0.6026E-12 0.4663E-13 - 0 . 3 4 3 7 E - 1 2 0.9462E-12 0 . 8236E-12
O 0.3486E-02 0-2S22E-03 -0.7947E-02 0.1143E-01 0.1021E-01
• TOTAL »» [-INSIDE C - C E N T E R O - O U T S I D E
SX S¥ sz sxy syz SXZ
I 4.383 -73.69 -0.7698E-01 -10.52 -26.86 1.872
c 5.001 -71.57 -12.51 -11.15 -37.81 1.863
o 5 .618 -69.45 -24.94 -11.79 -48.76 1 .854
SI S2 S3 SINT SEQU TEMP
I 12.31 1.763 -83.46 95.78 90.96 0.000
c 12.45 -0.6236 -90.90 103.3 97.47
o 14.29 -1.S24 -101.5 115.8 108.8 0.000

Table 5.3

29
Case4: Stress categorization factor when lifting angle is 60 degree

POSH AN
SIEE-1
SUB - 1
IIKE-1
SECTION PLOT
H031-57253 _
K02i-5166S ^ '" y.
3EQV 10,.S.J
/ \
>CEy+BEirr
lOIAl
ac«.3^i
r
/ \\
30«.J
\
lCi.C29 \
SEC^' 99.35-

9~.«B'^
___J\
95.51€

93.345

91.1-.

BS-QCa
0 3-1 *.S ".2 S-« 13-0C3
1.3 3-« e 5-4 iC .8
DIS7

d e s i g n a n a l y s i s cf l i f t i n g tiunnicn.

Fig. 5.10 SCL for case 4

PRINT LINEARIZED STRESS THROUGH A SECTION DEFINED BV PATH= C A S E 4 DSVS =
w—'Mt POSTl LINEARIZED STRESS LISTING — » »
INSIDE NODE - 57253 OUTSIDE NODE - 51668
LOAD STEP SUBSTEP=- 1
TIME= 1. LOAD CASE-
THE FOLLOWING X , V , Z STRESSES ARE IN T H E GLOBAL COORDINATE S V S T E n .
»» MEMBRANE «»•
sx sy sz sxv svz SXZ
2S.24 -52.09 -52.07 -14.34 -52.97 -2.512
SI S2 S3 SIHT SEQU
3.446 -26.04 -106.8 110.3 98.86
»» BENDING » « I-INSIDE G-CENTEB 0-OUTSIDE
SX sy SZ SXV syz SXZ
I 5 . 779 -10.85 14.73 -0.1578 1.147 8.1494
0.080 0.000 0.000 0.000 8.888
c0 a.eae
-5.779 10.85 -14.73 0.1570 -1.147 -8.1494
SI S2 S3 SINT SEQU
T 14.78 5.7^8 -10.91 25.69 22.58
r. a.aae 0.008 0.008 O.808 0.008
O 10.91 -5.778 -14.78 25.69 22.58
«* MEMBRANE PLUS BENDING « « I-INSIDE C-CENTER 0-OUTSIDE
SX sy SZ SXV SVZ SXZ
T -19.46 -62.95 -37.34 -14.50 -51.82 -2.363
C. -25.24 -52.09 -52.07 -14.34 -52.97 -2.512
-31.82 -66.79 -14.18 -54.12 -2.662
o SI
-41.24
S2 S3 SINT SEQU
I 5.385 -19.67 -185.5 110.8 108.7
3.446 -106.8 118.3 98.86
c.
O 4.214
-26 . 8 4
-32.15 -111.1 115.3 102.1
» PEAK • INSIDE C=CENTER 0=OUTSIDE
SX SV SZ SXV SVZ SXZ
T -3.216 6.826 5.329 0.3806 5.683 -0.3O88
C 3.215 -6.815 -5.309 -0.3787 -5.586 0.3074
O -3.238 6.857 5.296 0.3803 5.601 -0.3095
SI S2 S3 SINT SEQU
I 11.73 0.4873 -3.279 15.01 13.53
C 3.278 -0.4872 -11.70 14.98 13.49
O 11.73 0.4844 -3.382 15.83 13.54
» TOTAL " « I = I N S I D E C-CENTER O-OUTSIDE
SX sy SZ SXV SVZ SXZ
I -22.68 -32 . 81 -14.12 -46.22 -2.671
C -56.12 -57.38 -14.72 -58.56 -2.205
-22.02 -58.91
0 -34.26 -61.50 -13.88 -48.52 -2.971
SI -34.38 S3 SINT SEQU TEMP
I S2 -94.14 99.46 89.80 0.088
5.314 -21.98
c 3.574 -118.2 121.8 110.7
-23.66 -188.1 184.8 91.64 0.888
o 4.6V6 -34.73

Table 5.4

30
Case 5: Stress categorization factor when lifting angle is 75 degree

EC 311 AN
3TEP=1
SUB - 1
IIKE-1
5ECTIDH PLOT
irODl-561SS
tI002-S6507 *s=-*i'

MZy.+BElIZ 113. •'a

XCTAL
10- -"^S8
ZO^.€£€

SEO^' ==..= „

•:•" . 410

-Jl-39«

c :.43e < ;= - -B9

1-319 3-eS- C-CSS 5.333 IG.9
Disr

d e a i o n a n a l y s i s of l i f t i n Q -crunnlori

Fig. 5.11 SCLforcase5

PKINT LINERRIZES STRESS THROUGH ft SECTION DEFINED BY PftIH= CASES DS«S- 0
»»««• P O S H LINEftRIZES STRESS LISTING »•««"«
INSIDE NODE = SeiSS OUTSIDE NODE - 56587
LORD STEP 1 SUBSTEP= 1
TIME- 1 .0000 LOAD C n S E - 0
THE FOLLOWING X , V , Z STRESSES ftRE IN THE GLOBAL COORDINATE S V S T E n .
« » MEKBRnNE «c«
SX 8« sz SHV SVZ SXZ
2.611 -24.47 -61.51 -0.1381 -36.14 -12.54
SI S2 S3 SINT SEQU
V.896 -6.333 -84.93 92.83 86.60
» » BENDING • » I = I N S I D E G-GENTER 0-OUTSIDE
SX S¥ SZ SXV SVZ SXZ
I 3.562 22.36 -38.0S 2.503 -3.633 -2.926
C B.000 0.000 0.000 0.000 0.000 0.000
0 -3.562 -22.36 38.05 -2.503 3.633 2.926
SI S2 S3 SINT SEQU
I 22.95 3.374 -38.45 61.40 54.33
C 0.000 0.000 0.000 0.000 0.000
O 38.45 -3.374 -22.95 61 . 4 0 54.33
•» MEMBRflNE PUIS BENDING < » I'INSIDE G-GENTER O-OUTSIDE
SX SV SZ sxy SVZ SXZ
I 6.173 -2.109 -99.57 2.365 -39.77 -15.47
G 2.611 -24.47 -61.51 -0.1381 -36.14 -12.54
0 -0.9506 -46.83 -23.46 -2.641 -32.51 -9.619
SI S2 83 SINT SEQU
I 17.59 2.217 -115.3 132.9 125.9
C 7.896 -6.333 -84.93 92.83 86.60
0 5.966 -6.664 -70.54 76.51 71.04
» » PEAK *"» I ^ I N S I D E C =CENTER 0=OUTSIDE
SX S« SZ SXV SVZ SXZ
I 0.2410 2.014 0.3402 0.9203E--01 3.464 0.4129
G -0.1199 -1.003 -0.1786 - 0 . 4 5 5 3 E -- 0 1 -1.735 -0.2074
0 0.2379 1.994 0.3733 0.8986E -01 3.468 0.4155
SI S2 S3 SINT SEQU
I 4.765 0.2443 -2.414 7.179 6.286
C 1.206 -0.1216 -2.386 3.593 3.147
O 4.769 0.2417 - 2 . 405 7.174 6.284
« ~ TOTftL •» I = I N S I D E C-GENTER 0=OUTSIDE
SX SV SZ SXV SVZ SXZ
I 6.414 -0.9S35E-01 -99.23 2.457 -36.31 -15.06
G 2.492 -25.47 -61.69 -0.1836 -37.87 -12.75
O -0.7127 -44.83 -23.09 -2.552 -29.04 -9.203
81 S2 S3 SINT SEQU TEMP
I 17.10 2.641 -112.6 129.7 123.2 0.000
C 8.240 -6 . 017 -86.90 95.14 88.87
O 4.844 -7.677 -65.80 70.65 65.29 0.000

Table 5.5

31
Case 6: Stress categorization factor when lifting angle is 90 degree

ECSTl AN
3IEE-1
S'JS -1
IIKE-1
SECTICH rLIT
HO:?l-473S4
H03J-46144
scav

d e s i g n analysis of lifting tr-^nnion

Fig. 5.12 S C L for case 6

PRINT L.INEARIZED STRESS THROUGH R SECTION DEFINED BV PflTH-

—»»- POSTl LIHEftRIZED STRESS L I S T I N G « « « « »
I N S I D E NODE - -4V3S4 OUTSIDE NODE - 4614-4
LX>AD STEP ± SUBSTEP- 1
TINE- i.aaee LOAD CnSE- 0
T H E F O L L O U I H G M , V .Z S T R E S S E S O R E IN T H E CLOBAI. C O O R D I N H T E SVSTEM.
«— liENBRnNE » »
SX SV SZ SKV SVZ SXZ
41. la -B.498BE-01 1B9.3 8.1V78 3.2492 -61.31
SI S2 S3 SIKT SEQU
± 4 5 -3 S.B4S -e.5B58E-ai 146.4 1 4 2 .9
•• B E N D I N G I-INS IDE C-CBNTER O-OUTSIDE
SX sy SZ SXV SVZ SXZ
B.5924E-B1 -0.1B34 0.4822 -6.62S 3.412 -e.9255E-Bl
B.aea B.aea e.aaa a.Bea B.B0e B.aea
0.1034 -0.4822 -3-412 e.92S5E-ai
-B-5924E-01 S2 S3 6.625
SI a.3178 -7.397 SI N T SEQU
7.S17 0.000 ±4.91 12.92
B.aea -7.517 e.aaa
B.aea -B.31V8 e.aee
V.397 MEMBRHNE PLUS BENDING 1 4 .I9-1I N S I D E C1-2C.E9N2T E R O ' O U T S I D E
SK sy SZ SXV SVZ SXZ
I 41.16 109.8 -6.447 3.163 -61.40
C 41.IB -0.1532 109-3 B.1778 -a.2492 -61-31
0 41.a4 -a.4980E-ai 108.8 6.802 -3.661 -61.22
SI 0.S36BE-01 S3 S I NT SEQU
1 146.a S2 -Z.460 148.5 143.9
C 14S.3 7.193 ~0.5a58E-ei 145.4 142.9
O 145.2 5.B45 -2.414 ±47.6 143.1
7.124
~ P E R K •"* I -INSIDE C-CENTER O-OUTSIDE
SX SV SZ SXy SVZ SXZ
-a.4438 -9.B72 12.7B -2-Sll -1-423 -3.SS6
-3.256 6.760 -6.653 0.8567E-01 -0.1434 3.289
-0.3507 -8.951 12.59 2.245 1.607 -3.649
SI S2 S3 SI N T SEQU
13.62 -0.4499 -9.993 23.62 2B.58
6 .V62 -1.253 -8.658 15.42 13.36
13.60 -a.5251 -9.778 23.37 20.39
- TOTAL — t-IHSIDE C-CEHTER O- O U T S I D E
SX sy SZ SXV SVZ SXZ
I 4B.V2 -9.22B 122.5 -8.958 1 .740 -64.96
c 3V.85 6.711 102.6 0.2635 -0.3926 -58.02
o 40.69 -8.897 121.4 9.048 -2-054 -64-86
61 S2 S3 SI N T SEQU TENP
I 7.702 -12.29 ±70.8
c isa .5 6.709 3.789 ±32-9
161.8 0.
o 136.•? 1 3 1 .5
7.518 -11.99 169.7 160.8
ISV.?

Table 5.6

32
5.2 FEM SOLUTION FOR MATERIAL A36

Using ANSYS the nodal solution of von mises stress distribution for the different
cases are shown below:

Case 1: When pressure vessel is in horizontal position i.e. 0 degree angle

HCDJLL SOLUII AN
SIEF=1
SUB - 1
TIKE-1
SE^',' i^'r
DKX - . 7
SKN -=.1
SKX =72 X
SMXB-12" . 5
I

I
deaian analysis of llfcino tr-^nniCT;

Fig. 5.13 Nodal Solution of Von Mises Stress for A36 case 1

Case 2: When pressure vessel is at 30 degree angle

HOSAL SOLOIIOH AN

26.7
I
35.5 I
44.4 I

53.3

62.2

I
design analys-s cf lifting trunnicn

Fig. 5.14 Nodal Solution of Von Mises Stress for case 2

33
Case 3: When pressure vessel is at 45 degree angle

HcoAi scurricH AN
SIEE-l
srj3 - 1
IIKE-1
3t3V (AV^
DHX - 1 . 1
SKH - . 1
SKX - 1 1 0 . 5
SKXB-152 . 4

49.3 1

61. 6 I

?6.

3=.5

I
d e s i g n a n a l y s i s of l i f t i n g trunnion

Fig. 5.15 Nodal Solution of Von Mises Stress for case 3

Case 4: When pressure vessel is at 60 degree angle

IICDJU. SCLUIIOH AN
SIEE-l
SOB - 1
IIKE-1
SEaV (JLV:
DKX = 1 . 4
SMI - . 1
SKX - 1 4 6 . 1
SKXB-132.5
16.5

52.5

45.-
I
65

129.9

146.1 I
deaigr. analysis of lifting trunnion

Fig 5.16 Nodal Solution of Von Mises Stress for case 4

34
Case 5: When pressure vessel is at 75 degree angle

HCCJAL SOLUTIDH AN
SIEF-1
SUE - 1
TIKE-1
SEfiV (A'/^ L

I
DKX = 1 . 2
SMI = . 1
SKX " 1 2 5
SKXB-1S4.1

41.7 ;

55.6 1

69. 5 j

;3. 4

I
design analysis of llfring trunnion

Fig. 5.17 Nodal Solution of Von Mises Stress for case 5

Case 6: When pressure vessel is at. 90 degree angle

HC-AL SDLUIICN AN

design analyse.3 c£ !.:.£t^ng trunnion

Fig 5.18 Nodal Solution of Von Mises Stress for case 6

35
Case 1: Stress categorization factor when lifting angle is 0 degree

ANSYS
STEe-1
SUB -X
IIMC-1
SCaiON PLOT
72.39C
tIOD2«55eiO
SEOV 71.93*
f~J-^1}JCt
KEM+BEND 7J.f€l
TOTAL
7i.afa

Ti.oes

SIQV •»0,?«7

70.Its

70.171

«S.D7S

C9.S7a

€8.277

dcJlgn aiiAlysis af lifclng crunnian

Fig. 5.19 S C L for easel

PRINT ]:.IHEARIZED STRESS THROUGH A S E C T I O N D E F I N E D BV F U T H - CA8E1

MWMMM POSTl L I N E A R I Z E D STRESS L I S T I N G WMMM
INSIDE N O D E - 5 6 B 9 8 OUTSIDE NODE - SSSIS
bOAD STEP BUBBTEP- 1.
TINE- 1. COAD CASE-
I H E FOLIIOWING x . y . z S T R E S S E S ARE I N THE <H.OBAI. COORDINATE S Y S T E M .
•»• MEMBRANE <
sx sy sz sxy svz sxz
58.60 -26.72
SI S2 3.404 SINT 0.3110 .5818E-ai
70.56 3.•404 S3 71.64 SEQU
-l.t 69.51
•«• B E N D I N G •« • I-INSIDE C-CENTER O - O U T S I D E
sx SV SZ sxy syz sxz
I - e . i 7 6 6 E - e i -B.9299E-B1 e.347aE-ei a.3267E-8i -ia.72 1.659
c a.aaa a.aaa a.aaa a.aaa a.aaa
0 fl.l.V66E-ai. -«.347aE-ai -e.3267E-ei 10.72 -i.6B9
SI a.9299E-01 S3 SINT SEQU
1 xm.a± S2 -10.88 21.69 18.78
c a.eaa -a.9545E-02
o le.sa a.aaa a.aaa a.aaa a.aaa
-ia.81 21.69 18.78
MEMBRANE FIAIS BENDING " •
a.9545E-02 I - I N S I D E C-CENTER O-OUTSIDE
SK SV
58.Sa
SZ
3.439
sxy SVZ SXZ
I la.s? -26.69 -ia.41 1.601
c la.ss 58.60 3.4a4 -26.72 a.3iia -e.saisE-ei
68.69 3.369 -26.75 11.83 -1.718
0 IB.9a S2 S3 SINT SEQU
SI 3.571 -2.724 74.68 71.74
1 VI.»6 3.404 -i.osa 71.64 69.51
C 7a.S6 3.521 -2.9a8 75.26 72.26
O 72.3S
P E A K m > I-INSIDB C-CENTER O - O U T S I D E
sx sy SZ sxy SVZ SXZ
I -z.lee -1.189 l.iaS 1.753 -a.3814 9.2634
C 1.4SS a.172a -a.4252 -0.6366 -e.7499E-02 B.2298E-02
0 -2.098 -1.181 l.ieS 1.756 a.3968 a. 2665
s± SZ „ S3 SINT SEQU
1 1.Z93 a.23Z4E- •Bl -3.456 4.749 4.24?
C 1.702 9.3867 „^ - 0 . 4 2 6 8 2.128 2.109
O 1.309 a.2518E- Bl -3.4S4 4.763 4.256
TOTAI. • » I-INSIDE C-CEHTER O - O U T S I D E
SK SV SZ sxy syz SXZ
I 8.766 57.32 4.541 -24.93 -10.79
C 12.37 58.43 1.338
0 8.803 2.979 -27.35 0.3035 a.6B48E-01
57.SI 4.477 -24.99 11.42 -1.451
SI S2 S3_ SINT SEQU
1 69.S2 4.275 TEMP
C 71.16 2.979 -3.177 72.7B 69.28 O.0OB
O 69.94 4.179 -a.362B 71.52 69:91
-3.325 73.26 69.81 e.BB0

Table 5.7

36
Case 2: Stress categori2ation factor when lifting angle is 30 degree
1
POST! ANsY^
STEP-1
SOB - 1
TIHE-1
StCTIOH PLOT
NODI'S2535
S0M-526e6 «-«»
SEQV „_„»
HEM+BEND <l.Ml
TOIM.

<0.ftl7
SECV ^0 ,13

Bl.SOfl ' ^
50.401

0 4.e *.e i«.« 19. Z 24

IS IC.S 21.e
DZST

desi-grn analysis or l i c c l n o cru2ini.on

Fig. 5.20 SCL for case 2

P R I N T t.IKEAItIZES S T R E S S T H R O U G H A S E C t l O M O E E I M E S BV I>ATH- C A S E 2 DSVS-

••H • F O S T l I.IHEARIZED S T R E S S I.ISTIHG MI
IHSIOE NODE - 52535 OUTSIDE HOBE •> 52686
UlAlt STEP 1 suasTEp- 1
TIME- 1 . aBBB
1.0nl> CASE-
THE FOI.I.OWIHG X,y,Z STRESSES ARE IN THE GI.OBAI. COORDINATE SVSTrai.
»• MEMRRANE •*>
8X SV SZ exy svz SXZ
41.61 34.04 2.SIS -2.104
SI S2 S3 -27.47 0.4691
65.62 10.24 2.616 SINT SEQU
63. eo 59. 5S
t-IMSISE C«CBNTE» O-OUTSIDE
SZ SXy SVZ siez
0.1488 0.3479 -7.609
4.760
-0.1488 -0.3479 7l609
0.276iaE-a2 - 9 S3
. 1SINT
7-97 SEQU
15.56
0.000 0.000
~0.376aE-a2 - 8 1771 17.97 15.S6
» nEHBRRNE FIiUS BENPING »» I-INSIPE C-CENTER O-OUTSIDE
sx SV SZ
I 41.27 33.81 3.964 sxy svz SXZ
C 41.61 34.04 2.816 -27.12 -7.140 Z.6S6
0 41.95 34.28 2.666 -27.47 0.4691 -2.104
SI S2 83 -27.82 8.079 -6.863
1 65.64 11.56 0.8448 SINT SEQU
C 65.62 10.24 2.616 64.79 60.15
O 67.SB 10.29 0.7199 63.00 59.55
67.16 62.93
I-INBIDE C-CENTER O-OUTSIDE
I
SX
-2.235
SZ syz sxy SXZ
-0.3990 1.156
-0.2713 -0.3100E-01
C 1.053 -0.9ei3E-'Bl -0.EE4E
-B.6S40E-01 O.2827E~01
0 -2.238 -0.3548 1.159
0.46S0 -0.8899E-01
S3 BINT
SEQU
1 -0.4214E-ai -2.904 2.862
2 7 M 7
C 1.343 0.4BS4E-B5 -0.1129 1.456
1.403 I
O 0.1057 -0.6203 -2.933 3.039
2.749
TOTAL I"INSIDE C>CENTER O-OUTSIDE
SX SV SZ sxy SVZ SXZ
I 39.04 32.92 2.565 -7.412 2.625
C 42.67 34.32 2.717 -25.97 0.4137 - 2.075
0 39.71 33.42 2.311 -28.03 8.544 -6.952
SI S2 83 -26.66 8EQU
1 62.92 11.32 BINT TEMP
0.2B95 £2.63 57.90 0.000
C 66.88 10.30 2.522 60.84
O 65.29 10.04 0.1190 64.36
65.17 60.82

Table 5.8

37
Case 3: Stress categorization factor when lifting angle is 45 degree

1
POSIl ANSY^
SIEP-1
SOB • !
IfflE-1
SBCIirat FIOI
NOD1-S72S9
H0D2-SH6S ""•'"
Stav 10...er

KEK+BEID IQS.ieA
lOIAl
lOi.aTi

101.873

^ ^ ...77,

97.877

Se.l7S

S4.3B1

fiz.saa

S0.7BS
0 l.Z S.4 a.6 <.e e.ooi
-e i.e 8 «.3 S.4
DIST

design analysis of lifcing trunnion

Fig. 5.21 SCL for case 3

PRINT IiINEARIZnED S T R E S S THROUGH R S E C T I O N D E F I N E D BV P A T H - CnSES
" - " " " P O S T l L I N E A R I Z E D S T R E S S t.ISTIMG — —
INSIDE NODE - 57259 OUTSIDE NODE - 51.666
LOAD STEP SUBSIEP- ±
TIME- 1.
I<OAD C A 8 E -
T H E FOI.I.OifIN<: K , y , Z S T R E S S E S A R E IN T H E GLOBAI. C O O R D I N A T E S Y S T E N .
~«> M E M B R A N E -»•
8K SKV SVZ SXZ
6.409 sy sz -11.39 -36.03 2.216
S± -69.Sr? - l i . 4 9 SINI 8EQU
14.30 _ S2 S3 1B3.7 99.42
e.3Q12 -B9.36
» S E N D I N G •»" I - I N S I D E C - C E H T E R O - O U T S I D E
8M _8y 8Z SKY SVZ SXZ
I -0.8854 —2.355 12.17 0.6859 10.82 '«.3101E-01
C 0.000 0.000 0.000 0T000 0.000
0 B.88S4 2.355 -ISA*^' -0.6859 -10782 B .3101E-01
81
1 17.94 _ 82 83 8INI 8EQU
C 0.000
O 8.176 "•*A*2Z3 -8.176 26.12 23133
0.000 0.000 0.000 0.000
>~» MEMBRANE P U I S BENDING <—• I > I N S I D E C«CENTER 0 < > 0 U T 8 I D E
SN 0.8 sy373 - 1S7. Z9 4 2 6.12
SKV S2V
3. Z3 3 SXZ
I 5.523 -72.03 0.6762 -10.71 -27.22 2.185
C 6.409 -69.67 -11.49 -11.39 -38.03 2.216
0 7.294 -67.32 -23.66 - 1 2 . 0 8 - 4 8 . 8 5 2.247
SI 82 S3 SINT SEQU
1 13.79 2.490 —82.12 95.91 90.79
C 14.30 0.3012 -89.36 103.7 97.42
O 16.45 -0.3987 -99.75 116.2 108.8
•• F E R K •« ' I - I N S I D E C - C E N X E R O - O U T S I B E
SX sy SXZ
I - 0 . 3 8 4 4 E - 0 3 -0.1 _ SZ Bxy syz
C 0 . 3 9 0 8 E - 1 3 -0.70 1
23E-
0 5 E -
-0.1347E-04
0 0 . 3 8 4 4 E - 0 3 0 . 1 0 2 3 E - •p? S-5SS5£~92
SI B.2978E-03 0.4698E-02 0.1 B . 954E-13
1347E-04
1 0 . 7 7 9 1 E - 0 2 - 0 . S3 2
636E' i 3 2 - i S S 5 i ~ i 2 0.39B8E-13 0.40E0E-12
C 0.5628E-12
O 0.3S50E-02 0 .3773E-
0 . 3 6 3 6 E - •02 - B . 5 2 8 4 E — 0 2 - O . 2 9 7 8 E - 0 3 - 0 . 4 6 9 8 E - 0 2
•• T O T A L • 0 3 - 0 . 3 5 5 0 E - e 2 0?il34E-01 0?1013E-O1
SX sy i l l2-33i?iZl:S 0-89SlE-^12 0:7790E-i2
I S.S23 -72.03 SXZ
C 6.409 -69.67 03 - 0 . 7 7 9 1 E - 0 2 0.1134E-01 0.1B13E-01 2.185
0 7.294 -67.32 " *~*!S*»E C-CENTER O-OUTSIDE 2.2ie
82 o 55._ SX* syz 2.247
1 13.79 2 . 4 9 1 ®-.-f*iS - 1 0 . 7 1 - 2 7 . 2 1 TEMP
C 14.30
O 16.46 0.301I -I|-fi7 ~}i-ai -38.03
^2A*' -12.08 -48.86 0.000
-0.3987
iSi-ie
Table 5.9 ?Si'i 90.79
IllS"?! i?I-^ 97.42
-99.75 116.2 108.8

38
Case 4: Stress categorization factor when lifting angle is 60 degree

ANSYS
STCP-l
SUB - 1
TlME-1
SCCTIOH ELOl
KOD1-572S3
110.S7<
NOD2-516ee
StQV 108.3TJ
K£KBJIAI:E
KEM+BEND loe.iTg
TOTAL
loa.fisi

101.788
SEQV
ss.sas

«.3fi7

95.IBS

92.991

90.793

es.sss

design analysis of lifting trunnion

Fig. 5.22 S C L for case 4

PRINT L I N E A R I Z E D STREftS T H R O U G H A S E C T I O N D E F I N E D B» P A T H - CASE'*

•«—•»«• POSTJl lilNEARIZED S T R E S S L I S T I N G
INSIDE N O D E - 57253 O U T S I D E N O D E - El 6 6 8
LORD STEP SUBSTEP*
TIME- 1. UMID C A S E - Q
T H E P O L I S H I N G X , y , Z S T R E S S E S A R E IN T H E GLOBAI. C O O R D I N A T E S Y S T E N .
•M> HEHBIMNE
SK S« SZ 8X9 SVZ SXZ
-4B.BB -50.46 -14.S0 -S3.IB -2.489
SI S2 83 SINT SE«U
6.365 -25.16 -104.2 110.5 98.63
I - I N S I D E C--CENTER O - O U T S I D E
sx SZ
5.036 14.65 sxy avz sxz
C a.eao O.00O -0.2377 0.9528 0.2032
O -5.836 -14.65 0 . 0 0 0 • O . O e O O.0O0
SI 8 3 0.2377 -0.9538 -0.3033
I -11.26 SINT SEQU
C e.aaa 0.000 2 5 .95 2 2 .85
o X.1..26 -14.69 0.O00 0.000
25.95 22.85
MEMBRANE PLUS BENDING •» I-INSIDE C - C E M T E R O - O U T S I D E
sx SV SZ SXV SVZ SXZ
I "- . 3 0 -35.80 -14.74 -S2.14 -2.285
C -18.60 -50.46 -14.50 -53.lO -a.489
o -30.2? -36.86 -65.11 -14.26 -54.05 -2.692
SI S2 S3 SINT SEOU
I -i8.se -103.0 111.1 100.4
c 8. ess -25.16 - 1 0 4 . 2 lie.5 98.63
o 6.365 -31.29 -108.4 115.8 102.1
7.415 •• PEAK •< I-INSIDE C - C E N T E R O - O U T S I D E
SM SV SZ sxy SVZ SXZ
I -3.513 6.603 5.193 e.402S 5.728 -0.3921
c 3.512 -6.592 -5.174 -0.4007 -5.711 0.3906
o -3.536 6.634
B2
5.161 0.4026 5.726 -0.3931
Sl S3 SINT SEOU
I 11.67 0.211S -3.598 15.27 13.76
c 3.596 -0.2119 -11.64 15.23 13.73
o 11.67 0.2BS3 -3.621 15.29 13.78
» TOTAL I-IHSIDE C-'CEHTER O - O U T S I D E
ex S» SZ sxy SVZ SXZ
-52.70
coI -- 22 20 .. 19 23 -54.67
- 3 0 . 2 3
-30.61
-55.63
-14.33
—14.90
-46.42
-58.81
-2.677
-2.098
-33.81 -S9.95 —13.86 -48.32 -3 .085
SI S2 S3 SINT SEOU TEMP
I 7.698 -31.35 -91.77 99.47 88.60 0.000
c 6.782 -22.52 -115.5 122.3 110.6
o 7.621 - 3 4 . 1 3 -97.47 105.1 91.65 e.aee

Table 5.10

39
Case 5: Stress categorization factor when lifting angle is 75 degree

AIMsrs
SIEP-l
SOB - 1
Tiia>i
seciioH that
139.<:«
Hoa2-seso7
SEC 111.C73

KEM+EEim iia.7n
IOTA!
107.76e

101.91a
Slav B9.9C

8S.g07

83.S94

79.001

72.049

CC.099

design analysis of lifting trunnion

Fig. 5.23 S C L for case 5

PRINT I.INEARIZE]> STRESS THROUGH ft SECTION PEFIHES BV PATH- CASES

'«•••••«'• POSTl 1.INEARIZED STRESS LISTING •€»••»•
INSIDE NOSE - 561B5 OUTS IDE NODE - S6Se7
I.OAD STEP SUBSTEP-
TINE- 1. I<OAD C A S E - a
THE POI.i:.OWING X . y . Z S T R E S S E S ARE I N THE GLOBAI. COORDINATE SySTEH.
>»• HEHBORANE
GX sy SZ sxy GVZ SXZ
4.136 -23.61 -59.63 -36.32 -12.63
B± 82 S3 0.1774 SEQU
9-67S -5.319 -83.46 SINT 86.62
93.14
•»• BENDING « I-INSIDE C-CENTER 0-OUTGIDE
GX GZ sxy GVZ 8XZ
I a-TB? _sy -37.69 2.616 -3.719 -3.049
c a.000 3 2 . 6S 0.000 0.000 0.000 0.000
0.000 37.69 -2.616 3.719 3.049
0 -3.707 -22.65 S3 SIHI SEQV
81 S2 -38.12 61.40 54.28
1 23.28 3.503 0.000 0.000 0.000
C 0.000 -3.503 -23.28 61.40 54.28
O 38.12
6X >»> MEHBRANE PLUS BENDING i»> I-INSIDE C-CENTER O-OUTSZDE
SZ sxy SVZ SXZ
I 7.843 sy -97.32 2.793 -40.04 -15.67
C 4.136 -0.9627 -59.63 0-1774 -36.32 -12.63
O 0.4294 -23.61 -21.94 -2.439 -32.60 -9.577
SI -46.26 S3 SIMT SEOU
I 19.62 S2 -113.4 133.0 125.6
C 9.675 3.298 -83.46 93.14 86.62
O 7.407 —5.319 -69.70 77.10 71.54
-5.481 •-INSIDE C-CEHTER O-OUTSIDE
8X •- PEAK ••" SZ sxy syz
sy SXZ
I 0.1703 1.897 0.2876 0.9079E-01 3.258 0.4087
C -0.8446E-ei -0.9449 -O.iSZZ -«.4489E-ei -X.632 -B.Z053
0 0.1671 1.878 0.3204 0.88S3E-O1 3.261 0.4114
61 S2 S3 SINT SEQU
1 4.472 0.1748 -2.292 6.764 5.929.
C 1.145 -0.S684E-0:I -2.240 3.385 2.968
O 4.476 0.1721 -2.283 6.759 5.926
"• TOTAL "*> I-INSIDE C-CENTER O-OUTBIDE
GX GZ BXy GVZ 8XZ
I 8.013 sy -97.04 2.884 -36.78 -15.27
C 4.052 0.9343 -59.79 0.1325 -37.95 - 1 2.83
0 0.6965 -24.55 -21.62 -2.350 -29.34 -9.16S
SI -44.38 S3 SINT SEQU TEHP
1 19.12 S2 -110.9 130.0 123.0 0.000
C 10.03 3.6S0 -8S.31 95.34 88.78
O 6.286 -6.0Bf7 -65.25 71.53 66.09
-6.443

Table 5.11

40
Case 6: Stress categorization factor when lifting angle is 90 degree

1
POSIl ANS^.S
SIEP-l
ST3B - 1
TIME-1
sECiicat pioi
NODl-47354
N0D2-46144 1«.10»
SEQV
MEJti,XAt:E 1 5 9 . OH
MEM+BEH3 ,,, „ ,
lOTJU. "S.«S
1S2.S49
14S.7«3

143.691
X4O.fi0S
137-419
134.333

0
\/X
4,e 9.6 14.4 19.2 24
3.4 7.2 12 l€.a 21.e
DIST

d e s i g n axialyais of Lifting ^mnnlon

Fig. 5.24 SCL for case 6

PRINT LINEARIZEB STRESS THROUCH A SECTION DEFIHED BV PATH- G

• » — P O S T ! LINEARIZES STRESS I.I8TIHG — —
INSIDE NODE - 47354 OUTSIDE NODE - 461.44
LOAD STEP 1 BUBStEP- 1
TINE- ±.mS>BB LOAD CASE- 8
THE FOIiLOHIHG K,V,Z STRESSES ARE IN THE GLOBAL COORDINATE SySTEH.
•»• MEHBRANE « »
SK
40.78 sy sz sxy syz SKZ
SI .176» -0.2S13 -61.30
il.l38aE-04 1B9.3 SINT SE4U
145.2 82 83 14S.S 142.9
4.809
• BENDING -s.TeesE-ea
SX -CENTER O-OUTSIDE
sy SXV s3 y. 4z 3 7 SXZ
I a.ssesE-ai -6.834 -O.8796E-01
C 0.000 -0.1057 0.000 0.00O 0.800
0 -0.S36SB-O1 0.000 6 . 8 3 4 - 3 .437 0.8796E-ei
SI e.l0S7 SINT SE4W
1 7.707 S2 1 5 . 3 1 1 3.26
C 0.000 0.3216
O 7.603 0.000 I S . 31 13.26
-a.3216
•~ MEHBRANE PLUS BENDING ~ I-INSIDE C-CENTER 0-OUT81SE
SX sy sz SXV syz SXZ
I 40.83 -0.10B7 109.7 -6.657 3.186 -61.39
C 40.78 0.138aE-a4 109.3 0.1769 -0.2513 -61.30
0 40.73 O.1057 108.B 7.011 -3.689 -61.21
SI 82 S3 SINT SEQU
1 14S.9 7.163 -2.630 148.6 143.9
C 145.2 4.809 -B.766SE~03 145.2 142.9
O 145.1 7.101 -2.6SS 147.7 143.1
m PEAK • - I N S I D E C-CENOrER O'OUTSIDE
SX sy SZ sxy syz SXZ
I -0.6603 -9.226 13.OS -2.438 -1.482 -3,565
C -3.207 6.870 -6.799 O.8469E-01 - 0 . 1 4 1 7 3.331
O -0.5677 -9.107 12.95 2.173 1.659 -3.655
SI 82 S3 SINT SEQU
t 13.96 -0.6718 -10.12 24.07 21.Ol
C 6.872 -1.218 -8.790 15.66 13.57
O 13.93 -0.7442 -9.906 23.83 20.82
» TOTAL I-INSIDE C-CENTER O-OUTSIDE
ex sy SZ SXV syz SXZ
I 40.17 -9.331 122.8 -9.095 1.704 -64.9S
C 37.57 6.870 102.5 0.2616 -0.3930 -57.97
O 40.16 -9.001 121.7 9.185 -2.030 -64.86
81 82 S3 SINT SEQU TEMP
I 158.7 7.506 -12.53 171.2 162.1
c 136.4 6.869 3.590 132.9 131.2
o 157.8 7.327 -12.24 170.0 161.1 e.00O

Table 5.12

41
 CHAPTER 6

RESULTS AND DISCUSSION

6.1 RESULTS OF ANSYS SOFTWARE

6.L1 For Material SA516 Grade 60
STRESSES FOR LIFTING TRUNNION ACCORDING TO ANSYS

Sr. No. Load case Maximum SCL

Von mises
stress
1 At angle 0 degree 71.2 68.59

2 At angle 30 degree 78.8 58.53

3 At angle 45 degree 108.8 97.47

4 At angle 60 degree 110.9 98.86

5 At angle 75 degree 146.1 86.60

6 At angle 90 degree 161.8 142.9 •

Table 7.1 FOR MATERIAL SA516 Grade 60 (ANSYS)

6.1.2 For Material A36

STRESSES FOR LIFTING TRUNNION ACCORDING TO ANSYS

Sr. No. Load case Maximum SCL

Von mises
stress
1 At angle 0 degree 72.1 69.51
2 At angle 30 degree 79.9 59.55
3 At angle 45 degree 108.8 96.10
4 At angle 60 degree 110.8 98.63
5 At angle 75 degree 146.1 86.62
6 At angle 90 degree 162.1 141.82

Table 7.2 FOR MATERL^L A36 (ANSYS)

All stress values have units in MPa.

42
6.2.1 Comparing the SCL results of SA516Gr60 and A36
115

105

95

85 -C—SA516 GR60

-D-A36
75

65

55
Case 1 Case 2 Case 3 Case 4 case5 case6

Graph 6.1

6.2.2 Comparison of maximum von mises stresses with allowable stress of the
respective material

•SA516Gr60

-D-A36

-ALLOWABLE SA5166r60
STRESS
-ALLOWABLE A36 STRESS
250
230 X- •^¥r • ^ • ^
=^ • ^ ^

210
-dr-
190
170
150
130
110
90
70
50
ANGLE 0 ANGLE 30 ANGLE 45 ANGLE 60 ANGLE 75 ANGLE 90

Graph 6.2
43
> The above graph shows that the stresses generated found by ANSYS software
are much less than the allowable stresses found by INDIAN STANDARDS
for the material SA516Gr60.
> This is found that by changing the material from SA516Gr60 to A36 does not
show the much change in the stresses value for respective angle of lift.
> When the lifting starts the lifting load amount was comparatively less than
other lift angles thus stress generated are also lowest at 0° and 30° lift angles,
> The maximum stresses are generated between angle 45° to angle 60°, then
slight decrease at angle 75°, and reaches to maximimi value when vessel is
completely erected at angle 90° and the overall load appears only on the
trunnions.'
> All stresses have the unit MPa.

44
 CHAPTER 8

CONCLUSION AND SCOPE FOR FUTURE WORK

8.1 Conclusion

In this report design of a lifting trunnion for Horizontal Pressure Vessel is analysed
using ansys. The stress variations are observed at various lifting angles while erecting
the horizontal pressure vessel to a vertical position. The results are found are
compared with different materials at critical locations.

It can be concluded that:

a) Stresses values are foimd larger at the angles 45° and 60** then there is slight
decrement and at 90^ of hft stresses are maximum,
b) There is no substantial change in stresses generated when material is changed
fromSA516Gr60toA36,
c) All stress values are imder the allowable stresses as found by Indian standard
for respective material, hence design is safe.

8.2 Scope for future work

a) The analysis can be done with various modifications in geometry like stiffeners
can have some grooves resulting to material saving thus cost reduction.
b) The analysis can be done with relatively cheaper materials since it is proved that
changing the material results in variation of stress values for same loading.
c) Better refined meshing can improve the results.
d) For liftmg vessel location of lifting attachments can be changed with or without
combined effort of other lifting attachments.

45
 REFERENCES

1. Y.S. Choo, C.K. Quah, N.E. Shanmugam, J.Y.R. Liew, Static strength of plate
trunnions subjected to shear loads — part I. Experimental study, "Journal of
Constructional Steel Research 58 (2002) 301-318".

2. Y.S. Choo, C.K. Quah, N.E. Shanmugam, J.Y.R. Liew, Static strength of plate
trunnions subjected to shear loads — part II, Computational study and design
considerations, "Journal of Constructional Steel Research 58 (2002) 319-
332".

3. S. Rajasekaran, D. Annet and Y. Sang Choo, optimal locations for heavy lifts
for offshore platforms, "asian journal of civil engineering (building and
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4. BUREAU OF INDIAN STANDARDS, IS 816-1998 Indian Standard, code of

practice for use of metal arc welding for general construction in mild steel
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5. BUREAU OF INDIAN STANDARDS, IS 800-2007 Indian Standard, general

construction in steel — code of practice (Third Revision)

6. T. Nguyen, M. Romios, O. S. Es-said, Failure of a conveyor trunnion shaft on

a centrifuge

7. Dennis R Moss, Chapter 7 - Transportation and Erection of Pressure Vessels,

Pressure vessel design manual By Dennis R Moss, Third edition

8. www.pes21 .com/home_56/engineering_web/str_lug_trunnion_9_H.asp

9. Shell U.K. Ltd. Guidelines for Lifting Points and Heavy Lift Criteria.
Engineering Reference Document No. EM/039 Rev. 3, 1991.

10. ASME Boiler and Pressure Vessel Code Section VIII, Div.l "Rules for
Construction of Pressure Vessels", 2010

11. ASME Boiler and Pressure Vessel Code Section VIII, Div.2 "Rules for
Construction of Pressure Vessels", 2010

46
12. ASME Boiler and Pressure Vessel Code Section II, Part A "Ferrous Material
Specifications", 2010.

13. C. Noordohoek, A Verheul, Static strength of high strength tubular joint.

U.ANSYSlOAPDLHelp.

47