Reduction of stresses in cylindrical pressure vessels using finite element analysis

Due to the differential operating pressure of pressure vessels, they are potentially dangerous and accidents involving pressure vessels can be deadly and poses lethal dangers when vessels contents are flammable/explosive, toxic or reactive. Stress induced operating factors (e.g., process-upset, catalyst regeneration) and stress related defects (e.g., fatigue creep, embrittlement, stress corrosion cracking) accounts for approximately 24.4% of reoccurring catastrophic pressure vessels failures in process industries, many of which has resulted in loss of several lives, properties and in some cases preventive measures of evacuation of residents and community enforced ( Sirosh & Niedzwiecki 2008 ). Pressure vessels store large amounts of energy; the higher the operating pressure and the bigger the vessel, the more the energy released in the event of a rupture and consequently the higher the extent of damage or disaster or the danger it poses, (American Petroleum Institute 2001). To prevent stress related vessel rupture and catastrophic failure, it is necessary to identify the main factors that contribute extensively to stress development in pressure vessels and how they can be mitigated. This work presents critical design analysis of stress development using 3D CAD models of cylindrical pressure vessels assembly and finite element engineering simulation of various stress and deformation tests at high temperature and pressure.