DESIGN AND STRESS ANALYSIS OF HIGH PRESSURE ACCUMULATOR MR. CHETAN KUMAR D S, MR. SHARATH KUMAR H A 1 Assistant Pofesso, Depatment of Mechanical Engineeing, New Hoizon College of Engineeing, Bangaloe 560103.Kanataka, INDIA 2 PG Student, Depatment of Mechanical Engineeing, New Hoizon College of Engineeing, Bangaloe 560103. Kanataka, INDIA -----------------------------------------------------------------------***-------------------------------------------------------------------- Abstact - The Main Objective of the poject is to educe to use of the pump fo the descaling puposes thus the accumulato is used instead of pumps the main pupose of the accumulato is to stoe the 250 ba wate with pessuized ai, wheneve we equied high volume and high pessue wate it will delive fom accumulato to descaling system. Fom this eason the designing of the high pessue accumulato as to be done. By this we can save the buying high volume & high pessue pumps, so that we can save the 160KW powe 3 times and also cost can be educe by using this mechanism. Keywods: Designing of accumulato, stess finding fo diffeent thickness (20mm, 30mm, 35mm, and 55mm), stain and displacement. I. INTRODUCTION A hydaulic accumulato is a device in which potential enegy is stoed in the fom of a compessed gas o sping, o by a aised weight to be used to exet a foce against a elatively incompessible fluid[2]. They ae used in fluid powe systems to accumulate enegy and to smooth out pulsations. A hydaulic system utilizing an accumulato can use a smalle fluid pump since the accumulato stoes enegy fom the pump duing low demand peiods. This enegy is available fo instantaneous use, eleased upon demand at a ate many times geate than could be supplied by the pump alone. Accumulatos can also act as suge o pulsation absobes, much as an ai dome is used on pulsating piston o otay pumps. They will cushion hydaulic hamme, educing shocks caused by apid opeation o sudden stating and stopping of powe cylindes in a hydaulic cicuit. A. Backgound & Motivation Befoe thought of designing an accumulato, As they was using diect descaling in which they didn t get that much of flow i.e.330lpm.i thought of stoing that in a we vessel so that we can get a desied pessue as well as flow. Even though we wee facing the same poblem. Finally we thought of designing the hydaulic accumulato in which will get a flow of 330lpm with a pessue of 250-300ba without using additional pump which might educe the additional pump setup cost,opeating cost as well as maintenance cost[1]. In addition to this they have to spend man powe and money fo maintenance of sepaate pumping system in opeation, this found them fo laboious job. As pe the study we had gone with the descaling pocess which will be equied in most of the steel plant so as to emove the laye of ion-oxide fom the billets/slab. The oxidation of slabs in the eheating funace is the fist and detemining pocess of the scaling of hot olled flat poducts. The stuctue of the scale fomed duing eheating and the width of the intenal oxidation zone ae not only influenced by the heating paametes, but also by the chemical composition of the steel. The pime scale fomed on the slab has to be efficiently emoved by hydaulic descaling. Pevious studies showed that, unde mechanical descaling conditions, the entanglement that aose at the steel-scale inteface was in fact effective to maintain steel-scale adhesion. Descaling poceeds by factue along chomite layes, which fomed on the austenite gain boundaies; fo this steel, the extend of descaling depended most stongly on austenite gain stuctue and the pesence of un oxidized metal tendils at the inteface and not pimaily on the conditions in the eheating funace. 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 243
II. METHODOLOGY Consideing the specification fo the accumulato design Calculating the total volume of the accumulato Selecting the mateial fo the accumulato Calculating equivalent hoop stess and longitudinal stess Modelling the accumulato using SOLIDWORKS softwae meshing of the accumulato fo diffeent thickness Analysis of the model using SOLIDWORKS softwae Result and discussion The methodology in this wok involves the calculation of accumulato paametes. The model, meshing and analysis is done by using SOLIDWORKS softwae. A. High Pessue Descaling Using Pump The costs which a steel plant can undestand fo its things on the planet maketplace depend on upon the stategy fo the thing. The time of five sta steel fo steel pieces and billets asks fo a completely pesuading descaling pocess. In case the descaling famewok is not did fittingly o is done not totally issues will ise ove the extent of the get pepaed since scale scaps ae moved into the steel. Figue1: High pessue pump unit B. The High Pessue Descaling System With Accumulato Descaling Systems can be poposed fo Billet/Slab/Plate /Foging/Seamless Pipe etc. fo Pimay descaling (Immediately metal taking out fom funace) and discetionay descaling (Just befoe convincing pass). Hot metal coming out fom the funace, hot metal the detecto will sense the hot metal and will send to signal to PLC. Spay will stat at high flow & pessue to emove the scales on the Billet. The high pessue Descaling system with accumulato is meant fo emoving funace scales fom hot billet befoe 1st pass in olling mill. This system consisting of Hp pump, valves & high pessue accumulato with shut off valve to contol the system with an intelocks system. The pe filteed wate fom custome wate system & feeds to descale heade mounted on descale box in the exit side of funace. Stating late, thee is a epesentation towads highe weights (above 200 ba) joined with a eduction in steam[3]. Constantly, tansmitting pumps with high steam ates and low weights ae used fo this application egadless they have two essential obstuctions: 1. The high weaken limit cools the steel too eally. 2. High centality costs fo wate supply, puification and in-plant pumping systems. Figue 2: Piping & instumentation diagam of accumulato 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 244
C. Tools Requied Design of accumulato is done by Solid woks even Meshing, analysis of accumulato is also caied out within Solid Woks Softwae. III CALCULATION OF ACCUMULATOR A. Total Volume Of Accumulato Total volume of vessel = volume of cylinde + 2(volume of hemisphee) D=1200mm h=2550mm Volume of Cylinde =π 2 h = π (600mm) 2 (2550) =2883982056mm 3 Volume of cylinde =2883982.056cm 3 Volume of Hemisphee= = ( ) =452389342.1mm 3 Volume of hemisphee =452389.342cm 3 The total volume of vessel= [2883982.056cm 3 +2(452389.342cm 3 )] The total volume of vessel =3788760.74 cm 3 Figue 4: Longitudinal stess Case - I (wall thickness=20mm) Pessue =250 ba, Wall thickness= 20mm 1 ba =1.019kgf/ cm 2 = (254.929 X 118cm)/ (4 X 2cm) σ L =3.760 X 103 kgf/ cm 2 Case II (Wall thickness= 30mm) Pessue =250 ba, Wall thickness= 30mm = (254.929 X 117cm)/ (4 X 3cm) σ L =2.485 X 103 kgf/ cm 2 Case - III (Wall thickness= 35mm) Pessue =250 ba, Wall thickness= 35mm = (254.929 X 116.5cm)/ (4 X 3.5cm) σ L =2.121 X 103 kgf/ cm 2 Case - IV (Wall thickness= 55mm) Pessue =250 ba, Wall thickness= 55mm = (254.929 X 114.5cm)/ (4 X 5.5cm) σ L =1.326 X 103 kgf/ cm2 C. Calculations Of Hoop Stess Figue3: Isometic view of Accumulato B. Calculation Of Longitudinal Stess Hoop stess: This acts in a tangential diection to the cicumfeence of the shell. This is the stess which is set up in esisting the busting effect of the applied pessue by consideing the equilibium of the cylinde. (σ h) Hoop stess= Pd/2t Whee P=intenal pessue d o Dm=mean diamete (outside diamete-thickness) t=wall thickness σ h=hoop stess Longitudinal stess: That is when the vessel has closed ends the intenal pessue acts on the vessel and then develop the foce along the axis of the cylinde. This foce acing is known as the longitudinal stess. (σ L) Longitudinal stess= Pd/4t Whee P=intenal pessue d=mean diamete (outside diamete-thickness) t=wall thickness σ L=hoop stess Figue 5: hoop stess 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 245
Case - I (wall thickness=20mm) Pessue =250 ba, Wall thickness= 20mm 1 ba =1.019kgf/ cm 2 = (254.929 X 118cm)/ (2 X 2cm) σ h =7.520 X 103 kgf/ cm 2 Case II (Wall thickness= 30mm) Pessue =250 ba, Wall thickness= 30mm = (254.929 X 117cm)/ (2X 3cm) σh =4.971 X 103 kgf/ cm 2 Case - III (Wall thickness= 35mm) Pessue =250 ba, Wall thickness= 35mm = (254.929 X 116.5cm)/ (2 X 3.5cm) σ h = 4.242X 103 kgf/ cm2 Case - IV (Wall thickness= 55mm) Pessue =250 ba, Wall thickness= 55mm = (254.929 X 114.5cm)/ (2 X 5.5cm) σ h = 2.653 X 103 kgf/ cm 2 espectively. The diffeent esults ae obtained fo diffeent thickness, the esults ae as followed. 1. Thee diffeent types of studies namely Stess, Stain the opeating pessue of 250bas (20mm) is applied the effect on body is studied[6]. Figue 7: 250-ba (20mm) Hoop Stess Analysis D. Mateial Selection The mateial of the Accumulato body was specified as Sheet (SS). steel sheet has a cabon content of 0.19-0.25% and is gouped unde s. Its low in pice (compaed to othe cabon steels) and multipupose application in many engineeing constuction makes it a vey economic engineeing mateial. It is elatively ductile and malleable. It has a density of 7858kg/m3 and Young s modulus of 210GPa. Due to these popeties and its availability, machinability and good stength quality, it was convenient to use in the constuction of accumulato. Figue 8: 250-ba (20mm) longitudinal Stess Analysis IV. RESULT ANALYSIS OF ACCUMULATOR A. Meshing Of Accumulato Figue 9: 250-ba (20mm) Displacement Analysis Figue 6: Meshing of Accumulato B. Analysis Model And Result Diagam The Pessue accumulato is analysed fo the pessue of 250ba. The analysis is done by consideing the diffeent wall thickness of 20mm, 30mm, 35mm and 55mm Figue 10: 250-ba (20mm) Stain Analysis 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 246
2. Thee diffeent types of studies namely Stess, Stain the opeating pessue of 250bas (30mm) is applied the effect on body is studied. 3. Thee diffeent types of studies namely Stess, Stain the opeating pessue of 250bas (35mm) is applied the effect on body is studied. Figue 11: 250-ba (30mm) Hoop Stess Analysis Figue 15: 250-ba (35mm) Hoop Stess Analysis Figue 12: 250-ba (30mm) longitudinal Stess Analysis Figue 16: 250-ba (35mm) longitudinal Stess Analysis Figue 13: 250-ba (30mm) Displacement Analysis Figue 17: 250-ba (35mm) Displacement Analysis Figue 14: 250-ba (30mm) Stain Analysis Figue 18: 250-ba (35mm) Stain Analysis 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 247
4. Thee diffeent types of studies namely Stess, Stain the opeating pessue of 250bas (55mm) is applied the effect on body is studied. V. RESULTS The compaison fo the theoetical and analytical wok is shown below with the help of table consists of vaious paametes. Meshing and analysis is done in Solid Woks and then esults which ae obtained as shown above. Compaison Table Table 1: Hoop stess compais Sl n o Pess ue (ba) Thickn ess (mm) Matei al Theoetic al Hoop Stess Analytica l Figue 19: 250-ba (55mm) Hoop Stess Analysis 1. 250ba 20mm 7.520e +3 7.817e +3 2. 250ba 30mm 4.971e +3 5.53e +3 3. 250ba 35mm 4.242e +3 4.60e +3 4. 250ba 55mm 2.653e +3 2.97e +3 Table 2: Longitudinal stess compaison Figue 20: 250-ba (55mm) Longitudinal Stess Analysis Longitudinal-Stess Theoetical Analytical 3.76e +3 2.485e +3 2.212e +3 1.326e +3 4.82e +3 3.18e +3 2.70e +3 1.66e +3 Figue 21: 250-ba (55mm) Stain Analysis Table 3: Displacement and stain esults Displacement Stain Max Min Max Min 2.67e +0 mm 1.0e - 2.948e - 3 8.67e -5 Figue 22: 250-ba (55mm) Displacement Analysis 1.66e +0 mm 1.0e - 1.38e +0 mm 1.0e - 7.95e -1 mm 1.0e - 1.96e -3 5.87e -7 1.65e -3 5.41e -7 1.03e -3 3.28e -7 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 248
VI CONCLUSION Fom the above table we can conclude that the pessue with 250ba and the thickness of 55mm will be safe. The stess obtained when the pessue of 250ba is applied on the accumulato is 2.97e+3kg/cm2 but the yield stength of the mateial is 3.670e+3kgf/cm2. Also displacement and stain obtained is also minimum at the 55mm thickness. As we go on educing the thickness defomation/displacement is moe which can be clealy seen in the displacement column along with that the stess is also inceasing with the decease in thickness. [9] Tsukiji, T., Hashimoto, K., and Sato, T., Numeical simulation of pessue-pulsation fo an automotive Accumulato, Poceeding of the 34th Japanese Joint Confeence on Ai-conditioning and Refigeation, 2000, pp.61-64. A. Futue Wok Futue we can eliminate the seies of pumps setup and can add the highe capacity accumulato fom which we can supply the equied pessue and flow fo multiple descaling setups. We can take it futhe investigation and futhe study so that we can educe setup cost, opeating cost and maintenance cost. REFRENCES [1] Chung, M. K. et al., A study on the descaling system using computational simulation and PIV, Poceeding of the 15th Intenational compesso engineeing confeence, 2000, 1, pp.377-382. [2] Cohen, R., "Valve Stess Analysis- fo Fatigue Poblems" (1972).Intenational Compesso Engineeing Confeence. Pape 21 http://docs.lib.pudue.edu/icec/21 [3] En, n, K. et al., Analysis of Booste pump, Hokkaido banch of the Japan Society of Mechanical Enginees, 1998, pp.55-56. [4] Hille, C. C. and Glicksman, L. R., "Compesso Capacity Contol via Ealy Suction-Valve closing" (1976).Intenational Compesso Engineeing Confeence. [5] John Mauice Towle, Haogate, and Fank HathonTowle, Otley, England, Unloading Valves fo Booste Pumps assignos to Electaulic Pesses Limited, Rodley, England Application Febuay 17, 1944, Seial No. 522,843 [6] Myung, H. J., and Lee, I. S., Investigation of the dischage flow of a ecipocating compesso using PIV, Poceeding of the 15th Intenational compesso engineeing confeence, 2000, 1,pp.391-396. [7]Ishii, N. et al., Flow-induced vibation of eed in efigeant compessos, The Japan Society of Mechanical Enginees (Seies B), 1991, 57, pp.1828-1833. [8] Tamschek, A.B., Boyle, R.J., 1988, A Cautionay Note on Recipocating Compesso Valve Design, Poceedings of 1988 Intenational Compesso Engineeing Confeence at Pudue, p. 124-132 2017, IRJET Impact Facto value: 5.181 ISO 9001:2008 Cetified Jounal Page 249