Microprotol Pressure Vessels and Shell & Tubes Heat Exchangers 66, route de Sartrouville Parc des Erables, B 3 78232 Le Pecq Cedex France Sofware distributed by Prode Via Spalato 2 Milano Tel. 02-680291 http://www.prode.com by Prode : http://www.prode.com 1
Vessel Input and 3D Model Heat Exchanger Input and 3D Model 2 Microprotol
Foreword Column Input and 3D Model Vertical vessel on legs by Prode : http://www.prode.com 3
Air Cooler induced and forced 4 Microprotol
Foreword 1. General description 8 1.1 General structure of the CAE-CAD-CAM software 8 1.1.1 Design 8 1.1.2 Estimate 9 1.1.3 Engineering Workflow 9 1.1.4 Planning and methods 9 1.1.5 Assistance with procurement 9 1. 1.6 Manufacturing operations 9 1.2 Advantages of Microprotol CAD-CAM 10 1.2.1 Productivity 10 1.2.2 Cost savings 10 1.2.3 Organization and communication system 11 1.2.4 Sales competition 12 1.2.5 Management of technical know-how 12 2. Functional Specification 13 2.1 Pressure Vessel Codes and Standards available 13 2.1.1 American : 13 2.1.2 English : 13 2.1.3 European : 13 2.1.4 French : 13 2.1.5 German : 13 2.1.6 Others : 13 2.2 Calculations and design 13 2.2.1 Design calculation principles 14 2.2.2 System performance 15 2.1.3 Files 15 2.2.3 Limitations and restrictions 16 2.3 Automatic drawing 16 2.3.1 General specifications for the graphic software 18 2.3.2 Item drawings 18 2.4 Estimate 20 Resume 24 3. Principle of use 25 3.1 Microprotol Organization diagram 25 3.2 Microprotol Sketcher 25 3.2 Microprotol Sketcher 26 3.3 Microprotol Vessel Review 27 3.4 Design calculation : examples 29 3.5 Drawings : Examples 31 4. Scope of supply 32 by Prode : http://www.prode.com 5
Microprotol is a suit of integrated software modules covering every stage of vessel production, from the project study estimates through to control of the manufacturing operations by numerical control machines. Available by module, it complies the needs of engineering as well as manufacturing purpose. Because Microprotol handles Pressure Vessel, Shell and Tube Heat Exchanger according all major Pressure Vessel design Codes as well as Air Cooler design, Microprotol makes Users efficient and save the company money. Only one tool always used. The advantages of using Microprotol are estimating, design, planning, materials, preparation, manufacturing. The benefits of using Microprotol are design optimization, code compliance, increased productivity and quality compliance. Fully parametric and true to scale drawings are generated for Cadgri, Microstation, SmartSketch or Autocad software. Data for production management are available through internal database. Microprotol is developed for MS Windows 98, Me, NT 4, 2000, XP. It can be operated on stand alone PC or on a Network. A license is valid for any system. Engineering Process data Requirement definition Conception Calculation Optimisation Bill of material Cost estimation Time allocation Engineering drawing Workshop drawing NC Machining Drilling Flame cutting Manufacturer 6 Microprotol
Foreword 3D Equipment Modeling Interface to Intergraph PDS enables a two-way communication between Pressure Vessel Engineering and 3D Plant Engineering. This Interface has been structured to allow sub-contractors to work together and provide an engineering workflow with respect of quality insurance policy.. by Prode : http://www.prode.com 7
1. General description 1.1 General structure of the CAE-CAD-CAM software Microprotol is an expert system for Pressure Vessel, Shell and Tube Heat Exchanger and Air Cooler. More than a calculation software, rules included in the software allows it to handle the complete data system. From engineering purpose to manufacturing operations using numerical control command, Microprotol is the solution. 1.1.1 Design Starting from a typical vessel, User can complete the Process Specification and Project Rules easily with Microprotol Sketcher. The software carries out all the mechanical calculations, defines the specifications and prepares the general layout and detailed drawings needed to order or build pressure vessels. The specialist remains completely free to modify the optimization criteria during processing. The data are progressively stored in a structured Database. This makes it possible to increase expertise and productivity(for example by using a previous design and introducing modifications to produce a new item, rather than a complete re-design). The User can handle several parallel projects and thus avoid punctual workloads. The risks of human error are reduced by automating calculations, preparing specifications and the producing drawings. 8 Microprotol
General description 1.1.2 Estimate The software allows : To study variants which could optimize the solution. To provides a Bill of Material and using a customizable Manufacturing Schedule Database, to deliver the estimate including raw weight, freight weight, hours and cost. Provides a time allocation sheet for all manufacturing operation. Automation saves time on all these operations, thus increase the company s capacity to answer calls for bids. 1.1.3 Engineering Workflow The link with HTRI Xchanger Suite, AspenTech Task and Intergraph PDS 3D allows maintaining the Engineering workflow between Process/Vessel Engineering and 3D Plant Engineering. 1.1.4 Planning and methods One of the automatic drawing option consists in creating the drawing of all individual components, each in an A4 format. Software had when necessary the developed flat view. This makes it available, to the Planning Methods Department, very early in the manufacturing cycle. 1.1.5 Assistance with procurement The software includes detail drawing per component, the easiest way for procurement specification establishment. 1. 1.6 Manufacturing operations Component flat development and associated report greatly help manufacturing preparation. by Prode http://www.prode.com 9
1.2 Advantages of Microprotol CAD-CAM A Company will state the advantages of using CAD-CAM on its pressure vessel production line in terms of its profits in PRODUCTIVITY-QUALITY and COMPETITIVITY. 1.2.1 Productivity An important increase in productivity is achieved by placing the complete production process, from design up to final manufacturing, under the control of the Microprotol system. The improvement in productivity in the design area, expressed in production hours, is 40/1 (See on this subject the December 1982 issue of «Chaudronnerie tôlerie».) 1.2.2 Cost savings Manufacturing costs are saved by reducing the labor content of the various tasks involved in producing the pressure vessel. Design office : The traditional tasks of the draftsman are made much easier and the time saved by project engineer can be devoted to their real specialist tasks since Microprotol takes over many of their more routine tasks (design, calculations, etc...). Manufacturing, planning and methods : For plate components as for tubesheet, the interactive dialogue between Microprotol and the user allows the system to take over, in showing the tool path, all the preparation phases such as programming, distribution of tasks with job slips, numerical control edited on punch tape, floppies or direct numerical command, gas consumption, occupation time of the machine. 10 Microprotol
General description 1.2.3 Organization and communication system Any co-ordination procedure between the design office and the methods department or the methods department and production can be integrated into the system. PRODUCTIVITY Increased Production Capacity Reduction of labour cots Organisation of information sytem Design Calculation Optimised Planning Design office Methodes Planning and Cost/Time/Quality Control of order Better use of machines Preparation Manufacturing Job co-ordination data Optimised use of material Shop floor Stock management data base by Prode http://www.prode.com 11
1.2.4 Sales competition Inquiries and answers to call for bid : Quality of the bid. Bids are more accurate and well set out (quality of the calculations and documents, cost estimations based on structured files...) Answer to inquiries. The design office can simultaneously handle a larger number of inquiries. A continuous dialogue can be held with customers and the design bases of projects can be modified without spending any additional design office hours. 1.2.5 Management of technical know-how All units designed by the company (whether simply planned or actually build) are stored in the database. The database can be progressively extended, increasing the system s potential productivity and the company s range of capabilities in the manufacture of pressure vessels and shell and tube heat exchangers. Manufacturing reliability (Drilling, Tracing, Cutting, Marking) QUALITY Design reliability (Check list, variants) Production management interface through nomenclature SALES Better call for bid answer with less time COMPETITIVITY CAPABILITY Know-how management and data coherence 12 Microprotol
Functional Specification 2. Functional Specification 2.1 Pressure Vessel Codes and Standards available 2.1.1 American : ASME VIII Division 1, Boiler and pressure vessel code TEMA standards, classes R, C and B. Uniform Building Code (UBC). ASCE. WRCB 107-297. ANSI B 16-5 standard for flanges. EJMA standard. 2.1.2 English : BS PD 5500 specification for unfired pressure vessels. BSI CP3 specification for wind loads. BS 6399 Part 2 specification for wind loads. 2.1.3 European : EN 13445 specification for unfired pressure vessels. EN 1591 specification for flange design. EN 1092 specification flange rating. 2.1.4 French : CODAP design codes for pressure vessels. NV rules for wind and snow. PS rules for earthquakes CM 66 rules for structural design. AFNOR standards. 2.1.5 German : AD-Merkblätter. DIN Standards. 2.1.6 Others : Indian Standards for wind and earthquake, Brazilian Standards for wind, Turkish Rules for earthquake, Hungary Code for earthquake, Portuguese Code for earthquake. 2.2 Calculations and design The design software is organized to be able to handle any kind of pressure vessel, according to several calculation codes and regulations. The structure of the data base and the modular break-down of the processing system makes it possible to begin a design study with only a minimum of information and then to develop it over a period of time. This has the particular advantage of allowing the design to be carried out in several phases depending on the contents of the database. by Prode http://www.prode.com 13
If no code covering the problem is found, proven conventional strength of material formulae will be applied. General loads due to external factors, such as the wind, the earthquake or loads introduced by the environmental installation are then introduced. Procedures are available to optimize the design calculations to satisfy weight or manufacturing cost criteria. Obviously, parts, which already exist in stock or the parameters for a revamped item, can also be introduced. After the input data checking, the software executes the design without break and results can be displayed on the screen. The user, who is an expert in pressure vessels, can vary the parameters to modify the optimization criteria. Once the result satisfies all his requirements, the calculation note is edited on the printer and the selected results added into the database. 2.2.1 Design calculation principles A. Calculation of dimensions including optimization of costs The data input possibilities, and the procedures for the use of the database, make it possible to determine optimum solutions for vessels subject to external pressure. The solutions will either involve increasing the shell thickness, modifying the pitch or the shape of stiffeners (i.e. by the use of a IPE or a flat bar). In the same way, when sizing a tubular heat exchanger, it is possible to optimize number of tubes in an OTL, to determine an OTL and an inside diameter of shell containing a number of tubes or, determine from the shell internal diameter the OTL and the number of tubes. This optimization is available for straight tubes as for U tubes in configuration from one to thirty channel passes and one to two shell passes. B. Special features of the system In addition to the special calculation procedures it includes, which are complementary to the codes, such as the flexibility matrices to determine the vibration period using the Rayleigh method, and the distortions caused to vertical vessels by external loads, the system is entirely compatible with the conditions applicable to a comprehensive design study. For example, when designing a column which is anchored at its base, it is scarcely possible to neglect the foundation. The differential settlement of the soil under the foundation leads to an initial rotation of the origin. This takes the form a=km, where M is the moment applied. Since wind and earthquake effects depend upon the vibration period, the load transfer effects depend of the foundation. The form of the matrices allows to include this parameter k. D = S. F where D is the displacement matrix including the deflection and the rotation. In the same way, when considering the stress analyses of pipes connected to a vessel, the local loads introduced into the vessel wall depend of the nozzle rigidity factor. If it is considered as a perfect anchor, it may be necessary to modify the pipe way, install flexible supports or at the worst, insert expansion joint bellows. Thorough knowledge of the anchor factor and the possibilities of local load analyses make it possible to reduce the costs of installations. 14 Microprotol
Functional Specification 2.2.2 System performance The vessel or tubular heat exchanger can have up to 42 main different components with the following kinds of head : Torispherical, Klopper, Elliptical (any axes ratio), Hemispherical, Korboggen, Flat, conical heads with or without knuckle radius. The vibration period and distortion can be studied using up to 100 sections. This guarantees highly accurate results. Strippers can be designed simultaneously with internal and external pressure, each chamber may have different pressure and temperature. The maximum number of chamber is 3. Stresses are calculated for each possible operating case. Up to 15 operating cases can be considered in calculating the tubesheet thickness for double-fixed tubesheet heat exchanger. The maximum number of nozzles on an item is 100 with or without penetration and integral reinforcement. Optimization of the bundle lay-out calculation and drawing up to 30 passes on tube side and 2 passes on shell side, with or without tubes in windows and the location of tie rods and sliding rails if required. Sectored passes are also available. A materials database, which contains all the material properties, greatly simplifies user data input. The system offers access to several issues of the codes used. A complete item can be designed and drawn from a process specification. Determination of the maximum allowable working pressure and de-pressure. Design of an item using partial data from components of stock. Checking of one or several components or the full vessel. Opening reinforcement can be designed with taking into account integral reinforcement, reinforcement plate, LWN nozzle, forged self-reinforcing nozzle, adjacent openings, set in and set on disposal. Local loads design. Expansion joint design, Beam design. 2.1.3 Files A. Materials file This file includes all usual material together with their mechanical properties depending of the temperature, in short, it contains all information required for the design calculations. It covers French, British, German, European and American material. It is supplied with the tools required to extend and/or update on site by the user. B. Pipes file According to ANSI, AFNOR and DIN standards C. File of flange ratings This file covers the flange rating design, depending of pressure, temperature and designation used. ANSI B 16.5, AFNOR NFA 36001, AFNOR NFA87508, DIN, EN 1092 can be used. by Prode http://www.prode.com 15
D. Standard files Support saddles, legs, anchors and skirt arrangement, lifting lugs and gussets are userparameterized components specific to each company. 2.2.3 Limitations and restrictions Microprotol does not design storage tanks but allows the drawing. 2.3 Automatic drawing A special application program, whose structure is similar to the design calculation program, scans and interprets the database to create a 2D true to scale drawing intended for the selected CAD Software. The drawing includes upon selection, parts lists, general arrangement and detailed drawings. Complements of the drawing are done either using the library of standards or the parameterized geometry, or again the basic interactive graphic software Cadgri, AutoCAD, SmartSketch or Microstation. After interactive completion, the drawing will be plotted. The drawing generation software is progressively expanded, since not all the data for the final drawing can be known at various stages in design. Moreover, options make it possible to generate the initial drawing, produce flat views to check interference and insert new components in existing drawings after validation. 16 Microprotol
Functional Specification by Prode http://www.prode.com 17
2.3.1 General specifications for the graphic software The internal CAD software Cadgri and its viewer Cadview allow to do not use any external CAD software. Cadgri is a French software build on a relational data base structure. It allows to create drawings using program, parameterized geometry and calling standards components, using a two dimensional model. 2.3.2 Item drawings The item drawings are generated in the graphic database using successively one of the drawing program options. This workflow allows to get a master and then revise it in adding nozzle orientation, then gussets. A. Shell rolling s drawing Done after a collision checking from the rolling width, the flat developed view and the outside view of the item are done and used for quality insurance. B. X-ray and Melt number drawing This is completed in the interactive mode by adding the position of the X-rays and the melt number on the shell rolling s drawing. C. Welded joint identification drawing The shell rolling s drawing can be completed by interactively adding the numbers of the joints for seam welds numbered by the program. D. General assembly production drawing This comprises : An external longitudinal view with the external components, gussets, supports and required stiffeners, An external longitudinal view with the nozzles and the internal accessories, Cross sections, Details for forged parts and supports, A drawing parts list. 18 Microprotol
Functional Specification The cross-sections indicate the position of the gussets and the nozzles, since these components are represented on the right-hand horizontal centerline on longitudinal views. Details show : The drawing of the tubesheet for shell and tube heat exchangers only. It indicates the position of the tubes and is prepared during the design calculation. This drawing will be interactively completed by the tie rods and sliding rails positions. The detail drawings of forged components such as flanges, tubesheet, floating head, and companion flange. A longitudinal section of the tube bundle, showing the position of baffles. This may either be a plan view for vertical cut baffles or a front view for horizontal cut baffles. The detail drawing of gaskets showing the passes partition with respect of the orientation to satisfy easily the installation. by Prode http://www.prode.com 19
2.4 Estimate The estimate module of Microprotol use a customizable Database allowing a personal cost and hours estimate. Principle of estimate is based on the Bill of material that represents the need expression. This Bill of Material is automatically produced after completion of the Microprotol calculation, but may be interactively introduced for a specific purpose. Manufacturing schedule database must be customized before the use. This database contains for each potential component a full description of the preparation, machining, assembly and control operation. This allows the software to calculate the manufacturing time using parameters from the data base and the nomenclature. Print out are available with or without compilation. The database also contains a full description of the welding procedures. The aim is to calculate the cost of the welding material as well as the welding time. Options are available for material cost : Price per material family for a quick estimate (Carbon steel, Stainless steel,...), Price per component at the nomenclature level using or not a tariff. 20 Microprotol
Functional Specification Except for bought components, prices are always price per kilo. Indexation formulae can be used to re-evaluate the prices. From customize tools, formulas editor allows weight conversion from net to raw weight, compilation of developed seams length, and options like sand blasting, transportation, packing and so on. This database is in fact the know-how of the company, the customization require a great attention and should take about one month for completion. At this point, a new cost estimation from a complete nomenclature takes a few seconds only. The print out provides detail of the material cost as well as the welding material cost. Cost estimation database contains all the existing nomenclatures so this allows for modifications or update to directly access the nomenclature, make the change and ask the new cost and manufacturing times. by Prode http://www.prode.com 21
Bill of Material 22 Microprotol
Functional Specification by Prode http://www.prode.com 23
Resume 24 Microprotol
Principle of Use 3. Principle of use 3.1 Microprotol Organization diagram The general organization of Microprotol consists of 3 consecutive sequences, ie : Data input with Microprotol Sketcher, Design calculation, review of the results with Microprotol Vessel Review and the report, Automatic drawing using one of the drawing option. The generated drawings are then used under the control of Cadgri, Microstation or Autocad from the workstation and are plotted after completion. For Design purpose, Cadview allows to simply view the drawing without any CAD knowledge. HTRI Interface AspenTech Interface by Prode http://www.prode.com 25
3.2 Microprotol Sketcher Data are inputted via propertysheet page using or not a Project Specification to simplify the input. A sketch of the vessel is displayed at the same time to allows the user to drag, copy, and erase components. All input data are stored in a database. This storage procedure ensures that the data are always available for subsequent modifications. The verification of the data is made at two levels : The syntax, during the data entry. The coherency when the problem is submitted to the design. If an error is detected, a message is displayed to indicate where the data is missing or which data is incoherent. The flexibility of the system, and the possibilities it offers, make possible to generate an optimized item, reuse part of the data for the item generated or retrieves parts of existing item in the database. 26 Microprotol
Principle of Use 3.3 Microprotol Vessel Review Microprotol Vessel Review is the best way to review both the input data and the calculation results. It offers a toggle switch between input and output. by Prode http://www.prode.com 27
Example of input data screen and contextual help during modification period. Viewing of an automatic drawing 28 Microprotol
Principle of Use 3.4 Design calculation : examples Lay out and examples of design report Design report indicate the operating and test conditions and the basic data used for the calculation(material, pressure temperature) applicable to the complete unit. Each note contains : Particular design conditions applicable to the family of components in question(shell, heads, tube sheet etc... ) A summary of the code formulae or the main stages in the calculation. The results obtained. Design calculations can be printed out in English, French or German, using SI units or American units. The contents is : A complete design note with summary tables. A family of components, with summary tables. A precis of the wind and the earthquake calculations. The worst case for the wind and earthquake loads. A trace back of the execution with debug options if necessary. by Prode http://www.prode.com 29
The following table shows a partial example of design report. 30 Microprotol
Principle of Use 3.5 Drawings : Examples by Prode http://www.prode.com 31
4. Scope of supply Bundle Bundle A Bundle B Bundle C Bundle D Description Air Cooler design. Calculation and automatic drawing using Cadgri format. Quick Estimate using Excel sheet. Conception and design of vessels, columns, reactors, steel chimney. This bundle allows the study of horizontal vessels on saddles, as well as vertical vessels on brackets or legs plus vertical vessels submitted to wind and/or earthquake like columns, reactors and steel chimney anchored at the base. This includes one pressure vessel Code and local load design. Conception and design of tubular heat exchangers TEMA or not This bundle allows the studies of tube sheet lay out and mechanical design of tubular heat exchangers. This includes one pressure vessel Code and local load design. Conception and design of all kind of vessels and tubular heat exchangers. This bundle allows the study of horizontal vessels on saddles, as well as vertical vessels on brackets or legs plus vertical vessels submitted to wind and/or earthquake like columns, reactors and steel chimney anchored at the base. This bundle also allows the studies of tube sheet layout and mechanical design of tubular heat exchangers. This includes one pressure vessel Code and local load design. All Bundles provide access to component and special studies such as local load or beam design. 32 Microprotol
Scope of supply Complementary modules to these bundles Reference Designation mpl 02A ASME VIII Div 1 Code mpl 02B BS PD 5500 Code mpl 02C CODAP Code mpl 02D AD MERKBLÄTTER Code mpl 02E EN 13445 EN 1591 mpl 03B Wind and earthquake calculation according : NV,UBC,BSI-CP3, BS 6399, ASCE, PS, AD, IS mpl 04D Air Cooler design and drawing mpl 03A TEMA and EJMA rules mpl 12A Intergraph PDS Interface mpl 12H Microstation Interface mpl 12F Autocad Interface mpl 12S SmartSketch Interface mpl 13F Drilling of tubesheet mpl 15 Cost and time estimation by Prode http://www.prode.com 33