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PRESSURE VESSEL DESIGN

MIET 1068

INTRODUCTION

Welcome to the Project Guidelines Document. This document serves as a guide to help you tackle your Mechanical Design 2 Project. Note, this project is not your typical uni assignment that can be completed at the last minute. Instead, it is a project typically encountered in a work setting requiring regular and consistent work throughout the project duration. Therefore, it requires effective time management skills. This document breaks down your project into smaller chunks and provides more detailed instructions on completing them. The course/project schedule on Canvas allocates time and deadlines for each task, which will help you to manage your time efficiently to avoid last-minute rushes and ensure a well-executed project.

Furthermore, this course uses Project-Based Learning (PBL) philosophy, which you may encounter for the first time. Thus, some changes to your learning habits may be required. This is a good thing! When we are met with new and novel “things”, we are more alert, stimulating better learning.

PBL is a teaching approach that engages students in active, hands-on learning experiences. Unlike traditional classroom methods that rely heavily on lectures and rote memorisation, PBL focuses on real-world challenges, interdisciplinary collaboration, and applying knowledge and skills in practical contexts. Central to PBL is the idea of active engagement, where students become self-directed learners, exploring topics in-depth and taking ownership of their learning journey.

Therefore, as a student, take the initiative to explore, ask questions, and seek solutions. Collaborate with your peers, share ideas, and work together to solve problems. Research and gather relevant information and explore different perspectives. Use reliable sources, analyse data, and draw evidence-based conclusions. Don’t hesitate to seek guidance from your teachers, mentors, or project supervisors. They can provide valuable insights, offer support, and help you navigate through challenges. Actively seek feedback from peers and mentors to improve your work and enhance your learning experience.

BACKGROUND STORY

Founded over five decades ago by visionary engineer, Dr. Richard Anderson, AceTech emerged as a pioneer in the field of engineering consulting. Dr. Anderson, armed with a burning passion for engineering and a dream to revolutionise the industry, assembled a team of brilliant minds who shared his vision. Together, they established AceTech on integrity, expertise, and a relentless pursuit of excellence. From its humble beginnings in a small office, AceTech quickly gained recognition for its unrivalled engineering solutions. Driven by a desire to provide clients with cutting-edge designs and strategies, the firm garnered a reputation for tackling the most complex and challenging projects across a myriad of industries. Over the years, AceTech’s talented team of engineers grew exponentially. Each member brought unique expertise and specialisation, covering a vast array of engineering disciplines. From structural engineering to renewable energy solutions, AceTech boasted a multidisciplinary team capable of tackling projects of any scale or complexity. However, it wasn’t just their technical prowess that set AceTech apart. The company placed a strong emphasis on ethical engineering practices, sustainability, and social responsibility. Their commitment to environmental stewardship and community development earned them accolades and the respect of industry peers.

AceTech grew into a dynamic organisation with a culture that celebrates collaboration, innovation, and excellence. Regular knowledge-sharing sessions, workshops, and mentorship programs foster an environment of continuous learning and professional growth. The company also encourages its employees to actively participate in industry conferences, publish research papers, and contribute to the advancement of engineering knowledge.

Today, AceTech Engineering Consultancy stands tall as an industry leader. Its name is synonymous with innovation, excellence, and unwavering commitment to delivering engineering solutions that shape our world. The legacy of AceTech is carried forward by a new generation of engineers, who, like their predecessors, strive to push the boundaries of what is possible and leave an indelible mark on the world of engineering.

YOU RECENTLY JOINED ACETECH AND WERE ASSIGNED TO WORK ON A PROJECT FOR AN OLD CLIENT.

As two promising novice engineers, you and your university colleague are about to embark on an exciting journey at AceTech Engineering Consultancy. You are both still in university and, thus, filled with enthusiasm and a hunger for knowledge. Recognising your potential, AceTech has placed great value on nurturing your talent and providing you with the tools and guidance necessary to thrive.

Upon joining the company, you have been welcomed into a supportive and collaborative environment and have been assigned experienced mentors who had excelled in their respective fields. With their wealth of knowledge and industry experience, these mentors will serve as trusted guides throughout your first project and further professional development.

Rather than simply being told how to start, you are encouraged to explore and question existing practices. The emphasis is on continuous improvement and finding innovative solutions to engineering challenges. You are encouraged to seek growth opportunities and actively engage in ongoing learning. Regular knowledge-sharing sessions and workshops are organised to enhance your skills and broaden your perspectives. While mentorship and growth are readily available, you are expected to put in the hard work necessary to make the most of these opportunities. The engineering industry demands dedication, discipline, and a strong work ethic. Therefore, you are encouraged to take ownership of your projects, be proactive in seeking new solutions, and constantly push the boundaries of your capabilities. Ultimately, while the company provides you with the mentorship, support, and resources you need to succeed, it is your hard work, dedication, and unwavering commitment to improvement that will ultimately determine your success.

BACKGROUND STORY

YOUR CLIENT - SHINVOZ

In the industrial suburb of Broadmeadows, the bustling factory of Shinvoz stands as a testament to engineering prowess and manufacturing excellence. Shinvoz has established itself as a leading provider of precision-engineered components and machinery for a wide range of industries, from automotive to heavy machinery. With a rich history dating back several decades, Shinvoz has earned a reputation for delivering high-quality products and innovative solutions. The company’s commitment to continuous improvement and customer satisfaction drove its growth and success.

The factory itself is a sprawling complex, housing various departments dedicated to different stages of the manufacturing process. From the forge, where raw materials are heated and shaped, to the fettling shop, machine shop, and paint booths, each area played a crucial role in bringing Shinvoz’s products to life. In the forge, skilled craftsmen meticulously craft metal components using traditional techniques combined with modern pneumatic tools. The rhythmic pounding of the large pneumatically operated hammer reverberates through the air, shaping the heated metal with precision and force. This hammer, driven by a double-acting cylinder, demands a substantial amount of compressed air to execute its set number of up and down strokes. The fettling shop, adjacent to the forge, houses a dedicated team responsible for refining and finishing the components. With handheld pneumatic tools such as riveters, screwdrivers, wrenches, grinders, and polishers, the fettling shop ensures that each piece meets Shinvoz’s stringent quality standards. In the machine shop, cutting-edge machinery transformes raw materials into intricate components. From milling machines to lathes and drills, pneumatic tools are used to drive linear actuators, operate control valves, and assist manufacturing. Adjacent to the machine shop, the paint booths provide a controlled environment for applying protective coatings to the components. Spray guns, operated by compressed air, ensure an even and precise paint application while adhering to the highest quality standards. As the parts flow through the assembly line, compressed air plays a vital role in operating clutches, brakes, and control valves, facilitating the smooth and efficient functioning of the machinery. The precision and reliability of the pneumatic system are essential in maintaining the high standards that Shinvoz has become known for. Finally, in the packaging department, the components are carefully assembled, inspected, and prepared for shipment to customers worldwide. Pneumatic tools continue to assist in this stage, ensuring the final touches are executed flawlessly

TO MEET THE PEAK DEMANDS FOR COMPRESSED AIR IN THE FORGE, SHINVOZ HAS EMPLOYED A CLEVER SOLUTION - AN AIR RECEIVER OR PRESSURE VESSEL. THIS STORAGE DEVICE EFFICIENTLY HANDLES THE DEMAND PEAKS CREATED BY THE HAMMER’S OPERATION, ENSURING A STEADY AND RELIABLE SUPPLY OF COMPRESSED AIR THROUGHOUT THE FACTORY.

DESIGN REQUIREMENTS

Shinvoz uses compressed air for a great variety of purposes e.g.: driving hand held pneumatic riveters, screwdrivers, wrenches, drills, grinders, polishers etc; spray painting; operating forging hammers; air jet cleaning; agitation of liquids; operation of hoists; driving linear actuators in automatic machinery; operating clutches and brakes; operating control valves. Air motor driven handheld tools, although in some cases not very energy efficient, have some advantages over their electric equivalents. These small air motor advantages include: being lighter and smaller for a given power output; being free of shock risk; and being able to stall without overheating.

From the background story, we can learn that Shinvoz requires compressed air in several areas of operation: forge, fettling shop, machine shop, paint booths, assembly, and packaging. The forge contains one large pneumatically operated hammer driven by a double acting cylinder. The piston executes a set number of up and down strokes at regular intervals, creating peak demands for compressed air. The air compressor cannot efficiently and directly meet these demand peaks, so a storage device in the form of an air receiver (pressure vessel) is commonly employed.

The air receiver in a compressed air system has several functions, namely: to reduce pressure pulsation in the piping system; to help separate water and oil mist from the air; to provide reserve capacity for times of peak load (during which time a small fall in pressure will occur); and, in the event that compressor capacity exceeds demand, to provide a buffer so that the compressor’s unloading or stop/start system does not cycle too often.

The factory manager and his team of engineers have assessed the demand and supply profile and determined what volume receiver is necessary to cope with the peak caused by the forge. The factory manager then approached AceTech, and you and your colleague were tasked to design an air receiver for them, which meets the following broad statement of Design Requirements.

REQUIREMENTS:

DESIGN PRESSURE: 862 kPa.g

UPPER DESIGN TEMPERATURE: 100O C

VOLUME: 8+X m3

ORIENTATION: longitudinal axis of cylinder vertical

CLASS (OF CONSTRUCTION AND ASSOCIATED INSPECTION): 2A

MATERIAL: AS 1548 PT 460 NR (L0)

The job is to be completed within 11 weeks, with Milestone 1 in the form of a progress report to be delivered by the fourth week. The payment is to be received upon completion.

The project deliverables are detailed design documentation, which includes the validating calculation and the necessary technical drawings for manufacturing.