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Strength analysis by method of the finite elements in construction of spray

sterilizer with restrictions of standard EN 13445-3

Article · April 2016

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Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan SZCZEPANIAK
Przemysłowy Instytut Maszyn Rolniczych
ul. Starołęcka 31, 60-963 Poznań, Poland
e-mail: office@pimr.poznan.pl

STRENGTH ANALYSIS BY METHOD OF THE FINITE ELEMENTS IN CONSTRUCTION

OF SPRAY STERILIZER WITH RESTRICTIONS OF STANDARD EN 13445-3
Summary
The article describes the problem of stress analysis in spray sterilizers according to EN 13445-3, widely used in the food
industry. Operating conditions of the test device were characterized and a method of design verification using FEM was de-
fined. Conditions of computer implementation research were determined and choice of a methods for assessing sterilizer
was made, based on stress analysis. It was found a criterial stress for material of which the vessel is made. The maps of
characteristic stress was generated, the areas of concentration was localized and confronted the results of set limits. More-
over, the fatigue life of welds and base material were estimated. As a result, an effort of the state system was determined.
It was found that the structure is characterized by level of safety, which allows to build a prototype for validation of numeri-
cal model by strain gauge methods.
Key words: pressure vessel, standards EN 13445-3, fatigue research, FEM

ANALIZA WYTRZYMAŁOŚCIOWA METODĄ ELEMENTÓW SKOŃCZONYCH

KONSTRUKCJI STERYLIZATORA NATRYSKOWEGO Z ZASTOSOWANIEM
OBOSTRZEŃ NORMY EN 13445-3
Streszczenie
W artykule opisano problematykę analiz wytrzymałościowych sterylizatorów natryskowych według normy EN 13445-3, sze-
roko stosowanych w przemyśle spożywczym. Scharakteryzowano warunki eksploatacyjne badanego urządzenia i określono
metodę weryfikacji konstrukcji z użyciem MES. Wytyczono warunki realizacji komputerowych badań i dokonano wyboru
metod oceny sterylizatora bazujących na analizie naprężeń. Ustalono naprężenia kryterialne dla materiału, z którego zbu-
dowany jest zbiornik. Wygenerowano mapy naprężeń charakterystycznych, zlokalizowano obszary koncentracji i skonfron-
towano wyniki badań z przyjętymi limitami. Przeprowadzono ponadto szacowanie trwałości zmęczeniowej spoin i materiału
rodzimego. W efekcie ustalono stan wytężenia ustroju. Stwierdzono, iż konstrukcja charakteryzuje się poziomem bezpieczeń-
stwa umożliwiającym zbudowanie prototypu dla potrzeb walidacji modelu numerycznego metodami tensometrycznymi.
Słowa kluczowe: zbiornik ciśnieniowy, norma EN 13445-3, badania zmęczeniowe, MES

1. Introduction loading and unloading of batch units is carried out by the

cover (blind system is equipped with a cap assembly, and
The sterilization process is one of the key steps in the the passage arrangement with two cover bands on both
food processing industry. It consists in an intensive thermal sides of sterilizer).
impact on the food product in a relatively short time (an- The pressure used in the spray sterilizer is usually from
nealing step takes on average 15 to 30 minutes). Steam or 2 to 4 bar, in which a steam is used as the working medium
hot water is usually a working medium. It can distinguish [6].
basically two temperature ranges of process, ie. 115 to Having regard to the specifics of the work sterilizer,
121°C and 130 to 145°C. Selection of appropriate process which is subjected to cyclic changes of temperature and
parameters are determined by processed food product. pressure and loaded with cargo, strength analysis process of
A consolidation of food through destroying all microorgan- its construction requires a specific approach.
isms and their form of survival structures is the result of
properly conducted sterilization process [1, 6]. The subject of studies described later in this article in-
To successfully carry out the process of sterilization of cludes spray sterilizer execution on four baskets of flow
food products, while reducing energy inputs, applies an in- system ie. loading and unloading takes place on opposite
creased pressure within the working chamber. By increas- sides of the work chamber (fig. 1).
ing the pressure an increase of enthalpy in used working
medium is achieved. That results also in an increased ther- Verification of safety level in sterilizer construction was
modynamic potential of the system which is capable of based on analysis using the Finite Element Method. Due to
more intense heat exchange with the sterilized product. the fact that the developed sterilizer construction is a very
Described process in industrial applications is carried responsible technical object, working under considerable
out usually using spray sterilizers [6]. The working cham- pressure, it was decided that the preparation of computa-
ber of these devices is a thin-walled pressure of vessel tional model, the relevant calculation and assessment of re-
armed with the supply system of working medium and sults will take place in accordance with the standard EN
proper control and measurement equipment. The process of 13445-3: 2014-11 Unfired pressure vessels - Part 3: Design.

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
97
 Presented above limits are used to determine limit val-
ues of stress characteristic, necessary for the analyzes of
ranges. They summarize them in Table 1.

Table 1. Specification of stress limits for austenitic steel

1.4541 [4]
Tab 1. Zestawienie limitów naprężeń dla stali austenitycz-
nej 1.4541 [4]

Source: own work / Źródło: opracowanie własne

Fig. 1. View of the tested spray sterilizer with loading and
unloading system of batch
Rys. 1. Widok badanego sterylizatora natryskowego wraz z
układem załadunku i rozładunku wsadu

2. Evaluation procedure according to standard EN

13445-3

To evaluate the strength of vessel guidelines comprised

in standard EN 13445-3 were used. In particular descrip- These values are determined using the recommendations of
tions of chapter 6 (defining the stresses limited), chapter 18 the EN 13445-3 listed in point. C.7.2. They are as follows:
(detailed fatigue analysis) and annex C (procedure to evalu- These values are determined using the recommendations of
ate load capacity based on stress analysis). the EN 13445-3 listed in point. C.7.2. They are as follows:
The standard specifies three types of loads, which must ,
cope with vessel in use. These are: ,
• „Normal operating load cases”. The loads occurs in ,
normal operation derived from the pressure and mass liquid
located inside vessel, mass vessel elements, mass elements .
attached to vessel, wind, snow, etc. In case:
• „Testing load cases”. The loads occurs during testing to:
vessel, from the pressure and mass liquid located inside
vessel, mass vessel elements and mass elements attached to ,
vessel, etc. to:
• „Exceptional load cases”. The unexpected loads associ-
ated with probability of explosion inside the vessel, earth- ,
quakes, etc.
where:
Depending on the load case stress limit is defined dif- – primary global membrane stresses (do not include the
ferently. For austenitic steel 1.4541, of which the vessel
effect of the notch, their presences are clearly visible of
was made, and which takes elongation at least 35% in ulti-
large distances from discontinuity section).
mate tensile (according to 6), the standard provides the fol-
– primary local membrane stresses. They are formed
lowing values:
• for a load generated during normal exploitation: near zones of stress concentration. Stresses may some-
• if the value
1
is unknown, stress limits are: where slightly exceed the yield strength. This assumption is
substantiated in [2], in the following way: after exceeding
2 the yield strength loads are redistributed to rigid areas of
.
vessel. Consequently there is no destruction and preserves
(1 Ultimate strength of material in tensile at the operating of the property object.
temperature T).
(2 Elastic limit is defined as the stress corresponding a tensile Values and are defined from relation:
force causing in sample permanent elongation of 1% of meas-
uring length at the operating temperature T).
• if the value is known, stress limits are determined
as less value of two presented below: However is:
. ,
• for loads generated during the research and in excep- where:
tional situations stress limits are determined as the greater .
value of two presented below: – it, in turn, primary bending stresses defined as:

. .

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
98
 is the sum of primary and secondary stresses,
which differentiator according to [2] is ability to self-
limiting (self-limiting stress). This means local plastic de-
formation and smaller deformation leads to a reduction
stresses without damaging the vessel. These stresses appear
in areas of high geometrical discontinuities which manifest
as stress concentrations and are caused by changes in coat-
ing plate thickness and temperature gradient (thermal ex-
pansion).
Source: own work / Źródło: opracowanie własne
To evaluate the fatigue strength another algorithm pro-
ceedings are used . It includes a statement that the vessel is Fig. 3. Types of joints used in the sterilizer
working of fatigue, joint quality for certain classes, the cal- Rys. 3. Typy spoin zastosowanych w sterylizatorze
culation of correction factors to calculate structural stresses
concentration in the place using extrapolative techniques Table 2. Specification of welds classes used in the sterilizer [4]
and characterization of fatigue (Whöler charts). Tab. 2. Zestawienie klas spoin zastosowanych w sterylizatorze [4]
According to EN 13445-3 vessel working of fatigue No. the detail in standard
while: No. Welds
PN EN 13445-3
, The detail classes
(According to Table 18-4)
1 90 1.1
where: 2 80 6.1
3 80 6.1
.
4 80 6.3
5 80 6.1
While is the predicted number of cycles of pressure 6 90 1.1
change during normal operation, and is maxi- 7 80 6.1
mum pressure limits. If inequality is satisfied it was consid- 8 80 6.1
ered that the vessel is not working of fatigue. If inequality 9 80 6.1
is not satisfied calculations are performed of fatigue, In the 10 80 6.1
present case: 11 63 2.1c
12 80 6.1
13 63 2.1c
– a pressure difference during normal opera- 14 63 2.1c
tion, – is a maximum pressure limits (ad- 15 63 7.3b
justed by pressure relief valve). Hence: 16 63 2.1c
17 63 2.1c
18 63 2.1c
19 63 2.1c
20 63 2.1c
– the test object working of fatigue.
21 63 2.1c
22 63 2.1c
The standard EN 13445-3 includes 10 weld classes 23 63 2.1c
(from 32 to 100). These classes define the fatigue strength 24 80 6.1
of welded joints in function of the number cycles (fig. 2). 25 63 2.1c
26 71 5.2
Assignment of welds classes for each category in ana- 27 90 1.1
lyzed vessel presents fig. 3 and table 2.
Correction factors were determined according to the
procedures contained in the standard are as follows:
For welded joints:
• Factor dependent on coating thickness:
, while g ≤ 25mm.
• Factor dependent on temperature:
, .
For base material:
• roughness factor dependent on parameter
, while it was accepted .
• – coating thickness factor , while g
≤ 25mm.
• – influence coefficient of average stress. Deter-
Source: own work / Źródło: opracowanie własne mined by equation:
Fig. 2. Stress limits for fatigue tests, in function of the for
number of cycles for different welds classes [4]
Rys. 2. Naprężenia dopuszczalne dla badań zmęczeniowych,
w funkcji liczby cykli dla różnych klas spoin [4]

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
99
where:
– equivalent stress range, El. 1D
– shaft
– stress range at which fatigue crack occurs at a given
number of cycles. El. 3D

• – temperature dependent. Calculated as for welded El. 2D

joints. Preserved
weld
The statement if the object was characterized by suitable thickness

fatigue strength being after confronted so-called structural

stresses with graphs fig. 2. The standard EN 13445-3 pro-
vides three techniques for determining these stresses in heat El. 2D placed on 3D
– weld model
affected zone:
• Linear extrapolation for components bending slightly,
Source: own work / Źródło: opracowanie własne
according to scheme (a) shown in fig. 4, when the finite el-
ement has most equal length to two times of the coating Fig. 6. The calculation model of cover
thickness. Rys. 6. Model obliczeniowy pokrywy
• Parabolic extrapolation for components bending signif-
icantly, according to the scheme (b) shown in fig. 4 when
the finite element has most equal length to two times of the It proposed two major load cases, corresponding to re-
coating thickness. quirements of standard:
• The linear extrapolation, according to the scheme (c) • Test - Pressure load 6.4 bar, in temperature 20°C
shown in fig. 4, when finite element has at least twice (strength test of vessel).
length of thickness. • Normal exploitation – Pressure load 4 bar, in tempera-
ture 150°C (the impact of thermal expansion stress chang-
es) and distributed force continuously applied to guides
with beam (35000N). This force is combined with weight
of baskets and sterilized container placed on them (normal
exploitation).

In both load cases, the model supported as illustrated in

fig. 7.

Fig. 4. Methods of stress extrapolation to crack initiation

place according to standard [4]
Rys. 4. Sposoby ekstrapolacji naprężeń do miejsca inicjacji
pęknięć według normy [4]

3. Preparation of analyzes – construction of a compu-

tional model

The computational model of vessel was developed using

FEM fig. 5 (according to [7]). In detail all the contact feed-
back occurring between the covers, covers clamps and the Source: own work / Źródło: opracowanie własne
vessel was modeled (according to [5]). There were used for
this purpose elements GAP (fig. 6). Fig. 7. Method of receiving degrees of freedom – green
vectors represent the direction along which the possibility
of movement is received. The angles of rotation remain un-
fettered for each node
Rys. 7. Sposób odebrania stopni swobody – zielone wektory
przedstawiają kierunki, wzdłuż których odebrano możli-
wość ruchu. Kąty obrotów pozostają nieskrępowane dla
każdego węzła

4. The results of analyzes

Source: own work / Źródło: opracowanie własne The results of analyzes for normal operation include
Fig. 5. A complete computational model of the sterilizer figures from 8 to 13.
Rys. 5. Kompletny model obliczeniowy sterylizatora

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
100
 Source: own work / Źródło: opracowanie własne
Fig. 8. Map of Huber-Mises stresses, for normal operation.
The view from the top of the vessel. Displacements of
nodes in scale 50:1
Rys. 8. Mapa naprężeń Hubera-Misesa, dla normalnej ek-
sploatacji. Widok od góry na zbiornik. Przemieszczenia wę- Source: own work / Źródło: opracowanie własne
złów w skali 50:1
Fig. 11. Map of the minimum principal stresses (maximum
in relation to absolute value) for normal operation. View of
the area of concentration A from fig. 8 .Displacements of
nodes in scale 50:1
Rys. 11. Mapa naprężeń głównych minimalnych (maksy-
malnych co do wartości bezwzględnej), dla normalnej eks-
ploatacji. Widok na obszar koncentracji A z rys. 8. Prze-
mieszczenia węzłów w skali 50:1

Source: own work / Źródło: opracowanie własne

Fig. 9. Huber-Mises stresses (and the maximum principal
stresses for the approximation of "B") for normal operation.
View from the bottom of the vessel. Displacements of
nodes in scale 50:1 Source: own work / Źródło: opracowanie własne
Rys. 9. Naprężenia Hubera-Misesa (oraz głównych maksy- Fig. 12. Map of the maximum principal stresses, for normal
malnych dla zbliżenia „B”), dla normalnej eksploatacji. operation. View of the area of concentration B from fig. 9.
Widok od dołu na zbiornik. Przemieszczenia węzłów w skali Displacements of nodes in scale 50:1
50:1 Rys. 12. Mapa naprężeń głównych maksymalnych, dla nor-
malnej eksploatacji. Widok na obszar koncentracji B
z rys. 9. Przemieszczenia węzłów w skali 50:1

Source: own work / Źródło: opracowanie własne

Source: own work / Źródło: opracowanie własne
Fig. 10. Map of membrane stresses, reduced by the Huber-
Mises hypothesis, for normal operation. The view from the Fig. 13. Map of the maximum principal stresses, for normal
top of the vessel. Displacements of nodes in scale 50:1 operation. View of the area of concentration of C fig. 8.
Rys. 10. Mapa naprężeń membranowych, zredukowanych Displacements of nodes in scale 50:1
według hipotezy Hubera-Misesa, dla normalnej eksploata- Rys. 13. Mapa naprężeń głównych maksymalnych, dla nor-
cji. Widok od góry na zbiornik. Przemieszczenia węzłów malnej eksploatacji. Widok na obszar koncentracji C
w skali 50:1 z rys. 8. Przemieszczenia węzłów w skali 50:1

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
101
 Based on drawings for the analyzes of acute states:
• Primary global membrane stresses do not ex-
ceed the limit of 130 MPa. These stresses reach a value
about 50 MPa (fig. 10).
• Primary local membrane stresses and do
not exceed the limit of 195 MPa. This is shown in the draw-
ings presenting concentrations. The stress limit range
= 390 MPa is not exceeded. This range is calculat- Source: own work / Źródło: opracowanie własne
ed as the difference stresses during normal operation and dur-
Fig. 16. Map of Huber-Misses stresses, for pressure test.
ing unloading, when the pressure inside it is equal to zero.
View of the area of stress concentration A from fig. 15.
With regard to the fatigue strength of construction it
Displacements of nodes in scale 50:1
was located several areas of stress concentration:
Rys. 16. Mapa naprężeń Hubera-Misesa, dla próby
• In the place where the flange connects to the upper pipeline.
ciśnieniowej. Widok na obszar koncentracji naprężeń A
• In the place where the tube connects to the lower steam
z rys. 15. Przemieszczenia węzłów w skali 50:1
circuit with a vessel.
• In weld metal supports, with the base plate.
• In strengthening sheet metal of rotation mechanism of
cover with buckles
According to EN 13445-3 and the data included in the
area of 1. corresponds to type of connection with designa-
tion 7.3b and it has a class 63, the area of 2. is 2.1a – class
63, the area of 3. is 6.3 – class 80, area of 4 is 6.1 – class 80
(fig. 14).

Area 1. Area 2. Area 3. Area 4.

Source: own work / Źródło: opracowanie własne

Fig. 17. Map of Huber-Misses stresses, for pressure test.
Fig. 14. Types of welded joints according to PN EN 13445-3 [4] View of the area of stress concentration B from fig. 15.
Rys. 14. Zestawienie typów połączeń spawanych według PN Displacements of nodes in scale 50:1
EN 13445-3 [4] Rys. 17. Mapa naprężeń Hubera-Misesa, dla próby
ciśnieniowej. Widok na obszar koncentracji naprężeń B
For the area 1. 100 MPa determined by the extrapolative z rys. 15. Przemieszczenia węzłów w skali 50:1
stresses techniques as it was described in, for area 2. - 250
MPa, for area 3. - 160 MPa, for area 4. - 250 MPa. With
these levels of stresses and with the established classes of
welds, it is estimated that a fatigue crack occurs when:
• Area 1 – 48500 cycles;
• Area 2 – 31040 cycles;
• Area 3 – 241552 cycles;
• Area 4 – 63321 cycles.
These values are determined using the relationship:
.
Source: own work / Źródło: opracowanie własne
The size of C and m are given in standards EN 13445-3
Fig. 18. Map of Huber-Misses stresses, for pressure test.
according to weld classes, and is a factor correction.
View from the bottom of the vessel. Displacements of
The results of analyzes for tests are presented in figures
nodes in scale 50:1
from 15 to 18.
Rys. 18. Mapa naprężeń Hubera-Misesa, dla próby
ciśnieniowej. Widok od dołu na zbiornik. Przemieszczenia
węzłów w skali 50:1

For the tests also found no exceedances of the limit val-

ues. Especially:
• The primary global membrane stress does not
exceed the limit values 260 MPa.
Source: own work / Źródło: opracowanie własne • The primary local membrane stress and
does not exceed the limit values 390 MPa. This is
Fig. 15. Map of Huber-Misses stresses, for pressure test.
shown in drawings presenting concentrations.
The view from the top of the vessel. Displacements of
nodes in scale 50:1 • The limit stress range = 780 MPa has not
Rys. 15. Mapa naprężeń Hubera-Misesa, dla próby been exceeded. This range is calculated as the difference of
ciśnieniowej. Widok od góry na zbiornik. Przemieszczenia stresses during normal operation and during unloading,
węzłów w skali 50:1 when the pressure inside it is equal to zero.

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
102
5. Summary and conclusions 6. References

Based on the stress analysis FEM of vessel it was found [1] Czarniecka-Skubina E., Nowak D. (red.): Technologia żywno-
that the stresses do not exceed the limit values set by rec- ści. Cz. 1. Podstawy technologii żywności. Warszawa, 2010.
ommendations of standard EN 13445-3 for static strength, [2] Moss R., Basic M.: Pressure Vessel Design Manual. 4th Edi-
both for pressure tests, as well as for normal operation. tion. Butterworth-Heinemann, 2012.
Therefore, it is concluded that there is a possibility to build
[3] Norma EN 10088-2:2005: Stale odporne na korozję - Część 2:
a sterilizer and conduct further research using a prototype.
Warunki techniczne dostawy blach i taśm ze stali nierdzew-
However, it was noted areas of stress concentration, nych ogólnego przeznaczenia.
which can lead to the destruction of structure (unsealing of
vessel) over a longer period of operation. Preliminary esti- [4] Norma PN EN 13445. Nieogrzewane płomieniem zbiorniki
mation of fatigue strength using recommendations of stand- ciśnieniowe. Część 3: Projektowanie.
ard EN 13445-3 takes place by calculating the number of [5] Spadło M., Szczepaniak J.: Aproksymacja naprężeń zreduko-
cycles at which destruction occurs. For the individual case, wanych z wykorzystaniem składowych tensora płaskiego sta-
it was found that the destruction occurs after more cycles nu naprężenia. Journal of Research and Applications in Agri-
than planned 20000. Therefore, it was found initially that cultural Engineering, 2011, 56(2), 136-138.
object is of sufficient fatigue strength to work for 10 years. [6] Szczepaniak J.: Construction solutions in modern food steri-
Nevertheless, at stress it is clearly indicated strain gauge lizers. Mechanization in Agriculture, Bulgaria, 2015, 3, 19-23.
measurements to confirm theoretical considerations. These [7] Szczepaniak J.: Klasyfikacja cienkościennych prętowych ele-
measurements must be performed in accordance with re- mentów skończonych w zagadnieniach stateczności konstruk-
quirements of standard EN 13445-3, ie. by method of Hot cji nośnych maszyn rolniczych. Journal of Research and Ap-
Spot using extrapolative techniques. plications in Agricultural Engineering, 1999, 44(2), 81-83.

Mikołaj SPADŁO, Dominik DEMBICKI, Paweł WOŹNIAK, Jan Szczepaniak „Journal of Research and Applications in Agricultural Engineering” 2016, Vol. 61(2)
103

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