Asme Pressure vessel calc

7/29/2019 Asme Pressure vessel calc

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Sample Job #24

ABC-123-456

Finite Element Analysis (FEA) Report

Heat Exchanger Analysis

September 29, 2009


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Table of Contents ver 4.00 Page 2 of 44

Contents PageCover 1Table of Contents 2Executive Summary 3Section - Materials 4

SA-240 304 5SA-213 TP304 6

Section - Model Information 7Model 8Mesh 9Error 10

Section - Restraints & Loads 11Restraints 1 12Restraints 2 13Pressure Loads 14Thermal Loads 1 15Thermal Loads 2 16X-Axis Reaction Area 17Z-Axis Reaction Area 18Reaction Forces 19

Section - Results 20Case 1 - Displacement 21Case 1 - General Stress 22Case 1 - Local Stress 23Case 1 - Buckling 24Case 2 - Displacement 25Case 2 - General Stress 26Case 2 - Buckling 27Case 3 - Displacement 28Case 3 - General Stress 29Case 3 - Local Stress 30Case 3 - Buckling 31Case 4 - Displacement 32


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Executive Summary ver 4.00 Page 3 of 44

Project Information:

Customer Vessel / Component(s)Part Number JobFEA Program UsedDate

Shell Side (psi) Tube Side (psi)

100 300Max Operating Temp (F) MDMT

300 -20

Goal:

Summary Conclusions:

Materials

Model InformationA 1/4 model is used to simplify the analysis due to symmetry A mesh size of 1" is applied globally the

Maximum Allowed Working Pressures

Maximum Design Metal Temperatures

Material properties used in this analysis are obtained from ASME IID, and are suitable for VIII-1components. The rules of ASME VIII-2 are used to set the stress limits.

The tubesheet cannot be calculated to ASME VIII-1 UHX code rules due to the unusual tube pattern.Instead the rules of ASME VIII-2 are used with VIII-1allowed stresses to determine the acceptability of the design.

All (7) load cases as per ASME VIII-1 UHX are analyzed for the following components:

- The tubesheet- The shell adjacent to the tubesheet- The tubes

SolidWorks Simulation 200926-Jun-2009

XYZ Vessel Corp.Heat Exchanger

ABC-123-456PVE-3520


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Materials ver 4.00 Page 4 of 44

Summary:

Contents:

Material properties used in this analysis are obtained from ASME IID, and are suitable for VIII-1components. The rules of ASME VIII-2 are used to set the stress limits.

Material properties are obtained from:

- ASME IID, Table 1A (allowable stress)- Table TE-1 (modulus of elasticity)

- Table TM-1 (thermal expansion coefficient)

The rules of VIII-2 have been applied to calculate the maximum allowable stresses.


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1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 5 of 442 Material: 3 Material4 Application

5 Strength Propert ies: 6 Source of strength properties7 300 T [F] temperature8 18,900 Sm [psi] basic allowable stress at temperature T9 22,400 Sy [psi] yield stress at temperature T (optional)10 1.0 k [] - stress intensity k factor 11 1.00 E1 [] - weld efficiency factor 12 1.00 E2 [] - casting efficiency factor

13 FEA Prop erties: 14 Source of FEA properties15 27,000,000 E [psi] - modulus of elasticity (at temperature)16 0.31 v [] - Poison's ratio17 9.2 E-006 Coef [in/in/F] - coefficient of thermal expansion (for thermal stress studies only)

18 Stress Lim its: 19 Pm =20 18,900

21 Pl =22 28,350

23 Pl+Pb =24 28,350

25 Pl+Pb+Q =26 56,700

27 Pl+Pb+Q+F = Use fatigue curves ~~ peak stress intensity limit

28 C o m m e n t s : 29 (1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it.30 (2) Refer to VIII-2 Table AD-150.1 for k values31 (3) The thermal expansion coeficient is only required for studies including thermal stresses

SA-240 304

ASME VIII-IID, 2007 Ed, 2008 Add.

Shell, Head, Tubesheet, Bellows


k*E1*E2*Sm ~~ general primary membrane stress intensity limit1*1*1*18900 =

1.5*k*E1*E2*Sm ~~ local membrane stress intensity limit1.5*1*1*1*18900 =

1.5*k*E1*E2*Sm ~~ primary membrane + primary bending stress intensity limit1.5*1*1*1*18900 =

Max(3*E1*E2*Sm,2*E1*E2*Sy) ~~ primary + secondary stress intensityMAX(3*1*1*18900,2*1*1*22400) =


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1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 6 of 442 Material: 3 Material4 Application

5 Strength Propert ies: 6 Source of strength properties7 300 T [F] temperature8 18,900 Sm [psi] basic allowable stress at temperature T9 22,400 Sy [psi] yield stress at temperature T (optional)10 1.0 k [] - stress intensity k factor 11 1.00 E1 [] - weld efficiency factor 12 1.00 E2 [] - casting efficiency factor

13 FEA Prop erties: 14 Source of FEA properties15 27,000,000 E [psi] - modulus of elasticity (at temperature)16 0.31 v [] - Poison's ratio17 9.2 E-006 Coef [in/in/F] - coefficient of thermal expansion (for thermal stress studies only)

18 Stress Lim its: 19 Pm =20 18,900

21 Pl =22 28,350

23 Pl+Pb =24 28,350

25 Pl+Pb+Q =26 56,700

27 Pl+Pb+Q+F = Use fatigue curves ~~ peak stress intensity limit

28 C o m m e n t s : 29 (1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it.30 (2) Refer to VIII-2 Table AD-150.1 for k values31 (3) The thermal expansion coeficient is only required for studies including thermal stresses

SA-213 TP304


Tubes


k*E1*E2*Sm ~~ general primary membrane stress intensity limit1*1*1*18900 =

1.5*k*E1*E2*Sm ~~ local membrane stress intensity limit1.5*1*1*1*18900 =

1.5*k*E1*E2*Sm ~~ primary membrane + primary bending stress intensity limit1.5*1*1*1*18900 =

Max(3*E1*E2*Sm,2*E1*E2*Sy) ~~ primary + secondary stress intensityMAX(3*1*1*18900,2*1*1*22400) =


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Model Information ver 4.00 Page 7 of 44

Summary:

Contents:

Model

Mesh

Error Plot

Reference Information:

A 1/4 model was used to simplify the analysis due to symmetry. 1/2 of the bellows is included andpositioned at mid length of the shell to compensate for the use of symmetry.

The tubesheet and adjacent shell are solid models, all other components are modeled as surfaces.

Please refer to Drawing PVE-3520.0 for details.

A 1/4 model is used to simplify the analysis due to symmetry. A mesh size of 1" is applied globally, thetubesheet and adjacent shell are refined to 3/8" and 1/4" respectively. Reported error is < 5% for allgeneral areas. The mesh selected is acceptable.

1" 2nd order shell elements are applied to all surfaces. A 2nd order tetrahedral solid mesh was applied tothe tubesheet and adjacent shell and refined to 3/8" and 1/4" respectively.

Reported error is < %5 for all general areas. Error in excess of %5 is limited to locations of discontinuityand does not affect the results.

The error plot justifies the mesh selected. The model may be used for analysis.

Please refer to the following links for additional information;

Including reference components in an FEA to provide appropriate boundary and load conditions.http://www.pveng.com/documents/content_80.pdf
http://www.pveng.com/documents/content_80.pdfhttp://www.pveng.com/documents/content_80.pdf


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1 Model Ver 4.06 Page 8 of 442

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Fig-A A view of the Heat Exchanger model. A 1/4 model was used to simplify the analysis due to symmetry.

Refer to drawing PVE-3520.0 for details.

Baffles SA-240 304

Bellows SA-240 304Head SA-240 304

Shell SA-240 304

Tubes SA-213 TP304

Tubesheet SA-240 304


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1 Mesh Ver 4.07 Page 9 of 442

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Fig-A A view of the mesh applied to the model. A 1" shell mesh is applied to all surfaces, solid elements are refined to 3/8" for the tubesheet and 1/4" for the

adjacent shell.

1" Shell Mesh

3/8" Solid Mesh

1/4" Solid Mesh


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1 Error Ver 4.06 Page 10 of 442

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Fig-A A view of the Error plot, scale set to 5% Error. Areas of error greater than 5% are limited to locations of discontinuity within (1) element of change.


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Restraints & Loads ver 4.00 Page 11 of 44

Summary:

Contents:

Restraints

Loads

Reaction Forces

Symmetry is applied to compensate for the use of a 1/4 model, a single fixed point is applied to preventrigid body motion. (7) load cases are applied as per ASME VIII-1 UHX-13.4(a). Reported reaction forcesclosely match theoretical reaction forces. The model is in balance and may be used for displacement andstress analysis.

A symmetry condition is applied to all faces & edges along symmetry planes. This compensates for theuse of a 1/4 model and provides results identical to that of a full analysis. A single point is restrained toprevent rigid body motion in all directions.

(7) load cases are analyzed as per ASME VIII-1 UHX 13.4(a)

1-TP (Tube pressure only)2-SP (Shell pressure only)3-TP+SP (Tube pressure + shell pressure)

4-T (Thermal loads only)5-T+TP (Thermal loads + tube pressure)6-T+SP (Thermal loads + shell pressure)7-T+TP+SP (Thermal loads + tube pressure + shell pressure)

The above load cases are all run and anal zed individuall .

The reported reaction forces closely match the theoretical reaction forces in all directions. The model is inbalance and can be used to calculate expected displacements and stresses.


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1 Restraints Ver 4.06 Page 12 of 442

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Fig-A A view of the symmetry restraint applied to all shell edges on the symmetry plane.This restraint compensates for the use of a 1/4 model and provides results identical to a complete analysis.


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1 Restraints Ver 4.06 Page 13 of 442

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Fig-A A view of the symmetry restraint applied to the midlength edges of the bellows and shell.Note only 1/2 of the bellows is included and positioned at mid-length to compensate symmetry.

This restraint prevents ridged body motion in the "Z" direction.


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1 Loads Ver 4.06 Page 14 of 442

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Fig-A A view of the tube side pressure (300 psi) applied.


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Fig-A A view of the shell side components set to the operating temperature of 200F.Thermal expansion will be calculated based on the temperature differential between 70F ambient to the

respective components temperature as shown in the following images.


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Fig-A A view of tubes set to 250F. An average temperature of 225F is taken between the shell side and the tube side.


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1 X-Axis Reaction Area Ver 4.02 Page 17 of 442

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Fig-A A view showing the tubeside pressure area on the X-Axis.This area will be used on the following pages to calculate reaction forces.

Area = 682.8 in^2


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1 Z-Axis Reaction Area Ver 4.02 Page 18 of 442

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Fig-A A view showing the tubeside pressure area on the Z-Axis.This area will be used on the following pages to calculate reaction forces.

Area =60.4 in^2


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1 Reaction Forces ver 4.08 Page 19 of 442

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27 App lied Pressure: 28 100 Ps [psi] - Pressure applied to the shell side29 300 Pt [psi] - Pressure applied to the tube side

30 X Axis : reaction forces on the YZ plane caused by loads in the X direction31 505.94 XArea1 [in2] - Pressurized area on YZ plane (Shell Side)32 682.80 XArea2 [in2] - Pressureized area on YZ plane (Tube Side)33 0 XForce [lbs] - Added force in the X direction34 255,920 XReaction [lbs] - Reaction force in X direction reported by FEA program

View showing global reaction forces from analysis "X" = 255,920 lb, "Y" = 25.521 lb, "Z" = -26,608 lbReported reaction forces = theorectical reaction forces within 2%.

Model is in balance and may be used for stress and displacement analysis.


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Results ver 4.00 Page 20 of 44

Summary:

Contents:

Displacement Plots

Stress Plots

Case Sa Result Cycle Life1 TP Acceptable NR

2 SP Acceptable NR3 TP+SP Acceptable NR4 T Acceptable NR5 TP+T Acceptable NR6 SP+T Acceptable NR7 TP+SP+T Acceptable NR

Displacement direction is as expected, displacement magnitude is acceptable for all (7) load cases.

All observed stresses are below their respective allowable for all (7) loads cases.

No further analysis is required.

Displacement direction is as expected, displacement magnitude is acceptable for all (7) load cases.

All observed stresses are below their respective allowable for all (7) loads cases.

Tubesheet Results

18,900 psi

56,700 psi(Sps)


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1 Case 1 TP Displacement Page 21 of 442

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Fig-A A view of the displacement plot, results magnified 100X.Maximum displacement is 0.019"

Tube bending


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1 Case 1 TP Stress Page 22 of 442

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Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.Maximum stresses are observed at the shell to tubesheet junction.

Shell to tubesheet junction


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Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.


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1 Case 1 TP Buckling Page 24 of 442

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Fig-A A view of the stress plot in the "Z" direction capped at the tube buckling allowable of -10,706 psi.


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1 Case 2 SP Displacement Page 25 of 442

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Tube bending


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1 Case 2 SP Stress Page 26 of 442

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Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.Maximum stresses are observed at the shell.

Shell


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1 Case 2 SP Buckling Page 27 of 442

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1 Case 3 TP + SP Displacement Page 28 of 442

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Tube bending


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1 Case 3 TP + SP Stress Page 29 of 442

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Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.Maximum stresses are observed at the shell to tubesheet junction.

Shell to tubesheet junction


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1 Case 3 TP + SP Stress Page 30 of 442

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Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.


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1 Case 3 TP + SP Buckling Page 31 of 442

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1 Case 4 TP Displacement Page 32 of 442

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Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.


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1 Case 4 T Buckling Page 34 of 442

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1 Case 5 TP + T Displacement Page 35 of 442

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1 Case 5 TP + T Stress Page 36 of 442

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1 Case 5 TP + T Buckling Page 37 of 442

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1 Case 6 SP + T Displacement Page 38 of 442

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1 Case 6 SP + T Stress Page 39 of 442

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1 Case 6 SP + T Buckling Page 40 of 442

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1 Case 7 TP + SP + T Displacement Page 41 of 442

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1 Case 7 TP + SP + T Stress Page 42 of 442

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1 Tube Buckling ver 4.00 ASME VIII-1 UHX-13.5.9(b)(3)(a) Page 14 of 192

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27 Inputs : VIII-1 UHX-13.328 SA-213 TP304 Mat - Tube material29 1.500 dt [in] - Tube OD30 0.109 tt [in] - Tube wall31 27,000,000 Et [psi] - Tube modulus of elasticity at design temp32 22,400 Sy [psi] - Tube yield strength at design temp33 18,900 St [psi] - Tube allowable stress at design temp34 16.750 l [in] - Unsupported length of tube

View showing the tube axial compression stress capped at the buckling allowable of 10,707 psi.Reported tube axial compression stress is less than the allowable.

Tube design is acceptable.


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Asme Pressure vessel calc

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