fea analysis of nozzle on condenser (e-2-09 ......doc. no: - fea/epm-142/r0 4 of 63 chapter 1...

FEA ANALYSIS OF NOZZLE ON CONDENSER

(E-2-09) EPM-142

PROJECT NO. – EPM-142

Document No.: FEA/EPM-142/R0 Rev: 0

TITLE: FEA ANALYSIS OF NOZZLE ON CONDENSER (E-2-09)

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Revision History:

00 Original issue 01/08/2020 H.P D.M K.M -

Rev. Description Date Prepared by Checked by Approved by Reviewed by


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Table of Contents

Chapter 1 – Introduction

Chapter 2 – Finite Element Model

Chapter 3 – FEA Analysis

Chapter 4 – Observations

Chapter 5 – Conclusion

Chapter 6 – References

Annexure A- FEA Validation

Annexure B- Summary of Nozzle Process Loads


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Chapter 1

Introduction

The objective of analysis was to check stress levels in the Nozzles on condenser (N1, N2, N3, N4, N5,

N6, N7, N8, N32, N33, N34). Condenser is designed as per ASME Section VIII, Div. 1 Ed. 2017, TEMA

R AXS, API 650 and FEA analysis of nozzle is carried out as per ASME Section VIII, Div.2, Part 5. To

investigate the stress levels in nozzles linear static finite element analysis is carried out. 3D CAD

model generated for analysis is as per geometric details provided, names of drawings are

mentioned in chapter 6. The Finite Element Analysis is carried out in ANSYS Workbench.

1.1: Design Parameters:

Design Code: ASME Sec VIII Div. I, Ed. 2017, TEMA R AXS, API 650

Shell side Tube Side

Design Temperature (°C) 18/200 18/121

Design Pressure (Max./ Min.) (kg/cm2 g) 3.5 / F.V. 13/F. V

Corrosion Allowance (mm) 6.0 None

Table 1.1- Design Parameters

1.2: Materials of Construction: Components Material Grade

Shell side shell, Nozzle RF pad N3, N4, N5 SA 516 Gr. 70

Nozzle neck N3, N4, N5, Nozzle Neck N6,

N7, N8, Nozzle N29 -N31, Nozzle Neck

N32-N34,

SA 106 B

Boot Head SA 234 WPB

Channel Shell, Nozzle N1, N2 RF pad SB 171 C70600

Nozzle Neck N1, N2 SB 466 C70600

Table 1.2- Materials of Construction 1.3: Material Properties for Analysis:

Material Design

Temperature (°C)

Elastic Modulus

(MPa)

Allowable Stress (MPa)

Yield Strength

(MPa)

Density (Kg/m3)

Poisson’s Ratio

SA 516 Gr. 70

200

192.0E03 138.0 225.0 7750.0 0.30

SA 106 B 192.0E03 118.0 207.0 7750.0 0.30

SA234 WPB 192.0E03 118.0 207.0 7750.0 0.30

SB 171 C70600 121 120.16E03 64.1 95.8 8940.0 0.33


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SB 466 C70600 120.16E03 55.1 82.5 8940.0 0.33

Table 1.3- Material Properties at maximum design temperature


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1.4: Methodology:

The study is conducted to determine the stress level in Nozzles N1, N2, N3, N4, N5, N6, N7, N8, N32,

N33, N34 on condenser. The study is conducted using the following methodology:

3D CAD model of Nozzle is generated with the help of drawings provided. 3D Model includes

part of shell, channel, Nozzles, saddle support, shell flange, channel flange. 3D model is

divided in to two models as per nozzles locations i.e. shell side nozzles & channel side

nozzles. Drawing used for FEA analysis are mentioned in chapter 6.

FEA Analysis is carried out for the following load cases:

o Shell Side Nozzle Analysis Load cases -

o Load Case 1 – Internal Design Pressure + Nozzle thrust + Nozzle Process Loads

(shell side nozzles)

o Load Case 2 – External Design Pressure + Nozzle thrust + Nozzle Process Loads

(shell side nozzles)

o Channel Side Nozzle Analysis Load cases -

o Load Case 3 – Internal Design Pressure + Nozzle thrust + Nozzle Process Loads

(channel Side Nozzles)

o Load Case 4 – External Design Pressure + Nozzle thrust + Nozzle Process Loads

(Channel Side Nozzles)

FEA Analysis Results are validated as per ASME Sec. VIII, Division 2, Part 5 Edition 2019.

Results are studied and presented in the following sections.

FEA Analysis is carried out in Ansys Workbench software.

Detailed procedure is presented in following pages with aid of supporting graphics.

1.5: Geometry Parameters:


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Figure 1.1 – 3D CAD model (Corroded Geometry)

Note: All dimensions are in mm.


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Chapter 2

FINITE ELEMENT MODEL

2.1: Geometry- 3D CAD model

Figure 2.1 – 3D CAD model – Shell Side Nozzles

Figure 2.2 – 3D CAD model – Channel Side Nozzles


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2.2 Finite Element Model:

Finite Element Model is based on 3D CAD model of Nozzle N2 Solid-186 elements are used for analysis for Nozzle N2

o Total numbers of Elements in Model = 248560 o Total numbers of Nodes in Model = 818379

Overall mesh quality checks with their acceptable limits and achieved values are shown below in Table 2.1

Quality Check Acceptable Value Achieved Valve Aspect Ratio < 5 2.69

Jacobian Ratio > 0.5 1.69

Skewness < 0.70 0.33

Element Quality > 0.1 0.69 Table 2.1- Mesh quality parameters

Figure 2.3: Meshed FEA model of shell side Nozzles


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Figure 2.4: Meshed FEA model of Channel side Nozzles


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Chapter 3

FEA Analysis for Nozzles

3.1: Load Case 1 – Internal Design Pressure + Nozzle Thrust + Nozzle Process Loads (Shell Side nozzles) 3.1.1: Structural loading condition

Self-weight of model is applied as a gravity load in downward direction as shown in figure

3.1.1

Internal design pressure of 3.5 kg/cm2g (0.3432 MPa) is applied on internal faces of shell,

shell side nozzle as shown in figure 3.1.1

Thrusts due to internal pressure is applied on nozzle flange face as shown in figure 3.1.2,

Thrust calculations are given in table 3.1

Nozzle Process loads is applied at nozzle flange face as shown in figure 3.1.3

Fixed boundary condition is applied at bottom face of fixed saddle support while

displacement support is applied at sliding saddle support as shown in figure 3.1.4

Figure 3.1.1 – Loading Condition for Load Case 1 – Gravity Load


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Figure 3.1.2 – Loading Condition for Load Case 1 – Nozzle Thrust

Figure 3.1.3 – Loading Condition for Load Case 1 – Nozzle Process Loads


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Figure 3.1.4 – Boundary condition – Fixed and sliding support 3.1.2: Loading Calculations

Thrust Calculation:

Location Nozzle Name Nozzle IR (mm) Area (mm2) Pressure (N/mm2) Nozzle Thrust (N)

Shell Side

N3, N4, N5 452.09 642095.5709 0.3432327 220388.1965

N29, N30, N31 156.81 77249.80331 0.3432327 26514.65857

N32, N33, N34 80.539 20378.03663 0.3432327 6994.408534

Shell Thrust 806 2040891.685 0.3432327 700500.7635

Channel Side N1, N2 150.81 71451.30292 1.274865 91090.7653

Location Nozzle Name Nozzle IR (mm) Area (mm2) Pressure (N/mm2) Nozzle Thrust (N)

Shell Side

N3, N4, N5 452.09 642095.5709 -0.101325 -65060.33372

N29, N30, N31 156.81 77249.80331 -0.101325 -7827.336321

N32, N33, N34 80.539 20378.03663 -0.101325 -2064.804562

Shell Thrust 806 2040891.685 -0.101325 -206793.35

Channel Side N1, N2 150.81 71451.30292 -0.101325 -7239.803268

Table 3.1.- Nozzle Thrust calculations


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Nozzle Size

6" 12" 18" 36" Unit

ML 5.62 22.46 50.54 202.18 KN.m

MC 4.32 17.28 38.88 155.52 KN.m

MR 7.09 28.34 63.77 255.07 KN.m

FA 14.4 28.8 43.2 86.40 KN

Table 3.2.- Nozzle process Loads


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3.1.3: Results for Load Case 1

Deformation Plot for Load Case 1

Figure 3.1.5: Total deformation plot

Maximum Von Mises Stress Plot


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Figure 3.1.6: maximum Von mises stress plot

Figure 3.1.7.a: Maximum Von mises stress plot – Nozzle N3


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Figure 3.1.7.b: Maximum Von mises stress plot – Nozzle N4

Figure 3.1.7.c: Maximum Von mises stress plot – Nozzle N5


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Linearized stress plot at max stress location at Nozzle N3 across nozzle pipe thickness


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3.2: Load Case 2 – Full Vacuum Pressure + Nozzle Thrust + Nozzle Process Loads (Shell Side nozzles) 3.2.1: structural loading condition

Self-weight of model is applied as a gravity load in downward direction as shown in figure

3.2.1

External design pressure of F.V. (-0.101325 MPa) is applied on internal faces of shell, shell

side nozzle as shown in figure 3.2.1

Thrusts due to vacuum pressure is applied on nozzle flange face as shown in figure 3.2.2,



Fixed boundary condition is applied at bottom face of fixed saddle support while

displacement support is applied at sliding saddle support as shown in figure 3.2.4

Figure 3.2.1 – Loading Condition for Load Case 2 – Gravity Load


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Figure 3.2.3 – Loading Condition for Load Case 2 – Nozzle Process Loads


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Figure 3.2.4 – Boundary condition – Fixed and sliding support


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Deformation Plot for Load Case 2

Figure 3.2.5: Total deformation plot


Figure 3.2.6: maximum Von mises stress plot


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3.3: Load Case 3 – Internal Design Pressure + Nozzle Thrust + Nozzle Process Loads (Channel Side Nozzles) 3.3.1: Structural loading condition

Internal Design pressure of 13 kg/cm2g (1.2749 MPa) is applied on internal faces of channel

shell and nozzle N1 and N2 as shown in figure 3.3.1




Polar coordinate-based ddisplacement boundary condition is provided at channel flange

such that it is restricted to move in axial and tangential direction and free to expand in radial

direction due to pressure as shown below in figure 3.3.4

Figure 3.3.1 – Loading Condition for Load Case 3 – Channel Side Internal Pressure


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Figure 3.3.3 – Loading Condition for Load Case 3 –Nozzle Moment


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Figure 3.3.4 – Displacement Boundary condition @ channel Flange


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Deformation Plot

Figure 3.3.5: Deformation Plot for Load case 3


Figure 3.3.6 – Maximum Von Mises Stress Plot for Load Case 3


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Figure 3.3.7 – Maximum Von Mises Stress Plot @Nozzle N1



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Linearized stress plot at maximum stress location at nozzle N1


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3.4: Load Case 4 – Full vacuum Pressure + Nozzle Thrust + Nozzle Process Loads (Channel Side Nozzles) 3.4.1: structural loading condition

Full vacuum pressure (-0.101325 MPa) is applied on internal faces of channel shell and

nozzle N1 and N2 as shown in figure 3.4.1




Polar coordinate-based ddisplacement boundary condition is provided at channel flange

such that it is restricted to move in axial and tangential direction and free to expand in radial

direction due to pressure as shown below in figure 3.4.4

Figure 3.4.1 – Loading Condition for Load Case 4 – Channel Side Internal Pressure


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Figure 3.4.3 – Loading Condition for Load Case 4 –Nozzle Moment


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Figure 3.4.4 – Displacement Boundary condition @ channel Flange


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Deformation Plot

Figure 3.4.5: Deformation Plot for Load case 4


Figure 3.4.6 – Maximum Von Mises Stress Plot for Load Case 4


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Chapter 4

Observations

Load Case

Location Pl (MPa) Pl + Pb +Q

(MPa)

LC 1

At max stress location at nozzle N3 across pipe thickness 151.21 345.2









LC 2










LC3 At max stress location at nozzle N1 across nozzle junction 71.357 131.74

At max stress location at nozzle N2 across nozzle junction 71.156 131.48

LC4 At max stress location at nozzle N1 across nozzle junction 48.539 111.93

At max stress location at nozzle N2 across nozzle junction 52.373 116.72

Table 4.1: Observations for Load Cases


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Chapter 5

Conclusion

Results for Design Pressure Condition are compared with ASME Section VIII, Division 2, Part 5.2 (Protection against Plastic Collapse). Stress comparisons are made as per ASME Sect VIII, Div. 2, Figure 5.1. (Ed.2019) PL+Pb+Q is compared with Sps PL is compared with SPL

Pm is compared with S, Where S = allowable stress for material SPL = 1.5*S or Sy (1.5*S shall be used when the ratio of the minimum specified yield strength to ultimate tensile strength exceeds 0.70) Sps = allowable stress for primary and secondary stresses (ASME Sect VIII, Div. 2, Part 5.5.6.1.d)

For Design Condition at 200°C Design temperature (Shell Side)

For SA 516 Gr. 70

S = 138.0 MPa for SA 516 Gr.70 SPL =Sy= 225.0 MPa for SA 516 Gr.70 Sps =2*Sy = 450.0 MPa for SA 516 Gr.70

For SA 106 Gr. B

S = 118.0 MPa for SA 106 B SPL =Sy= 207.0 MPa for SA 106 B Sps =2*Sy = 414.0 MPa for SA 106 B

For Design Condition at 121°C Design temperature (Channel Side)

For SB 171 C70600

S = 64.1 MPa for SB 171 C70600 SPL =Sy= 95.8 MPa for SB 171 C70600 Sps =2*Sy = 191.6 MPa for SB 171 C70600

For SB 466 C70600

S = 55.1 MPa for SB 466 C70600 SPL =Sy= 82.5 MPa for SB 466 C70600 Sps =2*Sy = 165.0 MPa for SB 466 C70600


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Conclusion for Primary local membrane stress

Load Case

Location Pl (MPa)


Result

LC1

At max stress location at nozzle N3 across pipe thickness 151.21 207.0 Pass









LC2










LC3 At max stress location at nozzle N1 across nozzle junction 71.357 82.5 Pass

At max stress location at nozzle N2 across nozzle junction 71.156 82.5 Pass



Table 5.1: Conclusion for Primary local membrane stress


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Conclusion for Primary membrane and bending stress

Load Case

Location PL+Pb+Q (MPa)


Result

LC1










LC2














Table 5.2: Conclusion for Primary membrane and bending stress


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Chapter 6

References

1. ASME Sec. II, Part D, Ed. 2019 – Physical Properties Tables

2. ASME Sec. VIII, Division 1, Edition 2019.

3. Reference Drawings

26071-V1A-E-2-09-00101(91638-XY-COND) REV000


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Annexure A

FEA Validation

A.1: FEA Validation (Software Validation):

Results are verified for stress due to pressure as follows Hoop stress in shell away from discontinuity

… (R. Norton, Machine Design: An Integrated Approach (2nd Edition) – Equation 4.47a)

Where, For shell at design Condition

Ro = Outer radius of shell = 815.9 mm Ri = Inner radius of shell = 806.0 mm P = 0.34323 MPa ------ Internal Pressure After solving this we get,

28.11 MPa Stress from FEA

28.19 MPa The stresses in tangential (Y) directions are matching with calculated value. Refer Figure below.

Figure A.1 – Hoop Stress on Shell – for Validation


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Annexure B

Summary of Nozzle Process Loads

Nozzle Process loads used for analysis of nozzles on shell side of condenser

Flange Rating Moment with unit Client Load Detail Endurable Nozzle Load

6” 150#

ML (kgf.m) 573.0805 573.0805

MC (kgf.m) 440.5174 440.5174

MR (kgf.m) 722.9788 722.9788

FA (kgf) 1468.391 1468.391

12” 150#

ML (kgf.m) 2290.283 1145.142

MC (kgf.m) 1762.07 881.035

MR (kgf.m) 2889.876 1444.938

FA (kgf) 2936.783 1468.392

18” 150#

ML (kgf.m) 5153.646 1546.094

MC (kgf.m) 3964.657 1189.397

MR (kgf.m) 6502.73 1950.819

FA (kgf) 4405.174 1321.552

36” 150#

ML (kgf.m) 20616.62 6184.986

MC (kgf.m) 15858.63 4757.589

MR (kgf.m) 26009.9 7802.97

FA (kgf) 8810.348 2643.104

Table B.1- Summary of Nozzle Process Loads


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Nozzle Process loads used for analysis of nozzles on channel side of condenser

Flange Rating Moment with unit Client Load Detail Endurable Nozzle Load

12” 150#

ML (kgf.m) 2290.283 2290.283

MC (kgf.m) 1762.07 1762.07

MR (kgf.m) 2889.876 2889.876

FA (kgf) 2936.783 2936.783

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