Avoid Exchanger Replacement Using Advanced Analysis and Fit for Service Approach

2021 ◽  
Author(s):  
Ibrahim M. Al Awadhi ◽  
Ashok M. Sharma ◽  
Sohail Akhter
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Service Life ◽  
Heat Exchangers ◽  
Structural Integrity ◽  
Design Code ◽  
Element Analysis ◽  
Fit For Purpose ◽  
Design Pressure

Abstract Objective/Scope (25 - 75 word) Shell & Tube Heat exchangers are critical for incessant operation of processing plant. These exchangers may face integrity threats due to reduction in shell thicknesses at Nozzle to Shell Junction below design code requirements. This paper presents the Cost Effective fit for purpose approach utilizing advance Finite Element analysis to explore and recommend the solutions for existing numerous exchangers that are to be safely used even after reported low thickness on account of manufacturing imperfection. Methods, Procedures, Process (75 - 100 word) Reduction in Shell thickness below design value can affect its ability to sustain design pressure & vacuum including nozzle integrity for associated piping loads and service life reduction for exclusion of corrosion allowance. As short-term Mitigation methodology, weld overlay was adopted to restore the areas with lower thickness. For long term solution, fit for purpose review approach was adopted for continued usage of exchangers which involves nozzle load analysis using WRC & FEA based on PAUT thickness data and utilizing actual piping loads, derating of design pressure, comparison of thickness data to establish corrosion rate and service life of exchanger. Results, Observations & Conclusions (100 - 200 words) Thorough Integrity review based on design Code (ASME BPVC Section VIII) and WRC analysis have confirmed that majority of the exchangers have thickness higher than that required to sustain design pressure, vacuum conditions when considered with piping loads acting on nozzles. Thickness data comparison between three (03) year old manual UT and latest Phase array UT confirmed that majority of the exchangers are in clean non-corrosive service thus allowance for corrosion is not required. Where in the nature of exchanger service require corrosion allowance, it is considered in analysis and usage of stiffeners at nozzle to shell intersection and/or on full circumference of shell is recommended to prevent overstress due to piping loads / buckling distortion due to vacuum conditions respectively, based on detailed Finite element analysis (FEA). In order to establish more reliable long-term corrosion rate, next inspection after four (04) years is recommended and impact on integrity can be further evaluated based on the latest data. Change in exchanger nameplate is recommended to consider for design pressure as MAWP and accordingly adjust hydro test pressure followed by R-stamp requirements for rerating and repair. Shell side hydro test is restricted until recommendations are implemented Novel/Additive Information (25 - 75 words) Although conventional approach of replacing complete Shells to meet code requirement would have ensured process safety, performance and structural integrity. However, alternative fit for purpose approach utilizing advanced FEA has not only ensured all these but also led to potential cost saving of multimillion US$. Associated risks of thickness reduction due to corrosion may still be observed, however analysis confirmed structural integrity and safety of heat exchangers with low thicknesses. Accordingly, potential risk is mitigated.

scholarly journals Long-Term Performance of Trestle Bridges: Case Study of an Indonesian Marine Port Structure

2020 ◽  
Vol 8 (5) ◽  
pp. 358 ◽  
Author(s):  
Yusak Oktavianus ◽  
Massoud Sofi ◽  
Elisa Lumantarna ◽  
Gideon Kusuma ◽  
Colin Duffield
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Service Life ◽  
Field Measurement ◽  
Field Measurements ◽  
Element Analysis ◽  
Moment Capacity ◽  
Non Destructive

A precast reinforced concrete (RC) T-beam located in seaport Terminal Peti Kemas (TPS) Surabaya built in 1984 is used as a case study to test the accuracy of non-destructive test techniques against more traditional bridge evaluation tools. This bridge is mainly used to connect the berth in Lamong gulf and the port in Java Island for the logistic purposes. The bridge was retrofitted 26 years into its life by adding two strips of carbon fiber reinforced polymer (CFRP) due to excessive cracks observed in the beams. Non-destructive field measurements were compared against a detailed finite element analysis of the structure to predict the performance of the girder in terms of deflection and moment capacity before and after the retrofitting work. The analysis was also used to predict the long-term deflections of the structure due to creep, crack distribution, and the ultimate moment capacity of the individual girder. Moreover, the finite element analysis was used to predict the deflection behavior of the overall bridge due to vehicle loading. Good agreement was obtained between the field measurement and the analytical study. A new service life of the structure considering the corrosion and new vehicle demand is carried out based on field measurement using non-destructive testing. Not only are the specific results beneficial for the Indonesian port authority as the stakeholder to manage this structure, but the approach detailed also paves the way for more efficient evaluation of bridges more generally over their service life.

Tire Bead Overheating in Urban Buses and Trucks Using Drum Brake Systems

1998 ◽  
Vol 26 (1) ◽  
pp. 51-62
Author(s):  
A. L. A. Costa ◽  
M. Natalini ◽  
M. F. Inglese ◽  
O. A. M. Xavier
Keyword(s):  
Heat Transfer ◽  
Finite Element Analysis ◽  
Finite Element ◽  
Thermal Energy ◽  
Structural Integrity ◽  
Experimental Temperature ◽  
Temperature Profiles ◽  
Element Analysis ◽  
Drum Brake ◽  
Fea Model

Abstract Because the structural integrity of brake systems and tires can be related to the temperature, this work proposes a transient heat transfer finite element analysis (FEA) model to study the overheating in drum brake systems used in trucks and urban buses. To understand the mechanics of overheating, some constructive variants have been modeled regarding the assemblage: brake, rims, and tires. The model simultaneously studies the thermal energy generated by brakes and tires and how the heat is transferred and dissipated by conduction, convection, and radiation. The simulated FEA data and the experimental temperature profiles measured with thermocouples have been compared giving good correlation.

scholarly journals Finite Element Analysis Study on Lattice Structure Fabricated Using Corn Husk Fibre Reinforced Recycled Polystyrene Composite

2021 ◽  
Vol 335 ◽  
pp. 03011
Author(s):  
Mohammed Shariff Mohamed Sulaiman ◽  
Seong Chun Koay ◽  
Ming Yeng Chan ◽  
Hui Leng Choo ◽  
Ming Meng Pang ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Structural Integrity ◽  
Lattice Structure ◽  
Lattice Parameter ◽  
Triangular Prism ◽  
Hexagonal Prism ◽  
Element Analysis ◽  
Corn Husk ◽  
Fea Simulation

This research investigated the lattice structure fabricated using corn husk fibre reinforced recycled polystyrene composite using Finite Element Analysis (FEA). The material’s properties of this composite material were obtained from previous study. Then, the lattice structure of lattice structure was created using Creo® software and the FEA simulation was done by ANSYS software. In this study, the lattice structures were created using triangular prism and hexagonal prism. The analysis was divided into two conditions: 1) lattice structure with different prism shape and similar surface area, 2) lattice structure with varies of strut thickness and 3) lattice structure with different prism shape and similar lattice parameter. The results show the lattice structure with triangular prism have more structural integrity than hexagonal prism. Then, lattice structure with triangular prism can be built with lesser material but stronger and stiffer than lattice structure with hexagonal prism.

Static Finite Element Analysis on Cast Shell of a 100 kW Single Screw Expander

2014 ◽  
Vol 694 ◽  
pp. 279-282
Author(s):  
Qi Liu ◽  
Hang Guo ◽  
Wei Wang ◽  
Yu Ting Wu ◽  
Fang Ye ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Thick Wall ◽  
Thin Wall ◽  
Element Analysis ◽  
Single Screw ◽  
Shell Design ◽  
Fundamental Research ◽  
Assembly Problem ◽  
Design Pressure

In the process of shell design of a 100kW single screw expander, the fundamental research on the screw chamber walls thickness is still lacking. Thin wall may cause deformation and the damage possibility of the inlet passage. Thick wall will increase the weight of the expander and led to assembly problem and transportation inconvenience. In this paper, static finite element analysis on cast shell of the 100 kW single screw expander was carried out. By calculating stress distribution and deformation of the expander shell under 1.5 times of the design pressure, the authors find the thickness of gate rotor chamber walls and inlet passage walls as 15 mm is acceptable, but the thickness of screw chamber walls should be at least 35 mm.

Coupled Field Analyses in MEMS With Finite Element Analysis

2005 ◽  
Vol 127 (1) ◽  
pp. 34-37 ◽  
Author(s):  
Ravi Chandra Sikakollu ◽  
Lemmy Meekisho ◽  
Andres LaRosa
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Structural Integrity ◽  
Operating Temperature ◽  
Design Tool ◽  
Thermal Actuator ◽  
Element Analysis ◽  
Thermal Boundary Conditions ◽  
Coupled Field ◽  
Fixed End

This paper deals with the design and analysis of a horizontal thermal actuator common in MEMS applications using Finite Element Analysis; with the objective of exploring means to improve its sensitivity. The influence of variables like voltage and the dimensions of the cold arm of the actuator unit were examined by comprehensive, coupled thermal-stress analyses. Simulation results from this study showed that the sensitivity of the actuator increases with the applied voltage as well as the width of the cold arm of the thermal actuator. An important observation made from this study is that the size and thermal boundary conditions at the fixed end of the actuator primarily control the stroke and the operating temperature of the actuator for a given potential difference between cold and hot arms. The coupled field analyses also provided a design tool for maximizing the service voltage and dimensional variables without compromising the thermal or structural integrity of the actuator.

Finite Element Analysis for the Stiffness and the Buckling of Corrugated Tubes in Heat Exchanger

2012 ◽  
Vol 468-471 ◽  
pp. 1675-1680 ◽  
Author(s):  
Xiao Jing Wang ◽  
Zhi Min Wang ◽  
Nian Wang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Stability Analysis ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
External Pressure ◽  
Element Analysis ◽  
Value Analysis ◽  
Compressive Pressure ◽  
The Stability

Corrugated tubes in a heat exchanger are analyzed by using the FEA methods. And the formula how to compute single wave’s rigidity is obtained. Besides, methods of analyzing the stability of corrugated tubes under internal compressive pressure and external pressure are proposed which include characteristic value analysis and non-linear stability analysis, thus providing theory basis for the stability research of heat exchangers.

scholarly journals Vibration and Modal Analysis of Low Earth Orbit Satellite

2014 ◽  
Vol 2014 ◽  
pp. 1-8 ◽  
Author(s):  
Asif Israr
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Structural Integrity ◽  
Center Of Mass ◽  
Low Earth Orbit ◽  
Element Analysis ◽  
Satellite Structure ◽  
Modeling And Analysis ◽  
Material Optimization ◽  
Theoretical Predictions

This paper presents design, modeling, and analysis of satellite model used for remote sensing. A detailed study is carried out for the design and modeling of the satellite structure focusing on the factors such as the selection of material, optimization of shape and geometry, and accommodation of different subsystems and payload. The center of mass is required to be kept within the range of (1-2) cm from its geometric center. Once the model is finalized it is required to be analyzed by the use ofAnsys, a tool for finite element analysis (FEA) under given loading and boundary conditions. Static, modal, and harmonic analyses inAnsysare performed at the time of ground testing and launching phase. The finite element analysis results are also validated and compared with the theoretical predictions. These analyses are quite helpful and suggest that the satellite structure does not fail and retains its structural integrity during launch environment.

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