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RELIANCE ENGINEERING ASSOCIATES (P) LTD

MODELLING AND STRESS ANALYSIS PROCEDURE


FOR HORIZONTAL SHELL AND TUBE EXCHANGER

MODELLING AND STRESS ANALYSIS PROCEDURE FOR SHELL


AND TUBE TYPE EXCHANGER
-----------------------------------------------------------------------------------------------------------PROCEDURE FOR STRESS ANALYSIS
1. REQUIRED DOCUMENTS
Isometric drawing of the lines.
Plot plan.
P & ID.
GA Drawing of heat exchanger and other associated equipment.
Mechanical data sheet of exchanger and other associated equipment.
LDT.
Allowable nozzle loads Data from 3PS-ME-001 and or from vendor.
CASE I:

FIG. 1

2. SHELL AND TUBE EXCHANGER MODELING IN CAESAR=II


Referring the fig1 that given with node marking, follow the same procedure as
given below.
1) Start from node 10, model the element 10-20 as rigid with Skirt temp. (For skirt
temp. calculations see on page no 8.) And Give anchor at node no 10 ,Take
Pressure=1 bar , Hydro pressure=0 Diameter and thickness of this element must be
same as the dia. of exchanger shell.
2) Element 20-30 model as rigid element and give Exchanger Shell side data like
Temp, pressure, Hydro pressure. Diameter and thickness should be same as
Exchanger shell side dimensions.
3) Elements 30-40, 40-50 and 50-60 are modeled as rigid element .and the condition
same as of Element 20-30
4) Element 60-70 model as rigid element and give Exchanger Shell side data like
Temp, pressure, Hydro pressure and diameter.
5) Model the element 70-80 as rigid with Skirt temp (For skirt temp. calculations
on page no 8.). And Give Restraint, Rigid Y with frication (for PTFE friction
factor is 0.1), and guide with 0.3 friction and 2 mm Gap , Take Pressure=1 bar ,
Hydro pressure=0 Diameter and thickness of this element must be same as the
shell dia. and shell thickness of exchanger respectively.
6) Model the element 50-89 as rigid and give Exchanger Shell side data like Temp,
pressure, Hydro pressure. And dimensions will be same as the shell side
dimensions of exchanger. And give Anchor at node 90 with C-Node 89.
7) The C-Node number 89 must comes on the element name 50-89. The C-Node
should be on equipment side and ANC node on nozzle side.
8) Model the element 90-100 as pipe, and take Temp, Pressure, Thickness, Hydro
Pressure, and Nozzle Projection from Equipment G.A./data sheet.
9) Model Element 100-110 as Flange.

FIG 2
Note: The above case in which both saddle are bolted at node no 240 and
270(without slot ) then followed modeling procedure as same as the above case.

3. MODELING OF STACKED EXCHANGER IN CAESAR II:


The way of modeling to be followed for stacked exchanger (Fig 2) case will be
same as modeling of the single exchanger case. The node numbering for this case is as
shown in the above figure. The sequence of modeling will be followed as per node
sequence.
Except the nozzle elements (i.e. 50-60, 60-70, 70-80, 80-90,140-150,150-160, 210215 and 215-220) all should be modeled as weightless rigid elements. Nozzle elements
should be modeled as pipe.

CASE III.

Fig 3
Note: The saddle support at node number 240 and 10 fixed and at node number 270
and 190 sliding (with provided slot with axial displacement) then follow the modeling
procedure as same as above case.

CASE IV

Fig 4
Note: The saddle support at node number 240 and 190 fixed and at node number 270
and 10 sliding (with provided slot with axial displacement) then follow the modeling
procedure as same as above case.

Abbreviation:
W = Weight;

T= Temperature;

HP = Hydro Pressure;

WW = Water Filled Weight;

P = Design Pressure.

U1 = Uniform load (NS Seismic);

U2 = Uniform load (NS Seismic);

4. LOAD CASES FOR STATIC ANALYSIS


CASE L1:
CASE L2:
CASE L3:
CASE L4:
CASE L 5:
CASE L6:
CASE L7:
CASE L8:
CASE L9:
CASE L10:
CASE L11:
CASE L12:
CASE L13:
CASE L14:
CASE L15:
CASE L16:
CASE L17:
CASE L18:

WW+HP (HYD)
W+T1+P1 (OPE) Design temp case.
W+T2+P1 (OPE) Operating temp case.
W+P1 (SUS)
W+T2+P1+Wind 1
W+T2+P1+Wind 2
W+T2+P1+Wind 3
W+T2+P1+Wind 4
L5-L3
L6-L3
L7-L3
L8-L3
L9+L4
L10+L4
L11+L4
L12+L4
L2-L4 (EXP)
L3-L4 (EXP)

NOTE:

If line from exchanger to other associated equipment going above 10m height
then wind case analysis is applicable.

For load case 1,4, 13, 14, 15, 16, 17 and 18 are check with code compliance.
and stress check.

Case 4 for check with displacement in all directions only.

Case 2, 3, 4, checks with restrain summary for load, moment and


displacement.

5, 6, 7, 8 checks with restrain summary for load in wind case only .

5. LOAD CASES FOR SEISMIC ANALYSIS


For seismic stress analysis make separate file as FILE NAME_ u. In this file
remove design and operating temperature and enter ambient temperature as T1. Replace all
+Y restraint by Y restraint. Remove all friction and guide gap at restraints. Click on
uniform load in CAESAR spread sheet and enter 0.34 value in UX and UZ direction.
7

Activate uniform load in Gs option in Kaux special execution parameters. Make load
cases as below:
CASE L1: W+P1 (SUS)
CASE L2: U1 (OCC)
CASE L3: U2 (OCC)
CASE L4: L1+L2 (OCC)
CASE L5: L1+L3 (OCC)

For load case no 4 and 5 stress value is checked and it should be less than

allowable stress as specified by relevant code.

Case 2 checked with Restrain summary for Fx Values.

Case 3 checked with Restrain summary for Fz Values.

6. CALCULATION
Skirt Expansion
The temperatures used for calculating skirt expansions are taken from the equation:
Ta = Ambient Temp. (C)
T = Temp @ top of Skirt (C)
83.6
K h

Kh
>
120

+ 15.5 t

t
K = Insulation Constant = 1.0 Firebrick Insulated
F=

= 1.6 Non-insulated
h = Skirt Height
t = Skirt wall thickness.
Average Skirt Temp (C)= (T-Ta)F + Ta
Note: This calculation is based on Bechtel Spec. 3PS-PL008, Appendix A - A.8