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Sample Job #24: Finite Element Analysis (FEA) Report
Sample Job #24: Finite Element Analysis (FEA) Report
PVE-3520
Derek Verstege C.Tech
Laurence Brundrett P. Eng.
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Table of Contents ver 4.00 Page 2 of 44
Contents Page
Cover 1
Table of Contents 2
Executive Summary 3
Section - Materials 4
SA-240 304 5
SA-213 TP304 6
Section - Model Information 7
Model 8
Mesh 9
Error 10
Section - Restraints & Loads 11
Restraints 1 12
Restraints 2 13
Pressure Loads 14
Thermal Loads 1 15
Thermal Loads 2 16
X-Axis Reaction Area 17
Z-Axis Reaction Area 18
Reaction Forces 19
Section - Results 20
Case 1 - Displacement 21
Case 1 - General Stress 22
Case 1 - Local Stress 23
Case 1 - Buckling 24
Case 2 - Displacement 25
Case 2 - General Stress 26
Case 2 - Buckling 27
Case 3 - Displacement 28
Case 3 - General Stress 29
Case 3 - Local Stress 30
Case 3 - Buckling 31
Case 4 - Displacement 32
Case 4 - Stress SPS 33
Case 4 - Buckling 34
Case 5 - Displacement 35
Case 5 - Stress SPS 36
Case 5 - Buckling 37
Case 6 - Displacement 38
Executive Summary ver 4.00 Page 3 of 44
Project Information:
Goal:
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
Summary Conclusions:
Materials
Material properties used in this analysis are obtained from ASME IID, and are suitable for VIII-1
components. The rules of ASME VIII-2 are used to set the stress limits.
Model Information
A 1/4 model is used to simplify the analysis due to symmetry. A mesh size of 1" is applied globally, the
tubesheet and adjacent shell are refined to 3/8" and 1/4" respectively. Reported error is < 5% for all
general areas. The mesh selected is acceptable.
Results
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.
Analysis Conclusion:
The heat exchanger meets ASME VIII-2 code rules using ASME VIII-1 allowables. The design is
acceptable.
Materials ver 4.00 Page 4 of 44
Summary:
Material properties used in this analysis are obtained from ASME IID, and are suitable for VIII-1
components. The rules of ASME VIII-2 are used to set the stress limits.
Contents:
The rules of VIII-2 have been applied to calculate the maximum allowable stresses.
1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 5 of 44
2 Material:
3 SA-240 304 Material
4 Shell, Head, Tubesheet, Bellows Application
5 Strength Properties:
6 ASME VIII-IID, 2007 Ed, 2008 Add. Source of strength properties
7 300 T [ºF] temperature
8 18,900 Sm [psi] basic allowable stress at temperature T
9 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 Properties:
14 ASME VIII-IID, 2007 Ed, 2008 Add. Source of FEA properties
15 27,000,000 E [psi] - modulus of elasticity (at temperature)
16 0.31 v [] - Poison's ratio
17 9.2 E-006 Coef [in/in/ºF]- coefficient of thermal expansion (for thermal stress studies only)
18 Stress Limits:
19 Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit
20 1*1*1*18900 = 18,900
21 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit
22 1.5*1*1*1*18900 = 28,350
23 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit
24 1.5*1*1*1*18900 = 28,350
25 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity
26 MAX(3*1*1*18900,2*1*1*22400) = 56,700
27 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit
28 Comments:
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 values
31 (3) The thermal expansion coeficient is only required for studies including thermal stresses
32 (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits
33 (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits
34 (6) Use IID tables 2A and 2B for Sm for VIII-2 studies
35 (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies
36 (8) Use B31.1 Table A for Sm values for B31.1 studies
37 (9) Use B31.3 Table A for Sm values for B31.3 studies
1 Material Stress Limits ver 4.00 ASME VIII-2 Fig 4-130.1 Page 6 of 44
2 Material:
3 SA-213 TP304 Material
4 Tubes Application
5 Strength Properties:
6 ASME VIII-IID, 2007 Ed, 2008 Add. Source of strength properties
7 300 T [ºF] temperature
8 18,900 Sm [psi] basic allowable stress at temperature T
9 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 Properties:
14 ASME VIII-IID, 2007 Ed, 2008 Add. Source of FEA properties
15 27,000,000 E [psi] - modulus of elasticity (at temperature)
16 0.31 v [] - Poison's ratio
17 9.2 E-006 Coef [in/in/ºF]- coefficient of thermal expansion (for thermal stress studies only)
18 Stress Limits:
19 Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit
20 1*1*1*18900 = 18,900
21 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit
22 1.5*1*1*1*18900 = 28,350
23 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit
24 1.5*1*1*1*18900 = 28,350
25 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity
26 MAX(3*1*1*18900,2*1*1*22400) = 56,700
27 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit
28 Comments:
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 values
31 (3) The thermal expansion coeficient is only required for studies including thermal stresses
32 (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits
33 (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits
34 (6) Use IID tables 2A and 2B for Sm for VIII-2 studies
35 (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies
36 (8) Use B31.1 Table A for Sm values for B31.1 studies
37 (9) Use B31.3 Table A for Sm values for B31.3 studies
Model Information ver 4.00 Page 7 of 44
Summary:
A 1/4 model is used to simplify the analysis due to symmetry. A mesh size of 1" is applied globally, the
tubesheet and adjacent shell are refined to 3/8" and 1/4" respectively. Reported error is < 5% for all
general areas. The mesh selected is acceptable.
Contents:
Model
A 1/4 model was used to simplify the analysis due to symmetry. 1/2 of the bellows is included and
positioned 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.
Mesh
1" 2nd order shell elements are applied to all surfaces. A 2nd order tetrahedral solid mesh was applied to
the tubesheet and adjacent shell and refined to 3/8" and 1/4" respectively.
Error Plot
Reported error is < %5 for all general areas. Error in excess of %5 is limited to locations of discontinuity
and does not affect the results.
The error plot justifies the mesh selected. The model may be used for analysis.
Reference Information:
Including reference components in an FEA to provide appropriate boundary and load conditions.
http://www.pveng.com/documents/content_80.pdf
Mesh Refinement Using the Error Function Results for Areas at Discontinuities.
http://www.pveng.com/documents/content_250.pdf
Mesh Refinement Using the Error Function Results for Areas near Discontinuities.
http://www.pveng.com/documents/content_251.pdf
Error Plots for Bolt Heads and Surface to Surface Contacts Areas.
http://www.pveng.com/documents/content_248.pdf
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Head SA-240 304 Bellows SA-240 304
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Tubes SA-213 TP304
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41 Solid bodies
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Summary:
Symmetry is applied to compensate for the use of a 1/4 model, a single fixed point is applied to prevent
rigid body motion. (7) load cases are applied as per ASME VIII-1 UHX-13.4(a). Reported reaction forces
closely match theoretical reaction forces. The model is in balance and may be used for displacement and
stress analysis.
Contents:
Restraints
A symmetry condition is applied to all faces & edges along symmetry planes. This compensates for the
use of a 1/4 model and provides results identical to that of a full analysis. A single point is restrained to
prevent rigid body motion in all directions.
Loads
(7) load cases are analyzed as per ASME VIII-1 UHX 13.4(a)
The above load cases are all run and analyzed individually.
Reaction Forces
The reported reaction forces closely match the theoretical reaction forces in all directions. The model is in
balance and can be used to calculate expected displacements and stresses.
1 Restraints Ver 4.06 Page 12 of 44
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24 Fig-A A view of the symmetry restraint applied to all shell edges on the symmetry plane.
25 This restraint compensates for the use of a 1/4 model and provides results identical to a complete analysis.
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50 Fig-B A view of the symmetry restraint applied to all solid faces on the symmetry plane.
51 These restraints prevent ridged body motion in the "X" direction.
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1 Restraints Ver 4.06 Page 13 of 44
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24 Fig-A A view of the symmetry restraint applied to the midlength edges of the bellows and shell.
25 Note only 1/2 of the bellows is included and positioned at mid-length to compensate symmetry.
26 This restraint prevents ridged body motion in the "Z" direction.
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1 Loads Ver 4.06 Page 15 of 44
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24 Fig-A A view of the shell side components set to the operating temperature of 200°F.
25 Thermal expansion will be calculated based on the temperature differential between 70°F ambient to the
26 respective components temperature as shown in the following images.
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1 Loads Ver 4.06 Page 16 of 44
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1 X-Axis Reaction Area Ver 4.02 Page 17 of 44
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24 View showing global reaction forces from analysis "X" = 255,920 lb, "Y" = 25.521 lb, "Z" = -26,608 lb
25 Reported reaction forces = theorectical reaction forces within 2%.
26 Model is in balance and may be used for stress and displacement analysis.
27 Applied Pressure:
28 100 Ps [psi] - Pressure applied to the shell side
29 300 Pt [psi] - Pressure applied to the tube side
30 X Axis: reaction forces on the YZ plane caused by loads in the X direction
31 505.94 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 direction
34 255,920 XReaction [lbs] - Reaction force in X direction reported by FEA program
35 TReactionX [lbs] = (XArea1*Ps)+(XArea2*Pt)+XForce ~~ Theoretical X reaction force
36 (505.94*100)+(682.8*300)+0 = 255,434
37 Z Axis: reaction forces on the XY plane caused by loads in the Z direction
38 92.80 ZArea1 [in2] - Pressurized area on XY plane (Shell Side)
39 60.38 ZArea2 [in2] - Pressurized area on XY plane (Tube Side)
40 0 ZForce [lbs] - Added force in the Z direction
41 -26,608 ZReaction [lbs] - Reaction force in Z direction reported by FEA program
42 TReactionZ [lbs] = (ZArea1*Ps)+(ZArea2*Pt)+ZForce ~~ Theoretical Z reaction force
43 (92.8*100)+(60.38*300)+0 = 27,393
44 Resultant of reaction forces in X, Y and Z:
45 TResultant [lbs] = sqrt(TReactionX^2+TReactionZ^2) ~~ Theoretical resultant
46 SQRT(255434^2+27393^2) = 256,898
47 Resultant [lbs] = sqrt(XReaction^2+ZReaction^2) ~~ Actual resultant
48 SQRT(255920^2+-26608^2) = 257,299
49 Error [%] = ABS(100*(TResultant-Resultant)/Resultant)
50 ABS(100*(256898-257299)/257299) = 0.2
51 CheckError = abs(Error)<2 ~~ Error should be less than 2% ABS(0.2)<2 = Acceptable
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Results ver 4.00 Page 20 of 44
Summary:
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.
Contents:
Displacement Plots
Displacement direction is as expected, displacement magnitude is acceptable for all (7) load cases.
Stress Plots
All observed stresses are below their respective allowable for all (7) loads cases.
Tubesheet Results
Case Sa Result Cycle Life
1 TP Acceptable NR
2 SP 18,900 psi Acceptable NR
3 TP+SP Acceptable NR
4T Acceptable NR
5 TP+T 56,700 psi Acceptable NR
6 SP+T (Sps) Acceptable NR
7 TP+SP+T Acceptable NR
1 Case 1 TP Displacement Page 21 of 44
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Shell to tubesheet junction
24 Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.
25 Maximum stresses are observed at the shell to tubesheet junction.
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24 Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.
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24 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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24 Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.
25 Maximum stresses are observed at the shell.
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24 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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24 Fig-A A view of the stress plot (von Mises), capped at the general membrane allowable of 18,900 psi.
25 Maximum stresses are observed at the shell to tubesheet junction.
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24 Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.
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24 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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24 Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
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24 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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24 Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
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24 Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
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24 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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24 Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
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24 View showing the tube axial compression stress capped at the buckling allowable of 10,707 psi.
25 Reported tube axial compression stress is less than the allowable.
26 Tube design is acceptable.
27 Inputs: VIII-1 UHX-13.3
28 SA-213 TP304 Mat - Tube material
29 1.500 dt [in] - Tube OD
30 0.109 tt [in] - Tube wall
31 27,000,000 Et [psi] - Tube modulus of elasticity at design temp
32 22,400 Sy [psi] - Tube yield strength at design temp
33 18,900 St [psi] - Tube allowable stress at design temp
34 16.750 l [in] - Unsupported length of tube
35 0.800 k - Support configuration
36 Variables:
37 lt [in] = k*l ~~ UHX-13.5.9(b)(1) Effective unsupported tube length 0.8*16.75 = 13.400
38 rt [in] = sqrt((dt^2+(dt-2*tt)^2)/4) ~~ UHX-13.5.9(b)(2)
39 SQRT((1.5^2+(1.5-2*0.109)^2)/4) = 0.987
40 Ft = lt/rt ~~ UHX-13.5.9(b)(2) 13.4/0.987 = 13.582
41 Ct = sqrt((2* ^2*Et)/Sy) ~~ UHX-13.5.9(b)(2) SQRT((2*3^2*27000000)/22400) = 154.171
42 Fs = 2.0 ~~ UHX-13.5.9(b)(2) 2.0 = 2.000
43 Allowable Stress: UHX-13.5.9(b)(3)(a)
44 Stb1 [psi] = min(( ^2*Et)/(Fs*Ft^2),St) ~~ UHX-13.5.9(b)(2)
45 MIN((3^2*27000000)/(2*13.582^2),18900) = 18900
46 Stb2 [psi] = min((Sy/Fs)*(1-(Ft/(2*Ct))),St) ~~ UHX-13.5.9(b)(2)
47 MIN((22400/2)*(1-(13.582/(2*154.171))),18900) = 10707
48 Stb [psi] = if(Ct<=Ft, Stb1, Stb2) ~~ UHX-13.5.9(b)(2)
49 IF(154.171<=13.582, 18900, 10707) = 10707
50
51 *The reported tube axial compression stress (not von Mises equivalent) must be < Stb