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PVE-3520
Derek Verstege C.Tech Laurence Brundrett P. Eng.
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Customer Vessel / Component(s) Part Number Job FEA Program Used Date Maximum Allowed Working Pressures Maximum Design Metal Temperatures
100
Max Operating Temp (F)
300
MDMT
300 Goal:
-20
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. Restraints & Loads 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. 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. No further analysis is required. Analysis Conclusion: The heat exchanger meets ASME VIII-2 code rules using ASME VIII-1 allowables. The design is acceptable.
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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: 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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FEA Properties: ASME VIII-IID, 2007 Ed, 2008 Add. Source of FEA properties 27,000,000 E [psi] - modulus of elasticity (at temperature) 0.31 v [] - Poison's ratio 9.2 E-006 Coef [in/in/F]- coefficient of thermal expansion (for thermal stress studies only) Stress Limits: Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit 1*1*1*18900 = 18,900 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit 1.5*1*1*1*18900 = 28,350 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit 1.5*1*1*1*18900 = 28,350 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity MAX(3*1*1*18900,2*1*1*22400) = 56,700 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit Comments:
(1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it. (2) Refer to VIII-2 Table AD-150.1 for k values (3) The thermal expansion coeficient is only required for studies including thermal stresses (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits (6) Use IID tables 2A and 2B for Sm for VIII-2 studies (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies (8) Use B31.1 Table A for Sm values for B31.1 studies (9) Use B31.3 Table A for Sm values for B31.3 studies
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FEA Properties: ASME VIII-IID, 2007 Ed, 2008 Add. Source of FEA properties 27,000,000 E [psi] - modulus of elasticity (at temperature) 0.31 v [] - Poison's ratio 9.2 E-006 Coef [in/in/F]- coefficient of thermal expansion (for thermal stress studies only) Stress Limits: Pm = k*E1*E2*Sm~~general primary membrane stress intensity limit 1*1*1*18900 = 18,900 Pl = 1.5*k*E1*E2*Sm~~local membrane stress intensity limit 1.5*1*1*1*18900 = 28,350 Pl+Pb = 1.5*k*E1*E2*Sm~~primary membrane + primary bending stress intensity limit 1.5*1*1*1*18900 = 28,350 Pl+Pb+Q = Max(3*E1*E2*Sm,2*E1*E2*Sy)~~primary + secondary stress intensity MAX(3*1*1*18900,2*1*1*22400) = 56,700 Pl+Pb+Q+F = Use fatigue curves~~peak stress intensity limit Comments:
(1) Sy material property is not required, more conservative Pl+Pb+Q limits might be computed without it. (2) Refer to VIII-2 Table AD-150.1 for k values (3) The thermal expansion coeficient is only required for studies including thermal stresses (4) Refer to VIII-2 App 4-130 and following for the Pm, Pl, Q and F stress limits (5) Refer to VIII-2 App 4-130 Table 4-120.1 for the correct application of the calculated stress limits (6) Use IID tables 2A and 2B for Sm for VIII-2 studies (7) Use IID tables 1A and 2A for Sm values (S) for VIII-1 studies (8) Use B31.1 Table A for Sm values for B31.1 studies (9) Use B31.3 Table A for Sm values for B31.3 studies
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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. Please refer to Drawing PVE-3520.0 for details. 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: 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 The use and effects of 2nd order integration elements. http://www.pveng.com/documents/content_151.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 FEA Software Validation - A comparison to theoretical results. http://www.pveng.com/documents/content_249.pdf COSMOSWorks Validation Examples. http://www.pveng.com/documents/content_247.pdf
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Tubesheet SA-240 304 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.
Solid bodies
Fig-B An alternative view of Fig-A. The tubesheet and shell are modeled as "solid" bodies; all other components are modeled as "surfaces". The shell is shown as transparent for clarity.
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3/8" Solid Mesh 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.
Fig-B A close up of Fig-A. All components are treated as "bonded" and meshed as a single body.
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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.
Fig-B An alternative view of Fig-A, with mesh overlaid. Error results are acceptable, the mesh may be used for analysis.
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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) 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 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.
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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.
Fig-B A view of the symmetry restraint applied to all solid faces on the symmetry plane. These restraints prevent ridged body motion in the "X" direction.
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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.
Fig-B A view of the no translation condition applied to a point on the model. This restraint prevent ridged body motion in the "Y" direction. The model is now fully restrained from ridged body motion in all directions.
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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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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
Fig-B A view showing the shellside pressure area on the X-Axis. This area will be used on the following pages to calculate reaction forces. Area = 504.6 in^2
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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
Fig-B A view showing the shellside pressure area on the Z-Axis. This area will be used on the following pages to calculate reaction forces. Area =92.8 in^2
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View showing global reaction forces from analysis "X" = 255,920 lb, "Y" = 25.521 lb, "Z" = -26,608 lb Reported reaction forces = theorectical reaction forces within 2%. Model is in balance and may be used for stress and displacement analysis. Applied Pressure: 100 Ps [psi] - Pressure applied to the shell side 300 Pt [psi] - Pressure applied to the tube side X Axis: reaction forces on the YZ plane caused by loads in the X direction 505.94 XArea1 [in2] - Pressurized area on YZ plane (Shell Side) 682.80 XArea2 [in2] - Pressureized area on YZ plane (Tube Side) 0 XForce [lbs] - Added force in the X direction 255,920 XReaction [lbs] - Reaction force in X direction reported by FEA program TReactionX [lbs] = (XArea1*Ps)+(XArea2*Pt)+XForce ~~ Theoretical X reaction force (505.94*100)+(682.8*300)+0 = 255,434 Z Axis: reaction forces on the XY plane caused by loads in the Z direction 92.80 ZArea1 [in2] - Pressurized area on XY plane (Shell Side) 60.38 ZArea2 [in2] - Pressurized area on XY plane (Tube Side) 0 ZForce [lbs] - Added force in the Z direction -26,608 ZReaction [lbs] - Reaction force in Z direction reported by FEA program TReactionZ [lbs] = (ZArea1*Ps)+(ZArea2*Pt)+ZForce ~~ Theoretical Z reaction force (92.8*100)+(60.38*300)+0 = 27,393 Resultant of reaction forces in X, Y and Z: TResultant [lbs] = sqrt(TReactionX^2+TReactionZ^2) ~~ Theoretical resultant SQRT(255434^2+27393^2) = Resultant [lbs] = sqrt(XReaction^2+ZReaction^2) ~~ Actual resultant SQRT(255920^2+-26608^2) = Error [%] = ABS(100*(TResultant-Resultant)/Resultant) ABS(100*(256898-257299)/257299) = CheckError = abs(Error)<2 ~~ Error should be less than 2% ABS(0.2)<2 =
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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. 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.
Sa 18,900 psi
Tubesheet Results Result Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable
Cycle Life NR NR NR NR NR NR NR
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Case 1 TP Displacement
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Fig-A A view of the displacement plot, results magnified 100X. Maximum displacement is 0.019"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The tubesheet observes bending do to the tubeside pressure acting on the head pulling it outwards while the tubes restrain it at center.
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Case 1 TP Stress
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Shell to tubesheet junction 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.
Local region Fig-B An "ISO clipped" view of Fig-A, clipped at 18,900 psi. The only areas or error in excess of the general membrane allowable are limited to local regions. These stresses will be further analyzed on the following page.
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Case 1 TP Stress
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Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 28,350 psi. No stresses in excess of 28,350 psi are observed. No further analysis is required, results are acceptable.
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Case 1 TP Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. No stresses in excess of -10,706 psi are observed in the tubes. No further analysis is required, results are acceptable.
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Case 2 SP Displacement
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Fig-A A view of the displacement plot, results magnified 500X. Maximum displacement is 0.006"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The shell observes radial expansion due to shell side pressure. The tubesheet observes bending do to the shell side pressure forcing it outwards while the tubes restrain it at center.
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Case 2 SP Stress
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Shell
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.
Fig-B An "ISO clipped" view of Fig-A, clipped at 18,900 psi. No stresses in excess of 18,900 psi are observed. No further analysis is required, results are acceptable.
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Case 2 SP Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. No stresses in excess of -10,706 psi are observed in the tubes. No furhter analysis is required, results are acceptable.
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Case 3 TP + SP Displacement
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Fig-A A view of the displacement plot, results magnified 100X. Maximum displacement is 0.023"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The shell observes radial expansion due to shell side pressure. The tubesheet observes bending do to combined shell side and tubeside pressure forcing it outwards while the tubes restrain it at center.
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Case 3 TP + SP Stress
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Shell to tubesheet junction 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.
Local region Fig-B An "ISO clipped" view of Fig-A, clipped at 18,900 psi. The only areas or error in excess of the general membrane allowable are limited to local regions. These stresses will be further analyzed on the following page.
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Case 3 TP + SP Stress
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Fig-A A view of the stress plot (von Mises), capped at the local membrane allowable of 28,350 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 28,350 psi. No stresses in excess of 28,350 psi are observed. No further analysis is required, results are acceptable.
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Case 3 TP + SP Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. No stresses in excess of -10,706 psi are observed in the tubes. No further analysis is required, results are acceptable.
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Case 4 TP Displacement
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Fig-A A view of the displacement plot, results magnified 50X. Maximum displacement is 0.091"
Fig-B An alternative view of Fig-A, with superimposed original geometry. The heat exchanger observes axial elongation due to thermal expansion.
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Case 4 TP Stress
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Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 56,700 psi. No stresses in excess of 56,700 psi are observed. No further analysis is required, results are acceptable.
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Case 4 T Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. Stresses in excess of -10,706 psi in the tubes are limited to a short length from the tubesheet. No further analysis is required, results are acceptable.
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Case 5 TP + T Displacement
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Fig-A A view of the displacement plot, results magnified 100X. Maximum displacement is 0.100"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The tubesheet observes bending do to the tubeside pressure acting on the head pulling it outwards while the tubes restrain it at center.
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Case 5 TP + T Stress
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Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 56,700 psi. No stresses in excess of 56,700 psi are observed. No further analysis is required, results are acceptable.
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Case 5 TP + T Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. Stresses in excess of -10,706 psi in the tubes are limited to a short length from the tubesheet. No further analysis is required, results are acceptable.
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Case 6 SP + T Displacement
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Fig-A A view of the displacement plot, results magnified 300X. Maximum displacement is 0.094"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The shell observes radial expansion due to shell side pressure. The tubesheet observes bending do to the shell side pressure forcing it outwards while the tubes restrain it at center.
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Case 6 SP + T Stress
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Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 56,700 psi. No stresses in excess of 56,700 psi are observed. No further analysis is required, results are acceptable.
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Case 6 SP + T Buckling
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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.
Fig-B An "ISO clipped" view of Fig-A, clipped at -10,706 psi. Stresses in excess of -10,706 psi in the tubes are limited to a short length from the tubesheet. No further analysis is required, results are acceptable.
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Case 7 TP + SP + T Displacement
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Fig-A A view of the displacement plot, results magnified 300X. Maximum displacement is 0.094"
Tube bending
Tube bending
Fig-B An alternative view of Fig-A. The shell observes radial expansion due to shell side pressure. The tubesheet observes bending do to combined shell side and tubeside pressure forcing it outwards while the tubes restrain it at center.
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Case 7 TP + SP + T Stress
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Fig-A A view of the stress plot (von Mises), capped at the secondary membrane allowable of 56,700 psi.
Fig-B An "ISO clipped" view of Fig-A, clipped at 56,700 psi. No stresses in excess of 56,700 psi are observed. No further analysis is required, results are acceptable.
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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. Inputs: VIII-1 UHX-13.3 SA-213 TP304 Mat - Tube material 1.500 dt [in] - Tube OD 0.109 tt [in] - Tube wall 27,000,000 Et [psi] - Tube modulus of elasticity at design temp 22,400 Sy [psi] - Tube yield strength at design temp 18,900 St [psi] - Tube allowable stress at design temp 16.750 l [in] - Unsupported length of tube 0.800 k - Support configuration Variables: lt [in] = k*l ~~ UHX-13.5.9(b)(1) Effective unsupported tube length 0.8*16.75 = rt [in] = sqrt((dt^2+(dt-2*tt)^2)/4) ~~ UHX-13.5.9(b)(2) SQRT((1.5^2+(1.5-2*0.109)^2)/4) = Ft = lt/rt ~~ UHX-13.5.9(b)(2) 13.4/0.987 = Ct = sqrt((2* ^2*Et)/Sy) ~~ UHX-13.5.9(b)(2) SQRT((2*3^2*27000000)/22400) = Fs = 2.0 ~~ UHX-13.5.9(b)(2) 2.0 = 13.400 0.987 13.582 154.171 2.000
Allowable Stress: UHX-13.5.9(b)(3)(a) Stb1 [psi] = min(( ^2*Et)/(Fs*Ft^2),St) ~~ UHX-13.5.9(b)(2) MIN((3^2*27000000)/(2*13.582^2),18900) = 18900 Stb2 [psi] = min((Sy/Fs)*(1-(Ft/(2*Ct))),St) ~~ UHX-13.5.9(b)(2) MIN((22400/2)*(1-(13.582/(2*154.171))),18900) = 10707 Stb [psi] = if(Ct<=Ft, Stb1, Stb2) ~~ UHX-13.5.9(b)(2) IF(154.171<=13.582, 18900, 10707) = 10707
*The reported tube axial compression stress (not von Mises equivalent) must be < Stb