Tube & Shell types of heat exchangers have their design procedure defined in ASME & TEMA Standards. But in some cases, the equipment are designed as per ASME Standards alone (e.g. Heat Exchanger for Air-cooled processing fluid). So such design needs FEA assistance in order to decide whether the design is safe or not ??
Process equipment manufacturer from India & Abroad approached ANALYZER to seek assistance in evaluating the design of their newly developed heat exchangers for a particular application to multiple loading conditions using simulation techniques & provide the solution in case of any observed failure either stress failure or tube to tube sheet weld failure.
The heat exchanger was analyzed for different loading conditions as per Table 5.3 of ASME BPVC Sec. VIII Div. 2 using Finite Element Analysis in ANSYS APDL Solver. Stress Linearization has been carried out at various locations. The tube to tubesheet weld qualifications was performed for the weld. The results showed that the induced stresses were well within the acceptable limits as per guidelines. Also, the load at the weld junction is found to be much below the allowable limit. Hence, the structure’s design was predicted to behave safely during operation without premature failure.