Sample Cal

DESIGN CALCULATION
PLATE HEAT EXCHANGER
(Fully Welded Hybrid Heat Exchanger

Cryogenic Application)
FEED GAS/ RESIDUE GAS EXCHANGER

ITEM No: 3E-251 (New)
Location:
BUHASA, Abu Dhabi
Rev:
Date:
Prepared:
01.10.2013
Frank Betzold
DESIGN CALCULATION
Issued for Approval
Calculation
Finite Element Analysis
Report
Finite Element Analysis
of the
Hybrid Heat Exchanger Gasco02
Version 1.0
powered by
NX NASTRAN + FEMAP
SMART Engineering GmbH

Dipl.-Ing. Marco Solterbeck
Herrenheide 15a
D-21244 Buchholz
Phone: +49 4181/215900
Fax: +49 4181/215909
eMail: marco.solterbeck@smart-fem.de
Internet: www.smart-fem.de
10-01-2013
Content
1.
Project Definition ................................................................ 3
2.
Regulations und design fundamentals................................. 3
3.
FE-Model ............................................................................. 3
4.
Material Properties.............................................................. 5
5.
Boundary Conditions ........................................................... 6
6.
Verification of static strength due to test pressure ............. 7
6.1.
6.2.
6.3.
6.4.
Loadings ............................................................................... 7
Allowable stresses according to AD 2000 S4 .............................. 8
Analysis Results ..................................................................... 9
Verification according to AD 2000 S4 .......................................19
7.
Verification of static strength due to operating pressure .. 19
7.1.
7.2.
7.3.
7.4.
Loadings ..............................................................................19
Allowable stresses according to AD 2000 S4 .............................21
Analysis Results ....................................................................22
8.
Verification of the side lugs............................................... 32
8.1.
8.2.
8.3.
8.4.
8.5.
Loadings ..............................................................................32
Allowable stresses according to AD 2000 S4 .............................33
Analysis Results ....................................................................33
Reaction forces side lugs ........................................................36
1. Project Definition
For the housing of a hybrid heat exchanger the proof of the deformations and stresses based
on the finite element method shall be performed. Thereby has to be verified the strength of
the assembly due to test pressure and operating pressure.
For the side lugs the following load components are to be considered in different combinations: dead weight of the structure, positive and negative nozzle loads, wind loads and earthquake loads.
The proofs will be carried out according to the rule type AD 2000 Guideline.
2. Regulations und design fundamentals

Used FEA-Software:
- Solver: NX Nastran, Release 8.5.1
- Pre-/Postprocessor: Femap, Release 11.0.1
Considered regulations and documents:
/1/
2D-Drawing WH0887_sketch6.pdf 08-29-2013
/2/
3D-Geometry data in Step-Format Gasco02_Bild_Step.stp
/3/
AD 2000 Guideline
/4/
Material data provided by SPX Flow Technology Rosista GmbH
/5/
Technical data provided by SPX Flow Technology Rosista GmbH

Table 1: Considered regulations and documents
3. FE-Model
The analysis model was created based on 3D-Geometry data in Step-Format. The discretization of the model has been done almost exclusively with linear plate elements under consideration of their corresponding wall thicknesses. The connections of the parts have been assumed
as ideal node couplings (merged coincident nodes). Welds and bolted connections have not
been represented in detail. The modeling of the horizontal and vertical tie rods has been done
by beam elements with the corresponding cross sections. These beams have been connected
to the structure with rigid elements. The first inner rows of the vertical tie rods were meshed
in detail with brick elements.
Attached parts which are not relevant for stiffness were neglected. The same applies also for
the inner plate package, due to the soft connection to the structure. To keep the equilibrium
under pressure loads all nozzles have been closed.
Figure 1 to Figure 3 show the analysis model which has following characteristics:
Number of elements
433,585
Number of nodes
465,773
Table 2: Characteristics of the FE-Model
Figure 1: FE-Model, exterior view
Figure 2: FE-Model, sectional view
Welding seam
(brick elements)
Tie rod
(beam elements)
Tie rod
(brick elements)
End plate
(brick elements)
Figure 3: FE-Model, detailed view, tie rod connection at first inner row
4. Material Properties
The used material was assumed to be linear-elastic according to Hookes law. As the stresses
and strains to be verified are associated with different temperature conditions, the consideration of appropriate material properties was required. As base for all further examination the
following properties / 4 / have been considered:
Temp.
Youngs
Modulus
Poisson's
Ratio
Yield Strength
Rp0,2
Tensile Strength
Rm
[C]
[N/mm2]
[-]
[N/mm]
[N/mm2]
20
200,000
0.29
260
530
85
195,125
0.29
210
20
200,000
0.29
260
540
85
195,125
0.29
225
Material
1.4404
1.4571
Table 3: Material Properties
The adjustment of the properties to AD 2000 is done in section 6.2, 7.2 and 8.2.
1.4571 (green)
1.4404 (red)
Figure 4: FE-Model, sectional view, used materials with different colors
5. Boundary Conditions
The housing was constrained with static definitions at the two lugs under consideration of
contact with the grounding plate. Additionally both bolts at each lug were fixed in all directions. The constraints of the model are shown in Figure 5.
Grounding plate and bolts

fixed in all directions
Contact considered
between lug and
grounding plate (grey)
Figure 5: FE-Model, supports (constraints)
6. Verification of static strength due to test pressure

6.1. Loadings
For the verification of static strength in the test case a test pressure of 41.5 bar was applied
to the entire housing. Figure 6 shows the pressure distribution in the FE-Model.
Test temperature T = 20 C
Test pressure
41.5 bar = 4.15 N/mm
Figure 6: FE-Model, pressure distribution under test conditions
6.2. Allowable stresses according to AD 2000 S4

The determinations of the allowable stresses according to AD 2000 S4 are based on the
material properties from Table 3. The allowable stresses have been calculated based on the
following equations and are listed in Table 4:
f20C = K20C / S with K20C = Rp1,0, safety factor S = 1.05 and welding factor v
Primary global membrane stress:
Pm20C = 1.0 f20C v
Primary local membrane stress:
Pl20C = 1.5 f20C v
Primary membrane + bending stress:
Pm20C + Pb20C = Pm20C + Pl20C = 1.5 f20C v
Primary membrane + bending Stress + secondary stress
Pm20C + Pb20C + Q20C = Pm20C + Pl20C + Q20C = 3 f20C v
Material
f20C
1.4404
247
1.4571
247
Welding
factor
Pm20C
[N/mm2]
Pl20C
[N/mm2]
Pm+Pb(l)
[N/mm2]
Pm+Pb(l)+Q
[N/mm2]
1,00
247
370
370
741
1,00
247
370
370
741
0,85
210
315
315
630
Table 4: Allowable stresses according to AD 2000 S4, test situation
6.3. Analysis Results

For result evaluation the established membrane stresses and von Mises equivalent stresses
have been used.
In Figure 7 to Figure 25 the stresses are given on the deformed structure. For clarification the
deflections are scaled by a factor of 50.
The stress legend of the first figures is limited to the maximum relevant stress value of the
shown model part. In further figures the legend was scaled to the allowable AD 2000 S4
values.
Figure 7: FE-Model, full model, top view, Equivalent Stress [N/mm]
10
Figure 8: FE-Model, full model, bottom view, Equivalent Stress [N/mm]
780 N/mm
(surface tension)
1.210 N/mm
(max. local stress peak)
Figure 9: FE-Model, top cover, Equivalent Stress [N/mm]
11
Figure 10: FE-Model, bottom cover, Equivalent Stress [N/mm]
290 N/mm
Figure 11: FE-Model, vertical tie rods, Equivalent Stress [N/mm]
12
193 N/mm
Figure 12: FE-Model, horizontal tie rods, Equivalent Stress [N/mm]
Legend scaled to allowable

stress according AD2000 S4
S4
blue:
Pm = 1,0 f
yellow: Pm+Pb = 1,5 f

orange: Pm+Pb +Q = 3,0 f
red: >
Pm+Pb +Q = 3,0 f
13

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Legend scaled to allowable stress

according AD2000 S4
blue:
Pm = 1,0 f 0.85
yellow: Pm+Pb = 1,5 f 0.85

orange: Pm+Pb +Q = 3,0 f 0.85
red: >
Pm+Pb +Q = 3,0 f 0.85
Welding seam
Welding seam
Figure 15: FE-Model, welding seams (welding factor 0.85), Equivalent Stress [N/mm]
Material
1.4404
14

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 16: FE-Model, middle end plate, Equivalent Stress [N/mm]

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
15

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Grey areas,
no values available

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 19: FE-Model, full model, top view, Membrane Stress [N/mm]
Grey areas,
no values available
16

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 20: FE-Model, full model, bottom view, Membrane Stress [N/mm]
Legend
Legend
scaledscaled
to allowable
to allowable
stress
according
stress
AD2000
according
S4 AD2000 S4
blue: blue:
Pm = P
1,0
= f1,0
0.85
f
m
=+P
1,5
= f1,5
0.85
f
yellow:
yellow:
Pm+PbPm
b
orange:
orange:
Pm+PbP+Q
+P=
+Q
3,0= f3,0
0.85
f
m
b
red: >
red:Pm>+PbP+Q
+P=
+Q
3,0= f3,0
0.85
f
m
b
Welding seam
Welding seam
Figure 21: FE-Model, welding seams (welding factor 0.85), Membrane Stress [N/mm]
17

Material
1.4404
S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 22: FE-Model, middle end plate, Membrane Stress [N/mm]

Grey areas,
no values available
S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
589 N/mm
Figure 23: FE-Model, top cover, Membrane Stress [N/mm]
18

Grey areas,
no values available
S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 24: FE-Model, bottom cover, Membrane Stress [N/mm]
Figure 25: FE-Model, displacements [mm]
19
6.4. Verification according to AD 2000 S4

have been used.
The proof of fatigue according to AD 2000 S4 is regarded as given under 6.3 when the calculated stresses are lower than the allowable stresses determined in 6.2.
The primary local membrane stresses are below the allowable value of 370 N/mm. Only at
the corners of the end plates the stresses locally exceeds this value.
Pl20C = 589 N/mm > 370 N/mm (Figure 23, upper end plate)
The Primary local membrane + bending stresses + secondary stresses are below the allowable
value of 370 N/mm. Only at the corners of the end plates and the welding seams of the tie
rods the stresses locally exceeds this value.
Pl20C + Pb20C + Q20C = 1.210 N/mm > 741 N/mm (Figure 9, upper end plate)
Pl20C + Pb20C + Q20C = 780 N/mm > 741 N/mm (Figure 9, welding seam tie rod)
Within the scope of the assumptions the strength proof of all components is regarded with the
exception of the end plate and the welding seams of the tie rods.
The stresses in these areas require a separate interpretation. The local stress distribution
allows the conclusion, that in these areas the material will yield causing a slight local plastic
deformation and thus the peak stresses will be reduced. Assuming that the pressure test is a
single event a failure of the structure is not to be expected
In the areas of the welding seams with the reduced welding factor of 0.85 the membrane and
equivalent stresses are below the allowable values (Figure 21 and Figure 15).
7. Verification of static strength due to operating pressure

7.1. Loadings
For the verification of static strength in the operating case an allowable pressure of 29.0 bar
was applied to the entire housing. Furthermore the nozzle loads in positive (Figure 27) and
negative (Figure 28) directions have been considered. Figure 26 shows the pressure distribution in the FE-Model.
20
Operating temperature T = 85 C
Operating pressure
29.0 bar = 2.9 N/mm
Figure 26: FE-Model, pressure distribution under operating conditions
Forces [N]
Moments [Nmm]
N1
N4
N1
N3
N2
N4
N3
N2
Resulting positive nozzle forces: Fx = -57.0 kN; Fy = 66.0 kN; Fz = 58.5 kN

Figure 27: FE-Model, positive nozzle loads (nozzle 1 to 4)
21
Forces [N]
Moments [Nmm]
N1
N1
N4
N4
N3
N3
N2
N2
Resulting negative nozzle forces: Fx = 57.0 kN; Fy = -66.0 kN; Fz = -58.5 kN

Figure 28: FE-Model, negative nozzle loads (nozzle 1 to 4)


Pm85C
= 1.0 f85C v

Pl85C
= 1.5 f85C v

Pm85C
+ Pb85C = Pm85C + Pl85C = 1.5 f85C v

Pm85C
+ Pb85C + Q85C = Pm85C + Pl85C + Q85C = 3 f85C v
Material
f85C
1.4404
140
1.4571
150
Welding
factor
Pm85C
[N/mm2]
Pl85C
[N/mm2]
Pm+Pb(l)
[N/mm2]
Pm+Pb(l)+Q
[N/mm2]
1,00
140
210
210
420
1,00
150
225
225
450
0,85
127
191
191
382
Table 5: Allowable stresses according to AD 2000 S4, operating situation
22

have been used. Relevant for the stress evaluation is the load case with negative nozzle loads.
At this load case the maximum stress appears in the structure.
In Figure 29 to Figure 46 the stresses are given on the deformed structure. For clarification
the deflections are scaled by a factor of 50.
The stress legend of the first figures is limited to the maximum relevant stress value of the
shown model part. In further figures the legend was scaled to the allowable AD 2000 S4
values.
23
549 N/mm
(surface tension)
858 N/mm
24
204 N/mm
Figure 33: FE-Model, vertical tie rods, Equivalent Stress [N/mm]
25
136 N/mm
Figure 34: FE-Model, horizontal tie rods, Equivalent Stress [N/mm]

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
26

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Legend scaled to allowable stress

according AD2000 S4
blue:
Pm = 1,0 f 0.85
yellow: Pm+Pb = 1,5 f 0.85

orange: Pm+Pb +Q = 3,0 f 0.85
red: >
Pm+Pb +Q = 3,0 f 0.85
Welding seam
Welding seam
Figure 37: FE-Model, welding seams (welding factor 0.85), Equivalent Stress [N/mm]
Material
1.4404
27

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 38: FE-Model, middle end plate, Equivalent Stress [N/mm]

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Grey areas,
no values available
28

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 40: FE-Model, full model, top view, Membrane Stress [N/mm]
Grey areas,
no values available

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 41: FE-Model, full model, bottom view, Membrane Stress [N/mm]
29
Legend
Legend
scaledscaled
to allowable
to allowable
stress
according
stress
AD2000
according
S4 AD2000 S4
blue: blue:
Pm = P
1,0
= f1,0
0.85
f
m
yellow:
yellow:
Pm+PbPm
=+P
1,5
= f1,5
0.85
f
b
orange:
orange:
Pm+PbP+Q
+P=
+Q
3,0= f3,0
0.85
f
m
b
red: >
red:Pm>+PbP+Q
+P=
+Q
3,0= f3,0
0.85
f
m
b
Welding seam
Welding seam
Figure 42: FE-Model, welding seams (welding factor 0.85), Membrane Stress [N/mm]
Material
1.4404

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 43: FE-Model, middle end plate, Membrane Stress [N/mm]
30

Grey areas,
no values available
S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
418 N/mm
Figure 44: FE-Model, top cover, Membrane Stress [N/mm]
Grey areas,
no values available

S4
blue:
Pm = 1,0 f

red: >
Pm+Pb +Q = 3,0 f
Figure 45: FE-Model, bottom cover, Membrane Stress [N/mm]
31
Figure 46: FE-Model, displacements [mm]

have been used.
The primary local membrane stresses are below the allowable value of 370 N/mm. Only at
the corners of the end plates the stresses locally exceeds this value.
Pl20C = 418 N/mm > 225 N/mm (Figure 44, upper end plate)
value of 370 N/mm. Only at the corners of the end plates and at the welding seams of the tie
rods the stresses locally exceeds this value.
Pl20C + Pb20C + Q20C = 859 N/mm > 450 N/mm (Figure 31, upper end plate)
Pl20C + Pb20C + Q20C = 549 N/mm > 450 N/mm (Figure 31, welding seam tie rod)
Within the scope of the assumptions the strength proof of all components is regarded with the
exception of the end plate and the welding seams of the tie rods.
The stresses in these areas require a separate interpretation. The local stress distribution
allows the conclusion, that in these areas the material will yield causing a slight local plastic
deformation and thus the peak stresses will be reduced. Assuming that the pressure test is a
single event a failure of the structure is not to be expected
In the areas of the welding seams with the reduced welding factor of 0.85 the membrane and
equivalent stresses are below the allowable values (Figure 42 and Figure 37).
32
8. Verification of the side lugs

8.1. Loadings
For the verification of the side lugs the load cases listed in Table 6 have been considered. The
pressure was neglected.
Load case
Self-weight, operation, full mop,full = 40.268 t
/5/
3a
3b
5a
5b
Self-weight, testing, full mtest,full= 67.740 t
/5/
Nozzle loads, positive direction (Figure 27)
/1/
Nozzle loads, negative direction (Figure 28)

Wind load, full (Figure 47)
Wind load, half
/5/
/5/
Earthquake loads (Figure 47)
/5/
/1/
Table 6: Load cases for verification of the lugs
The wind and earthquake loads were applied to the center of gravity of the heat exchanger.
The connection between the load point and the meshed structure was done with a nonstiffening interpolation element.
Wind loads [N]
Center of gravity
Earthquake loads [N]
Center of gravity
Figure 47: FE-Model, wind and earthquake loads
33


Pm85C = 1.0 f85C v

Pl85C = 1.5 f85C v

Pm85C + Pb85C = Pm85C + Pl85C = 1.5 f85C v

Pm85C + Pb85C + Q85C = Pm85C + Pl85C + Q85C = 3 f85C v
Material
Welding
factor
f85C
1.4571
150
1,00
Pm85C
[N/mm2]
Pl85C
[N/mm2]
150
Pm+Pb(l)
[N/mm2]
225
Pm+Pb(l)+Q
[N/mm2]
225
450
Table 7: Allowable stresses according to AD 2000 S4, operating situation

have been used. The maximum stresses and deformations of the considered load cases are
listed in Table 8.
Load case
Membrane Stress
[N/mm]
Equivalent Stress
[N/mm]
Displacement
[mm]
3a
36
49
1.03
3b
42
58
1.15
33
45
0.59
5a
39
85
1.05
5b
62
87
1.50
Table 8: Stresses and displacements of the lugs
In Figure 48 to Figure 50 only the stresses of the load case with the maximum stress value
are given on the deformed structure. For clarification the deflections are scaled by a factor of
50.
The stress legend of the following figures is limited to the maximum relevant stress value of
the shown model part.
87 N/mm
Figure 48: FE-Model, side lug, Equivalent Stress [N/mm]
62 N/mm
Figure 49: FE-Model, side lug, Membrane Stress [N/mm]
34
35
Figure 50: FE-Model, side lug, displacements [mm]

have been used.
The primary local membrane stresses are below the allowable value of 225 N/mm.
Pl20C = 62 N/mm < 225 N/mm (Figure 49)
value of 225 N/mm.
Pl20C + Pb20C + Q20C = 87 N/mm < 450 N/mm (Figure 48)
Within the scope of the assumptions the strength proof of the side lugs is regarded.
36
8.5. Reaction forces side lugs

The calculated values for the reaction forces of the both side lugs named in Figure 51 are
listed in Table 9.
Side lug A
Side lug B
Figure 51: FE-Model, side lug positions for reaction loads
Side lug A
Side lug B
Load case
FRx
[kN]
FRy
[kN]
FRz
[kN]
FRx
[kN]
3a
64,0
250,6
-51,3
-30,3
78,5
-19,8
3b
29,5
135,4
38,3
-109,8
325,6
7,5
90,5
332,4
-3,3
-102,2
332,1
-3,1
5a
13,9
212,3
-78,8
-80,4
116,8
-46,9
5b
-21,8
98,1
11,1
-158,7
362,9
-19,7
Table 9: Reaction forces side lugs
FRy
[kN]
FRz
[kN]

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DESIGN CALCULATION

PLATE HEAT EXCHANGER

(Fully Welded Hybrid Heat Exchanger

FEED GAS/ RESIDUE GAS EXCHANGER

BUHASA, Abu Dhabi

Issued for Approval

SMART Engineering GmbH

SMART Engineering GmbH

Project Definition ................................................................ 3

Regulations und design fundamentals................................. 3

Boundary Conditions ........................................................... 6

Verification of static strength due to test pressure ............. 7

Verification of static strength due to operating pressure .. 19

Verification of the side lugs............................................... 32

SMART Engineering GmbH

2. Regulations und design fundamentals

2D-Drawing WH0887_sketch6.pdf 08-29-2013

3D-Geometry data in Step-Format Gasco02_Bild_Step.stp

Material data provided by SPX Flow Technology Rosista GmbH

Technical data provided by SPX Flow Technology Rosista GmbH

Table 2: Characteristics of the FE-Model

SMART Engineering GmbH

Figure 1: FE-Model, exterior view

Figure 2: FE-Model, sectional view

SMART Engineering GmbH

Table 3: Material Properties

SMART Engineering GmbH

Figure 4: FE-Model, sectional view, used materials with different colors

SMART Engineering GmbH

Grounding plate and bolts

6. Verification of static strength due to test pressure

SMART Engineering GmbH

Figure 6: FE-Model, pressure distribution under test conditions

6.2. Allowable stresses according to AD 2000 S4

Table 4: Allowable stresses according to AD 2000 S4, test situation

SMART Engineering GmbH

6.3. Analysis Results

Figure 7: FE-Model, full model, top view, Equivalent Stress [N/mm]

SMART Engineering GmbH

Figure 8: FE-Model, full model, bottom view, Equivalent Stress [N/mm]

Figure 9: FE-Model, top cover, Equivalent Stress [N/mm]

SMART Engineering GmbH

Figure 10: FE-Model, bottom cover, Equivalent Stress [N/mm]

Figure 11: FE-Model, vertical tie rods, Equivalent Stress [N/mm]

SMART Engineering GmbH

Figure 12: FE-Model, horizontal tie rods, Equivalent Stress [N/mm]

Legend scaled to allowable

yellow: Pm+Pb = 1,5 f

SMART Engineering GmbH

Legend scaled to allowable

yellow: Pm+Pb = 1,5 f

Legend scaled to allowable stress

yellow: Pm+Pb = 1,5 f 0.85

Pm+Pb +Q = 3,0 f 0.85

SMART Engineering GmbH

Legend scaled to allowable

yellow: Pm+Pb = 1,5 f

Figure 16: FE-Model, middle end plate, Equivalent Stress [N/mm]

Legend scaled to allowable

yellow: Pm+Pb = 1,5 f

Figure 17: FE-Model, top cover, Equivalent Stress [N/mm]

SMART Engineering GmbH

Legend scaled to allowable

yellow: Pm+Pb = 1,5 f