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John Ajish

This document provides details of a project to analyze thermo-mechanical stresses in a tube sheet heat exchanger using finite element analysis software ANSYS. It includes details of the guiding staff, the research area of solar dryers, identified problems regarding stresses leading to failures, and a literature review summarizing previous related research on stress analysis of tube sheets. The work plan for phase 1 is to learn finite element methods and ANSYS to determine stresses, study factors influencing stresses, and conduct further literature review to aid the stress analysis, with ANSYS training planned for December 2013.

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PROJECT PHASE-1 REVIEW-1 Presented By Anto.V Reg. No : 950012407003 M.E. Energyl Engineering Regional Centre of Anna University, Tirunelveli. REGIONAL CENTRE OF ANNA UNIVERSITY, TIRUNELVELI
DETAILS OF GUIDING STAFF Name of the Internal Guide : Mr.K.Karuppasamy, M.E. Assistant Professor, Department of Mechanical Engineering, Regional Centre of Anna University, Tirunelveli. Name of the External Guide : Mr.C.Kathirvelu, Additional General Manager, Advanced Technology Products, Bharat Heavy Electricals Ltd., Tiruchirappalli-620014.
AREA OF RESEARCH SOLAR DRYER
PROBLEM IDENTIFICATION  Thermo mechanical stresses in the tube sheet heat exchanger is a very common problem which can lead to failure.  Thermo mechanical stress analysis can be done by two methods  FEM Method  ANSYS  With the results of the stress analysis, the design of the heat exchanger can be modified for safe standards.
LITERATURE REVIEW
ASME Section III Stress Analysis of a Heat Exchanger Tube sheet with a mis-drilled hole and irregular or thin ligaments  The methodology used to evaluate the structural integrity of a steam generator tube sheet with a mis-drilled hole is described and explained. The non-mandatory rules of ASME Appendix A, Article A-8000 [Ref. 3] contains several ambiguities that are addressed and clarified.  The analysis is applied to an actual, non-parallel mis-drilled hole and compared to a parallel mis-drilled hole as is assumed in Appendix A.  The presence of mis-drilled holes or locally thin ligaments do not affect the primary stress margin in the tube sheet and do not reduce its overall structural integrity.  The main influence of a mis-drilled hole is on the cumulative fatigue usage factor. the presence of mis-drilled holes within the tube sheet drilling pattern, although it may complicate tube installation, is a structurally acceptable condition. This is the research work of Dr. Enrique Gomez, Mr. Roberto Ruiz, ENSA Engineering Department and Mr. Robert M. (Con) Wilson, Private Consultant in the Proceedings of the ASME 2013 Pressure Vessels and Piping Conference, PVP2013-97075, July 14-18, 2013, Paris, France.
Technical Justification supporting operation with a tube installed in a mis-drilled hole of a steam generator tube sheet.  A tube installed in a mis-drilled tube sheet hole satisfies the identical structural requirements as a tube installed in a nominal hole based on the ASME Section III [Ref. 2] rules for pressure boundary structural integrity.  The relatively small changes in tube straightness and the presence of small elastic manufacturing-induced stresses are not detrimental to long- term operation. There is no technical basis to plug such tubes.  This conclusion is independent of tube sheet hole location and applicable to all tubes. This is the research work of Mr. Roberto Ruiz, Dr. Enrique Gomez, ENSA Engineering Department and Mr. Robert M. (Con) Wilson, Private Consultant in the Proceedings of the ASME 2013 Pressure Vessels and Piping Conference, PVP2013-97076, July 14-18, 2013, Paris, France.
Using FEM to determine the thermo-mechanical stress in tube to tube-sheet joint for the SCC failure analysis  Thermo-mechanical stress in tube to tube-sheet joints including welding effect is determined in this situation for failure analysis.  In this paper, the Finite Element Method (FEM) has been used to predict the thermo- mechanical stresses including welding residual stress in a tube to tube-sheet weld.  Both the thermo-mechanical stress distribution with and without the welding residual stress have also been investigated by numerical simulation.  The welding, operating temperature, and operating pressure have effect on total stresses. The welding residual stresses play an important role in total stress state in tube to tube-sheet joints.  A high tensile stress in the tube to tube-sheet region has been demonstrated by FEM, which is the stress aspect for the SCC phenomenon of austenitic stainless steel in chloride environment. This is the work of Shugen Xu, Yanling Zhao in Engineering Failure Analysis, Available online 25 July 2013, Elsevier.
Numerical simulation of thermal stress in tube-sheet of heat transfer equipment  The thermal stress induced by temperature difference in the tube-sheet of heat transfer equipment was studied in the paper.  Finite element method (FEM) was used to compute the temperature and the stress fields.  The effect of the tube-sheet thickness on the thermal stress has been discussed in terms of the results by FEM.  Some measures to reduce or eliminate the thermal stress in the tube sheet are suggested. A new design of the structure of the flexible tube sheet was proposed. This is the research work of M.S. Liu, Q.W. Dong, D.B. Wang, X. Ling in the International Journal of Pressure Vessels and Piping, Volume 76, Issue 10, August 1999, Pages 671–675, Elsevier.
Thermal stresses on the surface of tube-sheet plates of 10 and 33 1/3 percent ligament efficiency  A thermal shock ΔT was applied to the surface of tube-sheet models of 10 percent and 33 1/3 percent ligament efficiency. By means of a thin slice cemented with a reflective cement, it was possible to obtain photo-elastically the surface-stress variation with time.  By extrapolation, maximum stresses of 0.93 and 1.04 E p α p −ΔT p /(1−v p ) were obtained at zero time for the 10 percent and 33 1/3 percent ligament efficiencies, respectively.  Using the effective elastic constants and stress-intensification factors for tube sheets subjected to isotropic biaxial-plane stress, thermal stresses of 1.18 and 1.31 E p α p Δ p ΔT v /(1−v p ) were calculated for ligament efficiency of 10 and 33 1/3 percent, respectively.  It is felt that these are upper limits for the thermal stresses. This is the research work of M. M. Leven, R. L. Johnson published in the December 1964, Volume 4, Issue 12, pp. 356-365 edition of Experimental Mechanics of Springer.
Comparison of two FEA models for calculating stresses in shell- and-tube heat exchanger  Two finite element analysis models of tube sheet of shell-and-tube heat exchangers are highlighted. Traditional theory of elastic foundation model is used for tube to tube sheet interaction in model I. Pipe elements are used to represent actual interaction between tube and tube sheet in model II.  By the comparison of model I and model II results, it is confirmed that the distributions of the deformations and stress intensities for both models have very little differences under complicated mechanical and thermal loads.  Model I is suitable for FEA of shell-and-tube heat exchangers, because model I is enough accurate and model II is more complicated and it takes more time and memory spaces of computer.  The axial forces at tube-to-tube sheet for two models are nearly the same and the axial forces generated by bending moments are very small. The elastic foundation theory of the standards of design is suitable. This is the research work of Weiya Jin, Zengliang Gao, Lihua Liang, Jinsong Zheng, Kangda Zhang Institute of Process Equipment and Control Engineering, Zhejiang University of Technology, Hangzhou 310032, China in the International Journal of Pressure Vessels and Piping, Volume 81, Issue 6, June 2004, Pages 563–567, Elsevier.
WORK PLAN FOR PHASE I  Acquiring proper knowledge and usage of Finite Element Method(FEM) to determine the thermo mechanical stresses in a tube sheet heat exchanger.  Sufficient amount of knowledge to be acquired for using ANSYS as a tool for the thermo mechanical stress analysis of tube sheet heat exchanger.  The factors or parameters which influence the stress analysis have to be properly studied and a thorough investigation made before the actual analysis using ANSYS.  This is possible through literature review or survey of journals related to stress analysis of tube sheet heat exchangers.
WORK SCHEDULE  Planning to study ANSYS programming in first phase within December 2013.  Further literature surveys to be conducted which can aid in the stress analysis of the tube sheet heat exchanger.
THANK YOU.

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950012414021.pptx

  • 1. PROJECT PHASE-1 REVIEW-1 Presented By Anto.V Reg. No : 950012407003 M.E. Energyl Engineering Regional Centre of Anna University, Tirunelveli. REGIONAL CENTRE OF ANNA UNIVERSITY, TIRUNELVELI
  • 2. DETAILS OF GUIDING STAFF Name of the Internal Guide : Mr.K.Karuppasamy, M.E. Assistant Professor, Department of Mechanical Engineering, Regional Centre of Anna University, Tirunelveli. Name of the External Guide : Mr.C.Kathirvelu, Additional General Manager, Advanced Technology Products, Bharat Heavy Electricals Ltd., Tiruchirappalli-620014.
  • 4. PROBLEM IDENTIFICATION  Thermo mechanical stresses in the tube sheet heat exchanger is a very common problem which can lead to failure.  Thermo mechanical stress analysis can be done by two methods  FEM Method  ANSYS  With the results of the stress analysis, the design of the heat exchanger can be modified for safe standards.
  • 6. ASME Section III Stress Analysis of a Heat Exchanger Tube sheet with a mis-drilled hole and irregular or thin ligaments  The methodology used to evaluate the structural integrity of a steam generator tube sheet with a mis-drilled hole is described and explained. The non-mandatory rules of ASME Appendix A, Article A-8000 [Ref. 3] contains several ambiguities that are addressed and clarified.  The analysis is applied to an actual, non-parallel mis-drilled hole and compared to a parallel mis-drilled hole as is assumed in Appendix A.  The presence of mis-drilled holes or locally thin ligaments do not affect the primary stress margin in the tube sheet and do not reduce its overall structural integrity.  The main influence of a mis-drilled hole is on the cumulative fatigue usage factor. the presence of mis-drilled holes within the tube sheet drilling pattern, although it may complicate tube installation, is a structurally acceptable condition. This is the research work of Dr. Enrique Gomez, Mr. Roberto Ruiz, ENSA Engineering Department and Mr. Robert M. (Con) Wilson, Private Consultant in the Proceedings of the ASME 2013 Pressure Vessels and Piping Conference, PVP2013-97075, July 14-18, 2013, Paris, France.
  • 7. Technical Justification supporting operation with a tube installed in a mis-drilled hole of a steam generator tube sheet.  A tube installed in a mis-drilled tube sheet hole satisfies the identical structural requirements as a tube installed in a nominal hole based on the ASME Section III [Ref. 2] rules for pressure boundary structural integrity.  The relatively small changes in tube straightness and the presence of small elastic manufacturing-induced stresses are not detrimental to long- term operation. There is no technical basis to plug such tubes.  This conclusion is independent of tube sheet hole location and applicable to all tubes. This is the research work of Mr. Roberto Ruiz, Dr. Enrique Gomez, ENSA Engineering Department and Mr. Robert M. (Con) Wilson, Private Consultant in the Proceedings of the ASME 2013 Pressure Vessels and Piping Conference, PVP2013-97076, July 14-18, 2013, Paris, France.
  • 8. Using FEM to determine the thermo-mechanical stress in tube to tube-sheet joint for the SCC failure analysis  Thermo-mechanical stress in tube to tube-sheet joints including welding effect is determined in this situation for failure analysis.  In this paper, the Finite Element Method (FEM) has been used to predict the thermo- mechanical stresses including welding residual stress in a tube to tube-sheet weld.  Both the thermo-mechanical stress distribution with and without the welding residual stress have also been investigated by numerical simulation.  The welding, operating temperature, and operating pressure have effect on total stresses. The welding residual stresses play an important role in total stress state in tube to tube-sheet joints.  A high tensile stress in the tube to tube-sheet region has been demonstrated by FEM, which is the stress aspect for the SCC phenomenon of austenitic stainless steel in chloride environment. This is the work of Shugen Xu, Yanling Zhao in Engineering Failure Analysis, Available online 25 July 2013, Elsevier.
  • 9. Numerical simulation of thermal stress in tube-sheet of heat transfer equipment  The thermal stress induced by temperature difference in the tube-sheet of heat transfer equipment was studied in the paper.  Finite element method (FEM) was used to compute the temperature and the stress fields.  The effect of the tube-sheet thickness on the thermal stress has been discussed in terms of the results by FEM.  Some measures to reduce or eliminate the thermal stress in the tube sheet are suggested. A new design of the structure of the flexible tube sheet was proposed. This is the research work of M.S. Liu, Q.W. Dong, D.B. Wang, X. Ling in the International Journal of Pressure Vessels and Piping, Volume 76, Issue 10, August 1999, Pages 671–675, Elsevier.
  • 10. Thermal stresses on the surface of tube-sheet plates of 10 and 33 1/3 percent ligament efficiency  A thermal shock ΔT was applied to the surface of tube-sheet models of 10 percent and 33 1/3 percent ligament efficiency. By means of a thin slice cemented with a reflective cement, it was possible to obtain photo-elastically the surface-stress variation with time.  By extrapolation, maximum stresses of 0.93 and 1.04 E p α p −ΔT p /(1−v p ) were obtained at zero time for the 10 percent and 33 1/3 percent ligament efficiencies, respectively.  Using the effective elastic constants and stress-intensification factors for tube sheets subjected to isotropic biaxial-plane stress, thermal stresses of 1.18 and 1.31 E p α p Δ p ΔT v /(1−v p ) were calculated for ligament efficiency of 10 and 33 1/3 percent, respectively.  It is felt that these are upper limits for the thermal stresses. This is the research work of M. M. Leven, R. L. Johnson published in the December 1964, Volume 4, Issue 12, pp. 356-365 edition of Experimental Mechanics of Springer.
  • 11. Comparison of two FEA models for calculating stresses in shell- and-tube heat exchanger  Two finite element analysis models of tube sheet of shell-and-tube heat exchangers are highlighted. Traditional theory of elastic foundation model is used for tube to tube sheet interaction in model I. Pipe elements are used to represent actual interaction between tube and tube sheet in model II.  By the comparison of model I and model II results, it is confirmed that the distributions of the deformations and stress intensities for both models have very little differences under complicated mechanical and thermal loads.  Model I is suitable for FEA of shell-and-tube heat exchangers, because model I is enough accurate and model II is more complicated and it takes more time and memory spaces of computer.  The axial forces at tube-to-tube sheet for two models are nearly the same and the axial forces generated by bending moments are very small. The elastic foundation theory of the standards of design is suitable. This is the research work of Weiya Jin, Zengliang Gao, Lihua Liang, Jinsong Zheng, Kangda Zhang Institute of Process Equipment and Control Engineering, Zhejiang University of Technology, Hangzhou 310032, China in the International Journal of Pressure Vessels and Piping, Volume 81, Issue 6, June 2004, Pages 563–567, Elsevier.
  • 12. WORK PLAN FOR PHASE I  Acquiring proper knowledge and usage of Finite Element Method(FEM) to determine the thermo mechanical stresses in a tube sheet heat exchanger.  Sufficient amount of knowledge to be acquired for using ANSYS as a tool for the thermo mechanical stress analysis of tube sheet heat exchanger.  The factors or parameters which influence the stress analysis have to be properly studied and a thorough investigation made before the actual analysis using ANSYS.  This is possible through literature review or survey of journals related to stress analysis of tube sheet heat exchangers.
  • 13. WORK SCHEDULE  Planning to study ANSYS programming in first phase within December 2013.  Further literature surveys to be conducted which can aid in the stress analysis of the tube sheet heat exchanger.