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1 Available online at International ejournals ABSTRACT: STRUCTURAL AND THERMAL ANALYSIS OF CONDENSER BY USING FINITE ELEMENT ANALYSIS Sk. Abdul Mateen 1 and N. Amar Nageswara Rao 2 Mechanical Engineering Department, Nimra College of Engineering & Technology, Ibrahimpatnam, Vijayawada. In any power plant apart from the turbine, boiler and pump, the condenser is a vital component. Steam condenser is a device or an appliance in which steam condenses and heat released by steam is absorbed by water. The main considerations in the design of a condenser for a particular application are Thermal design and analysis, Mechanical design, Design for manufacture, physical size and cost. The condenser is analyzed for static and thermal loading.the geometry of condenser is created in CATIA software as per the drawing.this model is imported to HyperMesh through IGES format and then for sheet metal components we will extract the mid surface, now for that mid surface we will create shell elements, solid elements were created for remaining part, and a converged mesh is developed in HyperMesh. The finite element model with various loading conditions are design pressure, hydro test pressure,full vaccum, thermal loads and operating conditions (both mechanical and thermal loads) on the condenser.the supporting legs one is arrested in all the directions and the other one is arrested only in Z- direction and all rotations. All these are created by using HyperMesh and it is exported to ANSYS for solution. The deflections and stresses were obtained from analysis. Those values are correlated with material allowable values as per the ASME Section VIII Division 2. Keywords: Condenser Analysis, Structural and Thermal Analysis, Finite Element Analysis 1. INTRODUCTION A steam condenser is a device or an appliance in which steam condenses and heat released by steam is absorbed by water. Condenser are important heat and mass exchange apparatus in oil refining, chemical engineering, environmental protection, electric power generation, et al. Among different types of condenser, shell and tube condenser have been commonly used in

2 38 industries [1]. Master et al, [2] indicated that more than 35 40% of heat exchangers are of the shell and tube type, and this is primarily due to the robust construction geometry as well as easy maintenance and possible upgrades of shell and tube condenser. They are widely used as evaporators and condensers. The heat transfer effectiveness of shell and tube condenser can be improved by using baffles. Segmental baffles are most commonly used in conventional shell and tube condenser to support tubes and change fluid flow direction. Segmental baffles cause the shell-side fluid to flow in a tortuous, zigzag manner across the tube bundles, which can enhance the heat transfer on the shell side[3-6]. 2. DESCRIPTION In this work static and thermal analysis of the condenser made of carbon steel was carried out. Table 1. Material properties of Carbon Steel- SA 516 Gr 70 Material Magnitudes Properties Density, tons/mm e-8 Young s Modulus, 1.9e5 N/mm 2 Poisson s Ratio 0.3 Thermal Expansion coefficient 3. MODELLING AND MESHING 7.1*e-6 / o c With the dimensional parameters the structure is modeled in CATIA modeling software as shown in Fig.1 The model is meshed for further analysis using a Fig.1: The geometric model of the Condenser using CATIA. meshing package HYPERMESH with free and mapped mesh. Meshing of the component plays an important role in analysis, as it is the basis for analyzing the component in any software package, which supports finite element techniques. The model consists of elements. Appropriate boundary conditions are incorporated in the analysis. Fig 2 shows shell 63 element and Fig3 shows solid 45 element considered for meshing. FE model of the condenser is shown in Fig 4.

3 39 Shell 63 Elastic Shell It is defined by four nodes and six degrees of freedom i.e. UX, UY, UZ, ROTX, ROTY, ROTZ at each node. The element has stress stiffening, large deflection, and birth and death capabilities. Solid45 3d-Structural Solid Fig.2: Shell63 Geometry It is defined by eight nodes and three degrees of freedom i.e. UX, UY, UZ at each node. The element has plasticity, elasticity, large deflection Capabilities. Fig.3: Solid45 3d-Structural Solid Fig.4: The Finite Element Model of the Condenser

4 40 Table 2. Mesh is created in HyperMesh with the following quality parameters Max warpage 23 Aspect Ratio 3.95 Skew 60 Minangleof quad 35 Max angle of quad 152 Jacobian 0.55 Min angle of trias 21 Max angle of trias CONDENSER 4.1 Structural Analysis Static analysis was carried out to know the strength of the condenser, which includes the parameters such as the design pressure, full vaccum and hydro test pressure. The Analysis has been carried out for these cases: Case1). Design Pressure Pressure = Case2). Full Vaccum Pressure = Case3). Hydro static Pressure Pressure = Thermal Analysis Thermal analysis was carried out to know the thermal stresses of the condenser, which includes the parameters such as thermal loading (stresses due to temperature) and Combined loading (both structural and thermal).the Analysis has been carried out for these cases: Case4). Thermal loading (stresses due to temperature). T = 99 o c Case5).Combined loading (both structural and thermal) Pressure= and Temperature= c

5 41 RESULTS Case 1. Design Pressure Table 3. The induced displacements and stresses with Design Pressure of Name Displacement in X- Displacement in Y- Displacement in Z- Shear stress in XY-plane, Shear stress in YZ-plane, Shear stress in XZ-plane, Stress Intensity, Mpa Results as per Analysis Allowable stress as per ASME SEC VIII DIV.2 () Reference figure From the table 3 it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe as per the strength criteria. Fig 5 to Fig 7 shows the variation of max displacement in X, Y and Z-directions respectively 1.174, and mm. The max. allowable displacement is 7mm. Hence the design is safe based on rigidity. Fig.5: The Displacement in X-direction

6 42 Fig.6:The Displacement in Y-direction Fig.7: The Displacement in Z-direction Fig.8: The variation of Shear Stress in XY-plane Fig.9: The variation of Shear Stress in YZ-plane

7 43 Fig.10: The variation of Shear Stress in XZ-plane Fig.11:The variation of Stress Intensity Fig 8 to Fig 11 shows the variations of normal and shear stresses. From the figure it is observed that the maximum stresses induced is Mpa, which is less than allowable stress. Case 2. Full Vaccum Table 4. The induced displacements and stresses with Full Vaccum pressure of Name Displacement in X- Displacement in Y- Displacement in Z- Shear stress in XYplane, Shear stress in YZplane, Shear stress in XZplane, Stress Intensity, Mpa Results as per Analysis Allowable stress as per ASME SEC VIII DIV.2 () Reference figure

8 44 From the table 4 it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe as per the strength criteria. Fig 12 to Fig 14 shows the variation of max displacement in X, Y and Z-directions respectively 1.104, and 1.11 mm. The max. allowable displacement is 7mm. Hence the design is safe based on rigidity. Fig.12:The Displacement in X-direction. Fig.13:The Displacement in Y-direction Fig.14:The Displacement in Z-direction Fig.15:The variation of Shear Stress in XY-plane Fig.16:The variation of Shear Stress in YZ-plane

9 45 Fig.17:The variation of Shear Stress in XZ-plane Fig.18:The variation of Stress Intensity Fig 15 to Fig 18 shows the variations of normal and shear stresses. From the figure it is observed that the maximum stresses induced is Mpa, which is less than allowable stress. Case 3. Hydrotest Pressure Table 5. The induced displacements and stresses with Hydrotest pressure of Mpa Name Displacement in X- Displacement in Y- Displacement in Z- Results as per Analysis Allowable stress as per ASME SEC VIII DIV.2 () Reference figure Shear stress in XYplane, Shear stress in YZplane, Shear stress in XZplane, Stress Intensity, Mpa From the table 5 it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe as per the strength criteria. Fig 19 to Fig 21 shows the variation of max displacement in X, Y and Z-directions respectively 1.71, and 1.72 mm. The max.allowable displacement is 7mm. Hence the design is safe based on rigidity.

10 46 Fig.19: The Displacement in X-direction Fig.20: The Displacement in Y-direction Fig.21:The Displacement in Z-direction Fig.22:The variation of Shear Stress in XY-plane Fig.23:The variation of Shear Stress in YZ-plane

11 47 Fig.24:The variation of Shear Stress in XZ-plane Fig.25:The variation of Stress Intensity Fig 22 to Fig 25 shows the variations of normal and shear stresses. From the figure it is observed that the maximum stresses induced is Mpa, which is less than allowable stress. Case4. Thermal Loading Table 6. The induced displacements and stresses with uniform Temperature loading of 99 0 C Name Results as per Analysis Allowable stress as per ASME SEC VIII DIV.2 () Reference figure Displacement in X-direction, mm Displacement in Y-direction, mm Displacement in Z-direction, mm Shear stress in XY-plane, Shear stress in YZ-plane, Shear stress in XZ-plane, Stress Intensity, Mpa From the table 6 it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe as per the strength criteria. Fig 26 to Fig 28 shows the variation of max displacement in X, Y and Z-direction respectively , and mm. The max. allowable displacement is 7mm. Hence the design is safe based on rigidity.

12 48 Fig.26:The Displacement in X-direction Fig.27:The Displacement in Y-direction Fig.28:The Displacement in Z-direction Fig.29:The variation of Shear Stress in XY-plane Fig30:The variation of Shear Stress in YZ-plane

13 49 Fig31:The variation of Shear Stress in XZ-plane Fig.32:The variation of Stress Intensity. Fig 29 to Fig 32 shows the variations of normal and shear stresses. From the figure it is observed that the maximum stresses induced is Mpa, which is less than allowable stress. Case 5.Combined Loading. Table 7. The induced displacements and stresses with uniform Temperature loading of C and pressure Name Results as per Analysis Allowable stress as per ASME SEC VIII DIV.2 () Reference figure Displacement in X-direction, mm Displacement in Y-direction, mm Displacement in Z-direction, mm Shear stress in XY-plane, Shear stress in YZ-plane, Shear stress in XZ-plane, Stress Intensity, Mpa From the table 7 it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe as per the strength criteria. Fig 33 to Fig 35 shows the variation of max displacement in X, Y and Z-direction respectively 1.194, and mm. The max. allowable displacement is 7mm. Hence the design is safe based on rigidity.

14 50 Fig33:The Displacement in X-direction Fig34:The Displacement in Y-direction Fig35:The Displacement in Z-direction Fig.36:The variation of Shear Stress in XY-plane

15 51 Fig37:The variation of Shear Stress in YZ-plane Fig38:The variation of Shear Stress in XZ-plane Fig39:The variation of Stress Intensity Fig 36 to Fig 39 shows the variations of normal and shear stresses. From the figure it is observed that the maximum stresses induced is Mpa, which is less than allowable stress. For the material SA 516 Gr 70 KSm= Minimum yield stress = 262 Minimum tensile stress = 481

16 52 CONCLUSIONS The following conclusions are drawn from the present work. 1. The maximum deflection induced mm under loads which is with in the allowable limits i.e. < 7mm. 2. The maximum stress induced is 263 which is less than allowable limits of 524. Hence the factor of safety is The maximum deflection induced 1.11 mm under loads which is with in the allowable limits i.e. < 7mm. 4. The maximum stress induced is 245 which is less than allowable limits of 524. Hence the factor of safety is The maximum deflection induced 1.72 mm under loads which is with in the allowable limits i.e. < 7mm. 6. The maximum stress induced is 381 which is less than allowable limits of 524. Hence the factor of safety is The maximum deflection induced mm under uniform temperature of 99 0 C load which is with in the allowable limits i.e. < 7mm. 8. The maximum stress induced is which is less than allowable limits of 524. Hence the factor of safety is The maximum deflection induced mm under combined loading of and uniform temperature of 99 0 C load which is with in the allowable limits i.e. < 7mm. 10. The maximum stress induced is which is less than allowable limits of 524. Hence the factor of safety is REFERENCES 1 Gulyani, B. B., 2000, Estimating Number of Shells in Shell and Tube Heat Exchangers: A New Approach Based on Temperature Cross, ASME J. Heat Transfer, 122, pp Master, B. I., Chunangad,K. S., and Pushpanathan, V., 2003, Fouling Mitigation Using Helixchanger Heat Exchangers, Proceedings of the ECI Conference on Heat Exchanger Fouling and Cleaning: Fundamentals and Applica- tions, Santa Fe, NM, May 18 22, pp Reppich, M., and Zagermann, S., 1995, A New Design Method for Segmentally Baffled Heat Exchangers, Compute. Chem. Eng., 19, pp Li, H. D., and Kottke, V., 1998, Effect of the Leakage on Pressure Drop and Local Heat Transfer in Shell-and Tube Heat Exchangers for Staggered Tube Arrangement, Int. J. Heat Mass Transfer, 41 2, pp Naim, A., and Bar-Cohen, A., 1996, New Developments in Heat Exchangers, Gordon and Breach, Amsterdam, pp Van der Ploeg, H. J., and Master, B. I., 1997, A New Shell-and-Tube Option for Refineries, PTQ Autumn, pp