Thesis Certificate

The Graduate College, King Mongkut's University of Technology North Bangkok

Title Stress Analysis of Expansion Joint on a Fixed Tubesheet Heat Exchanger by
Finite Element Method
By Miss Ruetima Dhmmaraksa
Accepted by the Graduate College, King Mongkut ' s University of Technolog$
North Bangkok in Partial Fulfillment of the Requirements for the Master of

Engineering in Mechanical Engineering

Dean, Graduate ColIege

28

September

2009

Thesis Examination Committee

I.

Ikrz.

Chairperson

Member
( ~ r ! ~ ~ i c h chaengrJ/arn&
art

Member

QI

(Assistant Professor Dr-Virat Cbomkwah)

(Associate Professor Veera Chanvattana)

STRESS ANALYSIS OF EXPANSION JOINT ON A FIXED TUBESHEET HEAT EXCHANGER

BY FINITE ELEMENT METHOD

MISS RUETIMA DHAMMARAKSA

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE

MASTER OF ENGINEERING IN MECHANICAL ENGINEERING
GRADUATE COLLEGE
KING MONGKUTS UNIVERSITY OF TECHNOLOGY NORTH BANGKOK
ACADEMIC YEAR 2009
COPYRIGHT OF KING MONGKUTS UNIVERSITY OF TECHNOLOGY NORTH BANGKOK

Name
Thesis Title

: Miss Ruetima Dhammaraksa

: Stress Analysis of Expansion Joint on a Fixed Tubesheet Heat
Exchanger by Finite Element Method
Major Field
: Mechanical Engineering
King Mongkuts University of Technology North Bangkok
Thesis Advisor : Assistant Professor Dr.Virat Chomkwah
Co-Advisor
: Associate Professor Veera Chanvattana
Academic Year : 2009
Abstract
This research provides a selection graph and calculation method for a carbon
steel fixed tubesheet heat exchanger (ASTM A-515, A-516 and A-537) which
requires expansion joints for thermal stress relieving. Various shapes of expansion
joints for shell diameters from 200 to 2000 mm were simulated by varying the
thickness and the bending of circumferential radius.
From the simulation, the maximum Von-Mises stress was determined by FEA at
the maximum allowable displacement per TEMA Code. The expansion loop number
can be calculated by dividing the total displacement with the maximum allowable
displacement. The stress value from the simulation has to be combined with the
maximum bending stress to the saddle, then compare with 3 times of allowable stress
for each material as per ASME Code.
The result shows that the more thickness and the more bending of
circumferential radius, the less stress occurred to the shell.
Two heat exchangers as a case study which they are operating in one existing
petrochemical plant were analyzed by finite element method and also comparing to
the graphs and the method for this research. It shows slightly different and it can be
accepted as a guideline.
(Total 74 pages)
Keywords : Heat Exchanger, Expansion Joint, Thermal Stress, Finite Element
Analysis, Fixed Tubesheet

Advisor
ii

:
:

: .

:

: 2552

(Expansion Joint)
(A-515, A-516 A-537)
200 .
2000 .
(Von-Mises)
TEMA
TEMA

ASME 3

2

( 74 )
:

iii

ACKNOWLEDGEMENTS
I would like to express my deep appreciations to my advisor, Assistant Professor
Dr. Virat Chomkwah and co-advisor, Associate Professor Veera Chanvattana, for their
sincere guidance and intelligent suggestions to this study. Thanks also to the members
of my advisory committee, Dr. Apichart Chaengbamrung and Dr. Parpot Kunthong who
has spent their valuable time for me.
In addition, I would like to thank you especially to my company, my bosses and
all my colleagues in supporting many information.
Last, but in no sense the least, I express my thanks and appreciation to my family
for their understanding, motivation and patience.

Ruetima Dhammaraksa

iv

TABLE OF CONTENTS
Abstract (in English)
Abstract (in Thai)
Acknowledgements
List of Tables
List of Figures
List of Abbreviations and Symbols
Chapter 1 Introduction
1.1 Introduction
1.2 Motivation of the Research
1.3 Research Objectives
1.4 Scope of Research
1.5 Researchers Goal
Chapter 2 Literature Review and Background
2.1 Literature Review
2.2 Background
Chapter 3 Theories and Codes
3.1 Introduction
3.2 Uniform Internal Pressure
3.3 Maximum Longitudinal Bending Stress
3.4 Axisymmetric Elements for Finite Element Analysis
3.5 Von Mises Stress
3.6 Thermal Stress
3.7 Thermal Design Theory
Chapter 4 Simulation Procedure and Finite Element Analysis
4.1 Simulation Procedure
Chapter 5 Results of Finite Element Analysis
5.1 Summary of Results
5.2 Expansion Joint Selection
Chapter 6 Case Study
6.1 Case 1
6.2 Case 2
Chapter 7 Conclusions and Further Works
7.1 Conclusions
7.2 Further Works

Page
ii
iii
iv
vii
viii
x
1
1
3
3
4
4
5
5
8
14
14
14
15
16
18
19
20
22
22
36
36
43
46
46
48
51
51
53

TABLE OF CONTENTS (CONTINUED)

References
Appendix A General Arrangement Drawing for Case 1 before and
after detailed calculation
Appendix B General Arrangement Drawing for Case 2 before and
after detailed calculation
Appendix C Detailed Calculation for Case 1
Appendix D Detailed Calculation for Case 2
Biography

vi

Page
54
55
58
61
70
74

LIST OF TABLES
Table
2-1
2-2
2-3
2-4
2-5
2-6
4-1
4-2
4-3
4-4
4-5
5-1
6-1
6-2
C-1
C-2
C-3
C-4

A 515 Material Specification

A 516 Material Specification
A 537 Material Specification
Maximum Allowable Stress Value for Carbon Steel Materials
Modulus of Elasticity and Coefficient of Thermal for Carbon Steel
Materials
Minimum shell thickness
Various shape of expansion joint
Example of parameters input for 8 inch diameter
Dimensional inputs for each geometry
Observed elements for FEA
Results of maximum stress value
List Result for Maximum Stress at 25 mm Displacement
Design Conditions for Case 1
Design Conditions for Case 2
Values of T1 through the tube
Values of T2
Values of T3
Values of T4

vii

Page
9
9
10
11
12
13
24
27
27
33
34
36
46
48
66
67
67
69

LIST OF FIGURES
Figure
Page
1-1 Un-deformed and deformed shape of heat exchanger during thermal
expansion with a fix point
1
1-2 Model of fixed tubesheet heatexchanger (a) without expansion joint
(b) with expansion joint
2
1-3 Model of fixed tubesheet heatexchanger
(a) Piping movement connected to nozzle (b) Isometric view for
saddle with slot hole on the base plate for horizontal movement of the
shell
2
1-4 A Fixed tubesheet heat exchanger (a) before detailed calculation
(b) after detailed calculation
3
2-1 Bellows subjected to (a) an axial displacement x
(b) a lateral deflection y
5
2-2 (a) Flanged and Flued (b) Flanged Only expansion joint
6
2-3 Construction model of expansion joint
6
2-4 Equivalent model of expansion joint
7
2-5 Application of ASME Section VIII (Division I)
8
3-1 Stress in closed-end cylindrical shell under internal pressure
14
3-2 Loads and moment diagram for horizontal cylinder
15
3-3 (a) Typical slice through an axisymmetric solid discretized into
triangular element (b) Stresses in the axisymmetric problem
17
4-1 Flowchart of simulation procedure
22
4-2 Flowchart of Determining the Optimized Geometry
23
4-3 General geometry of expansion joint
24
4-4 (a) Maximum von-Mises stress vs Length of expansion joint at 5 mm
thickness (b) Maximum von-Mises stress vs Length of expansion joint
10 mm thickness
25
4-5 Expansion joint model with its parameters
25
4-6 Model of expansion joint for finite element analysis
26
4-7 Model of expansion joint with dimensions
27
4-8 Results of maximum stress value
34
4-9 Inputs for Boundary Conditions of FEA
35
5-1 (a) Shell Diameter vs Smax curve at (a) 3REJ (b) 4REJ (c) 5REJ
40
5-2 Stress value for Example 1
44
5-3 Stress value for Example 2
45
6-1 Preliminary sketch of Case 1
47
6-2 Geometry of expansion joint for Case 1
47
6-3 Expansion joint model for finite element analysis for Case 1
48
6-4 Preliminary sketch of Case 2
49
6-5 Geometry of expansion joint for Case 2
49

viii

LIST OF FIGURES (CONTINUED)

Figure
6-6 Expansion joint model for finite element analysis for Case 2
7-1 Expansion joint model with its parameter
7-2 Selection Graph for expansion joint design at (a) 3REJ (b) 4REJ (c)
5REJ.
7-3 Information supported model for expansion joint design
A-1 General Arrangement Drawing for Case 1 before detailed calculation
A-2 General Arrangement Drawing for Case 1 after detailed calculation
B-1 General Arrangement Drawing for Case 2 before detailed calculation
B-2 General Arrangement Drawing for Case 2 after detailed calculation
C-1 Shell Diameter vs Smax curve at 3REJ for Case 1
C-2 Input model of FEA for Case 1
C-3 Output model of FEA for Case 1
C-4 Thermal network for Case 1
C-5 Assumed fluid temperature in tubes
C-6 Temperature Distribution along the shell of heat exchanger Case 1
C-7 Condensing heat transfer coefficient by Chens method
D-1 Shell Diameter vs Smax curve at 3REJ for Case 2
D-2 Input model of FEA for Case 2
D-3 Output model of FEA for Case 2

ix

Page
50
51
52
53
56
57
59
60
63
64
64
65
66
68
68
72
73
73

LIST OF ABBREVIATIONS AND SYMBOLS

x,y,z
t
, ,
,
,
u,v,w
E
Ei
G
v
D
S
St,SL
S1,S2
A
H
L
Di
Ri
REJ
Q
M1,M2
,
,
,
h

k
T

Rectangular Coordinates
Thickness of a plate or a shell
Normal components of stress parallel to x,y and z axes
Shearing stress components in rectangular coordinates
Components of displacements
Modulus of elasticity in Tension and compression
Joint efficiency
Modulus of elasticity in shear
Poissons ratio
Displacement
Allowable Stress
Tangential Stress, Longitudinal Stress
Maximum bending stress at mid span and plane saddle
Distance from saddle to tangent line
Depth of head
Length of shell
Inner diameter
Inner radius
Circumferential radius of expansion joint
Load per saddle
Maximum moment at mid span and plane saddle
Bending moments per unit length of sections of a plate perpendicular
to x and y axes, respectively
Shearing forces parallel to z axis per unit length of sections of a
plate perpendicular to x and y axes, respectively
Normal forces per unit length of sections of a plate perpendicular to
x and y axes, respectively
Specific enthalpy
Specific enthalpy of the saturated liquid
Specific enthalpy of the saturated vapor
Thermal conductivity
Temperature
Thermal expansion coefficient
Viscosity
Density

CHAPTER 1
INTRODUCTION
1.1 Introduction
A heat exchanger is a device built for heat transfer from one medium to another,
whether the media are separated by a solid wall so that they never mix, or the media
are in direct contact. The widely used in petrochemical plants, petroleum refineries
and natural gas processing is the shell and tube heat exchangers.
Shell-and-tube heat exchangers consist of a series of tubes. One set of these
tubes contains the fluid that must be either heated or cooled. The second fluid runs
over the tubes that are being heated or cooled so that it can either provide the heat or
absorb the heat required. A set of tubes is called the tube bundle and can be made up
of several types of tubes.
Normally, the material of tubes is made of carbon steel or aluminum but in high
corrosive process, tubes are required to be stainless steel or titanium. The thermal
expansion of the shell and tubes are unequal to each other, this may occur because of
the difference temperature and difference material properties.
For heat exchangers which their temperature and material property are
difference, thermal expansion from the tube will expand into the tubesheet. The shell
of the heat exchanger will be at a significantly different temperature than tubes, the
shell will expand or contact relative to the tubes, resulting in stresses and affecting to
the tubesheet. It will pull the tubes and tubesheet apart and damage because there is
no provision to absorb the differential expansion. Figure 1-1 shows the un-deformed
and deformed incase of thermal expansion, the saddle, support of heat exchanger, is a
fix point so the shell will bend and damage
.

FIGURE 1-1 Un-deformed and deformed shape of heat exchanger during thermal
expansion with a fix point
The most obvious solution to the thermal expansion problem is to put an
expansion roll or joint in the shell. Figure 1-2 (a) shows the model of a fixed
tubesheet heat exchanger without expansion joint and Figure 1-2 (b) shows the model
with expansion joint.

2
6
4

2
7

(a)

1: Shell
2: Tubes
3: Tubesheet
4: Head
5: Saddle (Vessel Support)
6: Shell Inlet/Outlet
Nozzle
7: Tube Inlet/Outlet
Nozzle
8: Expansion Joint

(b)
FIGURE 1-2 Model of fixed tubesheet heatexchanger
(a) without expansion joint (b) with expansion joint
Another proposed of expansion joint installation is the movement of the
connected pipe which connects to the nozzle. The high temperature pipe will expand
along its axial. If the expansion joint is not installed, the welds on the nozzle branch
will damage. In this case the saddle has to be designed as fixed on one side and slide
on the other side. Figure 1-3 shows the un-deformed and deformed of the pipe
movement with the isometric view of the saddle base plate.
Nozzle damage

Fixed

Fixed
(b)

Fixed

Slide
(a)
FIGURE 1-3 Model of fixed tubesheet heatexchanger (a) Piping movement
connected to nozzle (b) Isometric view for saddle with slot hole on
the base plate for horizontal movement of the shell

3
This research will determine an appropriate design of expansion joint geometry
by using Finite Element Method and two case studies related to the research.
1.2 Motivation of the Research
A fixed tubesheet heat exchanger was designed to replace with the existing item
in a petrochemical plant purpose for warming up the propylene in one process unit.
Basic design drawing of the heat exchanger with its dimension as shown in Figure 1-4
(a) was given to the vessel manufacturer without a requirement for the expansion
joints. The returned detail drawings submitted together with the strength calculation
sheet, shown in Figure 1-4 (b), shows that three expansion joints have to be
constructed as an integrated part to the shell. The more constructed material, the more
manpower and cost increased. This research will determine the appropriate geometry
of the expansion by using finite element method.

(a)

(b)
FIGURE 1-4 A Fixed tubesheet heat exchanger (a) before detailed calculation (b)
after detailed calculation
1.3 Research Objectives
Specific objectives relating to this research are
1.3.1 To determine an alternative procedure of expansion joint design to the
ASME and TEMA code by using finite element method.

4
1.3.2 To determine the maximum stress and displacement location which occur
on the expansion joint.
1.3.3 To define a guideline and design recommendations for fixed tubesheet heat
exchangers with expansion joints.
1.4 Scope of Research
The scope to this research is
1.4.1 The material is carbon steel plate only. (ASTM Material code: A-515,
A-516 and A-537)
1.4.2 Only the axial force is applied to the geometry.
1.4.3 Plate thickness will be initiated from the minimum required thickness for
each shell diameter and times up in 2,3 and 4 (varied from 7 to 39 mm). For example,
a heat exchanger with 200 mm diameter requires 7 mm plate thickness. So the
simulation will be varied to input as 7,21 and 28 mm.
1.4.4 Shell inside diameter is varied from 200 to 2000 mm.
1.4.5 The length of the shell is not considered.
1.4.6 The bending radius of the expansion joint is 3,4 and 5 times with the
minimum required thickness for each size of shell diameter.
1.4.7 The maximum stress relates to 25 mm displacement on the expansion joint.
(TEMA allows 50 mm expansion of tubes to tubesheet and axisymmetry on both end
of a single expansion will be 25 mm).
1.4.8 The plate for vent and drain is not modeled.
1.4.9 Neglect the residual stress and strength of welds.
1.5 Researchers Goal
1.5.1 To know the stress behavior of the shell after installing the expansion
joints.
1.5.2 Predict the failure of the shell and prevent the shell from damage cases.
1.5.3 Results from this research to be a design guideline for fixed tubesheet heat
exchangers.

CHAPTER 2
LITERATURE REVIEW AND BACKGROUND
2.1 Literature Review
2.1.1 ASME Boiler and Pressure Vessel Code, Section VIII (Division I) [1]
ASME Boiler and Pressure Vessel Code, Section VIII (Division I), Rules for
Construction of Pressure Vessel, defines two types of expansion joints in the year
2001 edition. The first type is the bellows-type (Mandatory Appendix 26, p.469-480)
and second type is flanged-and-flued and flanged only expansion joint (Mandatory
Appendix CC, p.644-647).
For the bellow type expansion joint, its application is to be installed and
attached as a flexible element for pressure piping, not on pressure vessels. Figure 2-1
(a) shows the application of bellow expansion installation and its deflection in the xaxis and Figure 2-1 (b) subjected to a lateral deflection y-axis.

(a)

(b)
FIGURE 2-1 Bellows subjected to (a) an axial displacement x
(b) a lateral deflection y
Appendix CC for the flanged and flued and flanged only expansion joints, these
2 types of the expansion joints attached to the shell of the pressure vessel, doesnt give
much details in designing the expansion joint. It only shows the formula of cyclic
pressure and axial deflection.
Besides, paragraph (d) was indicated that

6
. . . This Division does not contain rules to cover all details of design and
construction of expansion joints. The criteria in this Appendix are therefore
established to cover most forms oflanged and flued and flanged only expansion
joints, but it is not intended otherwise to limit configuration or details . . .
The ASME code, Section VIII (Division I), year 2007 latest edition has been
revised and updated its edition twice from the year 2004 and 2007. Appendix 26
exists in the 2007 Edition with additional to the detail design of bellow expansion
joints, while Appendix CC was deleted since the 2004 Edition. Figure 2-2 shows a
typical drawing of the flanged and flued and flanged only expansion joint.

(a)
(b)
where
Ra, R = Inside radius of expansion joint straight flange, mm
t
= Uncorroded thickness of expansion joint straight flange, mm
FIGURE 2-2 (a) Flanged and Flued (b) Flanged Only expansion joint
2.1.2 Standard of the Tubular Exchanger Manufacturers Association (TEMA) [3]
Standard of the Tubular Exchanger Manufacturers Association (TEMA), Edition
th
8 , provides a sequence of calculation for a single element expansion joint. The
geometry of the expansion joint has to be figured out first before knowing the strength
of the designed element. Several construction model of expansion joint is shown is
Figure 2-3.

.
FIGURE 2-3 Construction model of expansion joint

7
The calculation to determine the stress for the flexible element will be
considering on an equivalent model as Figure 2-4.

FIGURE 2-4 Equivalent model of expansion joint

where
lo, li = Length of the cylinders welded to single flexible shell element, mm
tE if the flexible element has a knuckle radius at the inside junction, mm
ta = ts if the flexible element does not have a knuckle radius at the inside
junction, mm
tb
a
b

tE if the flexible element has a knuckle radius at the outside junction, mm

= to if the flexible element does not have a knuckle radius at the outside
junction, mm
= Mean radius from the centerline of the shell
= Mean radius from the centerline of the shell to the centerline of the expansion
joint

The next step will be concerning with many parameters and values which relates
to the curves, the element flexibility factor, the element geometry factor and stiffness
multiplier. The calculation will be calculated as per the stated formula in order to
determine the axial force, moments and stresses.
Finally, the obtained stress will be compared with the allowable stress to the
material code. If the calculated stress is greater than the allowable stress, the
geometry is not acceptable to be constructed as per the code. Thus, the recalculation
process has to be performed until the outcome value is lesser than the allowable. In
case, the calculated stress is lesser than the allowable stress, the designed geometry
can be accepted but it might be an overdesigning configuration.

8
2.2 Background
2.2.1 Definition of Pressure Vessel per ASME Boiler and Pressure Vessel Code,
Section VIII (Division I)
Any pressure retaining vessel, internal or external pressure container, can be
designed to meet the requirement of ASME Section VIII (Division I). Figure 2-5
shows the judgment of designation per this code.
No

Yes

Human occupancy ?

P > 15 psig (1.03 atm)

Yes
P < 300 psig (20.4 atm)

No
Water
flash point < 185 F (85 C)

Yes

No

Indirectly heated
No

Yes

No

Heat input < 200,000 Btu/hr

(211 MJoule)

No

Yes
T < 210 F (99 C)

No

Yes
Volume < 120 gallons
(454 liter)

No
Maximum cross-section
dimension < 6 in (150 mm)
Yes

Yes

No
Division 1 Applicable

Division 1 Exempt

FIGURE 2-5 Application of ASME Section VIII (Division I)

9
The code contains the general requirement for all methods of construction and
materials. These general requirements fall into 5 categories.
2.2.1.1 Materials design aspects of material such as allowable stress at
design temperature and physical properties of material
2.2.1.2 Design formula for selection and sizing of vessel and vessel
component
2.2.1.3 Inspection and Testing*
2.2.1.4 Marking and Report*
2.2.1.5 Pressure Relief Device*
(* not considered in this research)
Thus, every heat exchanger in petrochemical plant is classified as a Pressure
Vessel and has to be constructed per ASME code.
2.2.2 Material Specification, Allowable Stress and Physical Properties of Carbon
Steel Material (Plates and Sheets) [2]
2.2.2.1 A-515 Standard Specification for Pressure Vessel Plates, Carbon
Steel, for Intermediate- and Higher-Temperature Service
Scopes are defined as below :
a) This specification covers carbon-silicon steel plates primarily
for intermediate- and higher-temperature service in welded boilers and other pressure
vessels.
b) Plates under this specification are available in three grades
with different strength levels and limitations of the maximum thickness as Table 2-1.
TABLE 2-1 A-515 Material Specification
Maximum Thickness,
in. [mm]

Tensile Strength,
ksi [MPa]

60[415]

8 [200]

6080 [415550]

65 [450]

8 [200]

6585 [450585]

70 [485]

8 [200]

7090 [485620]

Grade U.S. [SI]

2.2.2.2 A-516 Standard Specification for Pressure Vessel Plates, Carbon

Steel, for Moderate- and Lower-Temperature Service
Scopes are defined as below :
a) This specification covers carbon steel plates intended
primarily for service in welded pressure vessels where improved notch toughness is
important.
b) Plates under this specification are available in four grades with
different strength levels and limitations of the maximum thickness as Table 2-2.
TABLE 2-2 A-516 Material Specification
Grade U.S. [SI]
55 [380]

Maximum Thickness,
in. [mm]

Tensile Strength,
ksi [MPa]

12 [305]

5575 [380515]

10
TABLE 2-2 A-516 Material Specification
Maximum Thickness,
in. [mm]

Tensile Strength,
ksi [MPa]

60 [415]

8 [205]

6080 [415550]

65 [450]

8 [205]

6585 [450585]

70 [485]

8 [205]

7090 [485620]

Grade U.S. [SI]

2.2.2.3 A-537 Standard Specification for Pressure Vessel Plates, HeatTreated, Carbon-Manganese-Silicon Steel
Scopes are defined as below :
a) This specification covers heat-treated carbon manganesesilicon steel plates intended for fusion welded pressure vessels and structures.
b) Plates under this specification are available in three grades
with different strength levels and limitations of the maximum thickness as Table 2-3.
TABLE 2-3 A-537 Material Specification
Grade U.S.
[SI]

Maximum
Thickness,
in. [mm]

Tensile
Strength,
ksi [MPa]

2 12 [65] < t 4[100]

65[450]

t 2 12 [65]

80 [550]

2 12 [65] < t 4[100]

75 [515]

4[100] < t 6[150]

70 [485]

t 2 12 [65]

80 [550]

2 12 [65] < t 4[100]

75 [515]

4[100] < t 6[150]

70 [485]

The maximum allowable stress and physical properties value are given in Table
2-4 and 2-5, respectively.

TABLE 2-4 Maximum Allowable Stress Value for Carbon Steel Materials [2]

Spec

Gr./
Cl.

Size/
Thickness
(in.)

Min
Min
Tensile
Yield
Strength Strength(k -20 to
(ksi)
si)
100

Maximum Allowable Stress, ksi

(Multiply by 1000 to obtain psi), for Metal Temperature, F, Not Exceeding
150

200

250

300

400

500

600

650

700

750

800

850

900

950 1000

SA-516 55

55

30

15.7

15.7 15.7

15.7 15.7 15.7 15.3 14.8 14.3

SA-515 60

60

32

17.1

17.1 17.1

17.1 17.1 17.1 16.4 15.8 15.3 13.0 10.8

8.7

5.9

4.0

2.5

SA-516 60

60

32

17.1

17.1 17.1

17.1 17.1 17.1 16.4 15.8 15.3 13.0 10.8

8.7

5.9

4.0

2.5

SA-515 65

65

35

18.6

18.6 18.6

18.6 18.6 18.6 17.9 17.3 16.7 13.9 11.4

8.7

5.9

SA-515 65

65

35

18.6

18.6 18.6

18.6 18.6 18.6 17.9 17.3 16.7 13.9 11.4

8.7

5.9

SA-537 1

65

45

18.6

18.6

18.6 18.6 18.6 18.6 18.6 16.9

SA-515 70

70

38

20.0

20.0 18.6

20.0 20.0 20.0 19.4 18.8 18.1 14.8 12.0

9.3

6.7

4.0

2.5

SA-516 70

70

38

20.0

20.0 20.0

20.0 20.0 20.0 19.4 18.8 18.1 14.8 12.0

9.3

6.7

SA-537 3

4<t6

70

40

20.0

20.0 20.0

19.7 19.5 19.5 18.0 17.6 17.2

10 SA-537 2

4<t6

70

46

20.0

20.0

19.7 19.5 19.5 19.5 19.5 18.3

75

50

21.4

21.4

21.1 20.9 20.9 20.9 20.9 18.3

75

55

21.4

21.4

21.1 20.9 20.9 20.9 20.9 19.6

80

55

22.9

22.9

22.6 22.3 22.3 22.3 22.3 19.6

80

60

22.9

22.9

22.6 22.3 22.3 22.3 22.3 19.6

11 SA-537 3
12 SA-537 2
13 SA-537 3
14 SA-537 2

2 12 < t 4

2 2 <t 4
2 12 < t 4
t 2 12
t 2 12
1

Note: Italic font means the allowable stress at design temperature are obtained from time-dependent properties.
11

TABLE 2-5 Modulus of Elasticity and Coefficient of Thermal for Carbon Steel Materials [2]
Value Given for Metal Temperature, F, of

Modulus of
Elasticity, E

-325

-200

-100

70

100

150

200

250

300

350

400

450

500

550

600

650

31.4

30.8

30.2

29.5

29.2

29.0

28.8

28.5

28.3

28.0

27.7

27.5

27.3

27.0

26.7

26.1

6.4

6.5

6.7

6.9

7.1

7.3

7.5

7.7

7.8

8.0

8.2

8.4

8.5

Coefficient of
thermal
expansion,

Value Given for Metal Temperature, F, of

700

750

800

850

900

950

1000

1050 1100 1150 1200 1250 1300 1350 1400 1450

Modulus of
Elasticity, E

25.5

26.1

24.0

23.1

22.3

21.3

20.2

19.1

17.9

Coefficient of
thermal
expansion,

8.6

8.8

8.9

9.0

9.1

9.2

9.3

9.4

9.5

9.5

9.6

9.6

9.6

Note
1) Modulus of Elasticity E= Value Given 106 psi, for Metal Temperature, F
2) Coefficient of thermal expansion 10-6 (in/in/F). For SI units, multiply coefficients by 1.8 to convert to mm/mm/C
12

13
2.2.3 Definition of TEMA heat exchanger [3]
2.2.3.1 Class R Specify design and fabrication of unfired shell and
tube heat exchangers for the generally severe requirements of petroleum and related
processing application.
2.2.3.2 Class C - Specify design and fabrication of unfired shell and
tube heat exchangers for the generally moderate requirements of commercial and
general processing application.
2.2.3.3 Class B - Specify design and fabrication of unfired shell and
tube heat exchangers for chemical process service.
Note : TEMA(R) heat exchanger is considered in this research only.
2.2.4 Minimum shell thickness for TEMA heat exchanger [3]
Minimum shell thickness for TEMA(R) heat exchanger plus corrosion
allowance should not be less than Table 2-6.
TABLE 2-6 Minimum shell thickness
Nominal Shell Diameter,
in. [mm]

Minimum Thickness,
in. [mm]

6 [150]]

1/4 [7]

8-12 [200-300]

5/16 [8]

13-29 [325-725]

5/16 - 3/8 [8-10]

30-39 [750-975]

3/8[10]

40-59 [1000-1475]

7/16 [12]

60-80 [1500-2000]

1/2 [13]

2.2.5 Length of Expansion for TEMA(R) heat exchanger

Regarding to RB-7.5.1, Expanded tube-to-tubesheet joints, tubes shall be
expanded through the tubesheet not greater than 2 inch (50 mm) or tubesheet thickness
minus 1/8 inch (3 mm).
As a fixed tubesheet heat exchanger and considering in a worst case, the shell is
permitted its expansion not greater than 2 inch (50 mm).

CHAPT
TER 3
TH
HEORIES
S AND ST
TANDARD
D CODES
S
duction
3.1 Introd
This section willl describe the
t relation of the theoory against the code, elasticity
e
theory, finite element method
m
andd thermal theory.
3.2 Uniforrm Internal Pressure [4]
The cylindrical
c
shell is the most frequ
uently used geometricaal shape in pressure
vessel desiggn. The strresses in a closed-end
c
cylindrical
c
shell under internal pressure P
can be com
mpute from the conditions of stattic equilibriium shown in Figure 3-1. Its
longitudinaal direction are written in Eq. 3-1.

FIGU
URE 3-1 Sttress in clossed-end cyliindrical sheell under inteernal pressu
ure

2 RSLt =

P R2 or SL = PR 2t or t = PR 2SL

Eq. 3-11

The tangent
t
stresss can be exxpressed as Equation 3.2

St =

PR
Rt

Eq. 3-22

Eq. 3-2 can be written

w
in thee term of in
nner radius with
w thickneess to determ
mine the
average tanngent stress as given inn Eq. 3-3. Itt can also been
b
shown for determiining the
shell thicknness as Eq. 3-4
3 [5].

St =

PR P ( Ri + 0.5t )
=
t
t

Eq. 3-33

PR
P i
St 0.5 P

Eq. 3-44

t=

15
ASM
ME code exppressed that the minimu
um thicknesss of the cyllindrical sheells shall
consider thhe circumferential stresss, which is the tangeent stress, aand the long
gitudinal
stress as givven in Eq. 3-5
3 and 3-6..
PRi
t=
Eq.
E 3-5
SEt 0.6 P
and
PRi
t=
Eq.
E 3-6
2 SE
Et + 0.4 P
wheree

S is the allowable stress

s
to thee code.
Et is thee joint coeffficient (defaault = 1)

3 has the 0.6

0 factor which
w
is thee correlationn that extennds the appllicability
Eq. 3-5
of the thin wall formuula for circuumferential stress to a thickness
t
eqqual to one-half the
mula will be use when P exceeds 0.385SE.
inside radiuus. The form
Eq. 3-6 will be use
u when P exceeds 1.2
25SE.

3.3 Maxim
mum Longiitudinal Bending Stress [6]
A horrizontal cyllindrical preessure vesseel will be reesting on tw
wo saddle supports.
s
A uniform load of the weight of the
t vessel and
a its conteents by bennding will be loaded
t the shell can be deteermined equ
ual as the
to the saddlle. The bennding stress occurring to
bending onn the saddlee because thhey are fixeed by the welding togeether. The load
l
and
the momennt diagramss are shownn in Figuree 3-2. Thee maximum
m bending moments
m
occur over supports annd its mid sppan.

= an
ngle of conttact, degrees
H = deepth of headd, ft
M
Maximum
M
Moment
at Midspan
M
b = width
w
of sadddle, inch
2 = efffective porttion of sadd
dle, rad
R = innner radius oof shell, ft
t = shhell thickness, in
th = heead thickness, in
Maximum Mom
ment at Plane of Saddle L = shhell length,fft
(b) Schhematic mom
ment diagraam xo = (rr sin ) /
Q = looad per one saddle.lb

(a) Loads
L
and reeaction

F
FIGURE
3-2 Loads annd moment diagram forr horizontall cylinder

16
The bending moment M1 at mid span can be calculated as Eq. 3-7

M1 =

2H
A
R 2 wH 3H
L
1 L

w A A w
A wA wR

3
2
4 3 8
2
2 2

2
2Q ( L 2 A) 2
A2 R 2 H 2
HA
+

L + 4H 3
8
3
2
4

2
2
2

QL 1 + 2 ( R H ) L 4 A

L
4
1 + ( 4 H 3L )

QL
, lb ft
where K1 is the expression in brackets
K1
4

Eq. 3-7

The maximum stress S1 can be determined as Eq. 3-8

S1 =

3QLK1 r 2t , psi

Eq. 3-8

The bending moment M2 in the plane of saddle as Eq. 3-9

M2 =

2H
2Q
A2 R 2 H 2
+

L + 4H 3 3
2
4

Eq. 3-9

1 ( A / L) + [( R 2 H 2 ) / 2 AL]
QA 1
lb ft
1 + [4 H / 3L]

The maximum stress S2 can be determined as Eq. 3-10

S2 =

3QL 4 A 1 ( A / L) + [( R 2 H 2 ) / 2 AL]
1

r 2t L
1 + [4 H / 3L]

Eq. 3-10

(sin / ) cos

2
+ sin cos (2sin / )
+3QLK 2 / r r t , psi where K2 is the expression in
brackets

Allowable Stress Limits. The tensile stress S1 or S2 combined with the

longitudinal pressure stress SL = PR/2t should not exceed the allowable tensile stress
of the shell material times the efficiency of the girth joints.
3.4 Axisymmetric Elements for Finite Element Analysis [7]
1
If, in generally, we let 1 E = D , then in general matrix form can be written as

D 1 +

Eq. 3-11

17
where is the thermal strain matrix. From Eq. 3-11, we solve for as

= D ( + )

Eq. 3-12

General steps of Finite Element Method is given below :

Step 1 : Select Element Type
In this research shall be referring to a typical triangular element which has three
nodes with two degrees of freedom. The stresses in the axisymmetric problem are
shown in Figure 3-3

FIGURE 3-3 (a) Typical slice through an axisymmetric solid discretized

into triangular element (b) Stresses in the axisymmetric problem

Step 2 : Select Displacement Function

The element displacement functions are taken to be

u ( x, z) =

w( x, z) =

a1 + a2 x + a3 z
b1 + b2 x + b3 z

Eq. 3-13
Eq. 3-14

The general displacement function is given below :

{ } =

u ( x, z)
=
w ( x, z )

Ni
0

0
Ni

Nj
0

0
Nj

Nm
0

We define the shape functions as

1
(i + i x + i z )
Ni =
2A

ui
w
i
0 u j

N m w j
um

wm

Eq. 3-15

Eq. 3-16

18
1
( j + j x + j z )
2A
1
(m + m x + m z )
Nm =
2A
where A is the area of the triangular element and

Nj =

i =
i =
i =

j =
j =
j =

x j zm z j xm
z j zm
xm x j

Eq. 3-17
Eq. 3-18

m =
m =
m =

xm zi zm xi
zm zi
xi xm

xi z j zi x j
zi z j

Eq. 3-19

x j xi

Step 3 : Define the Strain/Displacement and Stress/Strain Relationships

Rewriting Eq. 3-15 and 3-19, the strain matrix in the displacement terms
becomes

xx

0
zz 1
= =
iz
i
2 A x + i + x
xz

= { } =

D = [D] =

j
x

+ j +

jz
x

m
x

+ m +

mz
x

( xx )
T
( )

zz 1 T

=

(
)

2 G T

( xz )
0

1
E

1
(1 + )(1 2 )
0
0
0

0
m

0
m

ui
w
i
u j

wj
um

wm

Eq. 3-20

0
0
0
1 2
2

Eq. 3-21

Substituting Eq.3-20 and 3-21 into Eq. 3-12, we obtain the Stress Matrix.
3.5 Von Mises Stress [8]
In the case of uniaxial stress or simple tension, 1 0 , 2 = 3 = 0 , the von
Mises criterion reduces to 1 = y .

Therefore, the material starts to yield, when 1 reaches the yield strength of the
material, which is a characteristic material property. In practice, this parameter is
indeed determined in a tensile test satisfying the uniaxial stress condition.

19
It is also convenient to define an Equivalent tensile stress or von Mises stress,
v , which is used to predict yielding of materials under multiaxial loading conditions
using results from simple uniaxial tensile tests. Thus, we define

v =

2
2
2
xx yy ) + ( yy zz ) + ( xx zz ) + 6 xy + yz + xz
2

Eq. 3-22

2
or

v =

( 1 2 ) + ( 2 3 ) + ( 1 3 )
2

Eq. 3-23

2
where 1 , 2 and 3 are the Principal Stress.
3.6 Thermal Stress [9]
If a cylindrical shell with free edges undergoes a uniform temperature change,
no thermal stress will be produced. We now consider axisymmetric problems of a
cylindrical body. It is assumed that the coordinate axis z . Making use of the
cylindrical coordinate system, ( x , , z ), for axially symmetric problem the equilibrium
of the forces in the directions x and z are obtained below:
xx zx xx
+
+
+ Nx = 0
x
z
x
xz zz xz
+
+
+ Nz = 0
x
z
x

Eq. 3-24
Eq. 3-25

The constitutive equations for a homogeneous, isotropic body in the cylindrical

coordinate system, or the generalized Hookes law, are obtained as below

xx =

zz =
=

1
[ xx ( + zz )] +
E
1
[ zz ( xx + )] +
E
1
[ ( zz + xx )] +
E

zx =

zx

+
xx
2G
1 +

=
+
zz
2G
1 +
1

=
+

2G
1 +
=

2G

Eq. 3-26
Eq. 3-27
Eq. 3-28
Eq. 3-29

where = xx + zz + . An alternative form is

xx =

2 xx + e

Eq. 3-30

20

zz = 2 zz + e

Eq. 3-31

2 + e

Eq. 3-32

zx =

2 zx

Eq. 3-33

where e = xx + zz + , = G , = [2 G /(1 2 )] and = (3 + 2 ) = [ E /(1 2 )]

3.7 Thermal Design Theory [10]
3.7.1 Forced Convection Correlation for Heat Exchangers
Extensive efforts have been made to obtain empirical correlations that represent
a best-fit curve to experimental data or to adjust coefficients in the theoretical
equations to best fit the experiment data. Petukhov and Popovs correlation are for
fully developed turbulent flow with constant properties in a circular tube with constant
heat flux boundary conditions. A simplified form of this correlation is

Nub =

( f 2) Reb Prb
1.07 + 12.7( f 2)1 2 ( Prb

23

Eq. 3-34

1)

where f = (1.58 ln Reb 3.28) 2 . It predicts the results in the range

104 < Reb < 5 106 and 0.5 < Prb < 200 with 6% error, and the range 0.5 < Prb < 2000
with 10% error.
3.7.2 Condensing Coefficient
The equation for the mean condensing coefficient for a vapor condensing on the
outside of horizontal tubes is
14

g 2 h fg k 3

hct = 0.725

tND

where

Eq. 3-35

g acceleration due to gravity = 9.81 m / s

density of condensate, kg / m

h fg latent heat of vaporization, J / kg

k thermal conductivity of tubes, W / m C

viscosity of condensate, Pa s

t temperature difference between vapor and the plate, C

N number of tubes in vertical row
D outside diameter of tubes, m

3.7.3 Chens Method

The Chen Method was originally devised for saturated boiling but can easily be
extended to sub-cooled boiling by the superposition method.
hTP = hcb + hnb = hLO F + h p S

Eq. 3-36

21
where hLO is the heat transfer coefficient if the liquid were flowing on its own at
that point in the channel and hp is the pool boiling coefficient for the same wall
superheat. F is the boiling enhancement factor which allows for the increase in
velocity of the liquid vapor and S is the suppression factor which allows the decrease
in bubble activity due to the steeping of the temperature gradient.
By using experimental data from difference sources, Chen determined
experimental values of the convective boiling enhancement factor, F , and based it on
Lockhart-Martinelli parameter, X tt .
1
x
=
X tt (1 x) 0.9

0.5

0.1

Eq. 3-37

The enhancement factor, therefore, can be determined by the following equation

to fit the curve proposed by Chen:
For

1
0 .1 ; F = 1
X tt

1
1

> 0.1 ; F = 2.35 0.213 +

For
X tt
X tt

Eq. 3-38
0.736

Eq. 3-39

The convection boiling coefficient can be founded by

hcb = FO hLO

Eq. 3-40

where FO = F (1 x)0.8 . The parameter hp S is neglect in this case because there

is no bubble in steam.

CHAPTER 4
SIMULATION PROCEDURE AND FINITE ELEMENT ANALYSIS
4.1 Simulation Procedure
This section describes the methodology in steps of overall simulation procedure.
Figure 4-1 shows the steps for overall process. In Chapter 5 will show the method of
how to apply the real case with the result in this chapter.

Step 1: Determine the optimized expansion joint geometry

Determine the geometry which gives the minimum stress value.

Step 2 : Vary the shell diameter (200 2000 mm)

of the selected geometry
Define others concerned parameters to the real fabricated
heat exchanger .

Step 3 : Selection for element size

Select 3 geometries from step 2, vary the size of elements to compare
the accuracy result by applying the same boundary conditions.
Then, conclude the element size for the overall simulation.

Step 4 : Assumptions and Boundary Conditions

Apply the boundary conditions to the geometries in step 2 by using
the element size from step 4.

Step 5 : Record the maximum value for each cases.

FIGURE 4-1 Flowchart of simulation procedure

23
Step 1 : Determine the optimized expansion joint geometry
Figure 4-2 shows the steps of simulation procedure.
Define general geometry

(a)

Define Selected Geometry

Define 5 potential cases of expansion joint geometry varied
from the circumferential radius.
Specify the thickness of the expansion joint to be 5 and 10 mm
and fixed the height of the expansion joint as its minimum
value.

(b)

Vary the length of the expansion joint grown up 10 mm each

from 10 to 50 mm.
Apply a constant tension force at the edge of the
expansion joint.

The stress value versus the length

Plot the stress value versus the length for each thickness.
(2 graphs plotted)

(c)

Choose Appropriate Geometry

The geometry which gives the minimum stress value is the
optimization for the geometry of the expansion joint.

(d)

FIGURE 4-2 Flowchart of Determining the Optimized Geometry

(a) Define General Geometry

Cross section of one expansion joint can generally be described as Figure 4-3.
Bending portions for the solid material are only in 2 parts and it is symmetry to its
axis. First bending which can be defined as a shape of a partial annulus is the radius of
circumstance of expansion joint to the shell, . Second bending is also define as the
same shape to the first shape, this is the radius of circumstance of expansion joint, .

24
The expannsion joint can both extend its dimensionn in verticaal (its heig
ght) and
horizontal (its
( length).

(a)

1 = 90

(b)

2 = 90

1 = 135

2 = 135

FIGU
URE 4-3 General
G
geom
metry of exxpansion joiint
D
Seleccted Geomeetry
(b) Define
Five potential inn various shhapes of ex
xpansion joiint are seleccted to sim
mulate by
ode on bothh sides. Thee Youngs modulus
m
applying coonstant forcce at 100 N for each no
value at 1889 GPa. Thickness
T
o expansion joints aree varied intto two valu
of
ues only
which are in
i 5 and 10 mm Lengtth of expan
nsion joints are increasiing 10 mm for each
step from zero
z
to 50 mm
m . Table 4--1 provides the initial geometry
g
annd last geom
metry.

TABLE 4--1 Various shape

s
of exppansion join
nt
C
Case

Shapee

1 = 135
2 = 135

1 = 90
2 = 90

1 = 90
2 = 180

1 = 90
2 = 90

1 = 180
2 = 180

T stress value versus the length

(c) The
Deterrmine the maximum
m
v Mises stress
von
s
by ussing finite eelement anaalysis on
the model. Then, plott the maxim
mum von Mises
M
stress value versuus the lengtth of the
j
for eacch case in thhe same graaph. Figuree 4-4 showss the curvess of each
expansion joint
case.

2800.00

300

2550.00

280

2300.00

260

2050.00

240
Maximum von-Mises stress (Pa)

Maximum von-Mises stress (Pa)

25

1800.00

1550.00

220

200

1300.00

180

1050.00

160

800.00

140

550.00

120

300.00

100
0

10

20

30

40

50

Length of expansion joint (mm)

Case 1
(a)

10

20

30

40

50

Length of expansion joint (mm)

Case 2

Case 3

Case 4

Case 5
(b)

FIGURE 4-4 (a) Maximum von-Mises stress vs Length of expansion joint at 5 mm

thickness (b) Maximum von-Mises stress vs Length of expansion joint
at 10 mm thickness

(d) Choose Appropriate Geometry

Figure 4-4 (a) and (b), shows that geometry case 2 obtained the least stress value, so
this is the selected. Typical model for case 2 with interested parameters are shown in
Figure 4-5.

26

FIGURE 4-5 Expansion joint model with its parameters

where
a is the mean radius of the shell
b is the mean radius of the centerline to the height of expansion joint,
r is the radius of circumstance of expansion to the shell (r 3t ) as per ASME
R is the radius of circumstance of expansion joint and equal to r
h is the height of the expansion joint (h=a-b)
l is its length of the expansion joint

Step 2 : Vary the shell diameter (200 2000 mm) of the selected geometry
(a) General Model
The model of the expansion joint for finite element analysis consists of two
rectangles and four partial circles with thickness as Figure 4-6.

C
R

Rectangle

Partial Circle

C
R

FIGURE 4-6 Model of expansion joint for finite element analysis

Rectangle
Width : Thickness of expansion joint will be initiated at the minimum required
thickness, then times up with 2 and 3
Length : Half of circumferential radius

27
Partial Circle
Inner Radius : Initiated at the triple of minimum required thickness, then times
up with 4 and 5.
Outer Radius : Vary per the variation of the thickness
Example: If an 8 inch (200 mm) diameter with the minimum required thickness
as 7 mm. The parameter will have value for each as Table 4-2 and shown detail of
dimensions in Figure 4-7 for the highlighted item:
TABLE 4-2 Example of parameters input for 8 inch diameter

Width of Rectangle (mm)

Inner Circumferential Radius (mm)

Length of Rectangle (mm)

21

21

14
21

21

42

56

70

63

84 105

10.5 10.5 10.5 21

28

35 31.5 42 52.5

28

10.5
21
7

FIGURE 4-7 Model of expansion joint with dimensions

(b) Dimensional Inputs

As given in Section (a), the value of each parameter is shown in Table 4-3
totally ninety geometries.
TABLE 4-3 Dimensional inputs for each geometry

Di

tEJ
7

200
14

REJ
21
28
35
42
56
70

Di

tEJ
8

300
16

REJ
24
32
49
48
64
80

28
TABLE 4-3 (CONTINUED)

Di
200

tEJ
21

10

400

20

30

10

600

20

30

10

800

20

30

1000

12

REJ
63
84
105
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100
90
120
150
36
48
60

Di
300

tEJ
24

10

500

20

30

10

700

20

30

12

900

24

36

1100

13

REJ
72
96
120
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100
90
120
150
36
48
60
72
96
120
108
144
180
39
52
65

29
TABLE 4-3 (CONTINUED)

Di

tEJ
24

1000
36

13

1200

26

39

13

1400

26

39

13

1600

26

39

REJ
72
96
120
108
144
180
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195

Di

tEJ
26

1100
39

13

1300

26

39

13

1500

26

39

13

1700

26

39

REJ
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195

30
TABLE 4-3 (CONTINUED)

Di

tEJ
13

1800

26

39

10

400

20

30

10

600

20

30

10
800
20

REJ
39
52
65
78
104
130
117
156
195
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100

Di

tEJ
13

1900

26

39

10

500

20

30

10

700

20

30

12
900
24

REJ
39
52
65
78
104
130
117
156
195
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100
90
120
150
36
48
60
72
96
120

31
TABLE 4-3 (CONTINUED)

Di
800

tEJ
30

12

1000

24

36

13

1200

26

39

13

1400

26

39

1600

13

REJ
90
120
150
36
48
60
72
96
120
108
144
180
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65

Di
900

tEJ
36

13

1100

26

39

13

1300

26

39

13

1500

26

39

1700

13

REJ
108
144
180
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65

32
TABLE 4-3 (CONTINUED)

Di

tEJ
26

39

13

1800

26

39

13

2000

26

39

REJ
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195

Di

tEJ
26

39

13

1900

26

39

REJ
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195

Step 3 : Selection for element size

The comparison for finite element analysis will be compared by the number of
nodes and number of elements. Table 4-4 shows the observed elements for a given
type of triangular elements and its results are given in Table 4-5.

33
TABLE 4-4 Observed elements for FEA

(a)
Element Shape

Overall Element

No.
Element

No.
Node

320

300

No.
Element

No.
Node

640

460

No.
Element

No.
Node

416

239

(b)
Element Shape

Overall Element

(c)
Element Shape

Overall Element

34
TABLE 4-5 Results of maximum stress value

Di
200
300
400
500
600
700
800
900
1000
2000

Smax
(b)
112
87.5
80.9
75.3
70.3
65.8
61.6
57.8
54.3
31.3

(a)
112
87.5
80.9
75.3
70.3
65.8
61.6
57.8
54.3
31.3

(c)
111
87.8
79.9
74.9
68.7
64.9
60.7
57.2
54.0
30.8

(a)
29.4
29.1
29.1
28.9
28.5
27.9
27.0
26.0
25.0
15.3

Dmax
(b)
29.4
29.1
29.1
28.9
28.5
27.9
27.0
26.0
25.0
15.3

(c)
28.5
27.8
27.6
27.3
27.3
26.4
26.3
25.5
24.6
14.3

Figure 4-8 shows the trend for each element along the radius. The least node
from the analysis with the same trend will be the selected element.

Stress (MPa) and Dispalcement (mm)

120
Smax (a)

100

Smax (b)
Smax (c)

80

Dmax (a)
Dmax (b)
Dmax (c)

60

40

20

0
0

500

1000
1500
Shell Diameter (mm)

2000

FIGURE 4-8 Results of maximum stress value

2500

35
Step 4 : Assumptions and Boundary Conditions
Basic assumptions are given below:
(a) The material of the plate has a linear property.
(b) The Youngs modulus is constant at 189 GPa (at 200 C).
(c) Temperature affects are not considered.
(d) The maximum displacement is constant at 50 mm (per code). Because of
the axisymmetry, the displacement for each side will be 25 mm. So the forces will be
varied.
Boundary conditions are given below (Figure 4-9):
(a) Axisymmery FEA is applied along the axis of the model.
(b) Forces are varied on until the maximum displacement reaches 25 mm

Ri

FIGURE 4-9 Inputs for Boundary Conditions of FEA

Step 5 : Record the maximum value for each cases.

CHAPTER 5
RESULTS OF FINITE ELEMENT ANALYSIS
5.1 Summary of Results
The results will show the maximum stress at a constant displacement for 25 mm.
Table 5-1 shows the result as a list and Figure 5-1 shows the result in multicurves
plotted with the shell diameter versus the shell thickness and maximum stress value.
TABLE 5-1 List Result for Maximum Stress at 25 mm Displacement

Di

tEJ
7

200

14

21

10

400

20

30

10
600
20

REJ

Smax

21
28
35
42
56
70
63
84
105
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100

486
355
308
331
232
223
281
225
212
289
213
209
167
146
122
187
103
100
322
247
130
147
107
107

Di

tEJ
8

300

16

24

10

500

20

30

10
700
20

REJ

Smax

24
32
49
48
64
80
72
96
120
30
40
50
60
80
100
90
120
150
30
40
50
60
80
100

351
260
261
212
184
181
181
153
148
313
184
165
153
161
108
116
998
814
232
171
168
160
96.9
98.5

37
TABLE 5-1 (CONTINUED)

Di
600

tEJ
30

10

800

20

30

12

1000

24

36

13

1200

26

39

1400

13

REJ

Smax

90
120
150
30
40
50
60
80
100
90
120
150
36
48
60
72
96
120
108
144
180
39
52
65
78
104
130
117
156
195
39
52
65

109
98.8
69.8
232
183
126
137
93.4
78.6
105
87.2
79.2
182
126
102
124
91.9
74.5
96.4
69
58.7
175
112
95
121.5
86.6
64
98.4
69.2
52.9
165
106
79

Di
700

tEJ
30

12

900

24

36

13

1100

26

39

13

1300

26

39

1500

13

REJ

Smax

90
120
150
36
48
60
72
96
120
108
144
180
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65

108
96.1
79.9
209
143
115
127
94
75.4
104
67.9
62
180
120
98
123.4
89.4
66.5
99.8
71.7
57.3
170
104
93
118.9
84.3
61.5
95.3
66.7
52.1
150
100
79

38
TABLE 5-1 (CONTINUED)

Di

tEJ

REJ

Smax

Di

78
118.3
26
104
81.5
130
59
1400
1500
117
94
39
156
64.2
195
48.6
39
158
52
98
13
65
79
78
114
1600
26
104
76.9
1700
130
54
117
90
39
156
59.2
195
46.8
39
155
52
95
13
65
71
78
110.3
1800
26
104
71.2
1900
130
49
117
87.7
39
156
54.2
195
41.9
39
145
52
107
13
65
84.5
78
87
2000
26
104
68.5
130
48.9
117
66.6
39
156
46.9
195
38.6
Di , tEJ and REJ units are in mm. Smax unit is in MPa.

tEJ
26

39

13

26

39

13

26

39

REJ

Smax

78
104
130
117
156
195
39
52
65
78
104
130
117
156
195
39
52
65
78
104
130
117
156
195

115.6
79
56.5
92.1
61.7
47.2
157
92
75
111.7
74.9
51.5
88.4
56.7
43.1
147
90
68
107.6
69.3
46.5
83.9
51.7
37.2

39
Figure 5-1 shows the relation of Di and Smax for each circumferential radius at 3,
4 and 5 times its thickness. The graphs for the results will be plotted into 3 curves
varying the circumferential radius as 3,4 and 5 times the shell thickness.
The x-axis of the graph is the shell diameter in mm and the primary y-axis is the
maximum stress.

500

450

tmin
400

2tmin

3tmin

300

250

200

150

100

50

2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

0
0

Maximum Stress (MPa)

350

Shell Diameter (mm)

FIGURE 5-1 (a) Shell Diameter vs Smax curve at 3REJ

40

500

450

tmin

400

2tmin

3tmin

300

250

200

150

100

50

2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

0
0

Maximum Stress (MPa)

350

Shell Diameter (mm)

FIGURE 5-1 (b) Shell Diameter vs Smax curve at 4REJ

41

500

tmin

450

2tmin
400

3tmin

300

250

200

150

100

50

2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

0
0

Maximum Stress (MPa)

350

Shell Diameter (mm)

FIGURE 5-1 (c) Shell Diameter vs Smax curve at 5REJ

42

43
5.2 Expansion Joint Selection
The results shown in Table 5-1 and Figure 5-1 shows the maximum stress at a
constant displacement for 25 mm. Once an expansion joint is required, the next step
should be followed by the below procedure for Expansion Joint Appropriate
Geometry.

1. The number of loop has to be calculated as below equation

n = Total Displacement (mm) / 50 ; round the result to integers.
2. Draw a vertical line at the shell diameter (perpendicular to the x-axis)
3. Calculate the correction factor for the allowable stress value in case that the
design temperature is greater than 200 C. Then draw a horizontal line at that
maximum stress value (perpendicular to the y-axis)
k = EDesign Temp (GPa) / 189
Smax = k x Sallowable@Design Temp
4. Select the geometry where the curve intersects nearer to the horizontal line.
5. Recalculate the stresses on the shell not to exceed 3Sallowable.
Example 1 : A 600 mm diameter heat exchanger with displacement at 105 mm
and design temperature at 300 C. Material of shell is A 516 Gr.70.
Solution
The allowable stress of the material at 300 C is 19.7 ksi [135 MPa]
The Youngs Modulus at 300 C is 26.8 106 psi [184.7 GPa]
k

184.7/189

0.97

Smax

0.97 19.7

19.1 ksi [131.7 MPa]

105/50

2.1 (round to be 2)

Loop number
n

Figure 5-2 shows the selection for the circumferential stress at 3REJ. The
thickness should be first selected at the minimum then increase in case the total stress
exceeds 3S.

44

500

Maximum Stress (MPa)

450
400
350
300
250
200
150
100
50
2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

Shell Diameter (mm)

FIGURE 5-2 Stress value for Example 1

Example 2 : An 10000 mm shell length, 1800 mm diameter heat exchanger with

design temperature at 370 C on the shell side and constructed with A 537 Gr.1
material.
Solution
The allowable stress of the material at 370 C is 16.9 ksi [116 MPa]
The Youngs Modulus at 300 C is 25.5 106 psi [175.8 GPa]
The thermal coefficient at 300 C is 1.55 10-5 (mm/mm)/ C
k

175.8/189

0.93

Smax

0.93 16.9

15.7 ksi [108.3 MPa]

1.55 10-5 10000 (370-30)

52.7 mm

52.7/50 = 1.054 (round to be 1)

Loop number
n

Figure 5-3 shows the selection for the circumferential stress at 3REJ. The
thickness should be first selected at the minimum then increase in case the total stress
exceeds 3S.

45

500

Maximum Stress (MPa)

450
400
350
300
250
200
150
100
50
2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

Shell Diameter (mm)

FIGURE 5-3 Stress value for Example 2

In Chapter 6 will describe the full method of expansion joint design but
determining backward from the code and real design. The maximum longitudinal
bending stress, S1, in the shell at the middle span, maximum longitudinal bending
stress, S2, in the shell in the plane of saddle and longitudinal Stress, SL, will be fully
calculated and compared with the FEA.

CHAPTER 6
CASE STUDY
6.1 Case 1
The design conditions, shell properties and tube properties are given in Table 6-1.
TABLE 6-1 Design Conditions for Case 1

Description
Fluid Name
Flow Rate, kg/hr
Temperature (Inlet/Outlet), C
Density (Inlet/Outlet), kg/m3
Viscosity (Inlet/Outlet),cP
Thermal Conductivity, W/mC
Material
Inner Diameter (mm)
Thickness (mm)
Internal Design Pressure (kPa)
Design Temperature (C)
Young Modulus of Material at
Design Temperature (GPa)
Thermal Expansion Coefficient
((mm/mm)/C)
Poisons Ratio
Length (mm)
Allowable Stress at Design
Condition (MPa)

Shell
LP Steam
697
150.7 / 150.7
2.6 / 917.3
0.01 / 0.18
35
A 516 Gr.70
250
13
2,825
15 / 230

Tube
Propylene
72,000
71 / 80
645.6 / 634.6
0.17 / 0.6
35
A 179
4.83
2.11
3,678
15 / 115

189

197.2

1.4 x10-5

1.2 x10-5

0.3
2,400

0.3
2,400

137 [20 ksi]

Notice that the inlet and outlet temperature of the shell are equal while the
density of the fluid change from the lower value of steam to the higher value of liquid.
This shows that the heat exchanger is operating as a condenser

47
Preliminary Sketch as shown in Figure 6-1.
H = 60 mm
A = 560 mm
L = 2,560 mm
2R = 250 mm
2Q = 1,160 kg
(full water)
Solution
FIGURE 6-1 Preliminary sketch of Case 1

Solution :
Selection from graph Figure 5-1 for Smax,EJ < 3S give Figure 6-2.
2tmin = 14 mm

3REJ = 42 mm

FIGURE 6-2 Geometry of expansion joint for Case 1

Smax,EJ

280

MPa [38.43 ksi]

Maximum Longitudinal Bending Stress, S1, in the Shell at the middle span
(per Eq. 3-8)
S1

81.33

psi

Maximum Longitudinal Bending Stress, S2, in the Shell in the plane of saddle
(per Eq. 3-10)
S2

3,712.71

psi

1,931.78

psi

Longitudinal Stress (per Eq. 3-1)

SL
Check 1

Check 2

S1+SL+Smax,EJ <

3S

42.62

<

60

S2+SL+Smax,EJ <

3S

46.25

60

<

ksi

Acceptable

ksi

Acceptable

48
Comparison to FEA (Only Shell) by Superposition Method as shown in Figure
6-3.
1. Thermal Load : Apply constant temperature along inside shell 230 C
2. Structural Load : Apply internal pressure inside shell 2825 kPa

FIGURE 6-3 Expansion joint model for finite element analysis for Case 1

Smax = 285 MPa [41.34 ksi] < 3S (411 MPa [60 ksi]) Acceptable
Note : Detailed calculation in Appendix C
6.2 Case 2
The design conditions, shell properties and tube properties are given in Table 6-2.
TABLE 6-2 Design Conditions for Case 2

Description
Fluid Name
Flow Rate, kg/hr
Temperature (Inlet/Outlet), C
Density (Inlet/Outlet), kg/m3
Viscosity (Inlet/Outlet),cP
Material
Inner Diameter (mm)
Thickness (mm)
Internal Design Pressure (kPa)
Design Temperature (C)
Young Modulus of Material at
Design Temperature (GPa)
Thermal Expansion Coefficient
((mm/mm)/C)
Poisons Ratio
Length (mm)
Allowable Stress at Design
Condition (MPa)

Shell
HP Deprop OVHD
179,800
-21.7 / 5.7
19.02
0.008
A 537 Gr. 1
1,800
28
2,648 @ 65C
-45 / 65

Tube
HP Deprop FEED
160,960
10.7 / 6.6
18.29
0.009
A 192
19.05
2.11
2,648 @ 65C
-45 / 65

199

199

1.24 x10-5

1.24 x10-5

0.3
8,000

0.3
8,000

128.24 [18.6 ksi]

49
Preliminary Sketch as shown in Figure 6-4.
H = 0 mm
A = 1,560 mm
L = 4,920 mm
2R = 1,800 mm
2Q = 90,890 kg
(full water)

FIGURE 6-4 Preliminary sketch of Case 2

Solution :
Selection from graph Figure 5-1 for Smax,EJ < 3S give Figure 6-5.
3tmin = 30 mm

3REJ = 90 mm

FIGURE 6-5 Geometry of expansion joint for Case 2

Smax,EJ

70

MPa [7.98 ksi]

Maximum Longitudinal Bending Stress, S1, in the Shell at the middle span
(per Eq. 3-8)
S1

415.62

psi

Maximum Longitudinal Bending Stress, S2, in the Shell in the plane of saddle
(per Eq. 3-10)
S2

4619.51

psi

5760.90

psi

Longitudinal Stress (per Eq. 3-1)

SL
Check 1

Check 2

S1+SL+Smax,EJ <

3S

16.33

55.8

<

S2+SL+Smax,EJ <

3S

20.53

55.8

<

ksi

Acceptable

ksi

Acceptable

50
Comparison to FEA (Only Shell) by Superposition Method as shown in Figure
6-6.
1. Thermal Load : Apply constant temperature along inside shell 65 C
2. Structural Load : Apply internal pressure inside shell 2648 kPa

FIGURE 6-6 Expansion joint model for finite element analysis for Case 2

Smax = 67.8 MPa [9.83 ksi] < 3S (385 MPa [55.8 ksi]) Acceptable
Note : Detailed calculation in Appendix D

CHAPTER 7
CONCLUSIONS AND FURTHER WORKS
7.1 Conclusions
The most appropriate model (Figure 7-1) which was selected has a radius of
circumstance of expansion joint to the shell,1 , 90 degree and radius of circumstance
of expansion joint, 2 , 90 degree. While h which equals b-a is the height of the
expansion joint and l is its length, where a is the mean radius of the shell, b is the
mean radius of the centerline to the height of expansion joint, R is the radius of
circumstance of expansion joint and r is the radius of circumstance of expansion joint
to the shell.

FIGURE 7-1 Expansion joint model with its parameter.

Figure 7-2 shows the selection graph for expansion joint at each diameter
starting at its minimum required thickness then times up 2 and 3. The method for
expansion selection are described in steps as below:
1. The number of loop has to be calculated as below equation
n = Total Displacement (mm) / 50 ; round the result to integers.
2. Draw a vertical line at the shell diameter (perpendicular to the x-axis)
3. Calculate the correction factor for the allowable stress value in case that the
design temperature is greater than 200 C. Then draw a horizontal line at that
maximum stress value (perpendicular to the y-axis)
k = EDesign Temp (GPa) / 189
Smax = k x Sallowable@Design Temp

52

2100

2000

1900

1800

1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

500
450
400
350
300
250
200
150
100
50
0
0

Maximum Stress (MPa)

4. Select the geometry where the curve intersects near to the horizontal line.
5. Recalculate the stresses on the shell not to exceed 3Sallowable.

Shell Diameter (mm)

1400

1500

1600

1700

1800

1900

2000

2100

1400

1500

1600

1700

1800

1900

2000

2100

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

500
450
400
350
300
250
200
150
100
50
0
0

Maximum Stress (MPa)

(a)

Shell Diameter (mm)

1300

1200

1100

1000

900

800

700

600

500

400

300

200

100

500
450
400
350
300
250
200
150
100
50
0
0

Maximum Stress (MPa)

(b)

Shell Diameter (mm)

(c)
FIGURE 7-2 Selection Graph for expansion joint design at (a) 3REJ (b) 4REJ (c) 5REJ.

53
m
thicknness and the more bending of circuumferential rradius, the less
l
The more
stress occurrred to the shell.
s
Case 1 and 2, reaal heat exchhangers, sho
ows the detaail of calculation and allso
xceed the 3S which meaans it is acceptable
comparing to the FEA. Both casees do not ex
and compliiance to the ASME codde.

7.2 Furtheer Works

Figurre 7-3 show
ws the inform
mation supp
ported for an
a appropriiate expansiion joint
design.
T graphs should be alternative
a
for
f other maaterials.
7.2.1 The
7.2.2 The
T design temperaturee and pressu
ure is should be input in for FEA. Only
the force off the maxim
mum allowabble movemeent to the shhell was appplied.
7.2.3 Stiffener
S
rinngs, saddle, tubesheet and
a channell should be m
modeled to
increase thee endurable of the shelll.

Material
M
(CS
S for this
ressearch)
Design
Teemperature
an
nd Design
P
Pressure

Stifffener
R
Ring
App
propraite
Design for
Exp
pansion
J
Joint
Chaannel /
H
Head

Tu
ubesheet

S
Saddle
Design
D

FIG
GURE 7-3 Informationn supported
d model for expansion jjoint design
n

REFERENCES
1. ASME Boiler and Pressure Vessel Committee. Rules for Construction of Pressure
Vessel-Section VIII Division I. New York : ASME Inc., 2001.
2.

. Materials-Section II, Part D, . New York : ASME Inc., 2001.

3. Technical Committee of TEMA. Standard of Tubular Exchanger Manufacturer

Association 8th Edition . New York : TEMA Inc., 1999.
4. Henry, H. Pressure Vessel Design Handbook. 2nd ed. Florida : Krieger
Publishing Co., 1991.
5. Eugene, F. Pressure Vessel Handbook. 12th ed. Oklahoma : Pressure Vessel
Publishing Inc., 2001.
6. James, R., and Maan, H. Guidebook for the Design of ASME Secttion VIII.
2nd ed. New York : ASME Pres., 2001.
7. Daryl, L. A First Course in the Finite Element Method. Kent : PWS-KENT
Publishing Company, 1996.
8. Saeed, M. Finite Element Analysis. 2nd ed. New York : Pearson Education Inc.,
2003.
9. Noatake, Noda, et al. Thermal Stress. 2nd ed. Tokyo : Taylor&Francis Group,
2003.
10. Sadik, K. and Hongtan, Liu. Heat Exchangers Selection, Rating , and Thermal
Design. 2nd ed. New York : CRC Press, 2002.

APPENDIX A
General Arrangement Drawing for Case 1 before and after detailed calculation

FIGURE A-1 General Arrangement Drawing for Case 1 before detailed calculation

56

FIGURE A-2 General Arrangement Drawing for Case 1 after detailed calculation

57

APPENDIX B
General Arrangement Drawing for Case 2 before and after detailed calculation

FIGURE B-1 General Arrangement Drawing for Case 2 before detailed calculation
59

FIGURE B-2 General Arrangement Drawing for Case 2 after detailed calculation

60

APPENDIX C
Detailed Calculation for Case

62

63

64

65

Nodal Temperature for Case 1

Simplification of thermal resistance is shown in Figure C-4

FIGURE C-4 Thermal network for Case 1

where T1 = Average temperature of the fluid inside the tube

T2 = Temperature of the inner surface of the tube
T3 = Temperature of the outer surface of the tube
T4 = Temperature of the inner surface of the shell
Ra = Thermal Resistance of the fluid in the tubes

Rb = Thermal Resistance of the tubes

Rc = Thermal Resistance of the condense fluid in the shell

The relationship of the heat transfer rate and the temperature can be given as below

Q = U i Ai (T ) =

1
Ai (Ti Ti +1 ) ; i = 1,2,3
Ri

Eq. C-1

Heat Transfer Rate

Calculated from shell side: Sat-vapor to Sat-liquid at 150 C gives
Q=

697
2114 = 409.293 kW
3600

Calculated from tube side: Inlet temperature 71 C and outlet temperature 80 C

gives
Q=

72000
2.290 (80 71) = 412 .232 kW
3600

Choose Q = 409.293 kW
Value for T1.
Design inlet temperature is 71 C and outlet temperature 80 C. Assuming the
increase of temperature to be linear function along the length of the tube (2.4 metres) as
Figure C-5.

Temperature (C )

66

Length (m)

FIGU
URE C-5 Asssumed fluid
d temperatuure in tubes
C
Equationn of Figure C-5
T1 =

15
x + T0
4

wherre T0 = 71 C

TAB
BLE C-1 Values
V
of T1 through thhe tube

x (m
( )

T1 ( C )

x (m
m)

T1 ( C )

x (m)

T1 ( C )

x (m)

T1 ( C )

00.0
0
0.1
0
0.2
0
0.3
0
0.4
0
0.5
0
0.6

71.0000
71.3375
71.7750
72.1125
72.5500
72.8875
73.2250

0.77
0.88
0.99
1.00
1.11
1.22
1.33

73.6225
74.0000
74.3775
74.7550
75.1225
75.5000
75.8775

1.4
1.5
1.6
1.7
1.8
1.9
2.0

76.2500
76.6255
77.0000
77.3755
77.7500
78.1255
78.5000

2.1
2.2
2.3
2.4

78.875
79.250
79.625
80.000

a ha .
Value for Ra and

1
ha iss the heat traansfer
w
which
ha
d from below
w equation
coeffficient of thhe tubes fluuid which caan be found

Ra is a convection
c
t
thermal
resiistance, thuss, Ra =

ha =

Nu k
D

Checkingg the R e annd P r givees :

Re =

6 .1 6.4775 0.016
640
= 40190.52882 >> 10 4
3
1.65 10
1

Eq
q. C-2

67
Pr =

1.65 10 3 2290 .1796

= 37.78
0.100018

Using Petukhovs correlation shall be suitable for this.

Nu = 529

Substituting above into Eq. C-2, gives ha = 3306.845 W / m 2 C

Value for T2 .
From Eq. C-1, gives
TABLE C-2 Values of T2

x (m)

T1 ( C )

T2 ( C)

x (m)

T1 ( C )

T2 ( C)

0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1

71.000
71.375
71.750
72.125
72.500
72.875
73.250
73.625
74.000
74.375
74.750
75.125

92.37676
92.75176
93.12676
93.50176
93.87676
94.25176
94.62676
95.00176
95.37676
95.75176
96.12676
96.50176

1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4

75.875
76.250
76.625
77.000
77.375
77.750
78.125
78.500
78.875
79.250
79.625
80.000

97.25176
97.62676
98.00176
98.37676
98.75176
99.12676
99.50176
99.87676
100.2518
100.6268
101.0018
101.3768

Value for Rb .

Rb is a conduction thermal resistance, thus, Rb = 4.65 10 5 m 2 C / W

Value for T3 .
From Eq. C-1, gives
TABLE C-3 Values of T3

x (m)

T2 ( C)

0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8

92.377
92.752
93.127
93.502
93.877
94.252
94.627
95.002
95.377

T3 ( C )
111.4214
111.7964
112.1714
112.5464
112.9214
113.2964
113.6714
114.0464
114.4214

x (m)

T2 ( C)

1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1

96.877
97.252
97.627
98.002
98.377
98.752
99.127
99.502
99.877

T3 ( C )
115.9214
116.2964
116.6714
117.0464
117.4214
117.7964
118.1714
118.5464
118.9214

68
TABLE C-3 (CONTINUED)

x (m)

T2 ( C)

T3 ( C )

x (m)

T2 ( C)

T3 ( C )

0.8
0.9
1.0
1.1

95.377
95.752
96.127
96.502

114.4214
114.7964
115.1714
115.5464

2.1
2.2
2.3
2.4

99.877
100.252
100.627
101.002

118.9214
119.2964
119.6714
120.0464

Value for Rc and hc .

Rc is a convection thermal resistance containing the two-phase fluid and the film
surface at the inner shell. Let hc to be the heat transfer coefficient of the two-phase fluid,
we obtained:
hc = 11897.4209 W / m 2 C
Applying Chens Method to find the heat convection coefficient of the film surface
and substitute in Eq. C-1, we obtained as shown in Table C-4 and Figure C-6.

FIGURE C-6 Temperature Distribution along the shell of heat exchanger Case 1

Figure C-6 shows that the temperature at the inlet is very high, this can be explained
by the turbulent flow at the initial stage and the temperature is related to the heat transfer
coefficient. Figure C-7 shows the heat transfer coefficient increased in high quality at the
inlet and low quality at the outlet. This shall effect to the film thickness, while the heat
transfer coefficient increased, the thickness of the film will decrease and this give a high
rate of heat transferring. A high rate of heat transferring shall produce a high temperature
at the shell of the heat exchanger.

FIGURE C-7 Condensing heat transfer coefficient by Chens method

Thus, the input temperature for the solid can be determined as constant.

TABLE C-4 Values of T4

0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4

0
0.041301
0.082601
0.123902
0.165202
0.206503
0.247803
0.289104
0.330404
0.371705
0.413005
0.454306
0.495606
0.536907
0.578207
0.619508
0.660808
0.702109
0.743409
0.78471
0.82601
0.867311
0.908611
0.949912
0.991212

1
X tt
0
0.830013
1.611475
2.419416
3.273631
4.188717
5.17889
6.259815
7.449865
8.771416
10.25246
11.92883
13.84743
16.07112
18.68636
21.81572
25.63929
30.43342
36.64603
45.05623
57.15499
76.21553
111.1667
198.7878
989.209

(1 x )0.8

F0

hcb

T3

T4

1
0.966821
0.933354
0.899585
0.865496
0.831068
0.796279
0.761106
0.725521
0.689495
0.652991
0.61597
0.578384
0.540176
0.501279
0.461612
0.421072
0.37953
0.336816
0.292698
0.246842
0.198733
0.147474
0.091157
0.022652

0.752931
2.42398
3.658182
4.791249
5.892216
6.994775
8.121369
9.290358
10.51913
11.82596
13.23153
14.7605
16.44352
18.32004
20.44245
22.88274
25.74347
29.17718
33.42291
38.88114
46.2859
57.1668
75.42533
115.6179
376.4165

0.752931
2.343554
3.414381
4.310137
5.09969
5.813132
6.466876
7.070947
7.631854
8.153941
8.640074
9.092025
9.510663
9.896038
10.24737
10.56294
10.83986
11.07363
11.25738
11.38043
11.42531
11.36091
11.12327
10.53939
8.526695

2663.226
8289.489
12077.16
15245.58
18038.34
20561.88
22874.27
25010.96
26994.97
28841.66
30561.19
32159.8
33640.58
35003.71
36246.43
37362.65
38342.14
39169.01
39818.98
40254.24
40412.98
40185.18
39344.6
37279.34
30160.15

1475.171
2363.855
2596.027
2717.422
2794.541
2848.705
2889.169
2920.684
2945.968
2966.698
2983.968
2998.521
3010.878
3021.409
3030.377
3037.965
3044.288
3049.399
3053.279
3055.813
3056.725
3055.414
3050.459
3037.413
2980.098

117.363
117.738
118.113
118.488
118.863
119.238
119.613
119.988
120.363
120.738
121.113
121.488
121.863
122.238
122.613
122.988
123.363
123.738
124.113
124.488
124.863
125.238
125.613
125.988
126.363

165.2826
147.6424
145.3429
144.5015
144.1586
144.0527
144.0801
144.1911
144.3584
144.5657
144.8028
145.0628
145.3411
145.6343
145.94
146.2568
146.5834
146.9195
147.265
147.6208
147.9889
148.3739
148.7864
149.261
150.0836

69

x (m)

APPENDIX D
Detailed Calculation for Case 2

71

72

73

74

BIOGRAPHY
Name
: Miss Ruetima Dhammaraksa
Thesis Title : Stress Analysis of Expansion Joint on a Fixed Tubesheet Heat
Exchanger by Finite Element Method
Major Field : Mechanical Engineering
Biography
Ruetima graduated in the Bachelor of Electrical Engineering from Kasetsart
University in 2005 with 1st Class Honorable Degree. After graduated, she joined one
of the worlds top ten engineering company as an assistant to the Engineering
Manager. She was involved in many technical clarifications for mechanical and
piping concerns. The company had set up an internal training program for the new
graduate mechanical engineer and she also joined.
A year later, she decided to continue her master degree in Mechanical
Engineering to improve her knowledge. Besides, the problem is this thesis is
originated from her real work while she was working with the engineering company.