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International Journal of Mathematical Sciences, Technology and Humanities 4 (2011) 37 – 52
STRUCTURAL AND THERMAL ANALYSIS OF CONDENSER

BY USING FINITE ELEMENT ANALYSIS
Sk. Abdul Mateen1 and N. Amar Nageswara Rao2
Mechanical Engineering Department,

Nimra College of Engineering & Technology,
Ibrahimpatnam, Vijayawada.
ABSTRACT:
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
Sk. Abdul Mateen and N. Amar Nageswara Rao 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/mm3 1.3738e-8
Young’s Modulus, 1.9e5
N/mm2
Poisson’s Ratio 0.3
Thermal 7.1*e-6 / oc
Expansion
coefficient
3. MODELLING AND MESHING
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 74798
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.
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.
Fig.2: Shell63 Geometry
Solid45 3d-Structural Solid
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

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 110
4. 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 = 0.1078 MPa.
Case2). Full Vaccum
Pressure = 0.10135 MPa
Case3). Hydro static Pressure
Pressure =0.157 MPa
4.2 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=0.09316MPa and
Temperature=44.450c
RESULTS
Case 1. Design Pressure
Table 3. The induced displacements and stresses with Design Pressure of 0.1078 MPa
Name Results as per Allowable stress as per ASME SEC Reference figure
Analysis VIII DIV.2 (MPa)
Displacement 1.174 7 5
in X-
direction, mm
in Y-
direction, mm
in Z-
direction, mm
Shear stress 19.409 157.2 8
in XY-plane,
MPa
Shear stress 36.53 157.2 9
in YZ-plane,
MPa
Shear stress 94.738 157.2 10
in XZ-plane,
MPa
Stress 261.689 524 11
Intensity ,
Mpa
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, 0.7962 and 1.267 mm. The max.
allowable displacement is 7mm. Hence the design is safe based on rigidity.
Fig.5: The Displacement in X-direction

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

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 261.689 Mpa, which is less than allowable stress.
Case 2. Full Vaccum

Table 4. The induced displacements and stresses with Full Vaccum pressure of 0.01035
MPa
Name Results as per Allowable stress as per Reference figure

Analysis ASME SEC VIII DIV.2
(MPa)
Displacement in X- 1.104 7 12
direction, mm
Displacement in Y- 0.7485 7 13
direction, mm
Displacement in Z- 1.11 7 14
direction, mm
Shear stress in XY- 18.248 157.2 15
plane, MPa
Shear stress in YZ- 89.07 157.2 16
plane, MPa
Shear stress in XZ- 34.184 157.2 17
plane, MPa
Stress Intensity , 245.94 524 18
Mpa
displacement in X, Y and Z-directions respectively 1.104, 0.7485 and 1.11 mm. The max.
Fig.12:The Displacement in X-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

Fig.17:The variation of Shear Stress in XZ-plane
Case 3. Hydrotest Pressure
Table 5. The induced displacements and stresses with Hydrotest pressure of 0.157 Mpa
Name Results as per Allowable stress as per Reference

Analysis ASME SEC VIII DIV.2 figure
(MPa)
Displacement in X- 1.71 7 19
direction, mm
Displacement in Y- 1.158 7 20
direction, mm
Displacement in Z- 1.72 7 21
direction, mm
Shear stress in XY- 28.268 157.2 22
plane, MPa
Shear stress in YZ- 52.955 157.2 23
plane, MPa
Shear stress in XZ- 137.977 157.2 24
plane, MPa
Stress Intensity , Mpa 381.125 524 25
displacement in X, Y and Z-directions respectively 1.71, 1.158 and 1.72 mm. The max.allowable
displacement is 7mm. Hence the design is safe based on rigidity.
Fig.19: The Displacement in X-direction
Fig.20: The Displacement in Y-direction
Fig.23:The variation of Shear Stress in YZ-plane

Fig.24:The variation of Shear Stress in XZ-plane
Case4. Thermal Loading
Table 6. The induced displacements and stresses with uniform Temperature loading of
990C
Name Results as Allowable stress as per Reference

per Analysis ASME SEC VIII DIV.2 figure
(MPa)
Displacement in X-direction, 0.6241 7 26
mm
Displacement in Y-direction, 3.004 7 27
mm
Displacement in Z-direction, 1.461 7 28
mm
Shear stress in XY-plane, 32.88 157.2 29
MPa
Shear stress in YZ-plane, 119.665 157.2 30
MPa
Shear stress in XZ-plane, 86.462 157.2 31
MPa
displacement in X, Y and Z-direction respectively 0.6241, 3.004 and 1.461 mm. The max.
Fig.26:The Displacement in X-direction
Fig30:The variation of Shear Stress in YZ-plane

Fig31:The variation of Shear Stress in XZ-plane
Fig.32:The variation of Stress Intensity.

Case 5.Combined Loading.
Table 7. The induced displacements and stresses with uniform Temperature loading of
44.450C and pressure 0.09316 MPa.
Name Results as Allowable stress as per Reference

per Analysis ASME SEC VIII DIV.2 figure
(MPa)
Displacement in X-direction, 1.194 7 33
mm
Displacement in Y-direction, 1.658 7 34
mm
Displacement in Z-direction, 0.8783 7 35
mm
Shear stress in XY-plane, 16.771 157.2 36
MPa
Shear stress in YZ-plane, 81.874 157.2 37
MPa
Shear stress in XZ-plane, 39.734 157.2 38
MPa
displacement in X, Y and Z-direction respectively 1.194, 1.658 and 0.8783 mm. The max.
Fig33:The Displacement in X-direction
Fig34:The Displacement in Y-direction
Fig35:The Displacement in Z-direction

Fig37:The variation of Shear Stress in YZ-plane
Fig38:The variation of Shear Stress in XZ-plane
Fig39:The variation of Stress Intensity
For the material SA 516 Gr 70

KSm= 157.2 MPa
Minimum yield stress = 262 MPa
Minimum tensile stress = 481 MPa
CONCLUSIONS
The following conclusions are drawn from the present work.

1. The maximum deflection induced 1.267 mm under 0.1078 MPa loads which is with in the
allowable limits i.e. < 7mm.
2. The maximum stress induced is 263 MPa which is less than allowable limits of 524 MPa.
Hence the factor of safety is 1.992.
7. The maximum deflection induced 3.004 mm under uniform temperature of 990C load
which is with in the allowable limits i.e. < 7mm.
8. The maximum stress induced is 361.782 MPa which is less than allowable limits of 524
MPa. Hence the factor of safety is 1.45.
9. The maximum deflection induced 1.658 mm under combined loading of 0.09316 MPa
and uniform temperature of 990C load which is with in the allowable limits i.e. < 7mm.
10. The maximum stress induced is 226.085 MPa which is less than allowable limits of 524
MPa. Hence the factor of safety is 2.318.
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. 566–571.
2 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.
317–322.
3 Reppich, M., and Zagermann, S., 1995, “A New Design Method for Segmentally Baffled
Heat Exchangers,” Compute. Chem. Eng., 19, pp. 137–142.
4 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. 425–433.
5 Naim, A., and Bar-Cohen, A., 1996, New Developments in Heat Exchangers, Gordon and
Breach, Amsterdam, pp. 467–499.
6 Van der Ploeg, H. J., and Master, B. I., 1997, “A New Shell-and-Tube Option for
Refineries,” PTQ Autumn, pp. 91–95.

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STRUCTURAL AND THERMAL ANALYSIS OF CONDENSER

Mechanical Engineering Department,

3. MODELLING AND MESHING

Fig.1: The geometric model of the Condenser using CATIA.

Shell 63 Elastic Shell

Fig.2: Shell63 Geometry

Solid45 3d-Structural Solid

Fig.3: Solid45 3d-Structural Solid

Fig.4: The Finite Element Model of the Condenser

Table 2. Mesh is created in HyperMesh with the following quality parameters

4.1 Structural Analysis

Case1). Design Pressure

4.2 Thermal Analysis

Case4). Thermal loading (stresses due to temperature).

Fig.5: The Displacement in X-direction

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

Fig.10: The variation of Shear Stress in XZ-plane

Fig.11:The variation of Stress Intensity

Case 2. Full Vaccum

Name Results as per Allowable stress as per Reference figure

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

Fig.17:The variation of Shear Stress in XZ-plane

Fig.18:The variation of Stress Intensity

Name Results as per Allowable stress as per Reference

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

Fig.24:The variation of Shear Stress in XZ-plane

Fig.25:The variation of Stress Intensity

Name Results as Allowable stress as per Reference

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

Fig31:The variation of Shear Stress in XZ-plane

Fig.32:The variation of Stress Intensity.

Name Results as Allowable stress as per Reference

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

Fig37:The variation of Shear Stress in YZ-plane

Fig38:The variation of Shear Stress in XZ-plane

Fig39:The variation of Stress Intensity

For the material SA 516 Gr 70

The following conclusions are drawn from the present work.

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