PROCEDURE FOR AFC LINE STRESS ANALYSIS INTRODUCTION:- Principle application of a heat exchanger is to maintain a heat balance through the addition or removal of heat between streams of two different operating temperature. AFC is air fin cooler, one type of exchanger which uses air stream as cooling medium. Air is circulated by multi blade propeller type fans as a heat exchange media. AFC unit consist of fin-tube bundles with a header box attached to each end, supported horizontally by a C- shape steel frame or structure. TYPES OF AFC:: 1) FORCED DRAFT TYPE :- Bundle located on discharge side of the fan. Fan is below the finned tube bundle. 2) INDUCED DRAFT TYPE:- Tube bundle located on the suction side of the fan. i.e. fan is above the tube bundle and sucking the air from bottom. 3) EVEN PASS ARRANGEMENT :-Inlet nozzle is at top side of header and outlet at same side but at bottom of that header 4) ODD PASS ARRANGEMENT:- Inlet at top of header and outlet at ‘opposite header side but at bottom of header. 5) SPLIT HEADER TYPE:- When differential temperature between inlet and outlet exceeds 111°C then split header arrangement is used. CONSTRUCTION OF AFC: 1 Consist of inlet and outlet header box, interconnecting finned tubes. 2. Multi blade propeller type fans are provided to force the air. 3. To maintain the product against freezing steam heating coils are provided below the bundle which maintains the minimum required temperature of the tube bundle. DOCUMENTS REQUIRED FOR AFC LINE ANALYSIS:- Latest Stress isometrics LDT,P&ID Latest revision of equipment GA drawing (covering weight of AFC) Allowable nozzle load as per Jamnagar refinery spec Mechanical datasheet 28.215/2017.12.13 10:52/Piping_Stress/Ashutosh Kanaujia/ashul sh_Do not distribute this material without permissionSTRESS ANALYSIS WITH KNOWN DISPLACEMENT OF AFC FROM VENDOR If vendor gives thermal displacement value in GA drawing then with known value of displacement we can analyze the system. At piping flange connecting to equipment nozzle enter the value of DX , DY and DZ value in displacement vector -1, keep RX RY and RZ value zero. In this case no need to model the equipment in CAESAR-II PIPING AND AFC MODELLING IN CAESAR -Il When vendor is not giving thermal displacement we are modeling the AFC. with available temperature and weight data ‘» MODELLING UP TO TOP OR BOTTOM OF HEADER NODE 1. Model piping up to matching flange of piping and AFC nozzle as per stress isometrics given. 2. From equipment GA drawing, model as per dimensions given up to top or bottom of header, with proper thickness and size of nozzle. 3. Give C-node anchor at junction of header and inlet or outlet nozzle ‘» MODELLING PART AFTER DEFINING C-NODE ANCHOR NODE > As per Fig-1, define 520 and 620 both as “ANCHOR” nodes with C-node (Connecting node) as 521 and 621 respectively for checking of nozzle load >» Model equipment part from nodes 521 to 530 and 621 to 630 as rigid elements in with same temperature of piping up to center line of header , without weight. > Then model header as node nos. 530 to 535 , 630 to 635 and 530 to 630 with weight and temperature same as piping (15% of total empty weight, total weight between 535 to 635) > Break the element 530 to 630 giving node 700 with half of it's length + Model tube bundle with node 700 to 710 (rigid element) as per it's length given in GA drawing with weight (70% of total empty weight). & give supports REST + PTFE (0.1 friction) at every one meter distance along the bundle length >» Model 710 to 715,715 to 720,710 to 725 & 725 to 730 nodes as header elements with weight and same average temp. of inlet and outlet. (15% of total empty weight ,distribute it in this two nodes) + Model 715 to 921 & 725 to 821 as rigid without weight with average of inlet & outlet temperature of piping. (921 and 821 are C-nodes) Do not distribute thi 0:52/Piping_S shulosh Kanaujia/as' rial without permissior23.215/2017. eee WITT ACT WOE O ResTey 49.1 FRICTroNSTORACUIOE |e Oo RESTA 0-4 FRIETIOWOUIDE MODELING OF AFC IN CAESAR-IL (ODD PASS) FIGUR! ‘+ MODELLING PART OF EQUIPMENT RESTRAINT NODES ( FIXED HEADER) Whole AFC has been supported at four end on PTFE (Teflon) pad. One header act as fixed and other as floating end See vendor drawing for defining support nodes as fixed or floating. As per fig-1 , north side header (nodes 535 to 635) is fixed and hence south side header (nodes 720 to 730 ) is floating end. Define fixed end nodes 535 and 635. Give Rest (Y) support with 0.1 friction co-efficient, Axial stop (X) North-south directional stop with 2 mm gap , and Guide (Z)East-west with standard* 12 mm gap as per API-661 at both nodes. > Define floating end nodes 720 and 730. Give Rest (Y) support with 0.1 friction co-efficient and Guide ( Z ) East-west with standard* 12 mm gap as per API-661 at both nodes. vv y Not Guide gap can be increase as per lateral thermal movement of the AFC to avoid excessive nozzle load. Practically for that slot length can be increase after approval of equipment department and vendor. 2.13 10:52/Piping_St ess/Ashul sh Kanaujia/ashutosh Do not distribute this material without permission‘* MODELLING PART AFTER DEFINING C-NODE ANCHOR NODE (SPLIT HEADER) Split header case modeling in CAESAR -IL, will be as describe below. > As per Fig-2, define 310 and 410 both as “ANCHOR” nodes with C-node (Connecting node) as 311 and 411 respectively, of inlet nozzle and 510 & 610 are of outlet nozzle as C-nodes 511 and 611 for checking of nozzle load From C-nodes 311 and 411 model up to center line of upper header in split header case as rigid elements 311 0 315 and 411 to 415 without weight but with average of inlet & outlet temperature Then model half depth of top header elements as 315 to 320 and 415 to 420. > Top header rests on bottom header with Teflon pad so define nodes 320 and 420 “+Y” with 0.1 friction & C-node as 321 and 421 > Model 315 to 325 & 325 to 415 as rigid element with half of distance between two inlet nozzles with half weight of one header & average temp. _( Distribute weight in 315-325 and 325-415). > Model 325 to 330 as rigid tube bundle element with length of bundle given in drawing & provide supports along length. > Model element 330 to 340 as rigid element with distance between two header center line without weight. > Model 340 to 345 and 340 to 350 as fixed header elements with half weight of total header weight.(Follow GA drawing for fixed end) > Model element 340 to 355 as connecting tubes to bottom header with average temp. of inlet & outlet & half of weight of tube bundle. > Model 365 to 515, 515 to 520 and 355 to 615 , 615 to 620 as rigid elements indicating lower header with proper distance from GA & half of one header weight. + Model elements 321( C-node) to 515 and 421 ( C-node) to 615 as half of depth of lower header without weight. > Model elements 515 to 511 and 615 to 611 as rigid elements as half of depth of lower header. > Model bottom nozzle part and give 510 and 610 are “ANCHOR” with C-node restrain as 511 and 611 v v ‘+ MODELLING PART OF EQUIPMENT RESTRAINT NODES (SPLIT HEADER). » Defining of restraint for fixed and floating end will be same as mentioned in FIXED HEADER case. + Here in fig-2 nodes 345 and 350 are support nodes of fixed end and 520 and 620 are support nodes of floating end. > Only one extra support between two split header at nodes 320 and 420 are +Y with 0.1 friction co-efficient and C-node as 321 & 421. 3.215/2017.12.13 10: Ashutosh Kane iping_Stress, josh Do not distribute this material with missionHOOT WIN ANCH Noms] 5i0. 10 | bio.0| “a PEN HO. FRICTIONS TOPCULD RESTON WT FRIETIOHSUIOE AESTIYHo.t sRieriowsTopssuine | b MODELING OF SPLIT HEADER IN CAESAR-IL (EVEN PASS) FIGURE -2 23.215/2017.12.13 10:52/Piping_Stress/Ashutosh Kanaujia/ashutosh Oo not distribute this material without permission7.12. LOAD CASES IN CAESAR-II FOR STRESS ANALYSIS Abbreviation: W = Weight; Water Filled Weight; P1 = Design Pressure, U1 = Uniform load (N-S Seismic); U2 = Uniform load (E-W Seismic); WIN1= Wind Load Case in North; WIN2= Wind Load Case in South; WIN3= Wind Load Case in East; WIN4= Wind Load Case in West; Wind Shape Factor = 0.7. # Wind load profile should be used as shown in SAWP-PL-093. LOAD CASES FOR STATIC AND WIND ANALYSIS:- ‘emperature; HP = Hydro Pressure; WW = CASE4: — WW+HP(HYD) CASE2:- W+P1+T1 (OPE) -—---—-Design temperature case CASE3:- W+P1+T2 (OPE) Operating temperature case CASE4:- W+P1 (SUS) CASES :- — W+P1+T2 +WIN1 (OPE) CASE6 :- W+P1+T2 +WIN2 (OPE) CASE7 :- — W+P1+T2 +WIN3 (OPE) CASES: — W+P1+T2 +WIN4 (OPE) CASES:- _L5-L3 (OPE) CASE10:- L6-L3 (OPE) CASE11:- L7-L3 (OPE) CASE12:- L8-L3 (OPE) CASE13:- L9+L4 (OCC) CASE14:- L10+L4 (OCC) CASE15:- L11+L4 (OCC) CASE16:- L12+L4 (OCC) CASE1 L2-L4 (EXP) CASE1 L3-L4 (EXP) NOTE: ABOVE MENTIONED LOAD CASED WILL REMAIN SAME FOR BOTH TYPE OF HEADER FIXED AND SPLIT HEADER LOAD CASES FOR STATIC AND WIND ANALYSIS (for known displacement) CASE2:- W+P1+T1+D1 (OPE) Design temperature case CASES :- W+P1+T2#D1 (OPE) Operating temperature case CASE4 :- W+P1+D1 (SUS) CASES :- — W+P1+T2 +D1+WIN1 (OPE) CASE6 CASET CASES = W+P1+T2 +D1+WIN2 (OPE) W+P1+T2 +D1+WIN3 (OPE) W+P1+T2 +D1+WIN4 (OPE) D1 to be added in above mentioned cases and other load cases will be same . s/Ashutosh Kanaujia/ashutosh Do not distribute this material without permissionCHECK POINTS: * Check nozzle allowable for cases 2 , 3 and 4, must be less than allowable as per Jamnagar refinery spec of AFC or given by vendor. . Check sustain stresses in case 4. * Check occasional case (wind) stresses in case 13, 14, 15 and 16 cases. Check expansion stresses in 17 and 18 cases. Loads for support design to be taken from load summary sheet, and it is result of case 2, 3,4,5,6,7 and 8 . There is combination of load for maximum static and maximum composite loading, LOAD CASES FOR SESMIC ANALYSIS: For seismic stress analysis make separate file as “FILE NAME_sei’. In this file remove design and operating temperature and enter ambient temperature as TA. Replace all “+Y" restraint by "Y’ restraint. Remove all friction and guide gap at restraints. Click on uniform load in CAESAR spread sheet and enter 0.34 value in UX and UZ direction. Activate uniform load in G's option in Kaux ~ special execution parameters. Make load cases as below: CASE1: W+P1 (SUS) CASE2: U1 (OCC) CASES: U2 (OCC) CASE4: L1#L2 (OCC).............-Combination method--Abs CASES: L1+L3 (OCC) .... Combination method-—Abs CHECK POINTS: ¢ Check occasional case (sesmic) stresses in case 4 and 5 , and it must be less than allowable stress specified in relevant code. POINTS TO BE TAKEN CARE :- “Temperature in equipment part to be taken average of inlet & outlet. + Support to be provided along bundle length at every one meter. “» Weight distribution as mentioned in procedure. |_Siress/Ashutosh Kanaujia/ashutosh Do not distribute this m: ial without permission23.215/2017.12.13 10:52/Piping_Stress/Ashutosh Kanaujia/ashutosh Do not distribute this material without permission