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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
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 –II

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).
FIGURE – 1

 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.

Note:- * 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.
 MODELLING PART AFTER DEFINING C-NODE ANCHOR NODE
(SPLIT HEADER)

Split header case modeling in CAESAR –II , 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 t0 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.
 Model element 340 to 355 as connecting tubes to bottom header
with average temp. of inlet & outlet & half of weight of tube bundle.
 Model 355 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.

 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.
FIGURE -2
LOAD CASES IN CAESAR-II FOR STRESS ANALYSIS
Abbreviation: W = Weight; T= Temperature; HP = Hydro Pressure; WW =
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:-
CASE1 :- WW+HP(HYD)
CASE2 :- W+P1+T1 (OPE) ------------Design temperature case
CASE3 :- W+P1+T2 (OPE) ------------Operating temperature case
CASE4 :- W+P1 (SUS)
CASE5 :- W+P1+T2 +WIN1 (OPE)
CASE6 :- W+P1+T2 +WIN2 (OPE)
CASE7 :- W+P1+T2 +WIN3 (OPE)
CASE8 :- W+P1+T2 +WIN4 (OPE)
CASE9 :- 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)
CASE17:- L2-L4 (EXP)
CASE18:- 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
CASE3 :- W+P1+T2+D1 (OPE) ------------Operating temperature case
CASE4 :- W+P1+D1 (SUS)
CASE5 :- W+P1+T2 +D1+WIN1 (OPE)
CASE6 :- W+P1+T2 +D1+WIN2 (OPE)
CASE7 :- W+P1+T2 +D1+WIN3 (OPE)
CASE8 :- W+P1+T2 +D1+WIN4 (OPE)

D1 to be added in above mentioned cases and other load cases will be same .
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
T1. 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)
CASE3: U2 (OCC)
CASE4: L1+L2 (OCC)……………Combination method---Abs
CASE5: 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.

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