FEA OF FLANGE N4 OF GAS PHASE REACTOR

(132-RP-401)

FEA OF FLANGE N4 FOR GAS PHASE

REACTOR_(132-RP-401)

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TABLE OF CONTENTS

1. FEA OF FLANGE N4 FOR GAS PHASE REACTOR ......................................................... 3

1.1. Introduction ........................................................................................................................................ 3

1.2. Design Parameters ........................................................................................................................... 3

1.3. Material Properties .......................................................................................................................... 4

1.4. Acceptance Criteria for Design .................................................................................................... 5

2. FEA METHODOLOGY ........................................................................................................... 6

2.1. Finite Element 3D Model – Description ................................................................................... 7

2.2. Finite Element Model - Meshing ................................................................................................. 8

3. LOADING AND BOUNDARY CONDITIONS .................................................................. 10

4. FEA RESULTS FOR LOAD CASE 1 ................................................................................... 14

5. FEA RESULT SUMMARY & CONCLUSION .................................................................... 17

5.1. Results for Design Condition ...................................................................................................... 17

5.2. Conclusion ......................................................................................................................................... 18

REFERENCES.................................................................................................................................... 19

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1. FEA OF FLANGE N4 FOR GAS PHASE REACTOR

1.1. Introduction
FE analysis is preformed to check structural integrity of Flange N4 against
MAWP pressure, Nozzle opening Thrust and Nozzle process loads. The FEA
model consists of some part of shell and Nozzle N4 etc. FE analysis is
performed in ANSYS 2022R1 workbench software and results post
processing is performed as per Part-5 of ASME SEC VIII DIV-2.
The detail summary of FEA analysis and Result summary is present below.
The detail stress analysis of Flange is performed as per following load
combination:

Load Case 1: Self Weight + MAWP Pressure (25.5 bar) + Nozzle Process
Loads + Opening Thrust
The FEA model, loading and results are presented in below sections.

1.2. Design Parameters

Table 1-1 : Design Loads and Factor

Design Code: ASME Section VIII, Div. 2 Class 2, 2021 ED

MAWP Pressure (bar) 25.5

Design Temp. (0C) 150.0

Corrosion Allowance (mm) 1.0

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1.3. Material Properties

The physical properties used for various materials are listed below as per
the material specification.

Table 1-2 : Material Properties According to ASME Section II, part D

Yield Yield
Design Allowable
Strength Strength @ Density Poisson’s
Component Material Temperature Limit (S)
(Sy) Ambient (Sy) (Kg/m3) Ratio
(°C) MPa
MPa MPa
SA 516 Gr 232.0 262.0 7750.0
Shell, 150.0 154.0 0.30
70
SA 350 Gr.
Nozzle N4 150.0 146.0 219.0 248.0 7750.0 0.30
LF2 CL1

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1.4. Acceptance Criteria for Design

As per ASME section VIII Div. 2 Part 5 Ed. 2021 the allowable
criteria for stress are as follow

 General Primary Membrane stress (Pm) <S

 Local Primary Membrane stress (Pl) <Spl
 Primary + Bending stress (PL+Pb) < Spl
 Primary + secondary stress (PL+Pb+Q) < Sps

1) For Design condition

For SA 516 Gr 70 at Design temperature 150.00C

Allowable Stress for material (S) = 154.0 MPa,
SPl = 1.5*S = 231.0 MPa
SPs = 3*S = 462.0 MPa

For SA 350 Gr LF2 CL1 at Design temperature 150.00C

Allowable Stress for material (S) = 146.0 MPa,
SPl = 1.5*S = 219.0 MPa
SPs = 3*S = 438.0 MPa

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2. FEA METHODOLOGY
The Flange N4 is checked for different structural loads such as MAWP
pressure, Opening Thrust and Nozzle process loads. The major objective of
this analysis is to determine the stress levels on the Flange N4. The
structure analysis study was conducted using following methodology:

 FEA 3D model of Flange was considered as per provided input and details
of 3D model is shown in section 2.1

 In FEA model, Solid elements are used for Flange, Shell.

 For boundary conditions –The Shell Cut-out face has been given
displacement boundary condition.

 Details of structural analysis results are summarized in chapter 4.

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2.1. Finite Element 3D Model – Description

Figure 2-1 : 3D CAD model –N4

Figure 2-2 : CAD model dimensional details (Corroded)

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2.2. Finite Element Model - Meshing

The model is meshed with higher order hexahedral & tetrahedral solid 186
& solid187 elements.
1. Solid 186 Element: SOLID186 is a higher order 3-D 20-node solid
element that exhibits quadratic displacement behaviour. The
element is defined by 20 nodes having three degrees of freedom per
node: translations in the nodal x, y, and z directions. The element
supports plasticity, hyper elasticity, creep, stress stiffening, large
deflection, and large strain capabilities. It also has mixed
formulation capability for simulating deformations of nearly
incompressible elastoplastic materials, and fully incompressible
hyper elastic materials.

2. Solid 187 Element: SOLID187 element is a higher order 3-D, 10-

node element. SOLID187 has quadratic displacement behaviour and
is well suited to modelling irregular meshes (such as those
produced from various CAD/CAM systems). The element is defined
by 10 nodes having three degrees of freedom at each node:
translations in the nodal x, y, and z directions. The element has
plasticity, hyper elasticity, creep, stress stiffening, large deflection,
and large strain capabilities. It also has mixed formulation capability
for simulating deformations of nearly incompressible elastoplastic
materials, and fully incompressible hyper elastic materials.

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• The detail of meshing for structural analysis is as given below:

1. Total number of elements: 115666
2. Total number of nodes: 439384
Overall mesh quality parameters are maintained as per standard industrial
practice.

Quality Check Acceptable Value Achieved Valve

Aspect Ratio <5 1.71
Jacobian Ratio > 0.5 1.02
Skewness < 0.70 0.12
Element Quality > 0.1 0.86

Figure 2-3 : Meshed FEA model –Flange N4

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3. LOADING AND BOUNDARY CONDITIONS

Load Case 1: Self Weight + MAWP Pressure (25.5 bar) + Nozzle Process
Loads + Opening Thrust

Figure 3-1 : Unit consideration in FEA software

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• Structural Loading Conditions:

Figure 3-2 : Load case 1 – Internal pressure with thrust

Figure 3-3 : Load case 1 – Process Load

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Figure 3-4 : Load case 1 –Process Moment

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Boundary Condition: Displacement boundary condition is provided at the

Shell Cut-out face.

Figure 3-5 : Load case 1 – Radial free boundary condition at Shell Cut-out face

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4. FEA Results for Load Case 1

Figure 4-1 : Load case 1 - Total deformation

Figure 4-2 : Load case 1 – Maximum Equivalent Von Mises stress on N4

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Figure 4-3 : Linearized Equivalent Stress Plot – at Maximum Stress Location

across Crotch

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Figure 4-4 : Linearized Equivalent Stress Plot – At General Membrane Away

from Discontinuity

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5. FEA RESULT SUMMARY & CONCLUSION

5.1. Results for Design Condition
Table 5-1 : Summary for Local Primary Stresses
Allowable
Load PL
Location Limit Result
Case (MPa)
(MPa)
At Maximum Stress Location across
1 148.7 219.0 Safe
Crotch

Table 5-2 : Summary for Primary & Bending Stresses

Allowable
Load P L +P b
Location Limit Result
Case (MPa)
(MPa)
At Maximum Stress Location across
1 273.0 438.0 Safe
Crotch

Table 5-3 : Summary for General Primary Membrane stress

Allowable
Load Pm
Location Limit Result
Case (MPa)
(MPa)
At max stress Location @ away from
1 111.5 154.0 Safe
discontinuity

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5.2. Conclusion
• The maximum induced stresses are compared with the allowable limits of
constructional material. Flange is made up of SA 350 Gr. LF2 Cl1.
• Induced stresses are lower than allowable limiting stress criteria.
• It can be concluded that the Flange N4 is satisfying stress criteria. Hence,
Flange N4 design is adequate for provided loading.

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REFERENCES
 ASME Sec. II, Part D, Ed. 2021 – Physical Properties Tables
 ASME Section VIII Division 2 Ed 2021
 4300-CR-VD-LGP4132C02132RP40100_Q3 (4797-01 GAD)
 4797-01-Design Summary_N4ABCD_N17AB-Nozzle Calcs

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 FEA OF FLANGE N17 OF GAS PHASE REACTOR
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FEA OF FLANGE N17 FOR GAS PHASE REACTOR

(132-RP-401)

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TABLE OF CONTENTS

1. FEA OF FLANGE N17 FOR GAS PHASE REACTOR....................................................... 3

1.1. Introduction ........................................................................................................................................ 3

1.2. Design Parameters ........................................................................................................................... 3

1.3. Material Properties .......................................................................................................................... 4

1.4. Acceptance Criteria for Design .................................................................................................... 5

2. FEA METHODOLOGY ........................................................................................................... 6

2.1. Finite Element 3D Model – Description ................................................................................... 7

2.2. Finite Element Model - Meshing ................................................................................................. 8

3. LOADING AND BOUNDARY CONDITIONS .................................................................. 10

4. FEA RESULTS FOR LOAD CASE 1 ................................................................................... 13

5. FEA RESULT SUMMARY & CONCLUSION .................................................................... 16

5.1. Results for Design Condition ...................................................................................................... 16

5.2. Conclusion ......................................................................................................................................... 17

REFERENCES.................................................................................................................................... 18

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1. FEA OF FLANGE N17 FOR GAS PHASE REACTOR

1.1. Introduction
FE analysis is preformed to check structural integrity of Flange N17
against MAWP pressure, opening Thrust etc. The FEA model consists of
some part of shell and Nozzle N17 etc. FE analysis is performed in ANSYS
2022R1 workbench software and results post processing is performed as
per Part-5 of ASME SEC VIII DIV-2.
The detail summary of FEA analysis and Result summary is present below.
The detail stress analysis of Flange is performed as per following load
combination:

Load Case 1: Self Weight + MAWP Pressure (25.5 bar) + Opening Thrust
The FEA model, loading and results are presented in below sections.

1.2. Design Parameters

Table 1-1 : Design Loads and Factor

Design Code: ASME Section VIII, Div. 2 Class 2, 2021 ED

MAWP Pressure (bar) 25.5

Design Temp. (0C) 150.0

Corrosion Allowance (mm) 1.0

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1.3. Material Properties

The physical properties used for various materials are listed below as per
the material specification.

Table 1-2 : Material Properties According to ASME Section II, part D

Yield Yield
Design Allowable
Strength Strength @ Density Poisson’s
Component Material Temperature Limit (S)
(Sy) Ambient (Sy) (Kg/m3) Ratio
(°C) MPa
MPa MPa
SA 516 Gr 232.0 262.0 7750.0
Shell, 150.0 154.0 0.30
70
SA 350 Gr.
Nozzle N17 150.0 146.0 219.0 248.0 7750.0 0.30
LF2 CL1

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1.4. Acceptance Criteria for Design

As per ASME section VIII Div. 2 Part 5 Ed. 2021 the allowable
criteria for stress are as follow

 General Primary Membrane stress (Pm) <S

 Local Primary Membrane stress (Pl) <Spl
 Primary + Bending stress (PL+Pb) < Spl
 Primary + secondary stress (PL+Pb+Q) < Sps

1) For Design condition

For SA 516 Gr 70 at Design temperature 150.00C

Allowable Stress for material (S) = 154.0 MPa,
SPl = 1.5*S = 231.0 MPa
SPs = 3*S = 462.0 MPa

For SA 350 Gr LF2 CL1 at Design temperature 150.00C

Allowable Stress for material (S) = 146.0 MPa,
SPl = 1.5*S = 219.0 MPa
SPs = 3*S = 438.0 MPa

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2. FEA METHODOLOGY
The Flange N17 is checked for different structural loads such as MAWP
pressure, Opening Thrust etc. The major objective of this analysis is to
determine the stress levels on the Flange N17. The structure analysis study
was conducted using following methodology:

 FEA 3D model of Flange was considered as per provided input and details
of 3D model is shown in section 2.1

 In FEA model, Solid elements are used for Flange and Shell.

 For boundary conditions –The Shell Cut-out face has been given
displacement boundary condition.

 Details of structural analysis results are summarized in chapter 4.

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2.1. Finite Element 3D Model – Description

Figure 2-1 : 3D CAD model –N17

Figure 2-2 : CAD model dimensional details (Corroded)

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2.2. Finite Element Model - Meshing

The model is meshed with higher order hexahedral & tetrahedral solid 186
& solid187 elements.
1. Solid 186 Element: SOLID186 is a higher order 3-D 20-node solid
element that exhibits quadratic displacement behaviour. The
element is defined by 20 nodes having three degrees of freedom per
node: translations in the nodal x, y, and z directions. The element
supports plasticity, hyper elasticity, creep, stress stiffening, large
deflection, and large strain capabilities. It also has mixed
formulation capability for simulating deformations of nearly
incompressible elastoplastic materials, and fully incompressible
hyper elastic materials.

2. Solid 187 Element: SOLID187 element is a higher order 3-D, 10-

node element. SOLID187 has quadratic displacement behaviour and
is well suited to modelling irregular meshes (such as those
produced from various CAD/CAM systems). The element is defined
by 10 nodes having three degrees of freedom at each node:
translations in the nodal x, y, and z directions. The element has
plasticity, hyper elasticity, creep, stress stiffening, large deflection,
and large strain capabilities. It also has mixed formulation capability
for simulating deformations of nearly incompressible elastoplastic
materials, and fully incompressible hyper elastic materials.

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• The detail of meshing for structural analysis is as given below:

1. Total number of elements: 122159
2. Total number of nodes: 446908
Overall mesh quality parameters are maintained as per standard industrial
practice.

Quality Check Acceptable Value Achieved Valve

Aspect Ratio <5 1.76
Jacobian Ratio > 0.5 1.02
Skewness < 0.70 0.14
Element Quality > 0.1 0.85

Figure 2-3 : Meshed FEA model

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3. LOADING AND BOUNDARY CONDITIONS

Load Case 1: Self Weight + MAWP Pressure (25.5 bar) + Opening Thrust

Figure 3-1 : Unit consideration in FEA software

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• Structural Loading Conditions:

Figure 3-2 : Load case 1

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Boundary Condition: Displacement boundary condition is provided at the

Shell Cut-out face.

Figure 3-3 : Load case 1 – Radial free boundary condition at Shell Cut-out face

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4. FEA Results for Load Case 1

Figure 4-1 : Load case 1 - Total deformation

Figure 4-2 : Load case 1 – Maximum Equivalent Von Mises stress on N17

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Figure 4-3 : Linearized Equivalent Stress Plot – at Maximum Stress Location

across Crotch

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Figure 4-4 : Linearized Equivalent Stress Plot – At General Membrane Away

from Discontinuity

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5. FEA RESULT SUMMARY & CONCLUSION

5.1. Results for Design Condition
Table 5-1 : Summary for Local Primary Stresses
Allowable
Load PL
Location Limit Result
Case (MPa)
(MPa)
At Maximum Stress Location across
1 125.3 219.0 Safe
Crotch

Table 5-2 : Summary for Primary & Bending Stresses

Allowable
Load P L +P b
Location Limit Result
Case (MPa)
(MPa)
At Maximum Stress Location across
1 229.1 438.0 Safe
Crotch

Table 5-3 : Summary for General Primary Membrane stress

Allowable
Load Pm
Location Limit Result
Case (MPa)
(MPa)
At max stress Location @ away from
1 111.5 154.0 Safe
discontinuity

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5.2. Conclusion
• The maximum induced stresses are compared with the allowable limits of
constructional material. Flange is made up of SA 350 Gr. LF2 Cl1.
• Induced stresses are lower than allowable limiting stress criteria.
• It can be concluded that the Flange N17 is satisfying stress criteria. Hence,
Flange N17 design is adequate for provided loading.

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REFERENCES
 ASME Sec. II, Part D, Ed. 2021 – Physical Properties Tables
 ASME Section VIII Division 2 Ed 2021
 4300-CR-VD-LGP4132C02132RP40100_Q3 (4797-01 GAD)
 4797-01-Design Summary_N4ABCD_N17AB-Nozzle Calcs

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