#fesimulations

Designing and validating TEMA S-Class heat exchangers. Get expert tips and insights!

Our client is a leading manufacturer and supplier of Shell & Tube, Plate type Heat exchangers, Boilers and Pressure vessels. The client’s requirement is to design ’Floating Head Heat Exchanger’ in compliance with ASME Sec VIII and TEMA class S specifications.

What we Delivered:

3D CAD Model as per Client’s requirement/specifications

General Arrangement Drawings

Fabrication drawings

Machine drawings of various components

Parts drawings of various components

Detailed Bill of materials

CFD simulations to ensure customer’s design criteria is met

FE simulations to ensure structural integrity during lifting, transportation.

Design Specifications:

The Floating Head Heat Exchanger is designed for:

Pressure rating: Shell side: 38 kg/sq. cm, and Tube side: 30 kg/sq. cm

Temperature rating: Shell side: 150 °C and Tube side: 110 °C

Fluid capacity, Shell side: 2.8 cu.m., and Tube side: 1.8 cu.m

No. of passes: shell side (cross flow) and tube side (10).

Design wind reluctance: 50 m/s as per IS 875 Part 3

Seismic design code: IS: 1893-2005 

Insulation thickness is 15/50 mm.

Gross weight of Heat exchanger (empty): 13 tons

Through simulations, we were able to provide nozzle loads, wind seismic data, bolt torque and forces, and welding stresses and forces.

Detailed drawings were provided to Davit for cover, insulation clatters, tube bundles with tube-to-tube sheet joints, tube layouts, baffle layouts, tie roads, girth flanges, passage partitions, gaskets, hold points, name plates, etc.

Finally, all design information, like native 3D CAD data, drawings and simulation reports, was submitted to the customer.

CFD Analysis validation:

CFD simulations were performed to understand the velocity and temperature distribution on Shell and tube side. The heat exchanger was simulated with operating temperature and pressure. The intensity of turbulence, heat transfer rate was studied and the results are reported to ensure that the design is in compliance with requirement and efficiency of the system is achieved.