Expansion Joint Analysis 36 SQM Heat Exchanger for Alkyd Reactor
Figure 1: 2D axisymmetric expansion bellows geometry
1. Executive Summary
The 36 sq.m. Heat Exchanger expansion bellows for Alkyd Reactor CD-V51 required FEA validation per TEMA 10th Edition RCB-8.3.2. A comprehensive 2D axisymmetric FEA was performed with stress categorization per ASME VIII Div.2 Part 5.2.
- All 4 load cases PASS – within ASME allowables
- Max PL = 109.62 MPa vs 239 MPa allowable (46%)
- Max PL+Pb+Q = 462.03 MPa vs 478 MPa allowable (97%)
- Bellow stiffness validated per TEMA RCB-8.4
- Design approved for fabrication
2. Design Parameters
Figure 2: Full geometry with GAD details
3. Mesh & Model
Structured mesh with SHELL181 elements. All convolutions modeled in 2D axisymmetric.
Figure 3: Mesh overview
4. Load Cases & Boundary Conditions
Figure 4: BC for LC-1
Figure 5: BC for LC-3 (governing)
5. Stress Results
Figure 6: Von Mises – LC-1 & LC-2
Figure 7: Von Mises – LC-3 & LC-4
Figure 8: Deformation – LC-1 & LC-2
6. SCL Results
Figure 9: SCL for LC-1
Figure 10: SCL for LC-3 (governing)
7. Stress Summary - PL
8. Stress Summary - PL+Pb+Q
9. Stiffness Validation
10. Lessons Learned
Corroded Minimum Governs
LC-3 reaches 97% – corrosion has major effect.
2D Axisymmetric Is Sufficient
Captures all physics with excellent mesh quality.
Displacement BCs Are Critical
PV-Elite-derived displacements ensure accurate loading.
11. Conclusion
- All 4 LCs pass PL check – max 46%
- All 4 LCs pass PL+Pb+Q check – max 97%
- LC-3 governs (corroded minimum)
- Mesh quality excellent
- Design approved for fabrication
Download the Full Technical Case Study
The full technical report includes:
- Stress categorization (SCL) results for all governing load cases
- Detailed PL and PL+Pb+Q stress evaluation with ASME allowables
- Load case definitions including corroded and uncorroded conditions
- Stress contour plots and deformation results for all scenarios
- FEA modeling approach using 2D axisymmetric bellows representation
- Stiffness validation as per TEMA RCB guidelines
- Code references including ASME Section VIII Division 2 and TEMA standards