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This is an example of a customized online calculation of the properties of an H-beam. The customer logs in to the server and enters the data. There are all kinds of different types of beams, U-beam, I-beam, etc. All kinds of dimensions can be entered and all relevant data is calculated online. This way you have accurate output data. This online simulation can be accessed anywhere, provided you have an internet connection and the correct login details.
For example, thermal stress can be calculated using a voltage calculation in Finite Element Method (FEM) software. This example is about a thermal stress calculation in Exxon pipes. During the production of polymers, raw materials from petroleum are processed at high, constant temperatures. A heat exchanger provides cooling during the production of a polymer. The heat exchanger is flushed with a cleaning fluid approximately once or twice a week to keep it functioning optimally. During flushing, high stresses occur in the complex geometric structure in a short time due to the large temperature fluctuations. A thermal stress calculation was deemed necessary by Exxon.
The situation was recorded at the location of the petrochemical plant and the complex fluid flow was mapped using working drawings. Due to the complex geometric structure of the heat exchanger, the structure in the FEM model had to remain simple. Essential points and boundary conditions that cause the tensions were entered into the model. With this approach the variable temperature profile of a hot flushing fluid and the voltage calculation could be set up. The video below shows the mechanical effect of the temperature pulse in the system..
Localise stress spots in heat exchanger
Locate the places of highest stress in a heat exchanger with a stress calculation with FEM. These tensions occur several times a week. are caused by significant temperature fluctuations during rinsing or flushing. The FEM simulation resulted in an 80% reduction of the peak load in the material, which greatly improved its service life. The thermal cycle was simulated over time, and in this way insight was gained where the design could be further improved.
- Stress reduction during the flush cycle is 80%.
- Heat exchanger efficiency increased by 30%.
- Stress corrosion is now avoided.