Internal Sealing Performance of a

Hydrotreating High Pressure Heat Exchanger

Rafael Pavan Bagagli
21/05/2014
Summary
Company Overview;
Problem Description;
Methodology;
Goals;
Conclusions.

Company Overview


REPLAN Paulnia Refinery
Capacity: 420 mbpd
Location: Paulnia - SP
Problem Description



HDT Reaction Section simplified flowchart:


Feed
(S2000)
HDD
(S10/S500)
HHPHE
Furnace
Reactor
#1
Reactor
#2
H2
H2 H2
Problem Description
What is a HPHE?
Problem Description
Why contamination of hydrotreated Diesel
occurs?
Loss of internal gasket
sealing
Problem Description
Main questions:

Why gasket looses sealing?
How can we fix it?

LETS CREATE A NUMERICAL MODEL
AND EVALUATE!
Methodology: Physical Model
Physical model of HHPE is similar to springs in
series:


Methodology: Physical Model
Balancing the forces:




S
gT
is the THEORETICAL gasket stress
considering uniform distribuiton of W on gasket
surface.




F
G
F
H
Methodology: Physical Model
Bolt assembly selection criteria:













ASME: 1,8 ksi (12,5MPa) Min: 6,0 ksi (40MPa) Max: 60,0 ksi (420MPa)
Methodology: Physical Model
And how about diferential thermal expansion?

Operation temperature: 360C;

Heat expansion coeff. of internals (300SS)
greater than channel (1 1/4Cr1/2Mo);

Diferential thermal expansion (~1,79mm) will
tension the channel and compress internals.





Methodology: Physical Model
Diferential thermal expansion force (F
DTE
) IS
NOT ADDED to initial bolt load (W);

Internals behave like springs in series, so the
GREATER of them (W or F
DTE
) predominate;

Then, how define the sealing force? WILL
SEE BEFORE.







Methodology: Numerical Model
The numerical model was developed
considering solid elements and geometry,
material and contact nonlinearities;

Were modeled only the gasket, tubesheet,
partition and internal jack screws;





Methodology: Numerical Model
Components modeled:




Gasket
Partition Box
Jack
Screws
Tubesheet
Methodology: Numerical Model
Geometry and mesh:





Methodology: Numerical Model
Stiffness of non-modeled componets
considering linear elastic materials and no
bending:


It was computed changing jack screw Young
Modulus:



Methodology: Numerical Model
Details of material models:







* Modified Ey considering non-modeled components rigidity

Material SA-240 TP 347 SA-387 Gr11 SA-453 660B
Model EP kinematic hardening EP kinematic hardening Linear-elastic
Temperature (C) 22 360 22 360 22 360
Yield Strenght Sy (MPa) 276 185 380 316 655 601
Tensile Strenght Su
(MPa)
586 480 586 505 965 922
Young Modulus Ey (MPa) 194994 171358 204084 181844 65281* 57644*
Poisson Ratio 0,3 0,3 0,3 0,3 0,3 0,3
Methodology: Numerical Model
Stress-Strain curves (Ramberg-Oosgod model):


Methodology: Numerical Model
Contact setup:







Other parameters: default



Parameters Gasket x Tubesheet
Tubesheet x
Partition
Partition x Jack
Screw
CONTACT Gasket Partition Jack Screw
TARGET Espelho Espelho Caixa de Partio
Type Frictional Frictional Frictional
Friction Coefficient 0,1 0,7 0,7
Behavior Asymmetric Asymmetric Asymmetric
Formulation Augmented Lagrange Augmented Lagrange Augmented Lagrange
Interface
Adjustment
Adjust to Touch Adjust to Touch Adjust to Touch
Methodology: Numerical Model
Supports:

Frictionless on symmetry surfaces;

Frictionless on gasket surface oposite to the
tubesheet;

Fixed Support on jack screw surfaces
oposite to the partition.









Methodology: Numerical Model
Loads:

Assembly bolt load - W (Bolt Pretension);

Diferential thermal expansion load - F
ETD

(Bolt Pretension);

Diferential pressure - P
op
(Pressure on
tubesheet surface);








OR
Methodology: Numerical Model
Boundary conditions visualization:









Goals: Part 1 Gasket Loads Evaluation
Objective:

Evaluate influence of W and F
ETD
on gasket
stress.

Methodology:

Evaluation of Load x deflection (response)
curve









Goals: Part 1 Gasket Loads Evaluation









Goals: Part 1 Gasket Loads Evaluation
After heating up F
ETD
predominate over W;



Maximum load (GPD) is about 2,15e7N,
resulting ~ 23ksi gasket stress (theoretical);










Increase W
Use ferritic material
Counter Measure
Reduce gasket width Counter Measure
Goals: Part 2 Gasket Stress Distribution
Objective:

Evaluate gasket stress distribution on gasket
surface

Methodology:

Evaluation of pressure on gasket x tubesheet
contact pair









Goals: Part 2 Gasket Stress Distribution
Load sequence:













Determined from Load x Def. Curve

Goals: Part 2 Gasket Stress Distribution
Resultant gasket stress:













DISTRIBUTION
IS IRREGULAR
Goals: Part 2 Gasket Stress Distribution
Why gasket stress is zero near partition holes?














Goals: Part 3 Gasket Stress Distribution
Reduced stiffness on holes area promote:

Bending of partition;

Loss of partition x tubesheet contact areas;













Reinforce partition holes Counter measure
Goals: Part 3 Gasket Stress Distribution
Proposals for project improvement:

1. Reduce gasket width + increase W;

2. Change partition material to 1 1/4Cr1/2Mo;

3. Insert reinforcement on partition holes;












Increase gasket stress

Reduce temp. influence
Improve gasket stress distribution

Goals: Part 3 Gasket Stress Distribution
New geometry:











Original Partition
New Partition
Goals: Part 3 Gasket Stress Distribution
New load sequence:











S
g
= 30 ksi (Theoretical)

Goals: Part 3 Gasket Stress Distribution
New gasket stress distribution:











Mn. OK
Mx. OK
Stress distribution along gasket width (0):
Conclusions
For low bolt loads (W) diferential thermal
expansion load predominates and increase
gasket stress(S
g
);

However sealing performance depends on
T
op
, wich is not uniform for all exchangers and
can vary with process conditions;












Conclusions
Changing partition material to ferritic,
reducing gasket width and increasing W,
eliminate T
op
dependence;


However gasket stress distribution is
irregular, wich decrease sealing performance
in some areas;














Conclusions
Inserting a reinforcement on partition holes
and increasing shell thickness improve gasket
stress distribution;

Thus, a minimum of 6ksi gasket stress is
achieved in critical regions and leaking
probability during operation is quite reduced.














Conclusions


QUESTIONS?


THANK YOU!