• Conducted structural integrity analysis of a Neutralizer Flash Drum under multiple load conditions:

  • • Weight, nozzle loads, wind, seismic forces, pressure (design, operating, cyclic, testing, rigging).

• Developed 3D solid finite element model with mesh refinement in critical areas for accurate stress results.

• Evaluated stresses in accordance with ASME BPVC Sec. VIII, Div. 2 Part 5, Edition 2021.

• Verified compliance with design code requirements and ensured structural safety.

The analysis concluded that the Neutralizer Flash Drum exhibits no signs of failure due to cyclic fatigue, ensuring safe operation for its designed life of 3000 cycles (30 years). Therefore, the Neutralizer Flash Drum can be safely operated, tested, transported and lifted within the design limits specified.

• Designed U-Tube Bundle per ASME BPVC Div. 1 (2021) and TEMA 10th Edition to verify minimum required thicknesses.

• Applied linear static Finite Element Analysis (FEA) for components not covered by codes, including:

  • • Stuffing Box

    • Shell End Flange

    • Tube Coupling

    • Preformed Graphite Ring

• Evaluated von Mises stress levels and gasket contact pressure under internal design loads.

• Assessed results per ASME BPVC Sec. VIII, Div. 2, Part 5 (2021 Edition).

• Used refined 3D solid finite element model for accurate stress analysis.

FEA results show that the localized combined primary plus secondary stress levels did not exceed the allowable value of SPS at the maximum stress points for the load cases analysed. The combined primary membrane and bending von Mises stresses stayed within the permissible limits, with general primary membrane stresses below 1S, and local primary membrane plus bending stresses below 4S. Thus, all components outside ASME BPVC, Div. 1, met the code requirements. It's important to note that gaskets may leak, as ASME BPVC calculations are based on factors generally performing well in practice. Bolt-up conditions significantly impact gasket sealing, so best practices must be followed during installation. 

• Performed mechanical design of inlet header box, rear header box, and support structure for a Regenerator Overhead Condenser.

• Conducted ASME BPVC Sec. VIII, Div. 1 (2019 Edition) calculations.

• Performed linear static Finite Element Analysis (FEA) for components outside code scope per U-2(g) and Appendix 46.

• FEA assessed von Mises stress levels from internal pressure, weight, and nozzle loads.

• Developed complete 3D solid finite element model with refined mesh in critical areas for accuracy.

• Evaluated results per:

  • • ASME BPVC Sec. VIII, Div. 2, Part 5 (2019 Edition) for headers.

    • Sound Engineering Practice for support frame.

• Thermal, hydraulic, and lifting design excluded from project scope.

The code calculations confirmed that the material and thickness used in the design are sufficient for the required conditions. The Finite Element Analysis (FEA) results show that for all load cases analyzed, the localized combined primary plus secondary stresses did not exceed the allowable SPS values. The combined primary membrane and bending von Mises stresses also remained within the limits, and the general primary membrane stresses stayed below 1*S, meeting all code requirements. The Regenerator Overhead Condenser was designed per the client's specifications and relevant codes. It is safe to operate, provided all design and operating conditions in this report are followed.