管板结构分析与换热器性能数值仿真研究
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摘要
换热器是一种被广泛应用于化工、石油化工、动力、医药、冶金、制冷及轻工业等行业的通用设备。管壳式换热器制造容易,生产成本低,选材范围广,清洗方便,使用性强,处理量大,工作可靠,且能够适应高温高压,迄今为止任被当作一种传统的标准设备而在许多工业部门中大量应用。本文主要从以下几个方面分析了KLQ型换热器管板。
首先,根据换热器管板的理论,简化了其螺栓受力的数学模型,只考虑螺栓对螺栓孔的均布力与垫片的比压力。根据换热器的图纸,利用ANSYS的APDL语言建立了管板1／4模型,并分网、加载、最终求解,将其保存为宏文件,并且该宏文件中管板的结构参数都设置成变量。
然后,利用VB编写管板结构参数和流体参数的输入界面,可在其中修改宏文件中管板的参数。利用ANSYS的按钮方法调用宏文件,实现管板七种工况的自动分析。
通过管板七种工况的应力分析,得到了换热器管板的危险工况和危险路径。在较危险工况下,先改变管板的厚度而其它参数不变,得到厚度对管板强度的影响；然后研究了管板与管子胀接缝厚度对管板强度的影响。
根据之前的分析,得到了管板强度分析中的危险工况、危险路径以及对管板强度影响较大的因素。然后利用ANSYS的最优化模块对管板结构进行了最优化分析,并且对优化结果进行了安全评定,该结果对生产具有指导意义。
最后利用FLUENT软件,截取换热器中的一部分结构,对去掉翅片和保留翅片的情况进行了三维流体分析,并且分析了翅片对换热器换热效果的影响。
Heat exchanger is widely used in chemical, petrochemical, power, pharmaceutical, metallurgy, refrigeration and universal equipment of light industries. Tubular heat exchanger are easy to create, have low production cost and large select range, are easy to clean, have strong practicability. It is reliable, can adapt to the high temperature and high pressure. So far as it is considered as traditional standard equipment used in many industrial sector. This paper analyzed the KLQ type heat exchanger tube sheet from the following aspects.
At first, according to the heat exchanger tube plate theory, simplifies mathematical model of the bolt stress, considering only bolt to bolt hole of uniformly pressure and gasket pressure. According to the drawing, using ANSYS APDL language to establish the tube sheet 1/4 model, and finally mesh, loading, solution, save it as batch files. The tube plate structure parameters in batch files are set to variable.
Then, write the parameters input interface of the tube plate structure and fluid parameters using VB, the parameters in batch files can be modified in it. Using the ANSYS button call the batch files, realize the automatic analyses of the seven conditions.
Through stress analysis of the tube sheet seven conditions, we get the dangerous condition and dangerous path in it. In a more dangerous working condition, we change the thickness of the tube sheet and other parameters are fixed and get the strength influence by the thickness, and then study the intensity influence of the tube sheet and joint thickness.
According to the analysis before, get the risk working condition, risk path, big influence factors. Then do the tube sheet structure optimization analysis using the ANSYS optimization module, and safety evaluation the optimization result, the result has guiding significance for production.
Finally, using the FLUENT software, intercept part of the heat exchanger, does the three-dimensional flow analysis in the condition of remove the cooling fin and retain the cooling fin, and analysis the heat transfer effect of the cooling fin.
首先,根据换热器管板的理论,简化了其螺栓受力的数学模型,只考虑螺栓对螺栓孔的均布力与垫片的比压力。根据换热器的图纸,利用ANSYS的APDL语言建立了管板1／4模型,并分网、加载、最终求解,将其保存为宏文件,并且该宏文件中管板的结构参数都设置成变量。
然后,利用VB编写管板结构参数和流体参数的输入界面,可在其中修改宏文件中管板的参数。利用ANSYS的按钮方法调用宏文件,实现管板七种工况的自动分析。
通过管板七种工况的应力分析,得到了换热器管板的危险工况和危险路径。在较危险工况下,先改变管板的厚度而其它参数不变,得到厚度对管板强度的影响；然后研究了管板与管子胀接缝厚度对管板强度的影响。
根据之前的分析,得到了管板强度分析中的危险工况、危险路径以及对管板强度影响较大的因素。然后利用ANSYS的最优化模块对管板结构进行了最优化分析,并且对优化结果进行了安全评定,该结果对生产具有指导意义。
最后利用FLUENT软件,截取换热器中的一部分结构,对去掉翅片和保留翅片的情况进行了三维流体分析,并且分析了翅片对换热器换热效果的影响。
Heat exchanger is widely used in chemical, petrochemical, power, pharmaceutical, metallurgy, refrigeration and universal equipment of light industries. Tubular heat exchanger are easy to create, have low production cost and large select range, are easy to clean, have strong practicability. It is reliable, can adapt to the high temperature and high pressure. So far as it is considered as traditional standard equipment used in many industrial sector. This paper analyzed the KLQ type heat exchanger tube sheet from the following aspects.
At first, according to the heat exchanger tube plate theory, simplifies mathematical model of the bolt stress, considering only bolt to bolt hole of uniformly pressure and gasket pressure. According to the drawing, using ANSYS APDL language to establish the tube sheet 1/4 model, and finally mesh, loading, solution, save it as batch files. The tube plate structure parameters in batch files are set to variable.
Then, write the parameters input interface of the tube plate structure and fluid parameters using VB, the parameters in batch files can be modified in it. Using the ANSYS button call the batch files, realize the automatic analyses of the seven conditions.
Through stress analysis of the tube sheet seven conditions, we get the dangerous condition and dangerous path in it. In a more dangerous working condition, we change the thickness of the tube sheet and other parameters are fixed and get the strength influence by the thickness, and then study the intensity influence of the tube sheet and joint thickness.
According to the analysis before, get the risk working condition, risk path, big influence factors. Then do the tube sheet structure optimization analysis using the ANSYS optimization module, and safety evaluation the optimization result, the result has guiding significance for production.
Finally, using the FLUENT software, intercept part of the heat exchanger, does the three-dimensional flow analysis in the condition of remove the cooling fin and retain the cooling fin, and analysis the heat transfer effect of the cooling fin.
引文
[1]JB4732-95.钢制压力容器—分析标准[S].北京.全国压力容器标准化技术委员会.1995年10月：
[2]GB150-1998.钢制压力容器[S].北京.中国标准出版社.1998年5月.
[3]GB151-1999.管壳式换热器[S].北京.中国标准出版社.2000年12月.
[4]王志文,蔡仁良.化工容器设计[M].北京：化学工业出版社,2005：1-4
[5]ASME VIII. ASME Boiler and Pressure Vessel Code Section VIII Division 2[S].USA
[6]JIS B8250-1983.压力容器构造的另一规则[S] Japan
[7]BS5500-1978.非直接火压力容器规范[S]
[8]AD.AD压力容器规范[S]
[9]Gardener K A.Heat exchanger tubesheet temperature[J]. Journal of Applied Mechanics, Vol,5, 1948:377-385.
[10]Miller,K.A.G.The design of tubeplates in heat exchangers [J]. Proceedings of the Institate of mechanical Engineers.London,vol.1B,p,215(1952-1953).
[11]Singh K P,Holtz M.An Approximate Method for Evaluating the Temperature Field in Tubesheet Liaments of Tubular Heat Exchangers Under Steady State Conditions[J].ASME Journal of Engineering for Power,1982,104:985-900
[12]Ohol R D,Rane M T,Noras R A. A Finite Element Procedure for Temperature Distribution in Tubesheets[J].Proceedings of the 7th International Conference on Pressure Vessel Technology.Dusseldorf,Germang,1992
[13]Kasahara N,Iwata K.Simplified 2-di mensional Thermal Analysis Method Considering 3-di me nsional Heat Transfer[J].Computational Mechanis 86,Springer Verlag,1986,2:127-137
[14]薛明德、吴胜强.对流换热条件下换热器管板的热应力分析[J].北京：清华大学工程力学系,1998.6
[15]刘天丰.非对称管壳式换热器结构分析及改进中的问题研究[D].浙江：浙江大学材料与化学工程学院,2005.10：
[16]宋京凯、薛松龄、姚祺峰、姜任丘,管板和传热管胀接应力的应变的数值模拟及分析[J].哈尔滨工程大学学报,2009
[17]Laghzale NE,Bouzid AH.Analytical Modeling of hydraulically Expanded Tube-to-Tubesheet joints[J]. JOURNAL OF PRESSURE VESSEL TECHNOLOGY-TRANSACTIONS OF THE ASME,131 volumes 1 issue,2009.2.
[18]Laghzale NE,Bouzi d AH. Theoretical Analysis of Hydraulically Expanded Tube-to-tubesheet Joints With Linear Strian Hardening Material Behavio[J]r. JOURNAL OF PRESSURE VESSEL TECHNOLOGY-TRANSACTIONS OF THE ASME,131 volumes 1 issue,2009.9.
[19]Shah R K. Pigmotti A. Influence of a Finite Number of Baffles on shell-and-Tube Heat
Exchanger Performance[J]. Heat Transfer Engineering,1997,18(1)
[20]Khalifen Soltan B., Saffer-Avval M., Damangir E. Minimizing Capital and operation Costs of shell and tube Condensers using optimum baffle spacing[J].Applied Thermal Engineering,2004, (24):2801-2810
[21]Ravigururayan T.S., Rabas T.J., Tubulent Flow in Integrally Enhanced Tubes, Part Ⅰ:Analysis and performance Comparison[J]. Heat transfer engineering,1996,17(2):30-38
[22]Sivashanmugam P., Suresh S., Experimental Studiess on Heat Transfer and Friction Factor Characterristics of Laminar Flous Through a Circular Tube Fitted With Helical Screw-Take Inserts[J]. Applied Thermal Engineering 2006(26):1990-1997
[23]黄克智等.板壳理论[M].北京：清华大学出版社,1987
[24]S.Timoshenko, S.Woinowdky-Krieger.Theory of plate and shells[M].北京:科学出版社,1977
[25]傅福兴等译JIS B 8243-1981[M]北京：中国机械工程学会压力容器学会、化工部设备设计中心站,1981
[26]Gardner K.A..Heat exchanger Tubesheet Design-2 Fixed Tubesheets[J] Journal of Applied Mechanics,Vol,191952,PP.159-166.
[27]黄克智等.我国换热器设计规定管板设计规定分析[J],化工与通用机械,1979,12(19)
[28]Slot and O'Donnell.Effective Elastic Constants for Thick Perforated Plates With Square and Triangular Penetration Patterns[J].ASME Journal of Engineering for Industry, Vol.93,May 1971
[29]O'Donnell.Effective Constants for the Bending of Thin Perforated Plates With Triangular and Square Penetration Pattern[J].ASME Journal of Engineering forIndustry.Vol.95,Feb.1973
[30]O'Donnell,Langer.Perforated Plates and Shells(Introduction)[J].Pressure Vessels and Piping, Vol.2,1972
[31]Porowski,O'Donnell.Elastic Design Methods for Perforated Plates[J].Transactions of the ASME,VOL.100,APRIL 1978(356)
[32]Singh.Analysis of Vertically Mounted Through-Tube Heat Exchangers[J].Transactions of the ASME,Vol.100, April 1978(380)
[33]陈罕等.固定管板式换热器管板应力的有限元分析[A].第四届全国压力容器学术会议论文集,1997.4.
[34]冷纪桐.某固定管板式换热器的温度场与热应力分析[J].北京化工大学学报,Vol.31,No.2,2004.
[35]安维峥.考虑垫片时滞效应的管板—法兰—垫片—螺栓的连接系统的非线性三维有限元分析[D].北京：北京化工大学,15-16
[36]博弈出版社.APDL参数化有限元分析技术及其应用实例[M].中国水利水电出版社,2004,110
[37]博弈出版社.APDL参数化有限元分析技术及其应用实例[M].中国水利水电出版社,2004,111
[38]曹青,邱李华,郭志强Visual Basic程序设计教程[M].机械工业出版社,2001,12
[39]程昌钧.弹性力学[M].兰州大学出版社,1995：130-137
[40]GB150-1998.钢制压力容器[S].北京：中国标准出版社.1998.5：96
[41]GB150-1998.钢制压力容器[S].北京：中国标准出版社.1998.5：97
[42]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1980：20-31
[43]杨宏悦.大型固定管板式换热器管板的有限元分析[D]北京：北京化工大学：18
[44]JB4732-95.钢制压力容器-分析设计标准[S].北京：全国压力容器标准化技术委员会.1995：15-17
[45]博弈出版社,APDL参数化有限元分析技术及其应用实例[M].北京：中国水利水电出版社,2004,178-197
[46]王福军.计算流体动力学分析—CFD软件原理与应用[M].北京：清华大学出版社,2003：7-11
[47]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1980：37-44
[48]朱明善,刘颖,林兆庄等.工程热力学[M].北京：清华大学出版社,1995.：311
[49]Hines A L,Maddox P N. Mass transfer fundamentals and applications[J]. Englewood Cliffs: Prentice-Hall Inc,1985.1-12:60-86
[50]周兴禧.制冷空调工程中的热量传递[M].上海.上海交通大学出版社,1991：52-96
[2]GB150-1998.钢制压力容器[S].北京.中国标准出版社.1998年5月.
[3]GB151-1999.管壳式换热器[S].北京.中国标准出版社.2000年12月.
[4]王志文,蔡仁良.化工容器设计[M].北京：化学工业出版社,2005：1-4
[5]ASME VIII. ASME Boiler and Pressure Vessel Code Section VIII Division 2[S].USA
[6]JIS B8250-1983.压力容器构造的另一规则[S] Japan
[7]BS5500-1978.非直接火压力容器规范[S]
[8]AD.AD压力容器规范[S]
[9]Gardener K A.Heat exchanger tubesheet temperature[J]. Journal of Applied Mechanics, Vol,5, 1948:377-385.
[10]Miller,K.A.G.The design of tubeplates in heat exchangers [J]. Proceedings of the Institate of mechanical Engineers.London,vol.1B,p,215(1952-1953).
[11]Singh K P,Holtz M.An Approximate Method for Evaluating the Temperature Field in Tubesheet Liaments of Tubular Heat Exchangers Under Steady State Conditions[J].ASME Journal of Engineering for Power,1982,104:985-900
[12]Ohol R D,Rane M T,Noras R A. A Finite Element Procedure for Temperature Distribution in Tubesheets[J].Proceedings of the 7th International Conference on Pressure Vessel Technology.Dusseldorf,Germang,1992
[13]Kasahara N,Iwata K.Simplified 2-di mensional Thermal Analysis Method Considering 3-di me nsional Heat Transfer[J].Computational Mechanis 86,Springer Verlag,1986,2:127-137
[14]薛明德、吴胜强.对流换热条件下换热器管板的热应力分析[J].北京：清华大学工程力学系,1998.6
[15]刘天丰.非对称管壳式换热器结构分析及改进中的问题研究[D].浙江：浙江大学材料与化学工程学院,2005.10：
[16]宋京凯、薛松龄、姚祺峰、姜任丘,管板和传热管胀接应力的应变的数值模拟及分析[J].哈尔滨工程大学学报,2009
[17]Laghzale NE,Bouzid AH.Analytical Modeling of hydraulically Expanded Tube-to-Tubesheet joints[J]. JOURNAL OF PRESSURE VESSEL TECHNOLOGY-TRANSACTIONS OF THE ASME,131 volumes 1 issue,2009.2.
[18]Laghzale NE,Bouzi d AH. Theoretical Analysis of Hydraulically Expanded Tube-to-tubesheet Joints With Linear Strian Hardening Material Behavio[J]r. JOURNAL OF PRESSURE VESSEL TECHNOLOGY-TRANSACTIONS OF THE ASME,131 volumes 1 issue,2009.9.
[19]Shah R K. Pigmotti A. Influence of a Finite Number of Baffles on shell-and-Tube Heat
Exchanger Performance[J]. Heat Transfer Engineering,1997,18(1)
[20]Khalifen Soltan B., Saffer-Avval M., Damangir E. Minimizing Capital and operation Costs of shell and tube Condensers using optimum baffle spacing[J].Applied Thermal Engineering,2004, (24):2801-2810
[21]Ravigururayan T.S., Rabas T.J., Tubulent Flow in Integrally Enhanced Tubes, Part Ⅰ:Analysis and performance Comparison[J]. Heat transfer engineering,1996,17(2):30-38
[22]Sivashanmugam P., Suresh S., Experimental Studiess on Heat Transfer and Friction Factor Characterristics of Laminar Flous Through a Circular Tube Fitted With Helical Screw-Take Inserts[J]. Applied Thermal Engineering 2006(26):1990-1997
[23]黄克智等.板壳理论[M].北京：清华大学出版社,1987
[24]S.Timoshenko, S.Woinowdky-Krieger.Theory of plate and shells[M].北京:科学出版社,1977
[25]傅福兴等译JIS B 8243-1981[M]北京：中国机械工程学会压力容器学会、化工部设备设计中心站,1981
[26]Gardner K.A..Heat exchanger Tubesheet Design-2 Fixed Tubesheets[J] Journal of Applied Mechanics,Vol,191952,PP.159-166.
[27]黄克智等.我国换热器设计规定管板设计规定分析[J],化工与通用机械,1979,12(19)
[28]Slot and O'Donnell.Effective Elastic Constants for Thick Perforated Plates With Square and Triangular Penetration Patterns[J].ASME Journal of Engineering for Industry, Vol.93,May 1971
[29]O'Donnell.Effective Constants for the Bending of Thin Perforated Plates With Triangular and Square Penetration Pattern[J].ASME Journal of Engineering forIndustry.Vol.95,Feb.1973
[30]O'Donnell,Langer.Perforated Plates and Shells(Introduction)[J].Pressure Vessels and Piping, Vol.2,1972
[31]Porowski,O'Donnell.Elastic Design Methods for Perforated Plates[J].Transactions of the ASME,VOL.100,APRIL 1978(356)
[32]Singh.Analysis of Vertically Mounted Through-Tube Heat Exchangers[J].Transactions of the ASME,Vol.100, April 1978(380)
[33]陈罕等.固定管板式换热器管板应力的有限元分析[A].第四届全国压力容器学术会议论文集,1997.4.
[34]冷纪桐.某固定管板式换热器的温度场与热应力分析[J].北京化工大学学报,Vol.31,No.2,2004.
[35]安维峥.考虑垫片时滞效应的管板—法兰—垫片—螺栓的连接系统的非线性三维有限元分析[D].北京：北京化工大学,15-16
[36]博弈出版社.APDL参数化有限元分析技术及其应用实例[M].中国水利水电出版社,2004,110
[37]博弈出版社.APDL参数化有限元分析技术及其应用实例[M].中国水利水电出版社,2004,111
[38]曹青,邱李华,郭志强Visual Basic程序设计教程[M].机械工业出版社,2001,12
[39]程昌钧.弹性力学[M].兰州大学出版社,1995：130-137
[40]GB150-1998.钢制压力容器[S].北京：中国标准出版社.1998.5：96
[41]GB150-1998.钢制压力容器[S].北京：中国标准出版社.1998.5：97
[42]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1980：20-31
[43]杨宏悦.大型固定管板式换热器管板的有限元分析[D]北京：北京化工大学：18
[44]JB4732-95.钢制压力容器-分析设计标准[S].北京：全国压力容器标准化技术委员会.1995：15-17
[45]博弈出版社,APDL参数化有限元分析技术及其应用实例[M].北京：中国水利水电出版社,2004,178-197
[46]王福军.计算流体动力学分析—CFD软件原理与应用[M].北京：清华大学出版社,2003：7-11
[47]杨世铭,陶文铨.传热学[M].北京：高等教育出版社,1980：37-44
[48]朱明善,刘颖,林兆庄等.工程热力学[M].北京：清华大学出版社,1995.：311
[49]Hines A L,Maddox P N. Mass transfer fundamentals and applications[J]. Englewood Cliffs: Prentice-Hall Inc,1985.1-12:60-86
[50]周兴禧.制冷空调工程中的热量传递[M].上海.上海交通大学出版社,1991：52-96