| The Tubular Heat Exchangers are widely used in petroleum, chemical, refrigeration, nuclear power, food, power, electric and many other industries for China and abroad. The topic research object of the Inlet Gas Electric Heater is a special type of Tubular Heat Exchangers, is mainly used in Ledong 15-1Gas Decarbonization Plant Project, its main function is to complete decarburization process heating in a pre-treatment system. The Inlet Gas Electric Heater is typically representative of the perfect combination of Heat Exchanger and the Electric Control Equipment. Electric heating is a kind of clean energy and conform to the requirements of the national energy conservation and emissions reduction.In this paper, the study of the Inlet Gas Electric Heater has a very unique structure design, combining the structure features of fixed tubesheet heat exchanger and U-tube heat exchanger, and it also has its own characteristics. The Inlet Gas Electric Heater has one channel, and the tubesheet is welded to the shell of both tube side and shell side. The tube ends in shell side are enclosed structure welded with end caps, the fluid filled tube side cannot flow, after the channel medium heat conduction oil filled the tube,then the heat conduction oil is heated by the electric heating element which installed in the channel, then heating the shell side fluid medium.The fixed tubesheet of Inlet Gas Electric Heater is more complex. the structure design of the tube bundle is unique, it is not directly calculated with the common calculation model, for this heat exchanger tubesheet calculation, we choose U Tube Heat Exchanger tubesheet calculation model as the approximate traditional and conventional calculation method, and chooses the relatively harsh conditions of the tubesheet carrying on the Finite Element Analysis(FEA) to verify the correctness of the above conventional calculation.This paper adopts Mechanical APDL14.5 for Finite Element Analysis(FEA) of the tubesheet, through the analysis of the temperature of the temperature field on the tubesheet, the author verifies the ASME code stated in the "skin effect theory". In this paper, the finite element analysis of the tubesheet in design condition, it is concluded that the tubesheet of the conventional design has more conservative and exists a big thinning allowance. Thus it can be seen through the finite element analysis for the tubesheet can largely optimization of tubesheet structure to comply for lightweight design requirements.The design structure and material of Inlet Gas Electric Heater are special, the whole materials of the electric heater are 316 L series materials, this paper is briefly described the 316 L series material properties and the applicable welding technology.Due to the special design structure, the fabrication and inspection of Inlet Gas Electric Heater are increased a lot of difficulty. This paper discusses the fabrication difficulty of the heat exchanger. Combining with the actual manufacturing technology, this paper also illustrates the application of important manufacture process.The conventional design of Inlet Gas Electric Heater tubesheet is verified by finite element analysis that using approximate calculation methods of u-tube heat exchanger tubesheet meets the design requirements, and finally the electric heater is verified via many inspection and test procedures that the strength design, manufacturing processing technology, sealing performance and so on of the heat exchanger meet the requirement of user. The product design and fabrication is successful. |
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