STRESS ANALYSIS REPORT

FOR
FRP SPRAY BANK HEADER

EMPLOYER: NTPC LIMITED

PROJECT: FEROZE GANDHI UNCHAHAR THERMAL POWER PROJECT

STAGE- IV (1 x 500 MW)

LOCATION: UNCHAHAR THERMAL POWER

EPC CONTRACTOR: GE POWER INDIA LIMITED

SUPPLIER: SUNRISE INDUSTRIES INDIA LIMITED

DOCUMENT TITLE: STRESS ANALYSIS REPORT FOR FRP SPRAY BANK

HEADER

DOCUMENT NO: SIIL-FEA-3699-01

DOCUMENT REV. NO: 00

00 06.08.2019 FRP SPRAY BANK PRANJAL JALPESH

Revision Date Description Prepared By Reviewed By Approved By

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STRESS ANALYSIS REPORT
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FRP SPRAY BANK HEADER

Table of Content

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Stress Analysis (FEM) Results

Project : Spray Header

First Saved Wednesday, July 24, 2019
Last Saved Wednesday, July 31, 2019
Product Version 14.0 Release
Save Project Before Solution No
Save Project After Solution No

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Contents
 Units

 Model (A4)
o Geometry
 main header
o Coordinate Systems
o Symmetry
 Symmetry Region
o Mesh
 Body Sizing 2
o Static Structural (A5)
 Analysis Settings
 Standard Earth Gravity
 Loads
 Solution (A6)
 Solution Information
 Results
 Stress Tool
 Safety Factor

 Material Data
o GFRP

Units
TABLE 1
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational Velocity rad/s
Temperature Celsius

Model (A4)
Geometry

TABLE 2
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\\SUNRISE\SPRAY HEADER\Spray Header
Source
1_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler

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Length Unit Millimeters

Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 16791 mm
Length Y 7751. mm
Length Z 1683. mm
Properties
Volume 4.4705e+008 mm³
Mass 737.64 kg
Scale Factor Value 1.
Statistics
Bodies 1
Active Bodies 1
Nodes 603846
Elements 305857
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves Updated File No
Use Instances Yes
Smart CAD Update No
Attach File Via Temp File Yes
Temporary Directory C:\ AppData\Local\Temp
Analysis Type 3-D
Decompose Disjoint Faces Yes
Enclosure and Symmetry
Yes
Processing

TABLE 3
Model (A4) > Geometry > Parts
Object Name main header
State Meshed
Graphics Properties
Visible Yes
Transparency 1

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Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference Temperature By Environment
Material
Assignment GFRP
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 16791 mm
Length Y 7751. mm
Length Z 1683. mm
Properties
Volume 4.4705e+008 mm³
Mass 737.64 kg
Centroid X 9710.8 mm
Centroid Y 10199 mm
Centroid Z 15934 mm
Moment of Inertia Ip1 1.4846e+009 kg·mm²
Moment of Inertia Ip2 1.2726e+010 kg·mm²
Moment of Inertia Ip3 1.3974e+010 kg·mm²
Statistics
Nodes 603846
Elements 305857
Mesh Metric None

Coordinate Systems
TABLE 4
Model (A4) > Coordinate Systems > Coordinate System
Object Name Global Coordinate System
State Fully Defined
Definition
Type Cartesian
Coordinate System ID 0.
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]

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Z Axis Data [ 0. 0. 1. ]

Symmetry
TABLE 5
Model (A4) > Symmetry
Object Name Symmetry
State Fully Defined

TABLE 6
Model (A4) > Symmetry > Symmetry Region
Object Name Symmetry Region
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Face
Definition
Scope Mode Manual
Type Symmetric
Coordinate System Global Coordinate System
Symmetry Normal Y Axis
Suppressed No

Mesh

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TABLE 7
Model (A4) > Mesh
Object Name Mesh
State Solved
Defaults
Physics Preference Mechanical
Relevance 4
Sizing
Use Advanced Size Function Off
Relevance Center Medium
Element Size Default
Initial Size Seed Full Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 3.10 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Advanced

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Shape Checking Standard Mechanical

Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 603846
Elements 305857
Mesh Metric None

TABLE 8
Model (A4) > Mesh > Mesh Controls
Object Name Body Sizing 2
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 1 Body
Definition
Suppressed No
Type Element Size
Element Size 50. mm
Behavior Soft

Static Structural (A5)

TABLE 9
Model (A4) > Analysis
Object Name Static Structural (A5)
State Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment Temperature 60. °C
Generate Input Only No

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TABLE 10
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Program Controlled
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart Points Program Controlled
Retain Files After Full Solve No
Nonlinear Controls
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement Convergence Program Controlled
Rotation Convergence Program Controlled
Line Search Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact Miscellaneous No
General Miscellaneous No
Calculate Results At All Time Points
Max Number of Result Sets Program Controlled
Analysis Data Management
Solver Files Directory C:\SUNRISE\SPRAY HEADER\Spray Header 1_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files Directory
Save MAPDL db No
Delete Unneeded Files Yes
Nonlinear Solution No
Solver Units Active System
Solver Unit System nmm

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TABLE 11
Model (A4) > Static Structural (A5) > Accelerations
Object Name Standard Earth Gravity
State Fully Defined
Scope
Geometry All Bodies
Definition
Coordinate System Global Coordinate System
X Component 0. mm/s² (ramped)
Y Component 0. mm/s² (ramped)
Z Component 9806.6 mm/s² (ramped)
Suppressed No
Direction +Z Direction

FIGURE
Model (A4) > Static Structural (A5) > Standard Earth Gravity

TABLE
Model (A4) > Static Structural (A5) > Loads
Fixed Slurry weight in Slurry weight in Slurry weight in Slurry weight in
Object Name
Support main header branch header 8A branch header 7 branch header 6
State Fully Defined
Scope
Scoping
Geometry Selection
Method
Geometry 23 Faces 15 Faces 9 Faces 11 Faces
Definition
Fixed
Type Force
Support
Suppressed No
Define By   Components
Coordinate
  Global Coordinate System
System
X Component   0. N (ramped)
Y Component   0. N (ramped)
Z Component   3480. N (ramped) 1560. N (ramped) 3120. N (ramped) 5090. N (ramped)

FIGURE
Model (A4) > Static Structural (A5) > Slurry weight in main header
Model (A4) > Static Structural (A5) > Slurry weight in branch header 8A
Model (A4) > Static Structural (A5) > Slurry weight in branch header 7
Model (A4) > Static Structural (A5) > Slurry weight in branch header 6

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TABLE
Model (A4) > Static Structural (A5) > Loads
Slurry weight in Slurry weight in Slurry weight in Slurry weight in Slurry weight in
Object Name
branch header 5 branch header 4 branch header 3 branch header 2 branch header 1
State Fully Defined
Scope
Scoping
Geometry Selection
Method
Geometry 11 Faces 9 Faces
Definition
Type Force
Define By Components
Coordinate
Global Coordinate System
System
X Component 0. N (ramped)
Y Component 0. N (ramped)
Z Component 5280. N (ramped) 5160. N (ramped) 4800. N (ramped) 2640. N (ramped) 1080. N (ramped)
Suppressed No

FIGURE
Model (A4) > Static Structural (A5) > Slurry weight in branch header 5
Model (A4) > Static Structural (A5) > Slurry weight in branch header 4
Model (A4) > Static Structural (A5) > Slurry weight in branch header 3
Model (A4) > Static Structural (A5) > Slurry weight in branch header 2
Model (A4) > Static Structural (A5) > Slurry weight in branch header 1

TABLE
Model (A4) > Static Structural (A5) > Loads
Internal Load due to orifice Load due to orifice Load due to orifice
Pressure due to
Object Name pressure due weight + slurry on weight + slurry on weight + slurry on
maintenance load
to fluid branch header 8A branch header 7 branch header 6
State Fully Defined
Scope
Scoping
Geometry Selection
Method
Geometry 95 Faces 98 Faces 9 Faces 11 Faces
Definition
Type Pressure Force
Define By Normal To Components
0.2 MPa
Magnitude  
(ramped)
Suppressed No
Coordinate
  Global Coordinate System
System
X
  0. MPa (ramped) 0. N (ramped)
Component

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Y
  0. MPa (ramped) 0. N (ramped)
Component
1.44e-003 MPa
Z Component   2790. N (ramped) 4030. N (ramped) 4960. N (ramped)
(ramped)

FIGURE
Model (A4) > Static Structural (A5) > Internal pressure due to fluid
Model (A4) > Static Structural (A5) > Pressure due to maintenance load
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 8A
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 7
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 6

TABLE
Model (A4) > Static Structural (A5) > Loads
Load due to Load due to
Load due to orifice Load due to orifice Load due to orifice
orifice weight + orifice weight +
Object Name weight + slurry on weight + slurry on weight + slurry on
slurry on branch slurry on branch
branch header 3 branch header 2 branch header 1
header 5 header 4
State Fully Defined
Scope
Scoping
Geometry Selection
Method
Geometry 11 Faces 9 Faces
Definition
Type Force
Define By Components
Coordinate
Global Coordinate System
System
X
0. N (ramped)
Component
Y
0. N (ramped)
Component
Z
5270. N (ramped) 4960. N (ramped) 3410. N (ramped) 2170. N (ramped)
Component
Suppressed No

FIGURE
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 5
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 4
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 3
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 2
Model (A4) > Static Structural (A5) > Load due to orifice weight + slurry on branch header 1

Solution (A6)
TABLE
Model (A4) > Static Structural (A5) > Solution

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Object Name Solution (A6)

State Solved
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Done

TABLE
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information
Object Name Solution Information
State Solved
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached To All Nodes
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines

TABLE
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Object Name Equivalent Stress Equivalent Elastic Strain Directional Deformation
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Equivalent (von-Mises) Stress Equivalent Elastic Strain Directional Deformation
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Orientation   Z Axis

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Coordinate System   Global Coordinate System

Integration Point Results
Display Option Averaged  
Results
Minimum 6.5174e-002 MPa 4.8483e-006 mm/mm -0.99946 mm
Maximum 97.215 MPa 6.5687e-003 mm/mm 19.129 mm
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1

TABLE
Model (A4) > Static Structural (A5) > Solution (A6) > Stress Safety Tools
Object Name Stress Tool
State Solved
Definition
Theory Max Equivalent Stress
Stress Limit Type Tensile Yield Per Material

TABLE
Model (A4) > Static Structural (A5) > Solution (A6) > Stress Tool > Results
Object Name Safety Factor
State Solved
Scope
Scoping Method Geometry Selection
Geometry All Bodies
Definition
Type Safety Factor
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged
Results
Minimum 1.3372
Information
Time 1. s
Load Step 1

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Substep 1
Iteration Number 1

Supports:

LOADINGS
The following loadings are computed from the given design data. This considers service and design
conditions.

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These loadings are evenly

distributed over the surfaces
concerned.
Lumped masses of orifices are
distributed over the concerned
branch pipes.
Slurry weight and maintenance load
is evenly distributed.
Internal pressure of 0.2 MPa is
applied on all the internal surfaces.
Gravity load (dead load) is applied
towards gravity.

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Stress distribution

Maximum stress recorded is 20 MPa.

Strain distribution
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Maximum strain is 0.004 mm/mm

Deformation

Maximum deformation : 17 mm at the extremities. This is 1% of the overhung.

Safety factor
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STRESS ANALYSIS REPORT
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Minimum safety factor 5-6 is maintained

Material Data
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GFRP (Hand layed laminate contact type)

TABLE 21
GFRP > Constants
Density 1.65e-006 kg mm^-3

TABLE 22
GFRP > Orthotropic Elasticity
Young's Young's Young's
Shear Shear Shear
Temperature Modulus X Modulus Y Modulus Z Poisson's Poisson's Poisson's
Modulus Modulus Modulus
C direction direction direction Ratio XY Ratio YZ Ratio XZ
XY MPa YZ MPa XZ MPa
MPa MPa MPa
60 12000 12000 12000 0.3 0.3 0.3 10000 10000 10000

TABLE 23
GFRP > Tensile Yield Strength
Tensile Yield Strength MPa
130

TABLE 24
GFRP > Compressive Yield Strength
Compressive Yield Strength MPa
150

TABLE 25
GFRP > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
150

TABLE 26
GFRP > Compressive Ultimate Strength
Compressive Ultimate Strength MPa
160

Conclusion: The stress and strain distribution is studied for the spray header and concluded that they
are within allowable values. Static deflection is within 1% of the largest dimension.
Hence the design is acceptable.

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