Ensuring Structural Integrity: FEA- Buckling Analysis for Process Equipment

In process equipment manufacturing, structural integrity is key to reliability and safety. A major challenge is buckling failure, a structural collapse under compressive loads, commonly seen in long or large-diameter vessels with insufficient stiffeners.

The Challenge: Preventing Buckling Failure

A leading process equipment manufacturer, operating both in India and internationally, approached Analyzer CAE Solutions Pvt Ltd to evaluate the buckling resistance of their newly developed equipment. Their goal was to ensure that the design adhered to industry standards and remained structurally sound under operational loads.

One critical component under evaluation was the Centre Pipe of a Heat Exchanger, subjected to shell-side pressure. Since the consequences of buckling failure can be catastrophic, a robust simulation-based analysis was essential to predict and mitigate potential risks.

FEA-Based Approach for Buckling Analysis

Our approach involved a structured Finite Element Analysis (FEA) workflow to assess buckling failure modes:

1. Material Property & Design Parameter Identification

• Different Materials of Construction (MoCs) were considered.
• Essential design parameters were determined as per ASME BPVC Sec. VIII Div. 2.

2. Finite Element Model Preparation

• A high-fidelity elastic buckling analysis model was created.
• Special attention was given to the element type selection, as only a few elements provide reliable results in bifurcation analysis.

3. Bifurcation Analysis Using ANSYS APDL Solver

• The model was subjected to unit loading to determine eigenvalue buckling.
• Multiple mode shapes of buckling failure and their respective frequencies were extracted.

4. Design Factor Validation

• The calculated design factor was compared against the minimum required design factor per clause 5.4 of ASME BPVC Sec. VIII Div. 2.
• A safety margin was established to ensure operational reliability.

Results & Conclusion

Through detailed simulation and design validation, Analyzer CAE Solutions Pvt Ltd confirmed that the centre pipe’s design was structurally safe against buckling failure. The calculated design factor exceeded the ASME-defined minimum threshold, ensuring long-term operational safety and compliance with industry standards.

By leveraging advanced simulation techniques, process equipment manufacturers can significantly reduce the risk of structural failures, optimize designs, and enhance overall reliability.

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