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ABSTRACT
Steam boiler is a closed vessel in which water or other fluid is heated under pressure and the steam released out by the boiler is
used for various heating applications. The main considerations in the design of a boiler for a particular application are
Thermal design and analysis, Design for manufacture, physical size and cost. In the present work a fire tube boiler is analyzed
for static and Thermal loading. The geometric model of boiler is created in CATIA V5 software as per the drawing. This model
is imported to HYPERMESH through IGES format and FEA model with converged mesh is developed using shell elements. To
this FEA model various loading conditions like design pressure, thermal loads and operating conditions are applied. One of the
supporting legs is arrested in all the directions and the other one is arrested only in X, Z-directions and all rotations. All these
are created by using HYPERMESH and it is exported to ANSYS for solution to obtain the deflections, stresses. Those values
are correlated with material allowable values as per the ASME Section VIII Division 2.
1. INTRODUCTION
A boiler is a closed vessel in which water or other fluid is heated under pressure. The steam or hot fluid is then
circulated out of the boiler for use in various process or heating applications. They can be used in stationary
applications to provide heat, hot water, or steam for domestic use or in generators and they can be used in mobile
applications to provide steam for locomotion in applications such as trains, ships, and boats. Using a boiler is a way to
transfer stored energy from the fuel source to the water in the boiler, and then finally to the point of end use. A boiler is
usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel is virtually prohibited (by the
ASME Boiler Code) for use in wetted parts of modern boilers, but is used often in super heater sections that will not be
exposed to liquid boiler water. In live steam models, copper or brass is often used because it is more easily fabricated in
smaller size boilers. A fire-tube boiler is a type of boiler in which hot gases from a fire pass through one or more tubes
running through a sealed container of water. The heat energy from the gases passes through the sides of the tubes by
thermal conduction, heating the water and ultimately creating steam.
Page 1
336
25494
14120
57206
39950
Page 2
3.95
60
35
152
0.55
3.4 Validation:
Validation of a boiler is very complicated and it is very difficult to formulate mathematically. To validate a comparison
between the results obtained based on theoretical calculations and the results obtained form the ANSYS has been
carried out. For this purpose, a thin cylinder is subjected to same load theoretically and in the finite element solver. The
comparison of the results shows a very close conformance.
From the formula for thin cylinder,
= pd/2t Where, p= internal pressure, N/mm; d= internal diameter of the cylinder, in mm
t = thickness in mm
For, p=2.157 N/mm
d=3698mm; t = 45mm; We get, =88.62 N/mm
Table 4: Comaprision of Analytical and ANSYS result
Stress
Radial stress, MPa
Analytical
Result
88.62
Ansys Result
80.1
% Variation
9.7
From the above 9.7% variation is observed between the simulated and theoretical results. Therefore, the analysis results
can be considered in the design of the boiler.
Displacement in X-direction, mm
Displacement in Y-direction, mm
Displacement in Z-direction, mm
Stress in X-direction, MPa
Stress in Y-direction, MPa
Stress in Z-direction, MPa
Stress Intensity, MPa
Results as
per Analysis
1.071
0.913
1.089
239.871
310.446
116.043
377.022
7
7
7
524
524
524
524
From the table it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe
as per the strength criteria. Shows the variation of max displacement in X, Y and Z-directions respectively 1.071,
0.913and 1.089mm. The max. Allowable displacement is 7mm. Hence the design is safe based on rigidity.
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Results as per
Analysis
0.8893
0.5836
3.159
129.977
206.226
110.288
206.782
From the table it is observed that the maximum stress induced is less than allowable stresses. Hence the design is safe
as per the strength criteria. shows the variation of max displacement in X, Y and Z-direction respectively 0.8893,
0.5836 and 3.159mm. The maximum allowable displacement is 7mm. Hence the design is safe based on rigidity.
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5. CONCLUSIONS
Thermal structural analysis of a boiler shell has been performed as per ASME Section VIII Division 2. CATIA was
used to model the boiler shell while the structural and thermal analysis was carried out using ANSYS software. Under
structural loading, the maximum deflection induced 1.089 mm under 2.157 MPa loads which is with in the allowable
limits i.e. < 7mm. The maximum stress induced is 377.02 MPa which is less than allowable limits of 524 MPa. Hence
the factor of safety is 1.389. Under thermal loading the maximum stress intensity is 206.782MPa, while the allowable
value as per ASME is 524 MPa. Hence the givenBoiler is safe to use under the present loading conditions.
References
[1] Bathe, K. J., Finite Element Procedures in Engineering Analysis, Prentice Hall, 1982.
[2] ANSYS Release 10.0, Documentation for ANSYS, 2011
[3] Wang Xucheng, Tang Yongjin, An effective numerical procedure for inelastic analysis of structures under thermomechanical loading, Finite Elements in Analysis and Design, Volume 18, Issues 13, December 1994, Pages 341
348.
[4] Ukadgaonkar V. G. Kale P. A., Agnihotri N. A., R. Shanmuga Babu, Review of analysis of tube sheets,
International Journal of pressure vessel and piping, 1996, PP 279-297.
[5] An Approach to Finite Element Analysis of Boiler Tube-Sheet R. D. Patil, Dr. Bimlesh Kumar, American Journal
of Engineering Research, ISSN : 2320-0936 Volume-02, Issue-08, pp-08-11.Zaili Zhao, Jinsheng Xiao, Ying Wu,
Xiaojun Zhang, Zhiming Wang, Structural Analysis and Optimal Design for Water Tube Panel in an Alkali
Recovery Boiler, Engineering, Scientific research,2010, 2, 353-359 doi:10.4236/eng.2010.25046
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