AALBORG INDUSTRIES

Impact of Internal Pressure to D-type Boiler Panel Wall and Buckstay

Catur Indra Pratisto
10/13/2008

Table of Contents
Abstract............................................................................................................................................................ 3 Introduction ..................................................................................................................................................... 4 Analysis Panel Wall ....................................................................................................................................... 5 Manual Calculation Results.......................................................................................................................... 5 Finite Element Analysis Results.................................................................................................................... 7 Analysis H-beam / Buckstay .......................................................................................................................... 8 Manual Calculation Results.......................................................................................................................... 8 Finite Element Analysis Results.................................................................................................................. 10 Results Summary and Conclusions ................................................................................................................ 12 Panel Wall .................................................................................................................................................. 12 H-Beam/Buckstay....................................................................................................................................... 13

Abstract
During operation, boiler is constantly subjected to certain value of internal pressure. In D-type boiler, this pressure is directly applied to assembly of tube and flat bar commonly referred to as panel wall. In addition to panel wall, H-beams are normally added and used as buck stay/support belt to reduce the impact of internal pressure to the panel wall. In this paper, simplified model of panel was created using Autodesk Inventor. This model was then imported to ANSYS Workbench to be analyzed. As a comparison, manual calculation was carried out using simple Mechanics of Materials principles. Simplifications and assumptions were made to ease the process of manual calculation. Free structural beam analysis software called Beamax was utilized to create force diagram, bending moment, and displacement curve to aid manual calculation. The stress and deformation results from both manual calculation and simulation software were then compared and analyzed. Stress and deformation values for panel wall as well as buckstay showed that results from ANSYS Workbench do not vary significantly compared to those of manual calculation. It is recommended to further develop application of ANSYS Workbench to analyze other areas of boiler application, for instance: optimization of boiler tube fin design using Workbenchs thermal analysis.

Introduction
Panel wall used in D-type boiler is subjected to internal pressure of 500mm H2O (approximately 5,000 Pa). An H-beams is used as buck stay/support belt to reduce the impact of internal pressure in the panel wall.

H-beam buck stay

Analysis Panel Wall

Manual Calculation Results In order to simplify the calculation, one section of the panel wall is extracted for analysis. Section length is approximately 7,900 mm. Tube dimensions: Outer diameter, D Thickness, t Inner diameter, d = 63.5 mm = 4 mm = D 2t = 55.5 mm

Flat bar dimensions: L t I total = 26.5 mm = 6 mm

= I O-beam + I flat bar = = 332,684 mm4 = 3.33e-7 m4

=D/2 = 31.75 mm

For simplification, assume pressure is applied only to total length of extracted section perpendicular to pressure direction.

Tube outer diameter, D = 63.5 mm Flat bar length, L = 26.5 mm

Section Length for Applied Pressure LA =D+L = 90 mm Pressure, P Distributed Load = 5,000 Pa = P * LA = 450 N/m

Load and Bending Moment Diagrams

M max

= 911 Nm

Panel Wall Tube 63.5 x 4mm thk + Flat bar 26.5 mm x 6 mm I Total Material Temperature of saturated steam at 40 barg Yield Strength at 250C, yield@250C max = (M max * y) / I total = 8.69e+07 Pa = 86.94 MPa Thus, max 86.94 MPa < < yield@250C 165 MPa = 3.33e+05 mm4 = RSt 35.8 = 250C (approximation) = 165 MPa (approximation)

Finite Element Analysis Results

From FEA Simulation: max = 9.37e+07 Pa = 93.68 MPa

Panel Wall Tube 63.5 x 4mm thk + Flat bar 26.5 mm x 6 mm Material Temperature of saturated steam at 40 barg Yield Strength at 250C, yield@250C Thus, max 93.68 MPa < < yield@250C 165 MPa = RSt 35.8 = 250C (approximation) = 165 MPa (approximation)

Analysis H-beam / Buckstay

Manual Calculation Results

From previous analysis, take the maximum load for worst case scenario analysis: Load, F = 2,250 N

For simplification, assume pressure is applied only to total length of extracted section perpendicular to pressure direction.

Tube outer diameter, D = 63.5 mm Flat bar length, L = 26.5 mm

Section Length for Applied Pressure LA =D+L = 90 mm Distributed Load, w = F / LA = 25,000 N/m

Load and Bending Moment Diagrams

M max

= 117,045 Nm

H-beam 200 x 200 I H-beam Material Temperature of saturated steam at 40 barg Yield Strength at 250C, yield@250C y max = 100 mm = (M max * y) / I total = 2.05e+08 Pa = 205.34 MPa max 205.34 MPa < < yield@250C 225 MPa = 57e+06 mm4 = St 52.0 = 250C (approximation) = 225 MPa (approximation)

Thus,

Finite Element Analysis Results

From previous analysis, take the maximum load for worst case scenario analysis: Load, F = 2,250 N

This load is applied only to length of extracted section perpendicular to pressure direction.

Tube outer diameter, D = 63.5 mm Flat bar length, L = 26.5 mm

Section Length for Applied Load LA =D+L = 90 mm

H-beam length 1, LB1

= 6120 mm

H-beam length 2, LB2 = 5630 mm Total load applied to the whole H-beam length:

Load at H-beam 1, FB1

= F * LB1 / LA = 153,000 N = F * LB2 / LA = 140,750 N

Load at H-beam 2, FB2

Take the highest load (= FB1) for worst case scenario analysis and apply it to the model:

From FEA Simulation: max = 2.08e+08 Pa = 207.78 MPa

H-beam 200 x 200 Material Temperature of saturated steam at 40 barg Yield Strength at 250C, yield@250C Thus, max 207.78 MPa < < yield@250C 225 MPa = St 52.0 = 250C (approximation) = 225 MPa (approximation)

Results Summary and Conclusions

Panel Wall

Max. Bending Stress: 86.94 MPa

Max. Bending Stress: 93.68 MPa

Max. Deflection: 16.75 mm

Max. Deflection: 12.18 mm

Result of from calculation: max < yield@250C 86.94 MPa < 165 MPa Maximum stress in panel wall is lower than yield stress

Result of from FEA simulation: max < yield@250C 93.68 MPa < 165 MPa Maximum stress in panel wall is lower than yield stress

The result from FEA is higher than calculated result due to the assumptions made to simplify the calculation.

H-Beam/Buckstay

Max. Bending Stress: 205.34 MPa

Max. Bending Stress: 207.78 MPa

Max. Deflection: 38.15 mm

Max. Deflection: 40.99 mm

Result of from calculation: max < yield@250C 205.34 MPa < 225 MPa Maximum stress in H-beam buck stay is lower than yield stress

Result of from FEA simulation: max < yield@250C 207.78 MPa < 225 MPa Maximum stress in H-beam buck stay is lower than yield stress

The result from FEA is higher than calculated result due to the assumptions made to simplify the calculation.