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Research Papers: Fluid-Structure Interaction

Influence of Boiler Load Swing Rates on Effective Stresses of Drum Boiler Riser Tubes

[+] Author and Article Information
M. A. Habib1

Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabiamahabib@kfupm.edu.sa

I. Al-Zaharnah, M. El-Shafei, S. A. M. Said, N. Merah

Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia

S. Al-Anizi, M. Y. Al-Awwad, M. Hajji

Department of Consulting Services, Saudi Aramco, Dhahran 31311, Saudi Arabia

1

Corresponding author.

J. Pressure Vessel Technol 132(6), 061301 (Oct 20, 2010) (8 pages) doi:10.1115/1.4001653 History: Received July 27, 2009; Revised April 21, 2010; Published October 20, 2010; Online October 20, 2010

In this paper, different rates of steam flow (swing rates) are used to demonstrate the transient changes in both the drum-boiler steam pressure and the wall temperature levels in addition to stresses in the walls of steam risers. A MATLAB code was written to integrate the nonlinear dynamic governing equations for solving the water volume, the drum pressure, and the steam quality at the exit of the riser tubes. The same code is also used for calculating the steam riser inner and outer wall temperatures based on the inner wall heat transfer coefficient. The temporal riser pipe pressure and the inner and outer pipe wall temperatures have been incorporated into an ANSYS model for calculating the effective combined thermal and pressure-caused stresses numerically. The combined effective stress fluctuation for the highest swing rate (40%) is found to be too low to induce any damage in the riser tube. The controlled pressure level has been compared with an actual pressure reading from an existing drum boiler under operating conditions for the purpose of validating the control parameters employed in the study. An optimization method for reducing the steam pressure overshoot level in the boiler is also proposed.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

Construction of the boiler furnace: water circulation loop

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Figure 2

Steam flow rate reading of the current boiler

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Figure 3

Calculated and experimental results of response of drum pressure to variations in steam flow rate

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Figure 4

Calculated and experimental results (close view) of response of drum pressure to variations in steam flow rate

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Figure 5

Input schemes of steam flow rate

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Figure 6

Pressure profiles at the inner wall of the riser tube in response to variations in steam flow rate

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Figure 7

Temporal temperature profiles at inner and outer walls in response to variations in steam flow rate

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Figure 8

Temporal combined pressure and thermal stress profiles at the inner and outer walls in response to variations in steam flow rate

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Figure 9

Wall temperature distributions at 10 s, 60 s, and 120 s

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Figure 10

Wall stress distributions at 10 s, 60 s, and 120 s

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Figure 11

Current and optimized controlled combined thermal- and pressure-induced stresses for the 40% increase in steam flow rate

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