Stress in Boiler Drum

STRESS IN BOILER DRUM OBJECTIVE Upon completion of this lesson, students should be able to: Describe circumferential stress. Describe longitudinal stress. Describe need for compensation for holes cut in shell of a boiler. Discuss limitations of pressure imposed upon tank type boiler. Discuss reason for providing support to flat surface in a pressure vessel. State regulations relating to the materials used in boiler construction including tests.

LESSON OVERVIEW This lesson discusses circumferential and longitudinal stress in a boiler drum and need for providing strength to boiler by way of compensation rings at the openings and stays for the flat surfaces under pressure. Regulations regarding materials for construction and their tests are discussed.

REFERENCES Morton, Thomas D, Steam Engineering Knowledge for Marine Engineers (1994), Thomas Reed Publications Flanagan, G T H, Marine Boilers (2001) Milton, J H and Leach, Roy M, Marine Steam Boilers (1995)

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Stress in Boiler Drum

INTRODUCTION Stress in longitudinal joint is twice the stress in circumferential joint. CIRCUMFRENTIAL STRESS IN LONGITUDINAL SEAM

Fig.1 If pressure acting upon the circumference is resolved into horizontal components, the resulting horizontal force = pressure x projected area. This is resisted by the stresses setup in the longitudinal seam. Then for equilibrium conditions: Horizontal forces to left = Horizontal forces to right Horizontal forces to left = Resisting force in longitudinal seam Pressure x projected area = Stress x cross sect, area of seam Press. x dia. x length = Stress x 2 x thickness x length Pressure x diameter 2 x thickness = Stress in longitudinal seam

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Stress in Boiler Drum

LONGITUDINAL STRESS IN CIRCUMFRENTIAL SEAM

Fig. 2 The force acting upon the end plate is resisted by the stress set up in the circumferential seam. Then for equilibrium conditions: Horizontal forces to left = Horizontal forces to right Pressure x end plate area = Resisting force in circumferential joint Press. x x diameter2 4 Pressure x diameter 4 x thickness = Stress X cross sect. area of joint

= Stress in circumferential joint

Thus it follows that longitudinal stream stress is twice the circumferential seam stress.

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Stress in Boiler Drum

MAXIMUM WORKING PRESSURE IN TANK TYPE BOILERS

Fig 3 Arranging the circumferential stress formula in terms of pressure Max stress x 2 x thickness Max. Working pressure= diameter It has been shown that the seam subjected to the greatest stress will be the longitudinal joint. The strength of this joint governs the allowable working pressure. Thus it can be seen that if the stress in the material is to be kept within fixed limits (as is the case with boiler material) then, if the pressure or diameter increases, the plate thickness must also change if the ratio is to remain constant. Therefore if boiler pressure is increased, either the boiler shell diameter must decrease, or the boiler scantlings increase; the latter leading to increased cost and weight. In order to accommodate the combustion chamber, smoke tubes, etc., no great reduction in the shell diameter of tank type boilers is possible, and thus very thick shell plates would be required for high pressure. The furnace must also be considered, as its thickness must be kept within certain limits to prevent overheating. However, its diameter cannot be reduced too much; otherwise difficulties in burning the fuel in the furnace would arise. For these reasons the maximum pressure in tank type boilers is limited to about 17.5 bars. Table below shows reduction in allowable working pressure in bars with increase in diameter. Source ABS rules

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Stress in Boiler Drum

COMPENSATING PADS

Fig 4 Any material cut from the shell will weaken it by an extent related to the amount cut out. in general any holes cut in the shell, with a diameter greater than:2-5 x plate thickness + 70 mm must be provided with compensation for the loss of strength due to the material cut out. Some forms of compensating pads are shown in Fig. 4

Fig. 5

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Stress in Boiler Drum

The largest holes cut in the shell include the manholes, and where these are cut in the cylindrical portion of the shell they must be arranged with their minor axis parallel to the longitudinal axis of the boiler. This is due to the stress acting upon the longitudinal seam being twice that acting upon the circumferential seam. Thus the shell must not be weakened more than necessary along its longitudinal axis.

Fig. 6

SUPPORTING FLAT SURFACE WITH STAYS

Fig 7 When a force is applied to a curved plate as shown in Fig. 7, internal forces are set up which enable the plate to withstand the force without undue distortion. The bursting stress can be resolved into perpendicular components, one of which will oppose the force. The surface will bend until this component balances the pressure. It will then be found that the surface is in the form of an arc of a circle.

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Stress in Boiler Drum

Fig. 8 When the pressure acts upon a flat plate, it will tend to bend the plate until equilibrium is obtained as shown in Fig. 8. Thus to prevent undue distortion the flat plate must be very thick or supported by some form of stay. It follows that if the use of flat surfaces can be avoided in the design of a pressure vessel there will be no need to fit internal stays. Thus pressure vessels are often given hemispherical ends but, if this is not possible, any flat surfaces must be stayed or of sufficient thickness to resist the pressure without undue distortion.

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Stress in Boiler Drum

Fig.9 Diagrams of tank type boilers with stay and without stay BOILER MATERIALS Tube temperatures for the water cooled sections is considered to be saturation temperature plus 15oC. Tube temperatures for convection superheater sections is considered to be final superheat temperatures plus 30oC. For Radiant heat a higher temperature is considered. Tubes for water-tube boilers, superheaters and other parts of a boiler, where subjected to internal pressure, are of seamless steel or electric-resistance-welded tubing. For Superheater tubes operating above 455oC a Chrome Molybdenum alloyed steel is required.

SMA/May 2004