Professional Documents
Culture Documents
By
MAY 2010
i
ABSTRACT
ii
ACKNOWLEGEMENT
During the course of my thesis work, there were many people who were
instrumental and morally helping me. Without their guidance, help and
patience, I would have never been able to accomplish the work of this thesis.
I would like to take this opportunity to acknowledge some of them.
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DECLARATION
This thesis may be made available within the university library and
may be photocopied or loaned to other libraries for the purposes of
consultation.
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TABLE OF CONTENTS
ABSTRACT ..................................................................................................... ii
ACKNOWLEGEMENT ................................................................................... iii
DECLARATION ............................................................................................. iv
LlST OF TABLES .......................................................................................... vii
LIST OF FIGURES ........................................................................................ ix
LIST OF ABBREVATIONS ........................................................................... xii
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3.1 Introduction ......................................................................................26
3.2 Finite Element Modeling ..................................................................27
3.2.1 Correlation of Heat Transfer ......................................................28
3.2.2 Iteration Procedure....................................................................30
3.3 Remnant Life Estimation ..................................................................34
3.3.1 Cumulative Creep Damage .......................................................34
3.3.2 Cumulative Mechanical Fatigue Damage ..................................35
3.4 Summary .........................................................................................42
APPENDICIES. .............................................................................................84
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LlST OF TABLES
vii
Table 4.19. The estimated convection coefficients hs and hg for internal and
external surfaces respectively. ......................................................................66
Table 4.20. Remnant life estimation for Case 1 with the average steam
pressure, p =4.6 MPa ...................................................................................67
Table 4.21. Remnat life estimation for Case 2 with the average steam
pressure, p =4.0 MPa ...................................................................................67
Table 4.22 Steps of time used to estimate the remnant life of model 3. .......69
Table 4.23 Remnant life estimation for tube 1. .............................................70
Table 4.24 Remnant life estimation for tube 2. .............................................71
Table 4.25 Remnant life estimation for tube 3. .............................................71
Table 4.26. Remnant life estimation for tube 2 and 3 with LMP of 40600. ....73
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LIST OF FIGURES
Figure 2.9. Larson-Miller master curve for the SA213-T22 material [26]. .....16
Figure 2.10. Schematic presentation of temperature profile for a superheater
tube with an oxide layer on the inner surface. ...............................................18
Figure 2.11. Steam side scale formation for ferritic steels of 1-3% chromium
correlated withthe LMP [28]. .........................................................................21
Figure 3.1. The general description of the adopted methodology. ................26
Figure 3.2. Modeling of the boiler tube with scale on the inner surface. .......28
Figure 3.3. Inline and staggered arrangements of the bare tubes [45]. ........30
Figure 3.4. The iterative procedure to estimate average temperature and
scale thickness in boiler tubes. .....................................................................32
Figure 3.5.Maximum and minimum stress due to pressure fluctuation through
the day/night cycle. .......................................................................................36
Figure 3.6. Two possible cases for a component life prediction. ...................38
Figure 3.7. Remaining life estimation flow chart ...........................................41
Figure 4.1.Model of tow dimensional axisymmetric boiler. ............................46
Figure 4.2.Triangular elements meshing on tube model. ..............................47
Figure 4.3.Diagram of axisymmetric boiler tube with presence of oxide scale.
......................................................................................................................47
Figure 4.4.Diagram of axisymmetric boiler tube with presence of oxide scale.
......................................................................................................................49
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Figure 4.5.Temperature distribution along x-axis of Model 1 at time of 0
hours. ............................................................................................................50
Figure 4.6.Temperature distribution along x-axis of Model 1 at time of
160,000 hours. ..............................................................................................50
Figure 4.7. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 1. ...........51
Figure 4.8. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 2. ...........52
Figure 4.9. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 3. ...........52
Figure 4.10. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 4. ...........53
Figure 4.11. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 5. ...........53
Figure 4.12. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 6. ...........54
Figure 4.13. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 7. ...........54
Figure 4.14. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 8. ...........55
Figure 4.15. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 9. ...........55
Figure 4.16. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 10. .........56
Figure 4.17. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 11. .........56
Figure 4.18. Estimated scale thickness and average temperatures of the tube
metal as a function of time with different steam flow rate of Model 12. .........57
Figure 4.19. Average temperatures of the tube metal as a function of time
with different steam flow rate of Model 2.......................................................60
Figure 4.20. Estimated cumulative creep damage under an operational
pressure of 4.6 MPa with different steam flow rate of Model 8. ....................61
Figure 4.21. Estimated cumulative creep damage of Model 9 under different
operational pressuers with a steam flow rate of 3600 kg/h. ..........................61
Figure 4.22. Estimated cumlative creep damage of Model 10 with different
LMPs with a steam flow rate of 2600 kg/h an operational internal pressure of
4.6 MPa. .......................................................................................................62
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Figure 4.23. Cumulative creep damage with two different flue gas
temperatures of 800 and 900°C. ...................................................................74
Figure 4.24. Cumulative creep damage with two different steam temperatures
of 540 and 576°C. .........................................................................................75
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LIST OF ABBREVATIONS
Abbrevations
Symbols
µ Viscosity, Ms / m
∑ΔR Sum of all resistances
∑ΔT Sum of ΔT across individual layers,°R,°C
σref Tresca reference stress
Cp Specific heat, J / Kg.C
Cps Specific heat of the steam
Di Inner diameter of the tube
D Tube diameter
do Outer diameter of the tube
dxi Scale increase = (Xib – Xia)
Fe3O4 magnetite
G Gas mass velocity
ho Convection coefficient of flue gas
Hia Hardness value for the service hours tia
Hib Hardness value for the service hours tib
hs Convection coefficient steam
Kg Flue gas conductivity
Kmetal Thermal conductivityof the tube metal
ks Steam conductivity
kscale Thermal conductivity of the tube scale
L Length of the tube
L/D Ratio of length of the tube and tube diameter
P Larson-Miller Parameter
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Mass flow rate of the steam
mS
Nw Number of tube wide
p Operational pressure
Pr Prandtl number
Q/A Heat flux per unit of area, W / M2, Btu / hr.ft2
r1 Radius of inside surface
r2 Radius of scale / metal interface
r3 Radius of outside surface
Re Reynolds number
ri Inside radius
ro Outside radius
St Transverse pitch
T Temperature
C Constant ( taken to be 20 for SA213-T22)
t time
Tave-i Average of the inner surface and the scale / metal
interface temperature
Tri Time to rupture
tsi Service time
Wg Gas flow
X Scale thickness
Xia Scale thickness for the service hours tia
Xib Scale thickness for the incremental service hours tib
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