ISSN Vol.04,Issue.12, September-2016, Pages:

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1 ISSN Vol.04,Issue.12, September-2016, Pages: Finite Element Analysis of Boiler Shell with Riveted Joints using Composite Materials SENCHA OMPRAKASH 1, BASAWARAJ S HASU 2 1 PG Scholar, AVN Institute of Engineering and Technology, India, prakashsencha343@gmail.com. 2 Associate Professor, AVN Institute of Engineering and Technology, India. Abstract: In this project, finite element analysis is conducted on the boiler shell with riveted joints using composite materials for its strength. The 3D modelling of the boiler shell is done in Pro/Engineer.Static analysis, modal analysis is performed and compared for different materials steel, aluminium alloy, composite materials CFRP by using solid element. Analysis is also conducted using composite materials using shell element. Analysis is done in Ansys. Keywords: CFRP, Ansys, 3D Modelling. I. INTRODUCTION A. Boiler A boiler is an enclosed vessel that provides a means for combustion heat to be transferred into water until it becomes heated water or steam. The hot water or steam under pressure is then usable for transferring the heat to a process. Water is a useful and cheap medium for transferring heat to a process. When water is boiled into steam its volume increases about 1,600 times, producing a force that is almost as explosive as gunpowder. This causes the boiler to be extremely dangerous equipment that must be treated with utmost care. Fig1. The boiler system comprises of: feed water system, steam system and fuel system. The feed water system provides water to the boiler and regulates it automatically to meet the steam demand. Various valves provide access for maintenance and repair. The steam system collects and controls the steam produced in the boiler. Steam is directed through a piping system to the point of use. Throughout the system, steam pressure is regulated using valves and checked with steam pressure gauges.the fuel system includes all equipment used to provide fuel to generate the necessary heat. The equipment required in the fuel system depends on the type of fuel used in the system. B. Boiler Efficiency Boiler efficiency is a combined result of efficiencies of different components of a boiler. A boiler has many sub systems whose efficiency affects the overall boiler efficiency. Couple of efficiencies which finally decide the boiler efficiency are- Combustion Efficiency Thermal Efficiency Apart from these efficiencies, there are some other losses which also play a role while deciding the boiler efficiency and hence need to be considered while calculating the boiler efficiency. II. LITERATURE SURVEY In the paper by Gurpreet Singh, Vinod Kumar Mittal, SurjitAngra[1], stress analysis of boiler shell with riveted joints. By using finite element method, a stress analysis has been carried out under the application of pressure at the inner surface of boiler shell. Von-Mises stresses and maximum shear stresses are found. These stresses are compared with analytical results. Using the two materials, structural steel and aluminium alloy, stress values have been compared for same working conditions. It is found that structural steel is safer as compared to aluminum alloy at the same working conditions. Modeling has been done by CATIA V5 and analysis of riveted joint has been done by ANSYS (Workbench) with a version In the paper by Farah KamilAbid Muslim[2]establish software programs for designing and analyzing rivets for boiler shells as an example to use rivets in industry. In general rivets are considered as mechanical elements of wide range application. A software program using Visual Basic Version 5 with ACCESS database is used for design of rivets. When the user inters the input data to the system and depending on existing database, the software 2016 IJIT. All rights reserved.

2 carries out a series of complex computations, after which it produces a comprehensive report that includes all engineering dimensions and efficiency. The program, designed in this research, has feasible ability to deal with data base in an easy and reliable way especially for unprofessional users. This is a database that can be updated and edited at any time to get proper results. The program can be applied also to different types of riveted joint. SENCHA OMPRAKASH, BASAWARAJ S HASU IV. STRUCTURAL ANALYSIS OF SOLID WALL BIOLER SHELL WITH RIVETED JOINTS III. PRESSURE CALCULATIONS A double riveted lap joint has been analyzed. Diameter of the cylinder = 1500 mm. Pitch = 105 mm Thickness of the cylinder = 22 mm Diameter of the Rivet = 25 mm t = PD + 1 2σ t η l t = Thickness of Boiler Shell. P= Steam pressure in Boiler D= Internal diameter of Boiler shell σ t = Permissible tensile stress, and η l = Efficiency of the longitudinal joint Fig2. Displacement. 1. Tearing resistance of the plate pt =(p-d) t. σ t 2. Shearing resistance of the rivet Ps=n 2 π/4 d 2 τ 3. Crushing resistance of rivet Efficiency of the joint Strength of the un-riveted or solid plate P=P t σ t Efficiency of the joint Least of Pt,Ps & Pc = P t = PD + 1 2σ t η l Fig3. Pressure. A. Material Carbon Fiber: 1. Material properties of Carbon fiber Density :1800kg/m 3 Young s modulus :150000Mpa Poisson s ratio :0.23 Fig1. 3D Model Boiler Shell with Riveted Joints. Fig4. Deformation.

3 Finite Element Analysis of Boiler Shell with Riveted Joints using Composite Materials Fig5. Strain. Fig8. Mode 2. Fig6. Stress. 2. Modal Analysis Fig9. Mode 3. B. Layer Stacking Method 1. Structural Analysis with 3 Layers Fig7. Mode 1. Fig10. Deformation.

4 SENCHA OMPRAKASH, BASAWARAJ S HASU Fig11. Strain. Fig14. Mode 2. Fig12. Stress. 2. Modal Analysis Fig15. Mode 3. D. Structural Analysis with 5 Layers 1. Material Carbon Fiber Fig13. Mode 1. Fig16. Deformation.

5 Finite Element Analysis of Boiler Shell with Riveted Joints using Composite Materials Fig17. Strain. Fig20. Mode 2. Fig18. Stress. 2. Modal Analysis Fig21. Mode 3. Fig19. Mode 1. Fig22.

6 SENCHA OMPRAKASH, BASAWARAJ S HASU Fig23. Fig24. Fig25. Fig26. V. CONCLUSION By observing the static analysis results, the deformation and stress values are increasing by taking layer stacking method. The deformation and stress values are decreasing by adding thickness to the shell. By comparing the results between the materials, the deformation and stress values are less for CFRP when compared with of Steel and Aluminum Alloy. By observing the modal analysis the deformation values are more for Solid element than layers but the frequencies are less. The material CFRP has fewer frequencies so when CFRP is used boiler has less vibration. So it can be concluded that using CFRP is better. VI. REFERENCES [1] Gurpreet Singh, Vinod Kumar Mittal, SurjitAngra, Static structural analysis of boiler shell with riveted joints using ANSYS, International Journal of Research in Management, Science & Technology (E-ISSN: ), Vol. 1; No. 2, December [2] M.Sc. Farah KamilAbid Muslim Dr.Essam L. Esmail, Al- Qadisiya, Computer aided design of rivets for steam boiler shells, Journal For Engineering Sciences, Vol. 5, No. 4, , Year [3] John H. Cooper, On the longitudinal riveted joints v steam-boiler shells, Journal of the Franklin Institute, Volume 128, Issue 2, August 1889, Pages [4] AslamkhaKausarkhaPathan, Sheikh Kasim Sheikh Rauf, Nikhil V. Nandanwar, Static structural analysis of boiler shell with riveted joints using CAE Tool s, International Journal of Engineering Research and Development, e-issn: X, p-issn: X, Volume 10, Issue 3 (March 2014), PP [5] William Barnet LE Van, Riveted joints in boiler shells, Read at the state meeting of institute, held Nov 19,1890. [6] M. SuriBabu, Dr.B.Subbaratnam, Finite element analysis of steam boiler used in power plants, SSRG International Journal of Mechanical Engineering (SSRG-IJME) volume 1 Issue 6 October [7] Haitham A. Bogis, Ali AbouEzz, Abdulmalik A. Aljinaidi

7 Finite Element Analysis of Boiler Shell with Riveted Joints using Composite Materials and Mehmet Akyurt, An interactive software for the design of riveted joints, Research Gate. [8] Steam Boiler Room Questions & Answers, Third Edition by Stephen M.ElonkaandAlex Higgins. [9] Steam Boiler Operation by James J.Jackson, Prentice-Hall Inc, New Jersey, [10] Boilers by Carl D. Shields, McGraw Hill, Book Company, U.S, Author s Profile: Sencha Omprakash, PG Scholar, AVN Institute of Engineering and Technology, India, prakashsencha343@gmail.com. Basawaraj S Hasu, Associate Professor, AVN Institute of Engineering and Technology, India.