ICCBT 2008 - F - (14) pp157-170

ICCBT2008


Tube Temperature Distribution in Water Tube Boiler- A
Parametric Study by Finite Element Method


M. M. Rahman*, Universiti Tenaga Nasional, MALAYSIA
Sukahar, Universiti Tenaga Nasional, MALAYSIA


ABSTRACT

This paper presents the application of finite element method (FEM) to analyze the tube
temperature distribution in a water tube boiler. Two-dimensional (2-D) finite element models
are developed where the axi-symmetric triangular elements for the cross section area along
the water tube are applied in computer software namely MSC Patran-Nastran. The analysis
of the temperature distribution for every location inside the domain is conducted by setting
constant heat fluxes and varying parameters such as mass flow rate of steam, material
properties of the tube, steam inlet temperature, and scale thickness. The results showed that
the temperature distribution at the tube wall decreases due to increasing of mass flow rate of
steam, decreasing thermal conductivity of tube, steam inlet temperature, and increasing scale
thickness.

Keywords: finite element method, water tube boiler, temperature profile, mass flow rate.
















*Corresponding Author: Assoc. Prof. Dr. Md. Mujibur Rahman, Universiti Tenaga Nasional, Malaysia.
Tel: +60389297269, Fax: +60389212116. E-mail: [email protected]
Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 158
1. INTRODUCTION

The common causes of the metallurgical failure of the tubes in water tube boiler are due to
tube temperature higher than expected in the original design. Tube temperature increases
slowly over many years or rapidly caused either by loss of internal steam or water flow.
Internal oxide scale or deposit formation usually results in long term overheating that
gradually increases the temperature [1]. Although steam temperature occasionally measured
in a boiler, local tube temperature and temperature distribution are rarely measured and some
times impossible due to temperature range which is very high, load fluctuation and steam side
oxide scale growth during operation [2]. However, the remaining life span of the boiler tubes
that installed in a fossil fuelled power station can be predicted if the stress and average
temperature of the tubes are known, together with the way the tubing is thinned or scarred as a
result of erosion and corrosion processes [3]. Arguably, the average tube temperature plays a
more significant role than stress does in determining the creep life of a boiler tube. In order to
avoid the tube failure, detection of tube temperature distribution is necessary to take proper
action. Therefore, temperature distribution in the tubes in water tube boiler needs to be
analyzed numerically. Therefore, this paper presents the application of finite element method
(FEM) to analyze the tube temperature distribution in a water tube boiler.


2. LITERATURE REVIEW

In water tube boilers, water is converted into steam inside the tubes, while hot gases pass over
and around the outside of the tubes. Water tube boilers can operate at higher pressures than
fire tube boilers. The flow of steam and water within a water tube boiler is called circulation.
This circulation is critical in preventing tubes from overheating. When tubes are overheated,
metal softens, weakens and may eventually rupture. In a simple water tube circuit, bubbles of
steam form in the heated tubes or "risers". The resulting steam and water mixture is lighter
than cooler water on the unheated side of the boiler, and rises to a steam drum at the top of the
boiler. Here the bubbles rise to the surface and steam is released. The water then flows from
the drum down through the cooler rubes, or "downcomers", completing and repeating the
cycle. The water circulation in a water tube boiler is shown in Figure 1.


Figure 1. Water circulation in a water-tube boiler [4]
M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 159
The Metallurgy Department of the Riley Stoker Corp. [1] that has many experiences for the
25-years period ending in 1980 gives the list of the breakdown between mechanical and
corrosion failure and further classify the various kinds of failures, locations, and materials.
81% of the boiler tube failure is due to mechanical, consist of high temperature failure (short
time) 65.8%, creep (high temperature/long time) 8.6%, and others 6.6%, while boiler failures
caused by corrosion is 19%. Analysis of the North American Electric Reliability Council
(NERC data) indicates that the coal fired boilers are among the highest economic risk
components in any power plant. By far, the greatest number of forced outages in all types of
boiler is caused by failures [6]. Elimination of boiler tube failure could save the electric
power industry about $5 billion a year [7]. Metallurgists from David N. French, Inc. [1]
published data of the top 10 causes of failures where creep (long-term overheating) is 23.4%,
followed by fatigue (13.9%) (thermal 8.6%, corrosion 5.3%), ash corrosion (12.0%),
hydrogen damage (10.6%), weld failures (9.0%), high temperature (short-term overheating)
(8.8%), erosion (6.5%), oxygen pitting (5.6%), caustic attack (3.5%) and stress corrosion
cracking (2.6%). In general, 30% of all tube failures in boilers and reformers are caused by
creep [8].


2.1 Boiler Failure Analysis

Internal pressurized tubes are critical component in water tube boiler and steam superheater
element. Tubes in such application are vulnerable to temperature excursions, as a
consequence the material may enter the creep regime, and creep deformation and even
fracture may occur. Therefore, boiler tubes in power plants have finite life because of prolong
exposure to high temperature, stress, aggressive environment, corrosive degradation, etc.
However, uses of safe boiler tube material in thermal power plants is required to make sure
that these materials are safely used under higher temperatures and pressures for long periods
of operation [9].

Ray et al. [10] conducted assessment of service exposed to boiler tube of the super heater and
reheater made of 2.25 Cr-1 Mo steels in a 120 MW boiler of a thermal power plant. The
results show that although there was degradation of ultimate tensile strength (UTS), and stress
rupture of the boiler tubes due to increasing temperature and prolonged service exposure, but
at the operating condition of 540C/40 MPa, all these service exposed tubes have a remaining
life of more than 100,000 hours, provided that there are no defects in the materials due to long
term service exposure. Husain and Habib [11] investigated the steel tubes failure in a super
heater boiler at one of the Kuwait Electrical and Power plants which suffered localized
overheating. The tube was made of low alloy steel, SA 213-T12 and it has been in operation
for 109,415 hours before failed. The investigation indicated that the failure attributed to the
formation of thick scale of magnetite at the inner surface of the tube wall. This phenomenon
prevented the accessibility of heat to the tube materials and consequently local, prolong
overheating took place, in which the temperature raised up to 700
o
C in a frequent manner for
long period of time. The properties of the tube materials changed from its original design
values due to the effect of the localized prolong overheating as a consequence of increasing of
the temperature.

Baoyou et al. [12], analyzed a boiler tube rupture through chemical analysis, scanning
electron microscope, and energy dispersive spectroscopy. The results showed that the tube
burst due to overheating and excess temperature caused by obstruction of stream flow
Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 160
associated with the bubble clusters on the surface of local regions. Khajavi et al. [13] tested
including visual examination, optical microscope, scanning electron microscope (SEM), and
X-ray diffraction (XRD) revealed the root causes of the boiler tube failure due to waterside
corrosion problems. The results showed that corrosion failures are caused by a combination
of ineffective control of water chemistry, deficiencies in design and material selection and
operational problems such as inadequate waterside circulation which led to the formation of
deposits in localized zones along a water line.

Srikanth et al. [14] conducted failure analysis of several evaporator tubes during
commissioning and trial run of a waste heat recovery boiler using visual inspection, chemical
analysis, X ray radiography, fractography, microscopic examination at various locations,
mechanical properties measurement and analysis using SEM. The results showed that the
failure of the evaporator tubes at the tube bends have been initiated by lamellar tiring because
of inherent defects in the material, improper design of welding, and the absence of stress
relieving treatment after the cold bending and welding operations. Chattoraj et al. [15] have
investigated the corrosive degradation and failures of vertical furnace wall tubes of a co-
generation boiler. The investigations include chemical analysis of the corrosion deposit and
microstructural observations. The results showed that the most probable degradation
mechanism is acid corrosion and under deposit corrosion due to the presence of deposits,
leading to localized heating (due to scale formation), and eventual rupture assisted by
overheat and decarburization.


2.2 Numerical Analysis of Boiler Tube Failure

Finite element analysis is considered to apply because it is a powerful tool for the numerical
solution of a wide range of engineering problems such as; deformation and stress analysis,
heat transfer, fluid flow, and other problems. Some examples of commercial finite element
softwares are; Abaqus, SDRC-Ideas, Rasna and MCS/Nastran [16]. The other commercially
available softwares to conduct finite element analysis are Algor, Ansys, Cosmos/M, Stardyne,
and Image-3D. Hagihara and Miyazaki [17] conducted simulation using Abaqus to analyze
creep failure of coolant pipe in light water reactor due to local heating. The results showed
that under isothermal condition, the creep damage depends only on the stress. Since the stress
is higher in the inside of the wall, the creep damage is also higher in the inside of the wall. In
the distribution of the damage variable, higher damage is accumulated at the inside than at the
outside of the wall. On the other hand, under the non-isothermal condition, the damage
variable is affected not only by the stress but also by the temperature. It is found that the
stress is higher in the lower temperature region. In the higher temperature region, the stress
becomes lower due to the larger stress relaxation caused by larger creep rate. In the
distribution of the damage variable, higher damage is clearly higher at the outside than at the
inside in the higher temperature region.

Caligiuri [18] conducted simulation to identify the effect of thermal constraint in design of a
heat recovery boiler. The finite element model using thermal and structural analysis was
applied, and commercially available finite element software namely Ansys was used. The
results showed the maximum hoop stress varied as a function of location, with the peaks in the
range of 55-60 ksi generally at the uppermost tie welds and the outer-loop tubes, where the
tube to tube temperature differences were highest. Dini et al. [19] used the FEM to compute
the effect of increasing temperature on the tube service life and to define the critical regions.
M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 161
The result indicates that the increasing temperature causing a particular tube failure mode.
The simulation result also shows that the failed region in radiant tube is easily influenced by
high temperature creep. Zarrabi et al. [3] developed a non-dimensional parameter that can be
used to estimate the tube temperature variation in the locally damaged (scarred) boiler tube,
and also a method has been described for volume estimation and characteristics of a tube scar.
Although steady state heat transfer analysis of the scarred tube was performed using
MSC/Patran software in this analysis but effect of different mass flow rates, existence of scale
and other parameters are not involved. Therefore, analysis by involving these parameters
should be considered.



3. FINITE ELEMENT FORMULATION

The element conductance matrix [ ] k for the heat transfer problem can be written as [5]

[ ] [ ] [ ][ ] [ ] [ ]

+ =
v s
T T
dS N N h dV B D B k
3
(1)
where the first and second integral in equation (1) are the contributions of conduction and
convection, respectively. The elements thermal load matrix is expressed as

[ ] [ ] [ ] [ ]


+ + =
v s
T
s
T T
dS T h N dS q N dV Q N f
3 2
(2)
The first term in equation (2) is the heat source } {
Q
f , the second term is the heat flux } {
q
f ,
and the third term is convection heat transfer } {
h
f which is equivalent to

hT . The terms
2
s
and
3
s

are separate surface areas over which heat flow (flux) q and convection heat transfer
are specified. The global conductance matrix can be obtained using the direct stiffness
method; that is,
[ ] [ ]

=
=
N
e
e
k K
1
) (
(3)
The global thermal load matrix is the sum of all element heat source and is given by
{ } { }

=
=
N
e
e
f F
1
) (
(4)
The global equation is then
[ ]{ } [ ] K T K = (5)
or
{ } [ ] { } F K T
1
= (6)
where
{ } T = unknown nodal temperature
[ ]
1
K = inverse of global conductance matrix
{ } F = global thermal load matrix



Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 162
3.1 Geometrical Modeling

The model of the boiler tube is divided into three regions consist of steam region, scale
region, and steel region. Steam flows inside the tube, while flue gas flows outside the tube.
The overall tube section is 20.00 mm long with an inside diameter of 42.60 mm and an
outside diameter of 50.80 mm. In order to complete the model, internal scale thickness of 0.5
mm with 20 mm length is placed inside of tube wall. Figure 2 shows a 2-D model of boiler
tube.

Figure 2. Model of two dimensional axisymmetric boiler tube with inside scale

3.2 Material Properties

Data of material properties for this analysis have been taken from Asam-Asam Steam Power
Plant that located in South Kalimantan-Indonesia, with 2 times 65 MW of total capacity, and
starting for commercial operation on November 2000. All properties of steam, scale, steel and
flue gas that are used, shown in Table 1


Steam




20 mm
10 mm
z
r
25.40 mm
21.30 mm
20.80 mm
Tube
Wall
Scale
Flue gases
M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 163
3.3 Simulation

The simulation conducted for analyzing the temperature distribution along the region of scale
and tube wall, consist of four parts, i.e.
i. Analyzing with three different mass flow rates, which are
1
m& =68 kg/s,
2
m& =168 kg/s,
and
3
m& =268 kg/s,
ii. Analyzing by varying the tube materials which are Carbon steel SA-210 A-1 with thermal
conductivity, k =39.80 W/mK, Low alloy steel SA-213 T11 with thermal conductivity,
k =30.29 W/mK, and Stainless alloy 304 with thermal conductivity, k =16.20 W/mK.
Other properties of tube material such as; density and specific heat also changed
depending on the kinds of material,
iii. Analyzing by varying steam inlet temperature, which are
1
T =330C,
2
T =430C, and
3
T =530C. Uses of the different steam inlet temperature have been implication on the
different properties of steam such as density, specific heat, thermal conductivity, and
dynamic viscosity, and
iv. Analyzing using three different scale thickness, which are
1
t =0.5 mm,
2
t =1.0 mm, and
3
t =1.5 mm.

Table 1: Properties of steam, scale, steel, and flue gas

Properties Steam Scale

Low alloy steel
(SA-213 T11)
Flue gas
Temperature, C 430 - - 588
Thermal conductivity, W/m.C 0.05830 1.3 30.29 -
Convection coefficient, W/m
2
.C - - - 57
Specific heat, J /kg.C 2087 - - -
Density 0.3135 - - -
Dynamic viscosity, kg/m.s 2.566x10
-5
- - -
Mass flow rate, kg/s 68 - - -



4. RESULTS AND DISCUSSIONS

The temperature distribution in the boiler tube is affected by many variables such as; mass
flow rate of steam, boiler tube material, steam inlet temperature, and scale thickness.
Therefore, those variables are considered to be applied in this analysis.


4.1 Temperature Distribution Due To Different Mass Flow Rate

Figure 3 shows temperature distribution of boiler tube for 68 kg/s of mass flow rate, and the
effect of the existence of scale to the temperature distribution in the boiler tube if compared
with surface without scale. For 68 kg/s of mass flow rate, the minimum temperature is found
to be 569
o
C at the inner tube (in the scale region), and maximum is 587
o
C at the outer surface
of the tube wall.

It is evident from Figure 4 that the mass flow rate strongly influences the temperature
distribution of the water tube boiler. It is found that the increase of mass flow rate of steam
Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 164
through the boiler tube causes the decrease in temperature in the inner tube wall. This
behavior occurs due to heat releasing from flue gas to steam is not proportional, ability to
absorb heat from flue gas for higher mass flow is faster than lower mass flow rate.
Furthermore, from Figure 4 it can be compared that on the scale region, temperature
difference for different mass flow rate in the same position in x direction are larger than the
region without scale. As an illustration, for mass flow rate of 68 kg/s, tube temperature at
3 . 20 = x mm is 569
o
C. In contrast, for mass flow rate of 268 kg/s, the temperature is 542
o
C,
hence, there is 27
o
C difference in temperature at the same location. Of course, this matter has
to be a consideration in operation of power station. It means, if mass flow rate of steam
increased, as a consequence of it, temperature of flue gas must be increased to make heat
balance in equilibrium condition.


Figure 3. Temperature distribution for mass flow rate 68 kg/s

520
530
540
550
560
570
580
590
600
20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26
Distance from x (mm)
T
e
m
p
e
r
a
t
u
r
e

(
d
e
g

C
)
MFR 68
MFR 168
MFR 268

Figure 4. Plot of temperature distribution for different mass flow rate

x =20.8
x =21.3
M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 165
4.2 Temperature Distribution Due To Different Thermal Conductivity Of Tube

Thermal conductivity is an important property in heat transfer problems, especially in
conduction heat transfer. Materials with higher thermal conductivity have ability to absorb
heat more than material with lower thermal conductivity. Figure 5 illustrates the temperature
distribution of boiler tube for stainless alloy 304 with thermal conductivity of
k =16.20 W/mC, in which minimum temperature is found to be 566
o
C at the inner tube
(scale region), and maximum temperature is 587
o
C at the outer surface of the tube.

Figure 5. Temperature distributions for tube material of stainless alloy 304

Figure 6 illustrates the temperature distribution of the boiler tube for different thermal
conductivity of materials which are Carbon steel SA-210 A-1, Low alloy steel SA-213 T11, and
Stainless alloy 304. Referring to the Figure 6, it can be stated that material with lower thermal
conductivity causes lower temperature at the inner tube wall due to the lower ability to absorb
heat from the flue gas. Although, materials with higher thermal conductivity have ability to
absorb heat better than material with lower thermal conductivity, but in design of boiler tube,
occasionally other properties of material such as resistance to erosion and corrosion have to be
considered. Therefore, these matters should be considered so that performance of the boiler
can be maintained all the time.
Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 166
520
530
540
550
560
570
580
590
600
20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26
Distance from x (mm)
T
e
m
p
e
r
a
t
u
r
e

(
d
e
g

C
)
Carbon Steel
Low Alloy Steel
Stainless Alloy

Figure 6. Plot of temperature distribution for different tube materials

4.3 Temperature Distribution at Different Steam Inlet Temperature

The steam inlet temperature affects the thermal efficiency of a thermal power plant. The
higher steam inlet temperature increases thermal efficiency. In contrast, operating boiler with
higher temperature have some disadvantages, i.e., to make steam inlet temperature higher,
more time is required, and also strength of tube materials should be considered because higher
temperature will degrade the strength of material and also thermal conductivity. Higher
operating temperature also can increase scale growing [1]. Therefore, it is required to conduct
simulation on the effect of steam inlet temperature to the temperature distribution in the boiler
tube. Figure 7 shows the temperature distribution of the boiler tube for steam inlet temperature
of 330
o
C, in which minimum temperature is found to be 569
o
C at the inner tube (scale
region), and maximum temperature is 587
o
C at the outer surface of the tube.

Figure 8 illustrates the temperature distribution at the boiler tube for different steam inlet
temperatures. It is found that different steam inlet temperature has implication on the
temperature distribution at the boiler tube due to all properties of fluid such as; thermal
conductivity, density, specific heat, and dynamic viscosity are measured based on that
temperature. From the Figure 8, it is evident that in the tube region, implication of different
steam inlet temperature is not significant compare to the scale region. As an illustration, at
the tube region ( 3 . 21 = x mm), inner tube temperature for steam inlet temperature of 330C is
found to be 580
o
C while, for steam inlet temperature of 530C it is 586
o
C, hence there is 6C
of temperature difference. In contrast, at the scale region ( 8 . 20 = x mm), inner tube
temperature (scale region) for steam inlet temperature of 330C is found to be 560
o
C while,
for steam inlet temperature of 530C it is 581
o
C, hence there is 21C of temperature
difference.

M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 167

Figure 7. Temperature distributions for steam inlet temperature 330
o
C
Temperature Distribution for Different Steam Inlet Temperature
520
530
540
550
560
570
580
590
600
20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26
Distance from x (mm)
T
e
m
p
e
r
a
t
u
r
e

(
d
e
g

C
)
IT 330C
IT 430C
IT 530C

Figure 8. Plot of temperature distribution for different steam inlet temperature


4.4 Temperature Distribution At Different Scale Thickness

Existence of scale reduces heat transfer rate from flue gas to steam in the boiler tube because
thermal conductivity of scale is lower than the tube material. As the scale thickness increases,
the temperature of steam decreases. As a consequence, energy transferred from steam
decreases. In order to make equilibrium condition, temperature of flue gas has to be
increased. However, increasing the temperature of flue gas needs time and combustion of
x =20.8
x =21.3

Tube Temperature Distribution in Water Tube Boiler- A Parametric Study by Finite Element
Method
ICCBT 2008 - F - (14) pp157-170 168
additional fuel. The disadvantages of increasing the temperature of the flue gas is decreasing
rupture strength of material [10]. Therefore, existence of scale must be eliminated. Figure 9
shows the temperature distribution of the boiler tube for 1.5 mm of scale thickness, in which
the minimum temperature is found to be 548
o
C at the inner tube (scale region), and maximum
is 588
o
C at the outer surface of the tube.


Figure 9. Plot of temperature distribution for scale thickness of 1.5 mm

Figure 10 illustrates the temperature distribution of the boiler tube for different scale thickness
from where it is that implication of existence of scale is significant to the temperature
distribution in the boiler tube. For example, temperature at the inner tube (scale region) for
scale thickness of 1.5 mm is found to be 548
o
C while for tube without scale is 583
o
C, hence
there is 35
o
C of temperature difference.


















Figure 10. Plot of temperature distribution for different scale thickness

M. M. Rahman & Sukahar
ICCBT 2008 - F - (14) pp157-170 169
6. CONCLUSIONS

Two-dimensional (2-D) heat transfer mathematical model for axi-symetric problem using
finite element have been developed in order to determine temperature distribution in the water
tube boiler. Commercially available finite element software namely MSC Patran-Nastran is
used in his study. The analysis of the temperature distribution for every location inside the
domain is conducted by setting constant heat fluxes and varying parameters such as mass flow
rate of steam, material properties of the tube, scale thickness, etc. The results show that
temperature distribution in the boiler tube is influenced by those parameters. Although, all
parameters affect the temperature distribution in the boiler tube, but existence of scale is very
significant which decreases the temperature of tube wall, hence to make heat balance in the
equilibrium condition, temperature of the flue gas must be increased. The disadvantage of
increasing temperature of flue gas is increasing scale growing, and decreasing rupture strength
of material. Therefore, existence of scale must be eliminated.



ACKNOWLEDGEMENT

This work has been financially supported by Universiti Tenaga Nasional. The authors would
like express their best gratitude to TNB Research for allowing us to use MSC Patran-Nastan
software to conduct simulation. Appreciation also goes to PT. PLN (Persero) head office
management, PT. PLN (Persero) South Kalimantan and Central Kalimantan Region
management, and Asam-Asam Steam Power Plant management for their support in providing
the operational data of the boiler, specification and other data related to this study.


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