Parametric Modeling of ‘C ’ Class Boiler- A case study

International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 Parametric Modeling of ‘C’ Class Boiler- A case study Abhinav A Kherkar#1, Girish M Dhote*2, Dr.V.H.Tatwawadi*3 # CADMA Mechanical Department, RTMNU University, Nagpur (Maharashtra, INDIA) 1 [email protected], [email protected] Abstract—In order to reduce the pressures of reading drawings and dimensional analysis on engineering staffs, the use of CATIA to build 3D models by 2D drawings with the given information is suggested. Through the application of 3D modelling, the overall situation of the time consuming design can be avoided. The research focuses on the case of the ‗C‘ Class boiler owned by renowned company. 3D model is constructed by using information of 2D drawings to calculate the design parameters of boilers concerned with the project. It managed to shorten the design time, reduce the construction difficulties and ensure that the requirements on equipment, human resource and materials are all satisfied. Keywords— Parametric modelling , CATIA, 3D Model, boiler, ‗C‘ class boiler, 2D drawing, KBE, Design parameters, Design time. INTRODUCTION C Class boilers mainly used in Marine ships for the purpose of hot water supply, cooking and other basic purpose. These boilers need to be designed frequently as per change in dimensions for different types of marine ships. In the phase of multidisciplinary design optimization of boilers, according to the changes of the design parameters, structure and the shape need to be continuously adjusted. The parametric modeling can avoid the disadvantages of 3D modeling, such as long time consuming, low efficient, and poor interaction, and it will be the important method of multidisciplinary design optimization. A model of a Boiler by using the parametric modeling in CATIA software which will be the base of design and analysis using a Knowledge Based Engineering (KBE) as a parametric tool. 1.2 .Introduction to Boilers Steam boilers: It is a closed vessel made of steel. Its function is to transfer heat produced by combustion of fuel (solid, liquid or gaseous) to water and ultimately to generate steam. For producing hot water which can be used for heating installation at much lower pressure. 1.2.1 Classification of Pressure Vessels The pressure vessels may be classified as follows: 1. According to the dimensions. If the wall thickness of the shell (t) is less than 1/10 of the diameter of the shell (d), then it is called a thin shell. Ex: boilers, tanks and pipes. If the wall thickness of the shell is greater than 1/10 of the diameter of the shell, then it is said to be a thick shell. Ex: high pressure cylinders, tanks, gun barrels etc. 2. According to the end construction. A simple cylinder with a piston, such as cylinder of a press is an example of an open end vessel, In case of vessels having open ends, the circumferential or hoop stresses are induced by the fluid pressure, whereas a tank is an example of a closed end vessel. In case of closed ends, longitudinal stresses in addition to circumferential stresses are induced. 670 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 1.3 Problem Identification Boilers which were designed are produced as standard assembly and designed using traditional design methodology. According to this methodology the boilers design were tedious and time consuming Class boilers mainly used in Marine ships for the purpose of hot water supply, cooking and other basic purpose. These boilers need to be designed frequently as per change in dimensions for different types of marine ships. 1.4 Aim Design of C-Class Boiler by using a parametric modelling technique (A case study approach) 1.5 Objective To use parametric modelling technique to minimize the efforts of design engineer for designing similar objects with varying capacity. To reduce design time for repetitive jobs. 1.6 Challenges in typical design Due to change in dimensions redesign of boiler was tedious. Analysis was time consuming and end results were not satisfactory. 1.7 Concept used Basic concept of Knowledge Base Engineering (KBE) has been the approach for case study. The use of CATIA to build 3D models by 2D drawings with the given information is suggested. Through the application of 3D modelling, the overall situation of the time consuming design can be avoided. The research focuses on the case of the ‗C‘ Class boiler .3D model is constructed by using information of 2D drawings to calculate the design parameters of boilers concerned with the project. 1.8 Why CATIA for parametric modelling? The parametric modelling approach has elevated computer-aided design technology to the level of a very powerful design tool. Parametric modelling automates the design and revision procedures by the use of parametric features. Parametric features control the model geometry by the use of design variables. The word parametric means that the geometric definitions of the design, such as dimensions, can be varied at any time in the design process. Parametric Modelling is an approach to CAD that leaves the traditional 2 dimensional approach. Parametric modelling represents a different approach to CAD compared to 2D drafting. It is often called Feature Based modeling. Parts are composed of features of positive or negative space. A positive space can be an extruded boss, a negative space can be a hole or segment that is cut away. Often the feature is sketched 2 dimensionally and extruded, revolved or swept into a 3 dimensional object. 2. WORK DONE 2.1 Input data. ADCC Infocad ltd. Nagpur has been source for obtaining a 2D diagram of a boiler which has become a base for the start of case study. A knowledge based engineering approach is followed. From this figure we studied total number of parts, material of boiler, specification, dimensions and other dimensional attributes. 671 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 2.2 Design Formulae 2.2.1 Boiler Tubes up to and including 5 inches O.D. (125 mm): a) The minimum required thickness, according to ASME paragraph PG-27.2.1, use equation below: b) To calculate the Maximum Allowable Working Pressure (MAWP): 672 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 Where: t = Minimum Design Wall Thickness (in) P = Design Pressure (psi) D = Tube Outside Diameter (in) e = Thickness Factor (0.04 for expanded tubes; 0 = for strength welded tubes) S = Maximum Allowable Stress According to ASME Section II, Table 1A 2.2.2 Piping, Drums, and Headers a) Using the outside diameter b) Using the inside radius Where: t = Minimum Design Wall Thickness (in) P = Design Pressure (psi) D = Tube Outside Diameter (in) R = Tube Radius (in) E = Tube Welding Factor (1.0 for seamless pipe; 0.85 = for welded pipe) y = Wall Thickness Welding Factor (0.4 for 900°F & lower; 0.7 for 950°F & up) C = Corrosion Allowance (0 for no corrosion; 0.0625 in. commonly used; 0.125 in. maximum) S = Maximum Allowable Stress According to ASME Section II, Table 1A 2.2.3 - Thin Cylindrical Shells: The formulae in ASME Section VIII, Division 1, paragraph UG-27, used for calculating the wall thickness and design pressure of pressure vessels, are: 673 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 a) Circumferential Stress (longitudinal welds): When, P < 0.385SE: (R = Internal Radius) b) Longitudinal Stress (circumferential welds): When, P < 1.25SE 2.2.4 Thick Cylindrical Shells: For internal pressures higher than 3,000 psi, special considerations as specified in paragraph U-1 (d). As the ratio of t/R increases beyond 0.5, an accurate equation is required to determine the thickness. The formulae in ASME Appendix 1, Supplementary Design Formulas used for calculating thick wall and design pressure, are: a) For longitudinal welds: When, P > 0.385SE: And b) For circumferential welds: When, P > 1.25SE: And 674 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 Where: R = Design Radius (in.) Z = Dimensionless Factor 2.2.5 Pressure Piping - Minimum Wall Thickness: Where: t(min)= Minimum wall thickness required (in) P = Design pressure (psig) D = Outside diameter of pipe (in) S = Allowable stress in pipe material (psi) E = Longitudinal joint factor - E = 1.0 for seamless pipe, E = 0.85 for ERW pipe C = Corrosion allowance, typically 0.05 in. y = Wall thickness coefficient in ASME Table 304.1.1 for ferritic steels, is: y = 0.4 for T<= 900 ºF y = 0.5 for 900< T <= 950 ºF y = 0.7 for 950 < T <= 1000 ºF 2.2.6 Reinforcement Wall Thickness Plate: The standard design method uses an increased wall thickness plate at the equator line of the vessel to support the additional stresses caused by the attachment of the legs. The formula for calculation the wall thickness of a segmented plate of to be welded in a vessel or spherical shell is: t = (P x L) / (2xSxE – 0.2xP) + C Where L = Di/2 Where: t = Minimum Design Wall Thickness (in) P = Design Pressure (psi) Di = Inside Diameter of Sphere (in) L = Sphere Radius (in) E = Tube Welding Factor (1.0 for seamless pipe; 0.85 = for welded pipe) C = Corrosion Allowance (0 for no corrosion; 0.0625 in. commonly used; 0.125 in. maximum) 675 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 S = Maximum Allowable Stress According to ASME Section II, Table 1A 2.2.7 Dished Heads Formulae a) Blank, Unstayed Dished Heads: Where: t = Minimum thickness of head (in) P = maximum allowable working pressure (psi) L = Concave side radius (in) S = Maximum Allowable Working Stress (psi) b) Seamless or Full-Hemispherical Head t = Minimum thickness of head (in) P = Maximum Allowable Working Pressure (psi) L = Radius to which the head was formed (in) S = Maximum Allowable Working Stress (psi) Note: The above formula shall not be used when the required thickness of the head given by the formula exceeds 35.6% of the inside radius. Instead, use the following formula: c) Spherical or Hemispherical Heads: i) When t < 0.356R or P < 0.665SE - (Thin Spherical or Hemispherical Heads): and 676 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 ii)When t > 0.356R or P > 0.665SE – (Thick Spherical or Hemispherical Heads): d) Elliptical or Ellipsoidal Heads - Semi-Elliptical or Semi-Ellipsoidal Heads – 2:1: e)Torispherical Heads: i)Flanged & Dished Head (F&D heads): Where: P = Pressure on the concave side of the head S = Allowable stress t = Thickness of the head L = Inside spherical radius E = Joint efficiency factor 2.4 Preparing input database. An input data base is prepared in MS excel sheet, incorporating all the design parameters. Based on the above boiler design formulae integrated tool in VB is prepared with in the form of design software which gives design of each part of boiler. Steps for using this software. 1. Input the working pressure required in MPA. 2. Select the internal radius of boiler in mm. 3. Select the appropriate material as per the table of material from ASME handbook. These following parameters are to be entered before going to the calculation step. 677 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 678 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 Fig 2 Database in MS Excel 2.5 3D Model in CATIA After the calculation of the above data a 3D model is generated based on the calculation from the design. All the parameters are linked with the CATIA software to incorporate frequent the design changes. A 3D model is generated as shown in figure based upon the sample calculation for 400 mm internal radius. 679 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 Fig. 3 3D Modelling in CATIA FIG 4. FORMULA FOR PART 680 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 3. ANALYSIS Based on the calculation and 3D model an analysis report is generated with the help of analysis tool in CATIA. Each part is analysed based on the input parameters and results are formulated in a report. This report is generated by analysis tool in CATIA which gives details about stresses, deformation and other factors which affect the design because of the change in parameters or dimensions. Fig 5. Analysis Model Fig6.Static Case Solution.1 - Von Mises stress 681 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 FIG7. STATIC CASE SOLUTION.1 - TRANSLATIONAL DISPLACEMENT VECTOR 4. RESULT KBE is the key technology at the base of any design development. In the current design approach, too much time is wasted in lengthy and repetitive activities; not enough time remains available for investigating more product configurations and exploiting designers‘ skills and creativity. In this case study, it is demonstrated how KBE can be a suitable technology to help designers reducing time and cost for engineering applications by automating repetitive design tasks and supporting the systematic application of design best practices with the use of parametric modelling as a tool. 3D modelling is tool which help to save time in regards the capturing the design intent of particular equipment. The process is known as Knowledge base engineering. In this process all design intent of object is captured & save in term of relational formulas & on this basis the 3D object is prepared. Once the design requirement is change some parameters will require modifying. All other parameters are depended on the driving parameters. One driving parameter get updated, all relevant parameters will update automatically & relevant production drawings will update automatically. This helps to reduce time, which is the prime motive of this case study. It managed to shorten the project preparation time, reduce the construction difficulties and ensure that the requirements on equipment, human recourse and materials are all satisfied 5. ACKNOWLEDGMENT I would like to thank to my project guide Dr. V.H. Tatwawadi under whose necessary guidance I have completed my project successfully. Without his unending help, encouragement and motivation this would not have been possible. Dedication and perseverance when supported by inspiration and guidance leads to success. For me the inspiration and guidance was given by my guide Dr.V.H. Tatwawadi who was accessible for me to obviate the darkness of my problem with light of his knowledge of the relevant subject enriched by his hands on experienced in the field of Design and analysis. 682 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 I also thank Prof.G.M.Dhote for helping me in understanding the Modeling and Analysis regarding my project. I truly sense it was privilege for me, to have them as my guide. I fill highly honored working under them. I am also thankful to Dr.V.H. TATWAWADI, Principal , DBACER , Dr. S.V.Prayagi, HOD, Dept. of Mechanical Engineering. Mr G.M.Dhote , M.Tech Coordinator, Mr.S.M.Dhomne , M.Tech Project coordinator and Prof. B.S.Nandeshwar , M.Tech Project Co Coordinator for their support and for providing us all the necessary facilities. I would also like heartily thank Mr. Ajinkya Ambarkhane ,Manager ,ADCC Infocad Nagpur for spending his valuable time and providing the information regarding Design of system and help for selection of attributes . 6 CONCLUSION. In this study, in particular it is shown how, using KBE, it is possible to win one of the greatest design challenges at date: automate the generation and modification of boiler models, from geometry definition to the launch final design. Entire models of boiler & components can be generated in software and independently from the specific topology of the parameters. 7. FUTURE SCOPE Future developments will include the creation of a tooling module to be linked to the movable modeland a cost module, which will provide a smooth link to a cost calculation program. 8. REFERENCES [1] Kim Sørensen, Claus M. S. Karstensen “Modeling and simulating fire tube boiler performance” (Aalborg University, Institute of Energy Technology, Pontoppidanstræde Aalborg Industries A/S, Gasværksvej 24, P.O. Box 661, DK-9100 Aalborg, Denmark) [2] E. A. Morelli “Global nonlinear parametric modeling with application to F-16 aerodynamics” "Global Nonlinear Aerodynamic Modeling using Multivariate Orthogonal Functions", Journal of Aircraft, vol. 32, no. 2, pp.270 -277 1995) [3] Thomas Schmid, Dhruv Dhandhania ―High Speed Concept Development: full parametric surface modeling and automatic creation of simulation models using the Fast Concept Modeler (FCM)” (6th wiemer optimization and stochastic) [4] Won Uk Lee, Yeong Koo Yeo” Steady-state modeling of coal boilers”( Dept. of Chemical Engineering, Hanyang University, 17 Haengdang-dong, Sungdong-ku, 133-791, Seoul, Korea) [5] Julien Eynard, Stéphane Grieu1 and Monique Polit ―Modular approach for modeling a multi-energy district boiler” (Applied Mathematical Modelling journal , ELIAUS laboratory, University of Perpignan Via Domitia, 52 Avenue Paul Alduy, 66860,Perpignan, France; {julien.eynard; grieu; polit}@univ-perp.fr) [6] Gui-yu Zhou Guan-jun Liu “Parametric Modeling Based on KBE of CATIA”( Proceedings of the International Conference on Information Engineering and Applications (IEA) 2012 Lecture Notes in Electrical Engineering Volume 217, 2013, pp 581-586) [7] Jie Chen ―The parametric modeling and management system for boiler steel frame” ( Computer Supported Cooperative Work in Design (CSCWD), 2012 IEEE 16th International Conference) [8] S. J. Piboontum, S. M. Swift, and R. S. Conrad‖Boiler Performance Improvement Due to Intelligent Sootblowing Utilizing RealTime Boiler Modeling on UP® Boilers‖ (Electric Power 2005 Magazine, April 5-7, 2005 Chicago, IL, U.S.A ) [9] K.C. Rao “Case Study-Meeting India’s energy needs with fast design L&T MHI Boilers”(https://www.plm.automation.siemens.com/en_in/about_us/success/case_study.cfm?Component=74088&ComponentTemplate =1481) 683 www.ijergs.org International Journal of Engineering Research and General Science Volume 3, Issue 1, January-February, 2015 ISSN 2091-2730 [10] ASME Boiler Design fundamentals.(Handbook, Edition 2012 PDH Online | PDH Center 5272 Meadow Estates Drive Fairfax, VA 22030-6658 Phone & Fax: 703-988-0088 [11] Anshu Dwivedi “A Knowledge Based Engineering Approach for Design Automation - A Case Study”.( Mechanical Engineering Department Thapar Institute of Engineering and Technology) (Deemed University), Patiala [12] Gianfranco La Rocca* and Michel J.L. van Tooren ”A Knowledge Based Engineering Approach to Support Automatic Generation Of Fe Models In Aircraft Design” (Delft University of Technology, Delft, the Netherlands. www.dar.lr.tudelft.nl) [13] The ASME Boiler and Pressure Vessel Code (BPVC) ―ASME Codes and Standards (http:/ / files. asme. org/ ASMEORG/ Publications/ Codes/ 5134. pdf) & Boiler and Pressure Vessel Inspection According to ASME (http:/ / www. tuv. com/ en/ corporate/ business_customers/ plants_machinery_1/pressure_equipment_2/ asme_1/ asme. html) ― [14] Marcus Sandberg ―Knowledge Based Engineering - In Product Development‖ Technical report from Department of Applied Physics and Mechanical Engineering Division of Computer Aided Design Lulea University of Technology, Sweden. [15] Isad Šarić; Nedžad Repčić; Adil Muminović “PARAMETER MODELLING OF GEARS” 14th International Research/Expert Conference ‖Trends in the Development of Machinery and Associated Technology‖ TMT 2010, Mediterranean Cruise, 11-18 September 2010 [16] Robert Woodbury, Shane Williamson, Philip Beesley” Parametric Modelling as a Design Representation in Architecture:A Process Account” Canadian Design Research Network Simon Fraser University Central City250 - 13450 102nd Avenue Surrey BC V3T 0A3 [email protected]. 684 www.ijergs.org