Assessment of the Influence of the Use of Weld Overlay As a Repair Method on the Stress Level of Bulged Sections of Coke Drums

2017 ◽  
Author(s):  
Gabriel A. Vivas ◽  
Armando J. Moret ◽  
Roberto E. Bello ◽  
Luis M. Melian ◽  
Egler D. Araque
Keyword(s):  
Low Cycle Fatigue ◽  
Mechanical Analysis ◽  
Deformation Pattern ◽  
Cycle Fatigue ◽  
Weld Repair ◽  
Element Analysis ◽  
Weld Overlay ◽  
Repair Method ◽  
External Reinforcement ◽  
Repair Procedure

Several studies recognized that cracks in delayed coke drums resulted from low cycle fatigue induced by cyclic thermal stress [1], [2], [3]. According to a coke drum survey coordinated by API in 1996 [1], there are two different areas where cracks are produced. The first zone is located at the shell to skirt weld, and the second at the bulged areas found in the cylindrical section. In the second case, from 145 coke drums 57% reported that had shell bulging problems. Of the drums that bulged, 87 % also showed cracks. Recently, it has been reported the use of a novel weld repair procedure on bulged sections of a drum. In this repair, the bulge is overlaid with weld metal on the inside or outside on the bulge depending on the bulge shape. It has been reported that this repair procedure can stop further bulging on the shell, but detailed information about its influence has not yet been published. Finite element analysis of several bulged patterns that were identified from some laser mappings are used to compare the level of the stress after a weld overlay repair is made. The study was carried out running a sequentially-coupled thermo-mechanical analysis. The assessment shows the influence of the thickness and the extent of the weld overlay on the level of stress on bulged coke drums. The results indicated that depending on the initial bulged shape this repair method either reduces or increases the level of the stress. When an inward deformation pattern is observed, an external reinforcement is recommended; however, when an outward deformation pattern is developed in a coke drum, an external weld overlay repair is not recommended.

Assessment of the Influence of Bulging and the Thermal Gradients in the Stress Level in the Cylindrical Section of a Coke Drum

2013 ◽  
Author(s):  
Egler D. Araque ◽  
Gabriel A. Vivas
Keyword(s):  
Thermal Analysis ◽  
Low Cycle Fatigue ◽  
Mechanical Analysis ◽  
Second Step ◽  
Thermal Gradients ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Part D ◽  
Cylindrical Section ◽  
Made In

Several studies recognized that cracks in delayed coke drums resulted from low cycle fatigue induced by cyclic thermal stress [1], [2], [3]. According to a coke drum survey coordinated by API in 1996 [1], there are two different areas where cracks are produced. The first zone is located at the shell to skirt weld, and the second at the bulging areas found in the cylindrical section. In the second case, from 145 coke drums 57% reported that had shell bulging problems. Of the drums that bulged, 87% also showed cracks. In order to estimate the level of stress, finite element analysis of a bulged cylinder was performed. The study was carried out running a sequentially-coupled thermo-mechanical analysis. In the first step, a thermal analysis is used to estimate the variation of temperature with time. These temperatures serve as input to a mechanical stress analysis that was made in a second step. The assessment shows the influence of thermal gradients obtained for a period of 26 months for several bulging patterns that were identified from the analysis of 28 laser mappings of coke drums. The results indicated that the level of stress could reach the plastic deformation considering that the material has yield strength equal to the minimum specified in ASME Section II, part D. The zones where maximum axial stresses were found are consistent with areas where cracking has been reported in many coke drums.

Optimization of a Weld Overlay on a Plate Structure

2009 ◽  
Vol 132 (1) ◽  
Author(s):  
John Goldak ◽  
Mahyar Asadi ◽  
Jianguo Zhou ◽  
Stanislav Tchernov ◽  
Dan Downey
Keyword(s):  
Welding Process ◽  
Francis Turbine ◽  
Transient Temperature ◽  
Weld Repair ◽  
Weld Overlay ◽  
Hydroelectric Project ◽  
Repair Procedure ◽  
Strain Stress ◽  
Welding Direction ◽  
Interpass Temperature

An overlay weld repair procedure on a 1066.8×1066.8 mm2 square plate 25.4 mm thick was simulated to compute the 3D transient temperature, microstructure, strain, stress, and displacement of the overlay weld repair procedure. The application for the overlay was the repair of cavitation erosion damage on a large Francis turbine used in a hydroelectric project. The overlay weld consisted of a 4×6 pattern of 100×100 mm2 squares. Each square was covered by 15 weld passes. Each weld pass was 100 mm long. The total length of weld in the six squares was 36 m. The welds in each square were oriented either front-to-back or left-to-right. The welding process was shielded metal arc. The analysis shows that alternating the welding direction in each square produces the least distortion. A delay time of 950 s between the end of one weld pass and the start of the next weld pass was imposed to meet the requirement of a maximum interpass temperature to 50°C.

Component Low Cycle Fatigue Behavior Based on Standard Calculation Procedure and Non-Linear FEA

2017 ◽  
Author(s):  
Jürgen Rudolph ◽  
Adrian Willuweit ◽  
Steffen Bergholz ◽  
Christian Philippek ◽  
Jevgenij Kobzarev
Keyword(s):  
Power Plants ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Hybrid Approach ◽  
Combined Cycle ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Constitutive Material Model ◽  
Standard Design ◽  
Creep Fatigue

Components of conventional power plants are subject to potential damage mechanisms such as creep, fatigue and their combination. These mechanisms have to be considered in the mechanical design process. Against this general background — as an example — the paper focusses on the low cycle fatigue behavior of a main steam shut off valve. The first design check based on standard design rules and linear Finite Element Analysis (FEA) identifies fatigue sensitive locations and potentially high fatigue usage. This will often occur in the context of flexible operational modes of combined cycle power plants which are a characteristic of the current demands of energy supply. In such a case a margin analysis constitutes a logical second step. It may comprise the identification of a more realistic description of the real operational loads and load-time histories and a refinement of the (creep-) fatigue assessment methods. This constitutes the basis of an advanced component design and assessment. In this work, nonlinear FEA is applied based on a nonlinear kinematic constitutive material model, in order to simulate the thermo-mechanical behavior of the high-Cr steel component mentioned above. The required material parameters are identified based on data of the accessible reference literature and data from an own test series. The accompanying testing campaign was successfully concluded by a series of uniaxial thermo-mechanical fatigue (TMF) tests simulating the most critical load case of the component. This detailed and hybrid approach proved to be appropriate for ensuring the required lifetime period of the component.

The Revised Universal Slope Method to Predict the Low-Cycle Fatigue Lives of Elbow and Tee Pipes

2017 ◽  
Vol 139 (5) ◽  
Author(s):  
Hiun Nagamori ◽  
Koji Takahashi
Keyword(s):  
Experimental Data ◽  
Internal Pressure ◽  
Low Cycle Fatigue ◽  
Experimental Studies ◽  
High Accuracy ◽  
Universal Method ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Slope Method ◽  
Stress States

The stress states of elbow and tee pipes are complex and different from those of straight pipes. The low-cycle fatigue lives of elbows and tees cannot be predicted by Manson's universal slope method; however, a revised universal method proposed by Takahashi et al. was able to predict with high accuracy the low-cycle fatigue lives of elbows under combined cyclic bending and internal pressure. The objective of this study was to confirm the validity of the revised universal slope method for the prediction of low-cycle fatigue behaviors of elbows and tees of various shapes and dimensions under conditions of in-plane bending and internal pressure. Finite element analysis (FEA) was carried out to simulate the low-cycle fatigue behaviors observed in previous experimental studies of elbows and tees. The low-cycle fatigue behaviors, such as the area of crack initiation, the direction of crack growth, and the fatigue lives, obtained by the analysis were compared with previously obtained experimental data. Based on this comparison, the revised universal slope method was found to accurately predict the low-cycle fatigue behaviors of elbows and tees under internal pressure conditions regardless of differences in shape and dimensions.

Improved Low Cycle Fatigue Analysis for Ni-Based Turbine Nozzles

2018 ◽  
Author(s):  
Gianluca Maggiani ◽  
Matthew J. Roy ◽  
Simone Colantoni ◽  
Philip J. Withers
Keyword(s):  
Gas Turbines ◽  
Mechanical Test ◽  
Low Cycle Fatigue ◽  
Computation Time ◽  
Cyclic Hardening ◽  
Life Assessment ◽  
Type Model ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Material Models

The requirements for cleaner energy have driven industrial gas turbines manufacturers to increase firing temperatures and improve cooling of nozzles. The application of high temperature alloys having adequate thermo-mechanical requirements is critical, as assessed by low cycle fatigue performance. The effect of higher firing temperatures combined with higher cooling efficiencies has lead to operating cycles where the level of plastic strain imparted define component life. The capability of material models to account for non-linear effects such as ratchetting or shakedown, cyclic hardening or softening as well as Bauschinger or relaxation effects have been highlighted in this context. Neglecting these effects can lead to over and under-conservative life assessment analysis, while accounting for them using standard multilinear material models lead to convergence issues in finite element analysis. In this paper, Chaboche viscoplastic model has been applied to a transient structural of a first stage gas turbine nozzle. Fitting of the model based on experimental mechanical test data on MAR-M-247 alloy will be described, followed by an overview of how the model may be implemented to a benchmark nozzle thermo-mechanical transient analysis. Finally the details how the Chaboche-type model has provided up to 50% decrease in computation time when compared to using a standard multi-linear material modelling approach.

Low Cycle Fatigue Tests and Simulations on Steel Elbows

2013 ◽  
Author(s):  
Patricia Pappa ◽  
George E. Varelis ◽  
Spyros A. Karamanos ◽  
Arnold M. Gresnigt
Keyword(s):  
Finite Element ◽  
Low Cycle Fatigue ◽  
Local Strain ◽  
Fatigue Behaviour ◽  
Fatigue Tests ◽  
Cycle Fatigue ◽  
Element Analysis ◽  
Out Of Plane ◽  
Strain Gauge Measurements ◽  
Number Of Cycles

In this paper the low cycle fatigue behaviour of steel elbows under strong cyclic loading conditions (in-plane and out-of-plane) is examined. The investigation is conducted through advanced finite element analysis tools, supported by real-scale test data for in-plane bending. The numerical results are successfully compared with the experimental measurements. In addition, a parametric study is conducted, which is aimed at investigating the effects of the diameter-to-thickness ratio on the low-cycle fatigue of elbows, focusing on the stress and strain variations. Strain gauge measurements are compared with finite element models. Upon calculation of local strain variation at the critical location, the number of cycles to fracture can be estimated.

Influence of Initial and Welding Residual Stresses on Low Cycle Fatigue and Ratcheting Response Simulations of Elbows

2017 ◽  
Author(s):  
Nazrul Islam ◽  
Tasnim Hassan
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Low Cycle Fatigue ◽  
Simulation Models ◽  
Cycle Fatigue ◽  
Residual Stress Field ◽  
Element Analysis ◽  
Girth Welding ◽  
Stress States ◽  
Welding Processes

Earlier studies [1] showed that the ANSYS software package customized with an advanced rate-independent constitutive model was unable to simulate some of the low-cycle fatigue responses of elbow components. Hence, simulations are performed to investigate the influence of manufacturing and welding residual stresses on elbow low-cycle fatigue responses. The sequentially coupled thermo-mechanical finite element analysis is performed to determine the initial residual stress states in elbows due to the elbow manufacturing processes and welding of elbows to straight pipes. Real-time girth-welding processes are taken into account to simulate the welding induced residual stress field. Incorporating these initial residual stresses in the computations, low-cycle fatigue and strain ratcheting responses are simulated by ANSYS. The simulation responses demonstrate that the influence of manufacturing and welding residual stresses in elbows on its low-cycle fatigue responses is negligible. Hence, the question remains what is missing in the simulation models that some of the elbow low-cycle fatigue responses cannot be simulated.

Isothermal Low-Cycle Fatigue Evaluation of External Weld Repair Using Alloy 182 Filler Metal With Backing Plate Design

2020 ◽  
Author(s):  
Shutong Zhang ◽  
Sebastian A. Romo ◽  
Jorge Penso ◽  
Haixia Guo ◽  
Lisa Ely ◽  
...  
Keyword(s):  
Weld Metal ◽  
Low Cycle Fatigue ◽  
Fatigue Tests ◽  
Pressure Vessels ◽  
Cycle Fatigue ◽  
Residual Oil ◽  
Weld Repair ◽  
Oil Refineries ◽  
Backing Plate ◽  
Dog Bone

Abstract Coke drums are pressure vessels used in the delayed coking process at oil refineries, which transform heavy residual oil into light-weight hydrocarbon molecules and solid coke through thermal cracking. Due to the severe thermal and mechanical loadings during operation, these vessels experienced low-cycle fatigue failure, which led to shell and skirt damage such as bulging and cracking. External weld repairs using the temper bead technique have been widely applied to repair damaged regions caused by bulging and cracking for preventing the leaks of the residual oil contents. However, a substantial proportion of the external repairs have been reported to experience post-repair cracking issues. In this study, an external weld repair mockup with a backing plate was evaluated through metallurgical characterizations and isothermal low-cycle fatigue tests. The micro-hardness mapping identified the mismatching interfaces from base metal to weld metal (WM) and from root passes to internal clad. Four types of dog-bone samples were extracted from the weld: weld metal, heat affected zone, internal clad and backing plate. These samples were used to evaluate the fatigue resistance of weld metal and transition zone under low-cycle fatigue tests. Failure analysis showed that weld metal samples were susceptible to multiple-crack initiations, while other transition samples failed at mismatching interfaces or stress concentration points at weld toes.

A Nonlinear Dynamic Reduced-Order Model for a Large Gas Turbine Outer Casing Low Cycle Fatigue Prediction

2021 ◽  
Author(s):  
Aditya Dubey ◽  
Rishi Relan ◽  
Uwe Lohse ◽  
Jaroslaw Szwedowicz
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Gas Turbine ◽  
Nonlinear Dynamic ◽  
Low Cycle Fatigue ◽  
Reduced Order Model ◽  
Cycle Fatigue ◽  
Order Model ◽  
Element Analysis ◽  
Reduced Order

Abstract The secondary stresses that result from nonlinear and transient thermal gradients during the start-up and shut down of the large gas turbine engines drive low-cycle fatigue at specific locations of the outer casing. Typical service inspection of the outer casing is primarily based on finite element analysis estimates, considering various safety factors. However, as finite element analysis includes the worst possible combination of loading scenarios and operating conditions any engine may encounter in actual operation, this results in a conservative estimation of the service interval. Therefore, a generic preventive maintenance plan for the whole fleet often underutilises the casing capability and added cost. Hence, this paper proposes a data-driven nonlinear dynamic reduced-order model developed using the temperature data from low-cycle fatigue critical casing locations, ramp rates, and the percentage load of operation to predict the stresses. As a result, a reduced-order model can assess the damage for low-cycle fatigue critical locations in real-time using the operational data and propose an appropriate service intervention plan for each casing in a fleet.

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