Metallurgical Engineering

Metallurgical Engineering

Numerical and experimental investigation of the residual stress distribution in shell-tube pressure vessels weld joint

Document Type : Research Paper

Authors
Daryoush Danyali
Islam Ranjbarnodeh
Abstract
Tube-sheet to tube weld joint is a critical section in shell-tube pressure vessels. The leakage and failure are two common problems that happen in this joint. The tensile residual stresses associated with welding can play a major role in the mentioned problems. In the present study, residual stresses distribution is investigated by Finite Element Method and experimental tests. The joint includes a circumferential fillet weld in one pass by Gas Tungsten Arc Welding process. The thermo-mechanical behavior of the joint is simulated by a 2D axisymmetric model using a subroutine developed in ANSYS software. The thermography Method used to thermal analysis verification and the Whole Drilling Strain Gauge under Post Weld Heat Treatment used to mechanical analysis verification. The numerical and experimental results show that the residual stress as von Mises criteria is about 105 MPa and as stress intensity criteria is about 115 MPa in root of Tube-sheet to tube weld joint. Maximum defference between numerical and experimental results, in thermal analysis and mechanical analysis, is about 11% and 18% respectively.  
Keywords
Shell-tube
Tube-sheet
Pressure vessels
Residual Stress
Finite Element Method
Thermography
1-      پورمحمدی، حسین؛ کرمانپور، احمد؛ شمعانیان، مرتضی.(1388). پیش بینی تنش های پسماند حاصل از جوشکاری قوسی لوله های سوپر آلیاژ اینکولوی 800 به روش المان محدود. استقلال، 29، 57-39.
2-      مجذوبی، غلامحسین؛ سیفی، رحمن؛ علی اکبر، شاهد.(1390). بررسی تجربی و عددی توزیع دما و تعیین تنش های پسماند در جوشکاری ورق ها. مجله مدل سازی در مهندسی، 27، 60- 50.
3-      مشایخی، محمد؛ هدایتی، هادی.(1390). بررسی تاثیر ترتیب جوشکاری و فرایند هیدروتست بر تنش های پسماند جوشکاری در لوله های فولادی زنگ نزنSUS304 . نشریه علوم کاربردی و محاسباتی در مکانیک، 22، 34-17.
4-       Akbari, D., Sattari-Far, I. (2009). "Effect of the welding heat input on residual stresses in butt-welds of dissimilar pipe joints". International Journal of Pressure Vessels and Piping, Vol. 86, Pp. 769-776.
5-       British Standards Institute, BS2790 (1992). "Design and manufacturing of shell boilers of welded construction".
6-       Carbon  Steel Handbook, (2007).
7-       Deng D., Murakawa H. (2006)."Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements". Comp Mater. Sci., Vol. 37, No.3, Pp.269-277.
8-       Kermanpur, A., Shamanian, M., Esfahani Yeganeh, V. (2008). "Three-Dimensional thermal simulation and experimental investigation of GTAW circumferentially butt welded incoloy 800 Pipe". Journal of Materials Processing Technology, Vol. 99, Pp. 295-303.
9-       Lee, C.H., Chang, K.H. (2008). "Numerical investigation of residual stresses in strength-mismatched dissimillar steel butt welds, J.Strain Analysis". Vol. 43, Pp. 55-66.
10-   Masubuchi, K. (1980). "Analysis of Welded Structures". Pergamon Press, New York.
11-   Rendler N.J., Vigness I. (1966). "Hole drilling strain gauge method of measuring residual stresses, Experimental Mechanics". Vol. 6, Pp. 577-586.
12-   Rybicki, E.F., Schmuser, D.W., Stonesifer, R.B., Groom, J.J. and Mishler, H.W. (1978). "A finite element method for residual stress in girth-butt welded pPipes". ASME, Journal of Pressure Vessel Technology, Vol.100, Pp. 256-262.
13-   Sattari-Far, I., Javadi,Y. (2008). "Influences of welding sequence on welding distortion in pipes". International Journal of Pressure Vessels and Piping, Vol.85, Pp. 265-274.
14-   Shugen, X., Weiqiang, W., Huadong, L. (2010). "The stress corrosion cracking of austenitic stainless steel heat exchange tubes, three cases study". ASME Pressure Vessels and Piping Division, Vol. 5, Pp. 335-343.
15-   Shugen, X., Weiqiang, W. (2013). "Numerical investigation on weld residual stresses in tube to tube sheet joint of a heat exchanger". International Journal of Pressure Vessels and Piping, Vol. 101, Pp. 37-44.
16-   Soanes TPT, Bell W, Vibert AJ. (2005). "Optimizing residual stresses at a repair in a steam header to tube plate weld". International Journal of Pressure Vessels and Piping, Vol.82, Pp. 311–318.
17-   Tait, R.B, Press, J. (2001). "Investigation An experimental study of the residual stresses, and their alleviation, in tube to tube-sheet welds of industrial boilers". Engineering Failure Analysis, Vol. 8, Pp. 15-27.
18-   Tait, R.B., Coetzee CE, Shephed RJ. (1994). "The effectiveness of PWHT for reduction of weld residual stresses using the air abrasive hole drilling technique". Society Experimental Mechanics, in Proceedings of the Fourth International Conference on Residual Stress, Vol. 6, Pp. 514-520.

  • Receive Date 02 January 2016