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BOILER COMPONENT FATIGUE LIFE MONITORING USING THE DUHAMEL INTEGRAL METHOD AND RAINFLOW CYCLE COUNTING ALGORITHM

F. D. Fitzgerald
Foster Wheeler Energy Corporation, Penyville Corporate Park, Clinton, NJ, USA 08809-4000

T. V. Narayanan
Foster Wheeler Development Corporation, Peach Tree Hill Road, Livingston, NJ USA 07039

Sinopsis

A method of monitoring the thermal stress at the ID of boiler headers and steam drums is described, using a single thermocouple mounted at the ID. The conduction heat transfer differential equation is solved, using the monitored ID temperature as the non-homogenous first boundary condition, and using separation of variables and the Duhamel Integral method in a retrograde form.
The total elastic stress at the inside surface of a hollow cylinder is obtained by adding the mechanical stress caused by the monitored fluid pressure to the calculated thermal stress and is transformed to the inelastic stress-strain history of the tube stub bore hole edge using Neubers Rule and the local strain approach. The patterns of closed stress-strain hysteresis loops are recognized by the Rainflow Cycle counting Algorithm. The fatigue life consumption of individual closed loops is calculated using a modified Coffin-Manson-Basquin-Goodman relationship.

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