JOURNAL OF MECHANICAL ENGINEERING, MANUFACTURES, MATERIALS AND ENERGY

The important part which has a function as supporting of superheater header on the boiler recovery type (RB) is a couple of support plate which is hanged on the hanger rod. This part is very difficult to analyze by experimental because there are in a tight insulation and heavy duty condition. This research aim to obtain the stress distribution that happened on the plate as the effect of static load in simulation mode. The model is designed base on the dimension of real support plate size 400x200 mm and thickness 15 mm. It is use the FEM software of Ansys version 5.4. The theory of failure analysis of Tresca and von Mises become the reference for materials strength. The area contact theory of b represents the reference to determine the length of stress area along curve of both contact area. The material that is used is from steel ASTM A514 with the yield strength 690 MPa. The Result is stress distribution along curve and also critical point which has possibility failure occurs on the support plate. The analysis result could be a reference for the development of the further construction

Amrinsyah, Amrinsyah

syam, amir

Darianto, Darianto

zulfikar, zulfikar

27	
 
 
 
JMEMME,	2		(1)	June	2018																																		p‐ISSN:	2549‐6220e‐ISSN:	2549‐6239	
	
JOURNAL OF MECHANICAL ENGINEERING, 
MANUFACTURES, MATERIALS AND ENERGY 
	
Available	online	http://ojs.uma.ac.id/index.php/jmemme	
 
	
Numerical	Study	on	Plate	Holders	Pipe	Recovery	Boiler	Superheater		
	
Amrinsyah*,	Amir	Syam,	Darianto,	Zulfikar 
Mechanical	Engineering	Dept.,	Univ.	Medan	Area,	Indonesia	
	
*Corresponding	author:		E‐mail:	amrin_syah56@yahoo.com 
	
Abstrak	
	
Bagian	penting	yang	berfungsi	 sebagai	penahan	 superheater	header	pada	 jenis	 boiler	Recovery	 (RB)	
ialah	sepasang	plat	penahan	yang	digantungkan	pada	batang	gantungan.	Bagian	ini	sangat	sulit	dianalisa	
secara	eksperimental	karena	terdapat	bahan	isolasi	yang	tebal	dan	kondisi	kerja	yang	berat.	Penelitian	
ini	bertujuan	untuk	mendapatkan	distribusi	tegangan	yang	terjadi	pada	plat	sebagai	efek	beban	statik	
dengan	mode	simulasi.	Model	dirancang	berdasarkan	ukuran	sebenarnya,	yaitu	400	x	200	mm	dengan	
ketebalan	 15	mm.	 Simulasi	 ini	menggunakan	 software	 FEM	Ansys	 versi	 5.4.	 Teori	 analisa	 kegagalan	
Tresca	 dan	 von	 Mises	 menjadi	 rujukan	 untuk	 kekuatan	 bahan.	 Teori	 kontak	 area	 yang	 diwakili	 b	
ditujukan	untuk	menentukan	panjang	area	 tegangan	sepanjang	kurva	dari	kedua	kontak	area.	Bahan	
yang	digunakan	ialah	dari	baja	ASTM	A514	dengan	kekuatan	luluh	690	MPa.	HAsilnya	adalah	distribusi	
tegangan	sepanjang	kurva	dan	juga	titik	kritis	dimana	memiliki	kemungkinan	kegagalan	terjadi	pada	plat	
penahan.	Hasil	analisa	dapat	menjadi	referensi	untuk	pengembangan	konstruksi	lebih	lanjut.	
	
Kata	kunci:	Analisa	Kegagalan,	Area	Kontak,	Plat	Pendukung,	Simulasi	Numerik	
	
Abstract	
	
The	important	part	which	has	a	function	as	supporting	of	superheater	header	on	the	boiler	recovery	type	
(RB)	is	a	couple	of	support	plate	which	is	hanged	on	the	hanger	rod.	This	part	is	very	difficult	to	analyze	by	
experimental	because	there	are	in	a	tight	insulation	and	heavy	duty	condition.	This	research	aim	to	obtain	
the	stress	distribution	that	happened	on	the	plate	as	the	effect	of	static	load	in	simulation	mode.	The	model	
is	designed	base	on	the	dimension	of	real	support	plate	size	400x200	mm	and	thickness	15	mm.	It	is	use	the	
FEM	 software	 of	Ansys	 version	 5.4.	The	 theory	 of	 failure	analysis	 of	Tresca	and	 von	Mises	become	 the	
reference	for	materials	strength.	The	area	contact	theory	of	b	represents	the	reference	to	determine	the	
length	of	stress	area	along	curve	of	both	contact	area.	The	material	that	is	used	is	from	steel	ASTM	A514	
with	the	yield	strength	690	MPa.	The	Result	is	stress	distribution	along	curve	and	also	critical	point	which	
has	 possibility	 failure	 occurs	 on	 the	 support	 plate.	 The	 analysis	 result	 could	 be	 a	 reference	 for	 the	
development	of	the	further	construction.	
 
Keywords:	Support	Plate,	Simulation,	Failure	Analysis,	Contact	Area.	
 
How	to	Cite:	Amrinsyah	(2018),	Numerical	Study	on	Plate	Holders	Pipe	Recovery	Boiler	Superheater,	
JMEMME	(Journal	Of	Mechanical	Engineering,	Manufactures,	Materials	And	Energy),	2	(1):	27‐32	
	
Amrinsyah,	Numerical Study on Plate Holders Pipe Recovery Boiler Superheater 
28 
INTRODUCTION		
The	most	 important	part	 to	hold	 the	
weight	of	Superheater	on	Boiler	Recovery	
type	 is	 a	 pair	 of	 plates	 hung	 through	 a	
hanger	 rod	 and	 bound	 by	 two	 pins.	 Pins	
and	 plates	 are	 not	 permanently	 tied,	 but	
only	 loose	 and	 flexible	 so	 as	 to	 hold	 the	
weight	at	once	can	overcome	the	load	in	the	
axial	direction.	To	maintain	stability	during	
operation,	usually	at	 the	end	of	 the	pin	 is	
given	a	ring	that	is	connected	through	the	
point	weld	(	Yasniy,	Pyndus,	Brevus,	Iasnii,	
&	 Lapusta,	 2016).	 The	 location	 of	 these	
sections	 is	 just	 above	 the	 combustion	
chamber	 with	 a	 very	 high	 working	
temperature.	
Stress	distribution	that	occurs	on	the	
plate	 is	 very	 difficult	 once	 determined	
experimentally.	This	is	due	to	the	difficulty	
of	retrieving	test	data	with	the	position	of	
the	element	is	at	a	height	up	to	reach	more	
than	80	m	from	the	ground	floor	and	also	
covered	 a	 very	 thick	 insulation	 material	
(Barma,	et	al.,	2017).	Therefore,	one	of	the	
best	methods	to	get	stress	distribution	in	a	
particular	 location	 is	 to	 use	 a	 numerical	
simulation	method	(Sankar,	Rao,	Seshadri,	
&	Balasubramanian,	 2016)	 (Taler,	 Trojan,	
Dzierwa,	Kaczmarski,	&	Taler,	2018).	
Failure	on	the	type	of	ductile	material	
may	occur	when	the	maximum	shear	stress	
is	equal	to	or	exceeds	the	maximum	shear	
stress	 value	 in	 a	 test	 of	 the	 material	
(Shokouhmand,	 Ghadimi,	 &	 Espanani,	
2015).	 Thus,	 when	 associated	 with	 main	
stress	on	a	mechanical	element,	the	failure	
of	 a	 material	 will	 occur	 when	 1	 and	 3	
have	 exceeded	 the	 tensile	 stress.	 When	
viewed	 from	 the	 amount	 of	 distortion	
energy	that	occurs,	the	material	failure	will	
occur	when	the	strain	energy	distortion	per	
unit	volume	reaches	or	exceeds	the	strain	
energy	 distortion	 per	 unit	 volume	 in	 a	
tensile	 or	 compression	 test	 on	 the	 same	
material.	This	theory	is	also	known	as	the	
von	Mises	theory.	In	other	words,	failure	of	
ductile	 material	 will	 occur	 if	 von	 Mises	
stress	 (')	 reaches	 or	 exceeds	 its	 tensile	
stress	(Sy).	
	If	 it	 is	 considered	 that	 the	 normal	
stress	 section	 on	 each	 surface	 is	 equal	 to	
the	hydrostatic	stress	(AV),	then	there	will	
be	eight	symmetrical	surfaces	 in	the	main	
direction	 that	 will	 be	 subjected	 to	 the	
stress.	 Failure	 is	 expected	 to	 occur	 when	
the	octahedral	shear	stress	at	each	section	
undergoing	 stress	 equals	 or	 exceeds	 the	
octahedral	shear	stress	in	a	simple	tensile	
test	 of	 a	 test	 specimen	 to	 failure.	 This	 is	
similar	 to	 the	 prediction	 of	 a	 material	
failure	 based	 on	 the	 theory	 of	 distorted	
energy,	 where	 the	 shear	 stress	 that	 can	
cause	failure	occurs	when	the	shear	stress	
reaches	up	to	57.7%	of	the	tensile	stress	of	
the	 material	 (Shokouhmand,	 Ghadimi,	 &	
Espanani,	2015).		
When	the	surface	of	two	objects	that	
have	a	shape	like	the	curves	touching	each	
other,	 then	 the	 contacts	 that	 occur	 at	 the	
point	 and	 the	 line	 will	 turn	 into	 contact	
area	(	Tavares,	et	al.,	2014).	The	stress	that	
occurs	 will	 also	 evolve	 from	 two	
dimensional	models	into	three	dimensions.	
The	contact	area	of	the	two	cylindrical	
portions	with	a	thickness	of	l,	the	diameter	
of	the	first	part	d1	and	the	second	part	d2	
is	denoted	by	2b,	as	shown	in	Figure	1.	The	
stress	 that	 occurs	 in	 the	 contact	 area	
consists	 of	 the	 normal	 stresses	 in	 the	
direction	of	the	x	axis	(x)	and	y	(y),	and	
the	principal	stress	3.	For	0		z		0.436b,	
then	1	=	x,	and	max	=	(1	‐	3)	/	2	=	(x	‐	
z)	/	2.	For	z		0.436b,	then	1	=	y,	and	max	
=	(y	‐	z)	/	2.	
JMEMME, Vol 2 (No. 1) (2018): 27‐32 
 
29 
This	study	aims	to	obtain	the	amount	
of	 nodal	 displacement	 and	 stress	
distribution	that	occurs	on	the	superheater	
holder	plate.	The	 results	of	 this	 simulation	
will	be	useful	to	provide	information	to	the	
manufacturer	so	that	it	can	produce	a	better	
design	and	safe.	
	
Figure	1.	Area	cotact	2b	
METHODOLOGY		
The	superheater	recovery	boiler	plate	
form	 is	 shown	 in	 Fig.	 2.	 Design	 of	 plate	
holder	 model	 is	 done	 by	 using	 software	
ANSYS	 5.4	with	 size	 400	 x	 200	 x	 15	mm.	
The	model	designs	in	this	study	begin	at	the	
starting	 point	 of	 the	 work	 sheet	
coordinates	 in	 WP	 X,	 Y	 (0,0),	 width	 200	
mm,	 and	 height	 400	 mm.	 This	 modeling	
step	is	done	on	the	Preprocessor	menu,	as	
shown	in	Figure	3.	
 
Figure	2.	Superheater	plate	holder 
 
Figure	3.	2D	object	modeling 
	In	the	model	are	given	2	(two)	holes	
with	a	diameter	of	50	mm	at	 the	distance	
WP	X,	Y	(100,300).	Then	the	model	is	given	
a	 pin	 hole	 with	 subtract	 method	 so	 that	
obtained	model	plate	holder	that	has	been	
equipped	with	hole	pin	as	shown	in	Figure	
4.		
Amrinsyah,	Numerical Study on Plate Holders Pipe Recovery Boiler Superheater 
30 
	
Figure	4.	Model	holder	plate	that	has	been	given	pin	
hole 
Type	of	material	used	for	this	plate	is	
ASTM	A514	high	strength	alloy	steel	with	
tensile	 strength	 690	 MPa,	 density	 7800	
kg/m3,	 modulus	 elasticity	 211	 GPa,	 and	
Poisson	 ratio	 0.35.	 Material	 is	 defined	 as	
having	isotropic	shape.	The	type	of	element	
corresponding	 to	 this	 structure	 in	 the	 2D	
Solid	 8Node	82	2D	analysis	model	with	 a	
uniform	thickness.		
Mesh	 selection	 is	 made	 as	 small	 as	
possible	 by	 taking	 into	 account	 the	
maximum	 value	 of	 nodes	 that	 can	 be	
analyzed	by	the	program.	In	this	study	the	
mesh	size	taken	is	6	mm	(figure	5).		
	
Figure	5.	Shape	Mesh	on	model 
RESULT	AND	DISCUSSION	
The	load	received	by	the	holder	plate	
comes	from	the	weight	of	the	superheater	
header	 plus	 the	 superheater	 pipe	 with	 a	
total	 weight	 (Q)	 of	 95	 tons.	 Then	 the	
amount	 of	 load	 received	 on	 each	 hanger	
rod	is	51.775	kN.	Because	the	hanger	plate	
on	each	hanger	rod	is	2	pieces,	then	on	each	
plate	will	receive	25.88	kN.		
Based	 on	 contact	 area	 theory,	 it	 is	
known	 that	 the	 length	 of	 half	 of	 contact	
area	is	b	=	0,0047	m.	Then	the	contact	area	
of	the	plate	is	2b	or	equal	to	0.0047	x	2	=	
0.0094	m	=	9.4	mm.	The	maximum	voltage	
that	occurs	 in	 the	contact	area	 is	560,985	
MN	 /	m2.	 The	 voltage	 distribution	 at	 the	
contact	 area	 lies	 between	 lengths	 of	 ‐
0.0047	s	/	d	0.0047	m.	The	amount	of	stress	
distribution	in	this	area	is	shown	in	Table	
1.		
JMEMME, Vol 2 (No. 1) (2018): 27‐32 
 
31 
Tabel	1.	Stress	distribution	on	contact	area	
z z 
0 -560.9852
0.0005 -554.6914
0.001 -536.6298
0.0015 -509.0065
0.002 -474.7903
0.0025 -437.0197
0.003 -398.2934
0.0035 -360.5359
0.004 -324.9879
0.0045 -292.3226
0.005 -262.8003
 
		The	 numerical	 simulation	 results	
with	the	help	of	Ansys	software	are	shown	
in	Figure	6.	Contour	color	changes	show	the	
occurrence	 of	 nodal	 displacement	 in	 the	
specimen.		
	
Figure	6.	Nodal	displacement	simulation 
	Maximum	displacement	occurs	in	the	
contact	 area.	 If	 the	 maximum	 area	 is	
enlarged	(Figure	7),	then	the	magnitude	of	
the	displacements	at	each	node	is	shown	in	
Table	2.		
	
Figure	7.	Maximum	displacement	area 
Tabel	2.	The	value	of	maximum	nodal	
displacement	
NODE UX  UY UZ USUM
8 .26860E-05 -.31273E-
01 
.0000 .31273E-01
532 24634E-02 -.28965E-
01 
.0000    .29069E-01
535 -.25390E-
02 
-.29346E-
01   
.0000    .29455E-01
3745 .64725E-04 -.27982E-
01   
.0000    .27982E-01
	
Maximum	stress	also	occurs	in	almost	
the	same	region.	The	numerical	simulation	
results	are	shown	in	Figure	8.	The	value	of	
the	 stress	 distribution	 at	 that	 maximum	
region	is	shown	in	Table	3.		
	
	
Figure	8.	Maximum	stress	area	
	
Tabel	2.	The	value	of	maximum	stress	
distribution	
NODE S1 S2 S3 SINT SEQV 
  8 .00000 -130.39 -164.36 164.36 150.29 
3745 .00000 -21.923 -160.14 160.14 150.38 
	
Amrinsyah,	Numerical Study on Plate Holders Pipe Recovery Boiler Superheater 
32 
		
CONCLUSION		
Based	 on	 the	 results	 of	 the	 analysis	
can	be	seen	that	the	displacement	and	the	
maximum	 voltage	 occurs	 in	 the	 contact	
area	 between	 the	 retaining	 plate	 and	
superheater	pin.	This	is	due	to	this	area	of	
superheater	 load	 directly	 transmitted	
through	 the	 pins	 to	 the	 retaining	 plate.	
Thus,	 the	 dampening	 part	 is	 strongly	
recommended	 to	maintain	 the	 stability	 of	
the	construction.		
	
ACKNOWLEDGMENTS		
Acknowledgments	to	PT.	GAKA	Karya	
Engineering,	 Pangkalan	 Kerinci,	 Riau	 for	
good	 cooperation	 and	 facilities	 so	 that	
researchers	 get	 the	 research	 data	 and	
complete	the	research	report	well.	
	
REFERENCES		
	
	
Tavares,	 S.,	 Pardal,	 J.,	 Souza,	 G.,	 Garcia,	 P.,	
Barbosa,	E.,	Barbosa,	C.,	&	Filho,	I.	C.	
(2014).	 Study	of	 cracks	 in	 the	weld	
metal	 joint	 of	 p91	 steel	 of	 a	
superheater	steam	pipe.	Engineering	
Failure	Analysis,	464‐473.	
Yasniy,	O.,	Pyndus,	Y.,	Brevus,	V.,	Iasnii,	V.,	&	
Lapusta,	 Y.	 (2016).	 Lifetime	
estimation	 of	 superheater	 header.	
21st	 European	 Conference	 on	
Fracture,	 ECF21	 (pp.	 840‐846).	
Catania:	Procedia.	
Barma,	M.,	Saidur,	R.,	Rahman,	S.,	Allouhi,	A.,	
Akash,	 B.,	 &	 Sait,	 S.	 M.	 (2017).	 A	
review	on	boilers	energy	use,	energy	
savings,	 and	 emissions	 reductions.	
Renewable	 and	 Sustainable	 Energy	
Reviews,	970–983.	
Sankar,	 G.,	 Rao,	 A.	 C.,	 Seshadri,	 P.,	 &	
Balasubramanian,	 K.	 (2016).	
Techniques	for	measurement	of	heat	
flux	in	furnace	waterwalls	of	boilers	
and	 prediction	 of	 heat	 flux.	Applied	
Thermal	Engineering,	1470‐1479.	
Shokouhmand,	H.,	Ghadimi,	B.,	&	Espanani,	
R.	 (2015).	 Failure	 analysis	 and	
retrofitting	 of	 superheater	 tubes	 in	
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Analysis,	20–28.	
Taler,	 D.,	 Trojan,	 M.,	 Dzierwa,	 P.,	
Kaczmarski,	 K.,	 &	 Taler,	 J.	 (2018).	
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International	 Journal	 of	 Thermal	
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English

Numerical Study on Plate Holders Pipe Recovery Boiler Superheater

Reliability Centered Maintenance (RCM) atau lebih dikenal dengan the expert system of maintenance merupakan suatu metode desain sistem manajemen perawatan yang mampu memberikan jaminan ketersediaan, keselamatan, lingkungan serta desain sistem applicable dan komprehensif. Rel conveyor oven Btu Pyramax 150N adalah salah satu bagian yang sangat berpengaruh pada proses manufacturing sebuah PCB (Papan Circuit board) pada PT.Flextronics Teknology Indonesia â€“ BatamÂ  (Indonesia). Tujuan yang ingin dicapai ialah melakukan perancangan sistem manajemen perawatan berdasarkan RCM untuk menghindari terjadinya kegagalan (failure) peralatan mesin pada saat operasi yang menyebabkan terganggunya produksi dapat dihindari. Metode yang dilakukan pada penelitian ini mengunakan metode FMEA (Failure Mode and effect analysis) dan penelitian dapat tiga peralatan kritis yaitu rantai conveyor, jaring baja dan alur poros melintang

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Numerical Study on Plate Holders Pipe Recovery Boiler Superheater

Analisis Reliability Centered Maintenance (RCM) Rel Conveyor pada Mesin Oven BTU Pyramax 150N di PT. Flextronics Teknology Indonesia - Batam

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