Title: Mild Steel MG Cylinders
1- Mild Steel MG Cylinders
- By
- D K Singhal
- Deveshklsinghal_at_rediffmail.com
2Mild Steel MG Cylinders
- Mild Steel MG Cylinders.
- Mechanical Design Considerations for Mild Steel
MG Cylinders. - Stress Relieving.
- Energy Audit of SR Process.
- First Grinding.
- Related BIS Specifications.
- About the Author
3Mild Steel MG Cylinders
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5Why Mild Steel MG Cylinder?
- Low initial cost.
- Short delivery periods.
- Equipment free from blowholes.
- Easy to grind whenever required.
6Is not CI better?
- Well, CI has some inherent problems related to
casting. With a huge job, in case of problem
related to uneven cast material properties,
blowholes etc., there is no other option to
discard a job. Furthermore, as ultrasonic testing
is not possible on CI, determination of such
defect is normally difficult.
7CI has better thermal conductivity!
- The thermal conductivity of CI is nearly 15
better than that of MS. But during papermaking,
other heat transfer resistances do add up in the
system resulting in an overall heat transfer
coefficient reduced by nearly 5-7 only. This too
can be compensated with reduced shell plate
thickness to some extent.
8CI is more hard than MS!
- Yes. From material properties it appears that CI
is harder and hence we need frequent grinding for
MS MG cylinder. But, being a softer material,
grinding takes smaller time. Also, well suited
doctor blades available now-a-days ensure longer
service life between two grindings. Furthermore,
today grades of MS are available that give better
hardness also.
9Who can make MS MG Cylinder?
- Your friendly machine manufacturer. Well, some
manufacturing facilities are must. As all the
operations involved can be done easily by a team
of skilled fabricators, welders, machinists etc.,
it is very easy to maintain quality.
10Manufacturer
- Must have good fabrication facilities.
- Must have good machining facilities.
- Must have good welding facilities.
- Must be capable of carrying SR (Stress Relieving)
11Ideal Time of Fabrication
- A higher temperature is generally advisable for
good welding. Hence, a summer season is normally
ideal for good welding. In winter, external
heating of plates to be weld may be done.
12Suitable MS for MG
- Boiler grade mild steel is most suitable for
fabrication of MG. It is extremely important that
if more than one plates are being used, all must
have same properties as well as chemical
composition. This is extremely important to have
uniform bending, to ensure uniform shell
thickness after final grinding.
13Testing of Plate Material
- To ensure the quality of plates, it is necessary
to get the plates checked for chemical
composition. This can be done by cutting a small
piece of each plate and sending to a laboratory
performing such tests. The plates should also be
tested ultrasonically for any hidden crack, or
abnormality.
14Chemical Composition
- Chemical composition of MS plate used for MG
fabrication is important as it provides some
useful information e.g. thermal and mechanical
properties, wear and corrosion resistance, etc.
Presence of different elements affects different
properties. Some of these are listed in following
slides.
15Effect of Carbon
- A higher amount of carbon means marginally better
strength and machinability, but poor wear
resistance. Typical values for some different
materials are as under- - IS2002 0.01-0.025
- IS 2062 0.01-0.02
- IS515 0.015-0.025
16Effect of Sulphur
- Presence of sulphur imparts strength, but in some
cases it results in poor ductability or
cracking.It makes steel harder, stronger, but
brittle.
17Effect of Nickel Chromium
- Presence of Nickel imparts strength, and wear
resistance, but it results in very hard steel,
that is difficult to machine, bend and hence
gives improved wear resistance. In Normal grades,
nickel is absent or found in negligible amounts.
Similar is the case with chromium.
18Chemical Composition
- Chemical composition plays a significant role in
physical and strength properties of material. - Presence of Ni and Cr imparts wear resistance,
though due to hardness, it becomes difficult to
bend the plate. - Other elements also affect different properties.
19Ultrasonic Testing
- Plates are made in re-rolling mills by pressing
red-hot iron Ingots. Sometimes, due to entrapment
of air due to some reason, an air film is left
between two layers of plate. This is normally
called as lamination in plate. The object of
ultrasonic testing is to ensure that the plate
should be free from such laminating defects.
20Plate Lamination
- During manufacturing of MS plates, hot ingots are
pressed together repeatedly to form a uniform
layer plate. - There exists a possibility that some air is
entrapped between two layers, which is not fully
removed during rolling operation of the plates.
This is called lamination.
21Plate Lamination
- Plate lamination reduces the strength of material
marginally, but greatest disadvantage is
significant reduction in heat transfer
coefficient at the location of lamination due to
a bad conductor (Air film) sandwiched between two
layers of metal. - Thus, laminated spots have lower heat transfer
coefficient and thus colder outside surface of MG
cylinder, thus paper drying is not uniform. This
result in poor quality paper, reduced production,
frequent grinding etc.
22Conducting UT
- It is recommended to mark the plate in 9X9
sections with the help of chalk. - Now, each section is carefully examined to with
approx. 1 outside all boundaries.This is done to
ensure that the the plate is completely tested
and no part is left untested.
23UT Results
- Normally, if the plate is perfect, there would
not be any defect. - In some cases there may be defects, particularly
at the edges, In many cases, these are small, to
the tune of 1-3 inch wide, and several feet long.
With such plate, there may be problems of wet
edges on paper. - In case there is a defect in between the plate,
and is more than the plate thickness in
dimension, the plate must be discarded, and not
used for fabricating MG.
24Ultrasonic Tester
- It is recommended that the ultrasonic testing is
done by a government approved ultrasonic tester. - Presence of customers representative during
ultrasonic test is preferable.
25Ensuring Plate Originality
- Sometimes, plate is procured by the customer and
handed over to MG manufacturer for MG
fabrication. - If customer is interested, he may get some mark
punched on the plates to ensure only the plates
checked in his presence have been used in
fabrication.
26During Plate Bending
- It is important to ensure that the plate bending
is done at a very slow rate. Too high a bending
speed may cause minor cracks in the plate, which
may create problems later on. The possible
problems could be- reduced localized heat
transfer from MG, under or over drying of paper,
frequent requirement of grinding etc.
27During Welding
- Being plates of sufficient thickness, it is
necessary to cut a Vee before welding. - Welding must be done with suitable electrodes
only, and in no case blow holes must remain in
the weld. Of course, this can be checked later on
using ultrasonic testing, but then it is too late
to rectify the problem.
28During Welding
- It is strongly recommended that the welding is
done at suitable temperature, and sudden cooling
is not done. In winter season, external
preheating of area nearby should be done.
29Welding Rods
- The welding rods used must be of same material as
that of plates. Rods of reputed manufactures,
having correct specification should be used.
Welding should be done at specified current only.
30Condensate Removal
- Particularly for slow speed machines, operating
under 400 mpm, rotary siphon can be effectively
used. The saveall treys should be of sufficient
size.
31Position of Rotary Joint
- Rotary joints can be placed at either location-
drive or tender side. In some cases mills prefer
to have separate rotary joints for steam and
condensate.
32Condensate Treys in MG
- Being MG a slow rpm device, installation of
condensate trays with siphon pipes is a good
arrangement. - The trey must be of sufficient size to collect
condensate in one rotation of MG, but should not
be overdesigned as it may result in imbalance
during operation.
33Mechanical Design Considerations for Mild Steel
MG Cylinders
34Shell Plate Thickness
- Obviously, a higher shell plate thickness means
longer operation life, possibilities of using
higher steam pressure, but also reduced heat
transfer coefficient, and hence reduced
productivity at a particular steam pressure.
35Shell Plate Thickness
- Checking of final shell plate thickness can be
done by subtracting thickness lost during
grinding from original shell plate thickness. - Thickness loss is obtained by dividing the weight
of peelings during machining and grinding by
density of plate material and by area of shell
plate.
36Shell Plate
- A uniform shell plate thickness is must in order
to get uniform bending force application during
drum fabrication. - If more than one plates are being used for shell
fabrication, it is extremely important that the
all plates are of same chemical composition as
well as mechanical properties. - To ensure this, use of shell plates from a single
manufacturer and with same batch number (or heat
number) should be used.
37Steam Entry
- Normally, steam entry and condensate outlet is
provided at the same side, but it can be made at
different ends. - The machine configuration (Right hand drive or
Left hand drive) and the operators ease are the
most important while deciding these factors. - Yet, many papermakers prefer tender side steam
entry as well as condensate removal.
38Condensate Removal
- On slow speed MG cylinders, scooping is the most
efficient method for condensate collection. This
becomes also the only method available as
position of tie rods does not allow fixed siphons
to be mounted. Since sufficient information is
not available on design of MS cylinders for
higher speeds, presently, we can use only the
scoops for condensate collection and use MG
cylinder for slow speed operation only.
39Tie Rods
- Dish ends face a significant load of few hundred
tons towards outside during operation. This load
tries to deform the dish end towards outside at
the center, resulting in increase in cylinder
diameter at both ends. - This results in camber disturbance locally at the
both ends. - For the same, tie rods are used to place the dish
ends in position.
40Diameter and Number of Tie Rods
- Due to huge loads, tie rods must be adequately
designed. - There could be 6, 8, 12, or 16 tie rods as per
requirement. - A normal rule of thumb is that the total cross
section area (in square centimeter) of tie rods
must be at least 1.5 times the outward force on
each dish end(calculated as multiplication of
pressure inside MG and area of dish end) in
metric tons.
41Manhole
- Usually, one manhole is provided in MG for access
to internal parts for inspection or repair. In
some cases, two manholes may be provided. - Manhole should be designed to provide easy access
of maintenance personnel to MG as well as a being
totally leak proof.
42Inside Surface
- Inside surface is important due to two reasons-
- 1. Uneven surface means variations in thickness,
and hence in heat transfer coefficient and hence
results in uneven drying of paper. - 2. In case, there is pitting on inside surface,
these pits wear off rapidly, and pose problems
related to poor runnability of paper.
43Defects on Inside Surface
- Pitting is first defect, as explained earlier.
This results in abnormal and non-uniform drying
of paper - Thickness variation across circumference is
another defect caused by ovality in MG during
manufacturing due to which, during machining and
grinding, different thickness of material are
removed from different circumferential locations. - This results in moisture variations in paper
across machine direction, relativerly lower
machine speeds, improper condensate removal etc.
44Drain Plug
- Drain plug is provided opposite to manhole. To
purpose is to easily drain the condensate in case
there is water filling due to poor steam trap,
rotary joint or siphon pipe operation. - Drain plug may be plugged with an ordinary mild
steel plug, tested under operating conditions, or
with a fusible plug, which will fuse off in case
of elevated temperature or a safety valve set to
bleed steam in case of increased pressure.
However, since pressure inside MG can never
exceed the inlet line pressure, putting a safety
valve at MG inlet would be sufficient to serve
the purpose.
45Journals
- In case journals are to be fitted by shrink
fitting/ or press fitting, these can be of EN-8
or EN-9. But, if these are to be welded with dish
ends and ribs, mild steel should be used. - Due to a large size of MG, it is often not
possible to machine the journals to make bearing
seats after mounting on MG, these must be
pre-machined. - Extra care should be taken to ensure that the
journals are mounted properly in position as
inaccurate fitting would finally result in extra
machining requirement for the shell plate during
grinding as well as uneven thickness of MG across
circumference.
46Journal Fitting
- Being MG a low RPM rotating equipment, mild steel
journals are normally used. These provide an
additional advantage of being welded with the
dish ends, and mounting is very easy. It is
strongly recommended that before welding of the
journal, position of the same is to be checked
with specially designed J hook shaped tool.
47Dish Ends
- Dish ends should have sufficient strength to
withstand the load applied to these due to
internal pressure. Typically, the force on an end
is of the order of 500 Tons.To avoid bending of
dish ends due to such pressures, tie rods are
used. Use of external ribs on dish ends also
helps in preventing bending of dish ends.
48Stress Relieving
49Heat Treatment
- Following are the reasons for heat treatment
- To relieve the effects of strain hardening
- To acquire the desired strength and toughness in
the finished product - To soften before shaping
50Heat Treatment Process
- Heat the metal to a temperature (Heating Phase)
- Hold at that temperature (Soaking Phase)
- Slowly cool (Cooling Phase)
51Purpose
- Reduce hardness and brittleness
- Alter the microstructure for a special property
(Better surface smoothness) - Soften the metal for better machinability
- Recrystallize cold worked (strain hardened)
metals - Relieve induced residual stresses
52Effect of Stress Relieving
- Stress relieving is necessary, as the process of
MG fabrication involves bending, which is never
completely done by the available techniques. If
you cut the shall of a newly formed and welded
shell it will split open in following form-
53Effect of Stress Relieving
- In this way, the fabricated job remains under
some stress for a long time. This stress is
reduced automatically, by a process called CREEP.
Under this, when any object is kept under stress
for a long time (years or decades), the stress
reduces with time the time reduces with increase
in temperature.
54Objects under Stress
- Unfortunately, MG is made of different plates,
which may come under different levels of stress
during fabrication, and thus stress reduction by
creep may not be a uniform process throughout MG
surface during routine operation. That is why, SS
coating is normally not recommended on new MG
cylinders without stress relieving.
55When should SR be done?
- During fabrication. Most common practice is to
carry out SR after MG is fabricated but before
machining. A better option is a double SR, one of
the bare shell duly rounded and welded, to remove
any fabrication and welding stresses. Afterwards,
rerolling should be done to make the shell more
uniform.
56When should SR be done?
- After SR rolling stresses and welding stresses
are removed, and during further rolling, minor
stresses are developed. Then we may put dish ends
in position, fix journals, ribs on dish end,
siphon pipes, treys etc., and then finally carry
out SR. This SR will result in minor shape
variations that can easily be corrected during
machining.
57From where the energy required for SR comes?
- For SR temperature of the object is raised to a
certain value. This requires a huge amount of
heat. This heat is achieved by following sources- - Electricity
- Liquid Fuel (HSD, LDO, FO etc.)
- Solid Fuel (Wood, Coal Etc.)
- Gaseous Fuel (LPG, CNG, Methane etc.)
58How to check whether SR is being properly done?
- There are different methods available for the
same- - Direct method in this temperature inside the
furnace is measured by calibrated instruments.
Customer may procure his own testing instruments
for the same. - Indirect Method In this an audit of the process
is conducted and it is evaluated whether the
required amount of fuel has been consumed or not.
A fuel consumption lesser than the calculated
directly indicated that there has been something
wrong.
59Direct Method
- Ensure that the thermocouples or RTDs as well as
the recording instruments are calibrated by
authorized labs. - Use of non contact type (Pyrometer type)
thermometer is also recommended. - Ensure that the thermocouples or RTDs are not
placed near the heat source.
60Indirect Method
- Evaluate the furnace and heating procedure and
make a detailed audit of the operation. - Collect sample of fuel for calorific value
determination, and details of furnace for heat
capacity of the same. - In case of electric fired furnace, either ensure
that the energy meter is calibrated, or use a
separate portable energy meter.
61Energy Audit of SR Process
62Objective
- To ensure that the SR operation is being done
correctly. - To explore the possibilities of energy
conservation and hence cost reduction during SR.
63Heating System
- Heating may be done by-
- Electricity
- Liquid Fuel (HSD/LDO/HCR/FO)
- Solid Fuel (Wood/Coal)
- Gas (Propane/Methane/LPG/CNG)
- Hot Air
64Heat Required By the Job
- For any object, the energy required by the job
for heating is calculated by the formula- - Energy m c ?t, where
- m is the mass of material
- c is specific heat and
- ?t is temperature rise.
65Heat Required by Furnace
- Some amount of heat is also absorbed by the
furnace material. The same can also be calculated
as given in previous sheet. In case exact mass of
furnace is not available, relevant calculations
and approximations may be used.
66Convection and Radiation Losses
- Being a small time operation, losses from furnace
walls, and small openings, if any can be
calculated. For most practical purposes, these
can be taken as 1-2 of the energy required by
the job per hour at soaking time. Well, these
vary substantially, and should be computed
properly for accurate observations. More detailed
information on convection and radiation losses
can be obtained in chemical engineering books.
67Stack Losses
- In case of electrically fired furnaces, there are
no stack losses. But, fuels require amounts of
oxygen and hence air for combustion. The air
requirement varies from 5-6 kg for coal to around
7 kg for wood, and 10-11 kg for HSD etc. per kg
of fuel. The flue gases, equal to the weight of
air and fuel leave furnace at a temperature
somewhat higher than the prevailing furnace
temperature and thus contribute to stack losses.
68Quantification of Stack Losses
- The stack losses can also be calculated as
explained earlier. In case specific heat of flue
gas is not available, it can be assumed to 0.29.
Stack temperature can be measured using suitable
instrumentation, and flue gas weight can be
calculated by multiplying stack area by flue gas
velocity by density of flue gases at operating
conditions. Alternatively, it can be assumed as
sum of fuel weight and theoretical air weight,
along with some excess air supplied, which can be
suitably assumed.
69Total Energy Supplied by Fuel
- Total energy supplied by the fuel is the sum of
all of these- - Energy required by the job
- Energy required by the furnace
- Convection and radiation losses
- Stack Losses
70Fuel Consumption
- From the above, the fuel consumption can be
calculated as- - Fuel Consumed
- Total energy supplied by fuel
- Calorific Value of Fuel
71Efficiency of Furnace
- Efficiency of furnace can be calculated as-
- Efficiency
- Heat given to job/Total heat consumed
72Internal Firing
- Often, some SR vendors suggest an internal firing
arrangement for minimizing time required in SR
operation, particularly if SR facility is away
from the manufacturer site. - They suggest use of mineral wool insulation
around MG cylinder, and put firing arrangement
inside MG, where the fuel (Conventionally the
liquid fuel) is fired.
73Internal Firing Typical Data
- If we consider a sample case of an MG cylinder
weighing say 40 tons, heat required to raise its
temperature to 620 deg. From initial 20 deg. At a
good 75 efficiency would require nearly 1600 kg
of HSD. With this, the flue gas would weight
18000 Kg, I.e. approx. 45000 cu.m. at exhaust
conditions. If the temperature has to be raised
in 8-10 hours, we require an exhaust of 4500
cu.m. per hour from the manhole of MG.
Furthermore, nearly, 1500 cu.m. per hour air has
also to be injected simultaneously for
combustion.
74Internal Firing Not Possible
- As the openings in completely built MG cannot
allow such huge volumes of air to be passed with
this information, it is not recommended to
conduct an SR with internal firing on completely
built MG cylinder. However, if found necessary,
it is suggested to evaluate the process before
taking SR to get it done properly. - However, in case only shell is being subjected to
SR, internal firing could be used effectively,
with reduced fuel consumption, and thus reduced
cost.
75First Grinding
76First Grinding
- First grinding is often most important. This is
due to the fact that no reference points are
usually available before proceeding for grinding. - Arrangements should also be made during first
grinding for the easy and rapid installation of
grinding lathe during subsequent grindings.
77Precautions in First Grinding
- To balance MG statically as well as dynamically.
- To position MG as per journal positions.
- Begin with initial tool cuts, with minimal
thickness loss. - To recheck and correct balancing.
- To conduct final grinding.
- To check and correct balancing finally.
78Imbalance in MG
- Imbalance in MG is due to inaccurate mounting of
journals, inadequate or improper bending of shell
plate, deformations caused during stress
relieving etc. - Imbalance results in decreased drive load on MG
section while the high weight section in moving
from up to down and vice versa during rotation of
the same during grinding or normal operation.
79Problems due to Imbalance
- Due to imbalance, load on the drive varies during
every rotation of MG. Due to such fluctuations,
particularly if the drive has not well
synchronized with the equipment (MG), there
exists minor speed variation. - Due to this speed variation, we neither get
uniform moisture of paper in machine direction,
nor get good runnability of the paper.
80How to Check Imbalance?
- In the initial stage, when there could be a good
imbalance, requiring say more than 50Kg weight on
one side imbalance can be checked by rotating MG
and allowing to stop by itself. - If MG stops at a particular position only in few
trials, or makes pendulum like motion before
stopping, this means that the top most position
after MG has stop needs some extra weight to be
put on.
81Fine Balancing Checking
- For further measurements, MG is allowed top
rotate with drive arrangement at moderate speed,
and the load of the drive is recorded. - In case of imbalance, load of drive will increase
and decrease alternatively in every rotation of
MG. - The difference between maximum and minimum load
can be used to calculate the amount of weight
required for MG balancing.
82Why should balancing be repeated during first
grinding?
- The first grinding is done on MG, which has a
surface that is not a perfect circle. During
initial cuts, a significant part of one side may
be lost, resulting in weight loss from that side. - Thus, the other side becomes heavier, and hence,
MG becomes imbalanced. - That is why, frequent balancing is a must during
initial grinding.
83BIS Specifications
84IS 8221970
- Code of practice for inspection of welds.
85IS 13371993
- Electroplated coatings of hard chromium for
engineering purpose. (Third revision)
86IS 15861988
- Method for Rockwell hardness test for metallic
material (scales S-B-C-E-F-G-H-K) (second
revision)
87IS 16081995
- Mechanical testing of metals tensile testing
(second revision) (superseding IS1521, 1663,
1816,1894,2078,2654,2655, 2657, 2658, 4713 and
8285)
88IS 20021992
- Steel plate for pressure vessels for Intermediate
high temperature service including boilers
(second revision) (Amendment 2)
89IS 20411995
- Steel plates for pressure vessels used at
moderate and low temperature (second revision)
(Amendment 1)
90IS 20621992
- Steel for general structural purpose (fourth
revision) (superseded Is 2261975) (amendments 4)
91IS 24781991
- Glossary of terms relating to industrial
radiography (second revision)
92IS 25951978
- Code of practice for radiographic testing (first
revision)
93IS 25981966
- Safety code for industrial radiographic practice
94IS 35311997
- Glossary of terms relating to corrosion of metals
(second revision)
95IS 36581999
- Code of practice for liquid penetrant flaw
detection (second revision)
96IS 42601986
- Recommended practice for ultrasonic testing of
butt welds in ferritic steel (second revision)
97IS 60091970
- Method for evaluation of result of accelerated
corrosion test
98IS 7307(Part 1)1974
- Approval tests for welding procedures Part 1
fusion welding of steel (Amendment 1)
99IS7310(Part 1)1974
- Approval tests for welders working to approved
welding procedures Part 1 fusion welding of
steel
100IS 7318(Part 1)1974
- Approval tests for welders when welding procedure
approval is not required Part 1 fusion welding
of steel
101IS 8062(Part 1)1976
- Code of practice for cathodic protection of steel
structures Part 1 General principles
102 IS 8629(Part 1)1977
- Code of practice for protection of iron and steel
structures from atmospheric corrosion Part
1-General principles of corrosion and its
prevention (Amendment 1)
103IS 8629(Part 2)1977
- Code of practice for protection of iron and steel
structures from atmospheric corrosion Part 2
pretreatment (Amendment 1)
104IS 8629(Part 3)1977
- Code of practice for protection of iron an steel
structures from atmospheric corrosion Part 3
protection schemes (Amendment 1)
105IS 91801991
- Recommendations for performance rating of fuel
fired furnace (first revision)
106IS 108011984
- Recommended procedure for heat treatment of
welded fabrications
107IS 110831984
- Method for evaluation of friction and wear
properties of materials against steel surface
108IS 116301986
- Method of ultrasonic testing of steel plates for
pressure vessels and special applications
109IS 124571988
- Code of practice for evaluation repairs and
acceptance limits of surface defects in steel
plates, and wide flats
110IS 134171992
- Code of practice for heat treatment of steel
111D K Singhal
- Basically an M.E. (Pulp Paper) from Institute
of Paper Technology, (University of Roorkee, now
IIT, Roorkee), Saharanpur, 1993. Did B.E. (Pulp
Paper) from the same institute in 1990. Certified
Energy Auditor from Bureau of Energy Efficiency
(BEE), India. - Having about 15 years of experience and author
of more than two dozen technical research
papers covering a vide range of topics including
waste paper sorting, pulping, waste paper
recycling, energy conservation, optimization,
chemical recovery, paper mill electricals, power
generation, rewinder optimization for trim loss
minimization, paper making, process
instrumentation automation, computer
simulation, quality monitoring etc. - Contact
- D K Singhal, Sargam Theatre,
- Chandpur 247 625, Dist. Bijnor
- Phone 01345220140,222330 (O)
- Fax 01345224140 Mobile 09412713426
- E-mail deveshksinghal_at_rediffmail.com
chandpurpapers_at_yahoo.com