Boilers are one of the most used units for both heat generation plants and
industry systems. Their operation is subjected to different working loads
and maintenance requirements. Exploitation experience points out critical
boiler zones where failures and break downs typically occur. This paper
analyzes critical zones in hot water fire-tube boiler. Experimental
procedure was performed on the model of this type of boilers and its
critical element. The tube plate of hot water boiler was identified as the
most critical one. Experimental analysis and numerical model verification
were performed using Aramis system based on 3D Digital Image Correlation
method. Numerical analysis was done in Ansys Software Package and
verification of results was done based on measurements obtained by strain
gauges and local measurements performed by the Aramis system. Stress-strain
analysis indicates the critical zones of boiler tube plate. The character of
change parameters such as strain and stress occurring in the critical zones
can be verified both by experimental and numerical data. The paper presents
a novel approach in experimental and numerical analyses that can be
conducted in similar units and used for existing unit optimization, as well
as for new product testing on different loads and provide opportunity for
further development and improvement for practical industrial application.