ABSTRACT

Boilers are pressure vessels designed to heat water or produce steam, which can then
be used to provide space heating and/or service water heating to a building. In most
commercial building heating applications, the heating source in the boiler is a natural
gas fired burner. Oil fired burners and electric resistance heaters can be used as well.
Steam is preferred over hot water in some applications, including absorption cooling,
kitchens, laundries, sterilizers, and steam driven equipment. Boilers have several
strengths that have made them a common feature of buildings. They have a long life,
can achieve efficiencies up to 95% or greater, provide an effective method of heating a
building, and in the case of steam systems, require little or no pumping energy.
However, fuel costs can be considerable, regular maintenance is required, and if
maintenance is delayed, repair can be costly. Guidance for the construction, operation,
and maintenance of boilers is provided primarily by the ASME (American Society of
Mechanical Engineers). Boilers are often one of the largest energy users in a building.
For every year a boiler system goes unattended, boiler costs can increase approximately
10%. Boiler operation and maintenance is therefore a good place to start when looking
for ways to reduce energy use and save money.

CONTENTS:

CHAPTER-1
INTRODUCTION

INTRODUCTION
COMPANY PROFILE

ENMAX ENGINEERING (INDIA) PRIVATE LIMITED

HYDERABAD 500 055, INDIA

Registered office & Works

Survey # 15, Suraram, Qutbullapur (Mandal), Rangareddy (Dt.), Hyderabad
500 055, India

Product range
1.0

Waste heat recovery systems for

Process plants like Sulphuric acid plants, Sulphur recovery units, Nitric acid

plants, Hydrogen plants, Ammonia plants etc.,

Coal based plants like Coke oven plants

Metallurgical plants like Blast furnaces, Zinc plants, Lead plants, Copper plants

and
Sponge iron plants etc..,

Carbon black industries

Combined cycle power plants like HRSG behind Gas turbines and Gas engines

Cement plants

DG Gensets

Incinerators

1.2

Engineering equipment

De-aerators cum feed water storage tanks,

Blow down systems

SCAPH (Steam coil air pre heaters)

LP heaters, MP heaters and HP heaters

Surface condensers and Dump condensers

Pressure vessels

Heat exchangers

1.3

Boiler spares

Bed coils (both plain & stud type)

Super heater coils

Economizer coils & bends

Water wall panels

Designs & Standards

We design and manufacture the equipment as per codes like

ASME

IBR

BS

DIN

IS

TRD

Manufacturing facilities
Enmax is situated at Balanagar-Narasapur state highway near Jeedimetla industrial area
in Hyderabad (India). Situated in the heavy fabrication and engineering zone where all
kind of facilities like transportation, heavy cranes for material handling, sub vendors
for dish end manufacturing, plate rolling (higher thickness) etc., are available.
Works is spread over 6000 Sq yards (both covered and un-covered) area with
ample natural and supporting lighting system, ventilation, water, Electric power and
ambience.
Shop & manufacturing facilities are approved by Indian Boiler Regulating authorities
(IBR), Lloyds and BVQI. Enmax is holding an ISO accreditation (9001:2008) through
BVQI since 2009.

Chapter-2
Boiler Introduction

1.INTRODUCTION OF BOILER
A boiler is a closed vessel in which water under pressure is transformed into steam by
the application of heat. In the boiler furnace, the chemical energy in the fuel is
converted into heat, and it is the function of the boiler to transfer this heat to the
contained water in the most efficient manner. The boiler should also be designed to
generate high quality steam for plant use.
A boiler must be designed to absorb the maximum amount of heat released in
the process of combustion. This heat is transferred to the boiler water through radiation,
conduction and convection. The relative percentage of each is dependent upon the type
of boiler, the designed heat transfer surface and the fuels. The boiler house or steam
generation facility within any given plant is frequently referred to as the heart.
Boilers have several
strengths that have made them a common feature of buildings. They have a long life,
can achieve efficiencies up to 95% or greater, provide an effective method of heating a
building, and in the case of steam systems, require little or no pumping energy.
However, fuel costs can be considerable, regular maintenance is required, and if
maintenance is delayed, repair can be costly.

Boilers are often one of the largest

energy users in a building. For every year a boiler system goes unattended, boiler costs
can increase approximately 10%. Boiler operation and maintenance is therefore a good
place to start when looking for ways to reduce energy use and save money.
Guidance for the construction, operation, and maintenance of boilers is
provided primarily by the ASME (American Society of Mechanical Engineers).

Figure(1):Refractory

2.1 DEFINITION OF BOILER

1. It is a closed vessel or arrangement of vessels and tubes, together with a furnace
or other heat source, in which steam or other vapour is generated from water to
drive turbines or engines, supply heat, process certain materials, etc.
2. A boiler is defined as a closed vessel in which water or other liquid is heated,
steam or vapor is generated, steam is superheated, or any combination thereof,
under pressure or vacuum, for use external to itself, by the direct application of
energy from the combustion of fuels, from electricity or nuclear energy."
The boiler is not the heating system; it is only one of the parts in the global heating
system.

2.2 CLASSIFICATION OF BOILER

Horizontal, Vertical or Inclined: Depending upon the orientation of the axis of a
boiler it can be classified as horizontal, vertical, or inclined. If the axis of the boiler is
horizontal, it is called horizontal boiler. If the axis is vertical, it is called vertical boiler
and if the axis is inclined at an angle then it is called inclined boiler.Fire Tube and
Water Tube: In fire tube boilers, hot flue gases flows through the tubes and water
surrounds the tubes. Examples: Cochran, Lancashire and Locomotive boilers.
In water tube boilers, water flows inside the tube and hot flue gases surrounds
the tubes. Examples: Babcock and Wilcox, Stirling, Yarrow boiler.
Externally Fired and Internally Fired: If the fire or burning of the fuel is done
outside the shell then it is called externally fired boiler. Examples: Babcock and
Wilcox, Stirling boiler. If the burning of fuel or the furnace is located inside the shell
then it is called internally fired boiler. Example: Cochran, Lancashire boiler.
Forced Circulation and Natural Circulation: In forced circulation boilers, a forced
pump is used for the circulation of water through the tubes. Examples: Velox, Lamont,
Benson boilers. In natural circulation boilers, circulation of water takes place due to
natural convection currents produced by the application of heat. Examples: Babcock
and Wilcox, Lancashire boiler.
High Pressure and Low Pressure Boilers: The boilers which produce steam at
pressures above 80 bar are called high pressure boilers. Example: Volex, Lamont,

Benson, Babcock and Wilcox boilers.

Boilers which produce steam at pressure below 80 bar are called low pressure
boilers. Example: Cochran, Lancashire and Locomotive boilers. Stationary and
Portable: Boiler which are fixed at one place are called portable boilers like the boiler
used in power plants. Portable boilers are small in size and are used in locomotive type,
and temporary on site purposes.
There are two general types of boilers: ''fire-tube'' and ''water-tube''. Boilers are
classified as "high-pressure" or "low-pressure" and "steam boiler" or "hot water boiler."
Boilers that operate higher than 15 psig are called "high-pressure" boilers. A hot water
boiler, strictly speaking, is not a boiler. It is a fuel-fired hot water heater. Because of its
similarities in many ways to a steam boiler, the term hot water boiler are used.

Hot water boilers that have temperatures above 250 Fahrenheit

or pressures higher than 160 psig are called ''high temperature hot water boilers''.

Hotwater boilers that have temperatures not exceeding 250 Fahrenheit or

pressures not exceeding 160 psig are called ''low temperature hot water boiler's.
Heating boilers are also classified as to the method of manufacture, i.e., by casting
(cast iron boilers) or fabrication (steel boilers). Those that are cast usually use iron,
bronze, or brass in their construction. Those that are fabricated use steel, copper, or
brass, with steel being the most common material.

i.

Fire-tube Boilers
Fire tube boilers consist of a series of straight tubes that are housed inside a
water-filled outer shell. The tubes are arranged so that hot combustion gases
flow through the tubes. As hot gases flow through the tubes, they heat the water
that surrounds the tubes. The water is confined by the outer shell of the boiler.
To avoid the need for a thick outer shell, fire tube boilers are used for lowerpressure applications. Generally, the heat input capacities for fire tube boilers
are limited to 50 MBtu/h or less, 5 but in recent years the size of fire tube
boilers has increased. Fire tube boilers are subdivided into three groups.
Horizontal return tubular (HRT) boilers typically have horizontal, selfcontained fire tubes with a separate combustion chamber. Scotch, Scotch
marine, or shell boilers have the fire tubes and combustion chamber housed
within the same shell. Firebox boilers have a water-jacketed firebox and

employ, at most, three passes of combustion gases. Most modern fire tube
boilers have cylindrical outer shells with a small round combustion chamber
located inside the bottom of the shell. Depending on construction details, these
boilers have tubes configured in either one, two, three, or four pass
arrangements. Because the design of fire tube boilers is simple, they are easy to
construct in a shop and can be shipped fully assembled as a package unit.
Table2.1.1 identifies various types of fire tube boilers and the associated fuels
that they typically burn.

Fuel Fire tube

Coal

Fuel oil

Natural gas

Biomass

boiler type
HRT boilers

Yes

Yes

Yes

Yes

Scotch boilers

Yes

Yes

Yes

No

Firebox boilers

Yes

Yes

Yes

Yes

Table(1):Fuels used

Figure(2):Fire tube boiler.

Advantages of fire-tube boilers:

Relatively inexpensive.

Easy to clean.

Compact in size.

Available in sizes from 600,000 btu/hr to 50,000,000 btu/hr.

Easy to replace tubes.

Well suited for space heating and industrial process applications.

Disadvantages of fire-tube boilers:

Not suitable for high pressure applications 250 psig and above.

Limitation for high capacity steam generation

ii.

Water-tube Boilers

In

a water-tube boiler, the water is inside the tubes and combustion gases pass
around the outside of the tubes. The advantages of a water-tube boiler are a
lower unit weight-per-pound of steam generated, less time required to raise
steam pressure, a greater flexibility for responding to load changes, and a
greater ability to operate at high rates of steam generation.
A water-tube design is the exact opposite of a fire-tube. Here, the water
flows through the tubes and is encased in a furnace in which the burner fires.
These tubes are connected to a steam drum and a mud drum. The water is
heated and steam is produced in the upper drum. Large steam users are better
suited for the water-tube design. The industrial water-tube boiler typically
produces steam or hot water primarily for industrial process applications, and is
used less frequently for heating applications. The best gauge of which design to
consider can be found in the duty in which the boiler is to perform. The ability
of water tube boilers to generate superheated steam makes these boilers
particularly attractive in applications that require dry, high-pressure, highenergy steam, including steam turbine power generation. Owing to their
superb working properties, the use of water tube boilers is highly preferred in
following major areas: Variety of process applications in industries Chemical
processing divisions Pulp and Paper manufacturing plants Refining units
Besides, they are frequently employed in power generation plants where large
quantities of steam (ranging up to 500 kg/s) having high pressures i.e.

approximately 160 bar and high temperatures reaching up to 550C are

generally require

Figure(3): Water-tube Boiler

Advantages of Water-tube boilers:

Are available in sizes far greater than a fire-tube design , up to several million
pounds-per-hour of steam.

Are able to handle higher pressures up to 5,000 psig.

Recover faster than their fire-tube cousin.

Have the ability to reach very high temperatures.

Disadvantages of the Water-tube boilers:

High initial capital cost.

Cleaning is more difficult due to the design.

No commonality between tubes.

Physical size may be an issue.

Applications of Water-tube Boiler

1. Boilers are used mainly in power plant for generating high pressure steam to
produce electricity. In power plant high pressure steam is expanded through
nozzles to run steam turbine which generates electricity.
2. In cold countries hot water producing boilers are used for heating the buildings.
3. Boilers also find its application in textile industries for sizing and bleaching,
and many other industries like sugar mills and chemical industries.

2.3 Advantages of Boiler

1.

Their silent work

2.

Programming modes of operation for different times of the day, that reduce the
amount of money for heating

3.

Their simple installation

4.

They are safer and there is no risk of fire or explosions

5.

There is no need for fuel

6.

It is possible to install a new heating system, or to replace a pre-existing one

7.

A chance for a parallel connection with other heat boilers

8.

The system cannot freeze (ion boiler heat carriers do not freeze until a
temperature of -40C),

9.

Environmental merit; An energy-saving product from a new generation

2.4 Essential qualities for a good Boiler:

1. Should meet large load fluctuations.
2. Occupy less floor space.
3. Should afford easy maintenance and inspection.
4. Light and simple in construction.
5. Tubes should be sufficiently strong to resist wear and corrosion.

6. Mud and other deposits should not collect on heated places.

7. The velocity of gases and other flue gases should be minimum.
8. The joints must be accessible and away from direct flame impact.
9. Capable of producing maximum steam with minimum fuel consumption.

2.5 Package Boiler Design

A package boiler or packaged boiler is a modern form of steam boiler. They are
factory-made to a range of standard designs, according to the size and evaporative
capacity required. The advantages of a package boiler are that they are available 'off the
shelf' without a lengthy design step and also that they are simpler to install. Package
boilers are also cheaper to operate as they automatically manage their burner and water
level, so not requiring the continual attention of a boiler man.
Package boilers are not used for large-scale power purposes such as electrical
power generation. These use more complex and more efficient custom-designed
boilers, usually today water-tube boilers working at high pressure.

Figure(4):Package Boiler

Fig 5 6

2.5.1 Package boiler models and types:

2.5.2Criteria for the selection of a Boiler:

The factors taken into account while selecting a boiler are as follows:
1. Power required to be generated.
2. Operating pressure.
3. Fuel quality and type.
4. Water availability and its quality.
5. Probable load factor.
6. Location of the power house or process plants.
7. Cost of operation and maintenance.
8. Cost of installation and erection.
9. Availability of floor space.

2.5.3Construction of Package boiler

1. Plates Marking, Cutting and Rolling.
2. Long seam fit up and welding.
3. C-seam fit up and welding.
4. Tube sheet holes marking and drilling.

5. Rear tube sheet fit up in main shell and welding.

6. Gusset plates fit up and welding for rear main tube sheet.
7. R.C shell to tube sheets(front and rear) fit up and welding.
8. Main shell nozzle orientation marking, cutting and grinding(including man
hole).

9. Nozzle pipes marking and cutting.

10. Nozzle Flanges Marking, Cutting, Machining and Drilling.
11. Nozzle pipe to flange fit up and welding.
12. Nozzles and M/H fit up on main shell ad welding.
13. Furnace end plate, stiffener rings fit up and welding.
14. Access shell fit up on rear tube sheet of R.C and welding.
15. Furnace shell-2 fit up and welding on furnace end plate.
16. Furnace shells mockup and welding to R.C chamber.
17. Furnace and R.C assembly box up on inside of the main shell.
18. Front main tube sheet fit up and welding.
19. Access shell to rear main tube sheet welding.
20. Saddle, Ash nozzle fit up and welding.
21. Stay rods fit up and welding
22. Stay tubes fit up and welding.
23. Fusible plug adopters fit up and welding.
24. Level gauge nozzles fit up and welding.
25. Steam dryer fit up and welding.

26. Insulation rings fit up and welding.

27. Lifting hooks, Platform pads fit up and welding.
28. Smoke and reversing chambers fit up and welding.
29. Nozzle stiffeners fit up and welding.
30. Furnace shell fit up and welding.
31. Dress up.
32. Hydro test.

After Hydro Test:

1. R.C Doors fit up with anchors and welding.
2. Smoke chamber door fit up with anchors and welding.
3. Air nozzle fit up and welding.
4. Grade bar fit up .
5. Furnace front door fit up and welding.
6. Fuel feeding line fit up and welding.
7. Air injection line fit up and welding.
8. Air entry duct fit up and welding.
9. Gates fit up and welding on chambers.
10. Refractory arrangements.
11. Access shell flange, door fit up and welding.
12. Refectory
2.5.4 Boiler Design

Whether the boiler is a drum or whether it is an individual unit or a small part of large
complex, it is necessary in design to give proper consideration to performance required
from the total complex of the steam generating unit. Within this frame work, there are
some important items, which must be accomplished in boiler design. The items which
are of importance are as stated below:
1. Determine the heat to be absorbed in the boiler and other heat transfer
equipment, the optimum efficiency to use and the type of fuel or fuels dor
which the unit is to be designed. When a particular fuel is selected, determine
the amount of fuel required the necessary or preferred preheated air temperature
and the quantities of air required and flue gases to be generated.
2. Determine the size and shape required for the furnace, giving considerations to
location, the space requirements of burners or fuel bed, and incorporating
sufficient furnace volume to accomplish complete combustion. Provision must
also be made for proper furnace walls to reduce the gas temperature leaving the
furnace to the desired value.
3. The general disposition of the convection heating surfaces must be so planned
that the super heater and the re-heater when provided, are located at the
optimum temperature zone where the gas temperature is high enough to afford
good heat transfer from the gas to the steam, yet not no high as to result in
excessive tube temperatures or excessive fouling from ash in the fuel.
4. Pressure parts must be designed in accordance with applicable codes using
approves materials with stresses not exceeding those allowable at the
temperatures experienced during operation.
5. A tight boiler setting or enclosure must be constructed around the furnace and
boiler, and gas tight flues or ducts must be provides to convey the gases of
combustion to the stack.
6. Supports for pressure and setting must be designed with adequate consideration
for expansion and local requirements, including wind and earthquake loading.

2.5.5 Basic Requirements of Boiler:

1. Proper workmanship and simple construction, using materials which experience

has shown to be the best, thus avoiding the necessity of early repairs.
2. A mud drum to receive all impurities deposited from the water, and so placed as
to be removed from the action of the fire.
3. A steam and water capacity sufficient to prevent any fluctuation in steam
pressure or water level.
4. A water surface for the disengagement of the steam from the water, of
sufficient extent to prevent foaming.
5. A constant and thorough circulation of water throughout the boiler, so as to
maintain all parts at the same temperature.
6. The water space divided into sections so arranged that, should any section fail,
no general explosion can occur and the destructive effects will be confined to
the escape of the contents. Large and free passages between the different
sections to equalize the water line and pressure in all.
7. A great excess of strength over any legitimate strain, the boiler being so
constructed as to be free from strains due to unequal expansion, and, if possible,
to avoid joints exposed to the direct action of the fire.
8. A combustion chamber so arranged that the combustion of the gases started in
the furnace may be completed before the gases escape to the chimney.
9. The heating surface as nearly as possible at right angles to the currents of
heated gases, so as to break up the currents and extract the entire available heat
from the gases.
10. All parts readily accessible for cleaning and repairs. This is a point of the
greatest importance as regards safety and economy.
11. Proportioned for the work to be done, and capable of working to its full rated
capacity with the highest economy.

12. Equipped with the very best gauges, safety valves and other fixtures.

Chapter-3
RAW MATERIALS

3.1 Raw Material used for Boiler:

3.1.1Plate material
3.1.2Tube material
3.1.3Pipe material

3.1.1 Plate Material: SA516 Gr.70

SA stands for American Society.This specication covers carbon steel plates
intended primarily for service in welded pressure vessels where improved notch
toughness is important.
Plates under this specification are available in four grades having different
strength levels as follows:
Tensile Strength,
Grade U.S. [SI]

ksi [MPa]

55 [380]

5575 [380-515]

60 [415]

6080 [415-550]

65 [450]

6585 [450-585]

70 [485]

7090 [485-

620]

Table(2):Tensile strengths

The maximum thickness of plates is limited only by the capacity of the composition to
meet the specified mechanical property requirements; however, current practice
normally limits the maximum thickness of plates furnished under this specification as
follows:

Maximum
Grade U.S. [SI]

Thickness,
in. [mm]

55 [380]

12 [305]

60 [415]

8 [205]

65 [450]

8 [205]

70 [485]

8 [205]

Table(3):Maximum thickness

Figure(7):Plate

Figure(8): Plate of SA516 Gr.70

3.1.2Tube material: SA 210 Gr A-1

This specification covers minimum-wall-thickness, seamless medium-carbon
steel, boiler tubes and boiler flues, including safe ends , arch and stay tubes, and super
heater tubes.

Element

Grade A-1

Grade C

Carbon, max

0.27

0.35

Manganese

0.93 max

0.291.06

Phosphorus, max

0.035

0.035

Sulphur, max

0.035

0.035

Silicon, min

0.10

0.10

Table(6): Chemical properties

Size of Tube

Size of Lot

2 in. (50.8 mm) and over in diameter

not more than 50 tubes

and 0.200 in. (5.1 mm) and over in

wall thickness
2 in. (50.8 mm) and over in outside

not more than 75 tubes

diameter and under 0.200 in. (5.1

mm) in wall thickness
Less than 2 in. (50.8 mm) but over 1
in. (25.4 mm) in outside diameter or

not more than 75 tubes

over 1 in. in outside diameter and

under 0.200 in. (5.08 mm) in wall
thickness
1 in. (25.4 mm) or less in outside

not more than 125 tubes

Diameter
Table(7): Number of tubes in a lot heat treated by the continuous process.
GradeA-1

GradeC

i.

Tensile strength, min, ksi [MPa]

60 [415]

70 [485]

ii.

Yield strength, min, ksi [MPa]

37 [255]

40 [275]

iii.

Elongation in 2 in. or 50 mm, min, %

30

30

iv.

For longitudinal strip tests, a deduction shall

1.50

1.50

be made for each 132 in. [0.8mm] decrease in

wall thickness under 516 in. [8 mm] from the
basic minimumelongation of the following
percentage points.
v.

When standard round 2 in. or 50 mm gage

length or smaller proportionally sized specimen
with the gauge length equal to 4D (four times
the diameter) is used.

22

20

Table(8) : Tensile requirements

Figure(9):Tubes

3.1.3 Pipe material : SA106 Gr.B

This specification covers seamless carbon steel pipe for high-temperature
service. Pipe ordered under this specification shall be suitable for bending, flanging,
and similar forming operations, and for welding. When the steel is to be welded,
it is presupposed that a welding procedure suitable to the grade of steel and intended
use or service will be utilized.
Supplementary requirements of an optional nature are provided for seamless
pipe intended for use in applications where a superior grade of pipe is required. These
supplementary requirements call for additional tests to be made and when desired shall
be so stated in the order.

Composition %

Carbon, max

Grade A
0.25

Grade B
0.30

Grade C
0.35

Manganese

0.270.93

0.291.06

0.291.06

Phosphorus, max

0.035

0.035

0.035

Sulphur, max

0.035

0.035

0.035

Silicon, min

0.10

0.10

0.10

Chrome, max

0.40

0.40

0.40

Copper, max

0.40

0.40

0.40

Molybdenum, max

0.15

0.15

0.15

Nickel, max

0.40

0.40

0.40

Vanadium, max

0.08

0.08

0.08

Table(9) : Chemical Requirements

Tensile strength, min,

psi
(MPa)

Yield strength, min, psi

(MPa)

Grade A

Grade B

Grade C

48 000 [330]

60 000 [415]

70 000 [485]

30 000 [205]

35 000 [240]

40 000 [275]

Table(10): Tensile requirments

Figure(10):Pipes

Chapter-4
Design Calculations

4.1Different codes
Codes used in Design of boiler are IBR-1950,ASME sec viii Div 1,ASME
sec-1.
4.2 Process design calculations for Boiler
Gas flow : 4000Nm^3/hr
4.2.1Gas composition:
H2O : 2.0% , O2 : 12% , N2 : 74% , CO2 : 12%.
Gas Inlet Temperature

: Tg2 = 9500 c

Gas Outlet Temperature

: Tg2 = 2400 c

Allowable Pressure Drop

: 100mm WG

Operating Pressure Of Gas : 1500mm WG

4.2.2Gas Properties At Average Temperature:
(Tavg)g = (Tg1+Tg2)/2
= (950+240)/2
= 5950c
Gas Density

: g : 1.4456 kg/Nm3

Dynamic Viscosity : g : 47.49 10-6 kg/ms

Specific Heat of gas : Cpg: 0.27
Prandtl number

: Pr : 0.68

Thermal conductivity : k

: 0.07 kcal/mhr0c

4.2.3Heat available from flue gas:

Q = mgCpgg0.98(Tg1-Tg2)
= 40000.271.44560.98(950-240)
Q = 1.0863106kcal/hr
4.2.4Heat Balance:
Amount of Steam : ms : kg/hr : 2500
Feed water inlet temperature : Tw1 : 0c : 100
At 1850c
Saturated Enthalpy h1 : kcal/kg :100 .001

= ms(h2-h1)

=>1.438 = 2500(h2-100.001)
=>h2 = 675
At Saturated Enthalpy h2 corresponding temperature is 1850c
Tw2 = 1850c
Average Temperature of steam (Tavg)s
(Tavg)s = (185+100)/2
= 142.50c
4.2.5Properties of steam at Tavg is
: w : kg/m3 : 21.3394

i.

Density

ii.

Kinematic viscosity : w : m2/sec : 0.063

iii.

Thermal conductivity : Kw : kcal/m hr0c : 0.0449

iv.

Prandtl number

: Pr : 1.3875

v.

Specific heat

: Cp : kcal/kg0c : 0.9820

Total number of tubes provided = 220

Number of stay tubes

= 128

Thickness of plain tubes = 4.06mm

Thickmess of stay tubes = 4.06mm
O.D of tube = 63.5mm
I.D of tube = 63.5-2(4.06)= 55.38mm
Length of Tube = 2500mm = 2.5m
Effective length of tube = 2.5-0.06 = 2.44m

mfg (m3/hr) =( mfg (Nm3/hr)(273+(Tavg)g) / (273gas pressure)

= 4000(273+595)/(2731.5)
= 8478.6
g (kg/m3) =( (kg/Nm3)273gas pressure) / (273+(Tavg)g)
= (1.44562731.5) / (273+595)
= 0.47773
As : Free gas area (As) = /4di2no of tubes
= /40.55382128
= 0.308m2
Velocity of gas = mfg/(As3600)
= 8478.6/( 0.308 3600)
vg = 7.646 m/sec
Reynolds number (Re) = gvgdi /
= 0.47737.6460.5538/(47.4910-6)
= 4256.11
4.2.6Nusselt number(Nug) :
= (1.82log(Re)-1.64)-2
= (1.82log(4256.11 )-1.64)-2
= 0.0405
Nu=( /8(Re-1000)Pr )(1+(Do/Le))/(1+(12.7 (/8)0.5(Pr-1))
Nu=
( 0.0405/8(4256.11-1000)0.68 )(1+(0.0635/2.5))/(1+(12.7(0.0405/8)0.5(0.68-1))
Nu= 15.34

4.2.7Gas side heat transfer coefficient : hg :

hg = kgNug/Di
= 0.0715.34/0.05538
= 19.39
4.2.8Log Mean Temperature Difference(LMTD):
T1 = Tg1-Ts2
= 950-185
= 7650c
T2 = Tg2-Ts1
= 240-100
= 1400c
LMTD = (T1-T2)/ln(T1/T2)
= (765-140)/ln(765/140)
= 368.02
4.2.9Outside Heat Trasfer Coefficient :
ho= 0.1011(225.6)0.69(0.7LMTDhg)0.7(1.8(Ps/225.6)0.17)+(4( Ps/225.6)1.2)
+(10( Ps/225.6)10)
= 0.1011(225.6)0.69(0.7368.0219.39)0.7(1.8(42.43/225.6)0.17)
+(4( 42.43/225.6)1.2)+(10( 42.43/225.6)10)
= 2238.66
4.2.10Overall Heat Transfer Coefficient:
U= 1/((1/ho)+0.0002+(0.0006(Do/Di))+(Do/(hgDi))
= 1/((1/2238.66)+0.0002+(0.0006(0.0635/0.05538))+(0.0635/(2238.660.05538))

= 33
4.2.11Required Area
A= Q/U LMTD
= 1.086316106/(33368.08)
= 89.43 m2

Required Area = 89.43 m2

Provided Area = 93 m2

4.3IBR Stress Calculations

4.4 Selection of Valves :

Choose a valve type depending on your application:
Our manual valve selection includes ball, check. diaphragm, elliptic, metring,
needle, pinch, plug, pressure relief, and stopcock valves.Our actuated valve selection
includes electrically actuated ball, elliptic, pinch, proportionating, and genaral-purpose
solenoid valves.
Consider your fluid type(gas or

liquid) and its characteristics to determine

compatible valve materials:

Teflon withstands many harsh or corrosive chemicals. For safety reasons,
always use metal valves for pressurized gases.
Determine the temperature, pressure, and flow rate under which your valve will
be operating.
In general, metal valves with stand higher temperatures and pressures than
plastic valves.
Consider your maintenance requirements:
Ball valves resist plugging an are easiest to sevice.

4.5 Welding detail of Boilers(As per ASME &IBR)

4.5.1 Welding Process:

SMAW SUBMERGED ARC WELDING PIPES: The pipes shall be manufactured

from plate, sheet or strip with either a single or double longitudinal seam or spiral seam
and welded across the abutting edges by an automatic submerged arc welding process
using at least two runs, one of which shall be on the inside of the pipes.
Reference

Steel Grades Applicable

Method of Manufacturing
(1)

(3)

(4)

(5)

Fe330

Fe410

Fe450

ERW

Fe330

Fe410

Fe450

SAW

Fe330

Fe410

Fe450

(2)

Seamless
Electric resistance including
induction welded
Submerged Arc Welding
(including spirally welded)

Figure(11):Arc Welding

TIG WELDING

Gas tungsten arc welding (GTAW), also known as tungsten inert gas (TIG) welding, is
an arc welding process that uses a non-consumable tungsten electrode to produce the weld.
The weld area is protected from atmospheric contamination by an inert shielding
gas (argon or helium), and a filler metal is normally used, though some welds, known as
autogenously welds, do not require it. A constant-current welding power supply produces
energy which is conducted across the arc through a column of highly ionized gas and metal
vapors known as a plasma.
GTAW is most commonly used to weld thin sections of stainless steel and non-ferrous
metals such as aluminum ,magnesium, and copper alloys. The process grants the operator
greater control over the weld than competing processes such as shielded metal arc
welding and gas metal arc welding, allowing for stronger, higher quality welds. However,
GTAW is comparatively more complex and difficult to master, and furthermore, it is
significantly slower than most other welding techniques. A related process, plasma arc welding,
uses a slightly different welding torch to create a more focused welding arc and as a result is
often automated.[

Figure(12):GTAW

Figure(13):Tungsten arc welding

GAS CUTTING:

Oxy-acetylene gas
The oxyacetylene process produces a high temperature flame, over 3000 degrees C, by
the combustion of pure oxygen and acetylene. It is the only gas mixture hot enough to
melt steel; other gases (propane, LPG or hydrogen) can be used for lower melting point
non-ferrous metals, for brazing and silver soldering and as a preheating/piercing gas for
cutting.
Handling compressed gases
Cylinders are fitted with regulators to reduce the gas pressure in the cylinder to the
working pressure of the torch. The regulator has two gauges, a high pressure gauge for
the gas in the cylinder and a low pressure gauge for the gas being fed to the torch. The
gas flow rate is controlled by a pressure adjusting screw which sets the outlet gas
pressure. The BCGA Code of Practice CP7 recommends the gauges are checked
annually and replaced every 5 years.
Factors to be considered are that the gas system is suitable for the pressure
rating and the hoses are connected without any leaks. Valve threads should be cleaned

before screwing in the regulator. The valve of an acetylene cylinder can be opened
slightly to blow out the threads but the threads in oxygen cylinders are best cleaned
using clean compressed air (the threads on hydrogen cylinders must always be blown
out using compressed air).
As oxygen can react violently with oils and grease, lubricating oils or sealant for the
threads must not be used.
Using compressed gases
Gases are mixed in the hand-held torch or blowpipe in the correct proportions. Hoses
between regulator and torch should be color coded; red for acetylene and blue for
oxygen. Hoses should be kept as short as possible and users should check periodically
that they are not near hot or sharp objects which could damage the hose wall. Acetylene
cylinders must always be used upright.
When connecting the system, and at least at the start of each shift, hoses and torch must
be purged to remove any inflammable gas mixtures. It is essential the oxygen stream
does not come into contact with oil which can ignite spontaneously. Purging should
also not be carried out in confined spaces.
The torch should be lit with a friction lighter or stationary pilot flame to avoid burning
the hands; matches should not be used and the flame should not be reignited from hot
metal, especially when working in a confined space.
Although very little UV is emitted, the welder must wear tinted goggles.

Figure(14):gas cutting

Chanper-5
Manufacturing, Operation and Maintainence Process

5.1 Manufacturing Process:

1. Raw material matching as per our requirement
2. Cutting plan
3. Shell rolling as per the design calculations
4. Welding process
5. Tube sheet cutting
6. Tube sheet Drilling
7. Shell box up
8. Tube sheet fit up
5.2 Preparation of Main Shell:

Raw material: Plates SA515 Gr.70 or SA516 Gr.70.

Approved plates shall be selected as per Bill of material.

Size of Main Shell as per drawing: OD 2224** x 3250 lg x 12mm thick.

(**Developed length of shell: OD thick= mean dia. of shell is required to calculate

development of shell

OD-T= 2224-12=2212 is mean diameter of shell, Developed length= 2212 x (22/7) =

6952mm. )

Hence required Plate for main shell is 6952 x 3250 x 12 mm

Plates are available in 2500 x 10000 x12. Marking of plates as mentioned below.

Inspection of marking on plates and clearance for Gas cutting.

After cutting of shell sections-I & II, edge preparation of plates is required for Long
seam and circumferential joints as mentioned below.

Rolling of Main Shell section I and Main Shell section-II.

Fit up of Long seam I and Long seam II, Fit up inspection and clearance for
welding.

After welding, visual inspection of welding and clearance for NDT (Radiography Test)

Interpretation of RT films and after acceptance- Clearance for Circumferential joints.

Fit up inspection of C-seam and clearance for welding.

After welding Visual inspection of Weld joint and clearance for NDT(RT)

Interpretation of RT films and after acceptance main shell is cleared for further
processing.

Figure(16): Rolling Machine

Figure(17):Shell Rolling

5.3 O&M process

5.3.1: Introduction to water treatment

Conclusion: