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BOILER GENERAL DATA:

Boiler No. : 111

Boiler Type : Single Drum Water Tube

Boiler Capacity : 90 TPH

Design Code : IBR

Maximum Working Pressure : 80 Kg/cm2 (g)

Super Heater Outlet Steam Pressure : 69 Kg/cm2 (g)

Super Heater Outlet Steam Temperature : 490 ± 5 0C

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 IBR CALCULATIONS FOR STAND PIPE

DESIGN DATA:

Maximum allowable working pressure = 80 Kg/cm2 (g)

Maximum metal working temperature = 295ºC

Size
Sl.
Description Material
No. OD Thickness
mm mm
STAND PIPE
1 Stand pipe 114.3 8.56 SA106Gr.B
2 Stubs 33.4 6.35 SA106Gr.B
3 End plate 114.3 20 SA515Gr.70
4 rod 29 5.2 SA105

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ALLOWABLE STRESS CALCULATIONS:
Max.metal
Asme Allow Allow
Sl. Working Uts Et Uts/ 2.7 Et/ 1.5
Material Stress Stress
No Description temperature
ºC Kgf/cm2 Kgf/cm2 Kgf/cm2 Kgf/cm2 Kgf/cm2 Kgf/cm2

1 PIPE SA 106 GR.B 295 4231.76 1203.34 1929.27 1567.32 1286.18 1203.34

2 STUB SA106GrB 295 4231.76 1203.34 1929.27 1567.32 1286.18 1203.34

3 ROD SA 105 295 4945.55 1297.00 1988.42 1831.68 1325.62 1297.00

4 END PLATE SA515Gr.70 295 4945.55 1389.04 2092.42 1831.68 1394.94 1389.04

Allowable stress value as per ASME sec II Part-D Table 1A.

Et values are as per ASME sec II Part-D Table Y1.

Minimum UTS value is taken from ASME sec II Part-D Table 1A.

Allowable stress = Minimum of Et/1.5 or UTS/2.7 or ASME Allow. Value.

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LIGAMENT EFFICIENCY CALCULATIONS:
(As per IBR Reg. No. 215)

LONGITUDINAL LIGAMENT EFFICIENCY:

PL – P D
E L1= Ligament efficiency =
(Between water wall tubes) PL

PD = Average diameter of hole in mm = 21.7 mm

PL = Pitch (Longitudinal)

E L1= Ligament efficiency = 450 - 21.7

450

= 0.952

CIRCUMFERENTIAL LIGAMENT EFFICIENCY:

PC - d A
Circumferential Ligament (EC) = 2x
Efficiency PC

Hole diameter Circumferential Ligament efficiency

Sl. Avg. dia Angle between Circumferential
Location d1 d2
No. (dA) two holes Pitch (PC) EC
mm mm mm θ mm
Stand pipe
1 Between two holes 21.7 21.7 21.7 90 83.05 1.477
2 Between two holes 21.7 21.7 21.7 180 166.10 1.739

CONCLUSION:

 The Least Ligament efficiency for Stand pipe is (E) = 0.952

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STAND PIPE THICKNESS CALCULATIONS:

(As per IBR Reg. No. 270)

2 x f x E x (T – 0.762)
WP= Working Pressure =
D + T – 0.762

Pmax = Maximum allowable working = 80 Kg/cm2 (g)

pressure
D = Maximum internal diameter = 114.3 mm

T = Thickness of stand pipe = 8.56 mm

= 7.49 mm (12.5% negative tolerance)

f = Allowable stress = 1203.34 Kg/cm2

E = Ligament efficiency = 0.952

2x1203.34x0.952x (7.49-0.762)
WP =
114.3+7.49-0.762

WP = 165.23 Kg/cm2 > Pmax

PxD
Tc = Minimum required thickness = +0.762
2xfxE-P

80x114.3
Tc = + 0.762
2x1203.34x0.952-80

Tc = Minimum required thickness = 4.897 mm < 7.49 mm (T)

Hence SAFE.

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NOZZLE THICKNESS CALCULATIONS :( As per IBR Reg. No. 350)

2 x f x E x (T –C)
WP= Calculated working pressure =
D–T+C

P = Maximum allowable working = 80 Kg/cm2 (g)

Pressure
D = Maximum outer diameter of pipe

T = Minimum provided thickness of pipe (-12.5% tolerance)

f = Allowable stress

E = Ligament efficiency = 1

C = Constant = 0.75

Pipe size Allowable Thk. Less

Sl. W.P
Description O.D / Thk Material stress –Ve Tol Remarks
No.
mm / mm Kg/cm2 mm Kg/cm2
STUB
1 33.4 / 6.35 SA106 Gr B 1203.34 5.56 404.90 Safe

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COMPENSATION CALCULATIONS FOR STUB ON STAND PIPE:(As per IBR Reg. No. 279 )

STUB
DATA UNIT
Ø 114.3 mm

dn = ID of nozzle 21.7 mm
tn = Actual thickness of nozzle 6.35 mm
fn = Allowable stress for nozzle 1203.34 Kg/cm2
en = Required thickness for nozzle 1.535 mm
P x dn
en = +0.75
2 x fn x E – P
Maximum hole diameter 21.7 mm

ts = Actual thickness of stand pipe 8.56 mm

fs = Allowable stress for stand 1203.34 Kg/cm2
pipe mm
es = Required thickness for Stand 4.897
pipe mm
mm
2.5 x tn A 15.875 mm
2.5 x ts B 21.4 mm
b = Smaller Value of (A or B) 15.875
bi = Inside projection of nozzle 0 mm
mm
ts + 76 C 84.56 mm
dn /2 D 10.85
Ci = Greater value of (C or D) 84.56

Cw = Total cross sectional area of ……

weld (Not considered)
fn / f s 1
mm2
Compensation to be provided
Max. hole I.D x Min. Req. thk of drum 106.26 mm2
Area available for compensation mm2
2 x (tn – en) x b x fn / fs + 152.87 mm2
2 x tn x bi x fn / fs + 0 mm2
2 x (ts – es) x Ci 619.48 mm2
Pad plate 0
Total area available 772.35
Remark SAFE

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END PLATE THICKNESS CALCULATION:

(As per Reg. No. 278)

P x D2 x K
T = Minimum required thickness = +C
f

P = Maximum allowable working = 80 Kg/cm2 (g)

pressure
D = inside diameter of end plate = 97.18 mm

t = provided thickness = 20 mm

f = Allowable stress = 1389.04 Kg/cm2

C = corrosion allowance = 1

K = Shape factor (As per Reg. No. 342b)

K factor for above value = 0.28

97.182x0.28x80
Minimum thickness required = +1
1389.04

Hence minimum thickness required = 13.34 mm < 20 mm (Actual thickness)

Hence end Plate thickness is SAFE.

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NOZZLE THICKNESS CALCULATIONS :( As per IBR Reg. No. 350)

2 x f x E x (T –C)
WP= Calculated working pressure =
D–T+C

P = Maximum allowable working = 80 Kg/cm2 (g)

pressure
D = Maximum outer diameter of pipe

T = Minimum provided thickness of pipe (-12.5% tolerance)

f = Allowable stress

E = Ligament efficiency = 1

C = Constant = 0.75

Pipe size Allowable Thk. Less

Sl. W.P
Description O.D / Thk Material stress –Ve Tol Remarks
No.
mm / mm Kg/cm2 mm Kg/cm2
1 ROD 29/ 5.2 SA105 1297 4.55 300.52 Safe

COMPENSATION CALCULATIONS FOR STUB ON DRUM:(As per IBR Reg. No. 279 )

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 rod
DATA UNIT
Ø 114.3 mm

dn = ID of nozzle 18.6 mm
tn = Actual thickness of nozzle 5.2 mm
fn = Allowable stress for nozzle 1297 Kg/cm2
en = Required thickness for nozzle 0.59 mm
P x dn
en = +0.75
2 x fn x E – P
Maximum hole diameter 18.6 mm

ts = Actual thickness of stand pipe 20 mm

fs = Allowable stress for stand 1389.04 Kg/cm2
pipe mm
es = Required thickness for Stand 13.34
pipe mm
mm
2.5 x tn A 13 mm
2.5 x ts B 50 mm
b = Smaller Value of (A or B) 13
bi = Inside projection of nozzle 0 mm
mm
ts + 76 C 96 mm
dn /2 D 7.88
Ci = Greater value of (C or D) 39.29

Cw = Total cross sectional area of ……

weld (Not considered)
fn / f s 0.934
mm2
Compensation to be provided
Max. hole I.D x Min. Req. thk of end 248.12 mm2
plate mm2
Area available for compensation 89.00 mm2
2 x (tn – en) x b x fn / fs + 0 mm2
2 x tn x bi x fn / fs + 523.34 mm2
2 x (ts – es) x Ci 0
Pad plate 612.34
Total area available SAFE
Remark

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