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MAX.

WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR


by G. Subhash Reddy, Rtd. Director of Boilers
shell - Reg. 270
efficiency of ligament - Reg. 215
p=
350 mm - pitch of tube holes
d=
50 mm - diameter of tube holes
E=
0.85714 (p-d)/p - efficiency of ligament
T=
12 mm - thickness, min. 6
D=
1500 mm - max. internal diameter
f=
1406 kg/sq.cm - permissible working stress at temp upto 250 C for SA515-70
WP = 17.9236 kg/sq.cm - 2 X f X E X(T-0.762)/(D+T-0.762) - working pressure
tube/end plate
1 pitch of the tubes -Reg.580
p=
90 mm - min. pitch of tube hole
D=
63.5 mm - diameter of the tube hole
L=
20.6375 mm - D/8+12.7 - ligament required
L1 =
26.5 mm - (p-D) - ligament provided
2 stayed flat surface - Reg. 574
e=
16 mm - thickness, min. 8
d=
450 mm - diameter of the largest circle taken between staying points of the plate
f=
1406 kg/sq.cm - permissible working stress at temp upto 250 C for SA515-70
f1 =
1195.1 kg/sq.cm - 0.85 X f
e1 =
0.75 mm
C=
0.4
P=
8.57825 kg/sq.cm - f1 X ((e-e1)/(C X d))2 - design pressure
headerl - Reg. 342(a) & eq. 72
efficiency of ligament - Reg. 215
p=
mm - pitch of tube holes
d=
mm - diameter of tube holes
E = (p-d)/p - efficiency of ligament
Tn = mm -nominal thickness
T=
mm - 0.875 X Tn - min. thickness
Do = mm - outside diameter
D = mm - (Do-2XT) - max. internal diameter
f=
1202 kg/sq.cm - permissible working stress at temperature upto 250 C for SA106-Gr.B
WP = kg/sq.cm - 2 X f X E X(T-0.762)/(D+T-0.762) - working pressure
p

d
100
100

E
50.8
50.8

fire tube eq. XII/14


t=
3.25
D=
63.5
C=
0.75
f=
870
WP = 54.8031

Tn
0.492
0.492

T
5.49
3.91

Do
4.6665
3.3235

D
88.9
60.3

mm - min. thickness of tube


mm - outside tube diameter
mm - corrosion allowance
kg/sq.cm - permissible working stress
kg/sq.cm - 1.6 X f X (T-C)/D - working pressure

water tube Reg. 338


T=
3.25 mm - min. thickness of tube

f
79.567
53.653

W.P.
1202 55.325682
1202 53.89464

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR


by G. Subhash Reddy, Rtd. Director of Boilers
D=
50.8
C=
0.75
f=
870
WP = 90.0621

mm - external diameter of the tube


mm - corrosion allowance
kg/sq.cm - permissible working stress
kg/sq.cm - 2 X f X (T-C)/(D-T+C) - working pressure

header end plates Reg. 342(b)


t=
10 mm - min. thickness of plate
d=
200 mm - diameter of plate
C=
1 mm - corrosion allowance
f=
1312 kg/sq.cm - permissible working stress
K=
0.28 for ends directly strength welded to header/shell
WP = 9.48857 kg/sq.cm - f X (T-C)2/(d2XK) - working pressure
stay tubes Reg.577
Tp
5.08
D
48.3
A
20000
C
1
T
4.08
f
713
a
566.8
WP 20.2064

mm
mm
mm
mm
mm
kg/cm2
mm2
kg/cm2

provided thickness of tube


outside tube diameter
max. area supported by tube
additional thickness
net thickness
permissible working stress at temperature Reg. 577(a)(IV)
cross sectional area of tube = 0.7854 X {D2- (D2-2 X T)2}
max. allowed working pressure = f X a/A

thickness of cylindrical parts under external pressure Reg. 592


kg/cm2 design pressure
P
10
Et
2051.6
kg/cm2 yield stress at design temperature
d
2200
mm
mean diameter
L
1187
mm
distance between centres of two effective points of support
E
2E+006 kg/cm2 youngs modulus at design temperature Reg. 592
S1
2.5
2.5 for clas I boiler
S2
3
3 for clas I boiler
u
1.5
mm
out of roundness = 1.5 for plain furnaces
B
11.9301
P*d*S1/(2*Et*(1+d/15/L))
e1
20.8615
mm
thk=u/2*(1+SQRT(1+0.12*d*u/B/(1+d/0.3/L)))+0.75
e2
17.6838
mm
thk = d^0.6*(L*S2*P/1.73/E)^0.4+0.75
Tp
11
mm
provided thickness
check for moment of inertia of stiffener Reg. 592(i)
mm4
second moment of area of stiffener = P X d3 X L/1.35X10 7
Is
9E+006
As
1024
mm2
cross sectional area of stiffener ring 16 X 64
4
I
349525
mm
available moment of inertia of stiffener ring
Lr
37.5
mm
distance of NA of stiffener ring from center lineof shell thickness
w
182.12
mm
width of shell contributing to MI = 1.1*sqrt(d*tp) Reg. 592
x
12.6845
mm
distance of NA of combined ring-shell from CL of shell thick=
As*Lr/(As+w*ts)
mm4
Ia
1E+006
available moment of inertia of combined ring-shell about its NA =
I+w X tp3/12+As X (Lr-x)2+ w X tp X x2
elliptical manhole cover, reg166
a
305 mm
minor axis of the opening to which door is fitted

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR


by G. Subhash Reddy, Rtd. Director of Boilers
b
d
tp
P
f
fb
W
t

410
20
16
10
1300
509.684
178471
12.9902

mm
mm
mm
kg/cm2
kg/cm2
kg/cm2
kg
mm

circular manhole cover, reg166


d
305 mm
ds
20 mm
P
10 kg/cm2
f
1300 kg/cm2
fb
509.684 kg/cm2
W
178471 kg
t
20.348 mm

major axis of the opening to which door is fitted


root diameter of stud
provided thickness
design pressure
allowed pressure
design stress value of stud up to 300 0C = 50 N/mm2
full load capacity of one stud = pi/4*d2*fb
calculated thickness =squre root of {(0.35*(2a-b)a^2+W)/f}

diameter of the opening to which door is fitted


root diameter of stud
design pressure
allowed pressure
design stress value of stud up to 300 0C = 50 N/mm2
full load capacity of one stud = pi/4*d2*fb
calculated thickness =squre root of {(0.35*d^2+W)/f}

stay bars
longitudinal stay bars, Reg.587
D
A
C
W.P.

50
74000
655.4
22.1419

mm
mm2
kg/cm2
kg/cm2

W.P.
diameter at its smallest part
area supported by one stay
depends on ten.strength,44.1-50.4=607.5, 47.25-53.55=655.4
max. allowed working pressure = C X D2/A

gusset , Reg 591


w
100
tp
40
A
110000
result 4922
f
703.143
L/L'
0.866
W.P. 22.1426

mm
mm
mm2
kg/cm2
kg/cm2
kg/cm2

material specification
width at its tangential section
provided thickness, not < 7/8 of shell thick & 11.113 mm
area supported by one stay
tensile stress
allowable stress =R / 7
cos( angle with shell) for 300 it is 0.866
max. allowed working pressure = f X w x tp X L / L' /A

flat plate margin for flat stayed plates


flat plate margin for flat stayed plates, Reg. 589
kg/cm2 design pressure
WP
10
t
29
mm
thickness of flat plate
C
3.7
3.47 for plates exposed to flame, 3.7 not exposed
FPM 280.094
mm
flat plate margin in inch=C X (t-1)/sqrtWP,t in inch/32, WP in psi
link stay Reg.591
fp
1040.79
A
212150
P
10
d
45
n
3
w
120

kg/cm2
mm2
kg/cm2
mm
kg/cm2
mm

allowable shear stress for pin, double shear, Reg 591(ss-562.5)


area supported by one gusset/anchor plate
design pressure
diameter of pin
number of pins per gusset
width of link stay

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR


by G. Subhash Reddy, Rtd. Director of Boilers
t
tg
Rl
Et
fb
fl
Sp
result
Sl
result
Sb
Sba
result
fw
La
Sw
result

20
40
4216
1652
1239
602.286
444.637
OK
272.197
OK
453.661
453.661
OK
10
700
kg/cm2
not safe

mm
mm
kg/cm2
mm
kg/cm2
kg/cm2
kg/cm2
kg/cm2
kg/cm2
kg/cm3
mm
mm
kg/cm2

thickness of link stay


thichness of anchor plate
tensile strength of link sec IID
yield stress of link/gusset at metal temperature
bearing stress for link and gusset=0.75Xyield stress at t, IS800
allowable stress for link = Rl/7 , Reg 591
shear stress induced in pin, double shear =P X A /(nX0.7854Xd 2)
fp > Sp
stress induced in link =P X A /{2XnX(w-d)XtX0.866}
fl > Sl
bearing stress induced in link = PXA/(0.866X2XnXdXt)
bearing stress induced in gusset = PXA/(0.866XnXdXtg)
fb. > max(Sb,Sba)
fillet leg for anchor plate to shell/ tube sheet
length of shortest anchor plate
stress in weld = P*A/(2*La*fw*0.7*0.55)
Sw < 1100