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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

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
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

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
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

## 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

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