Boiler Calculation

8th March 2015 boiler calculation
IBR CALCULATION
Boiler Maker’s No. - WT/SD – 500/F/208

Working Pressure - 10.5 Kg/Cm2(g)
Working Temp. - 185oC.
Hyd. Test Pressure - 15.75 Kg/Cm2 (g)
Ref. Drawing Nos. - WT/SD-500/F/8.1 R0
WT/SD-500/F/8.2, Sh.1/2 R0
WT/SD-500/F/8.2, Sh.2/2 R0
WT/SD-500/F/8.2, Sh.3/3 R0
WT/SD-500/F/8.3, Sh.1/2 R0
WT/SD-500/F/8.3, Sh.2/2 R0
WT/SD-500/F/8.3, Sh.3/3 R0
WT/SD-500/F/8.4, Sh.1/2 R0
WT/SD-500/F/8.4, Sh.2/2 R0
WT/SD-500/F/8.5, Sh.1/2 R0
WT/SD-500/F/8.5, Sh.2/2 R0
7
Drum:
1) Shell : -
Max. Working Temp. 454oC.
Min. UTS of Pl . = 42 Kg/mm2(g)
Permissible Stress = f = 0.36 x 42/1.5 = 10.08 Kg/mm2(g)
And, f = UTS / 2.7 = 42 / 2.7 = 15.55 Kg/mm2
Ligament Efficiency:-
(a) For Down Comer :- d = 76.6, P = 410
E =( P-d)/p =(410 – 76.6)/410 = 0.813
(b) For Roof Tubes : - d = 76.6, P = 320
E =( P-d )/p =( 320 – 76.6) / 320 = 0.760
Taking the minimum of the two, ligament efficiency for further calculations = E = 0.760
I.D. of Shell = 912 – 20 = 892 mm
Thk. of shell plate = T = 10 mm
W.P. = 2.f.E (T-C) /( D + T-C) Where, C = 0.762 (Constant)
= 2 x 10.08 x 0.760 (10-0.762) / (892 + 10 – 0.762)
= 0.1570 Kg/mm2
= 15.70 Kg/Cm2(g)
Therefore the thickness (10 mm) of shell plate proposed is adequate for a W.P. of 10.50
Kg/Cm2(g).
2) Dished End :- (Reg. 275, 277, 278)

UTS of d / e = 42 kg/mm2, f = 0.36 x 42 / 1.5 = 10.08 Kg/mm2
Thk. of d / e = 12 mm
Thk. of d / e after dishing (considering 12.5% thining )
= 12 – 0.125 x 12 = 10.50 mm.
r2 = 162 and R2 = 762
R2 = 762 mm, D = 912 mm
h = R2 - (R2 – D/2) (R2 + D/2 – 2 r2) … Eqn. 75
= 762 - (762 – 912/2) (762 + 912/2 – 2 x 162)
= 762 – 306 x 894
= 762 – 17.49 x 29.89
= 762 – 523 = 239
h/D ratio = 239 / 912 = 0. 262
Contd………P/2-
: 2 :
Opening in the d/e is elliptical by (345 x 446) mm

Max. dia of opening = 446 mm
Thk. of Comp. pad = 10 mm
Width of Comp. pad = 50 mm
Thk. of M.H. Ring = 20 mm
Ht. of M.H. Ring below the inside surface of d/e = 28 mm
Ht. of M.H. Ring above the inside surface of d/e = 52 mm
Additional Conditions to Comply :-
(i) T/D 0.1, Actual T/D = 10.5 / 912 = 0.011
(ii) d/D 0.5, Actual d/D = 446 / 912 = 0.489
The conditions are therefore satisfied.
Max. limit of area of reinforcement :-
(a) L1 (Max.) = 2RT for the width of reinforcing plate.
(b) L2 (Max.) = d.Tt for the height of nozzle.
R int. tadine of spherical part of the dished end C.R – ½ T = 762 – 10.5 / 2 = 756.75 mm
Tt = Actual thk. of nozzle = 20 mm
L1 = Width of Compensating = 50 mm
L2 = Height of nozzle ring = 80 mm
So (a) L1 = 2 RT = 2 x 756.75 x 10.5 = 126.06
Hence, the width provided ( 50 mm ) is within the limit.
(b) L2 (Max.) = d Tt = 446 x 20 = 94.45
Actual height provided (80 mm) is within the limit.
Hence O.K.
Calculation for Imaginary Diameter (d1)
d = Actual dia of opening in head.
T = Min. thk. in Head.
A= Effective Cross Section of Reinforcement.
W.P. = 10.50 Kg/Cm2, UTS of d/e = 42 Kg/mm2
UTS of Nozzle & Comp. Pad = 31 Kg/mm2
Contd……..P/3-
: 3 :
f = 10.08 Kg/mm2 (For D/E)
E = 0.95
te = Equivalent thk. of nozzle for opening of 406 mm at a pressure of 10.50 Kg/mm2
C = 0.762
W.P. = 2 x f x E (te – c) /( D + t – C)
0.105 = 2 x 10.08 x 0.95 x (te – 0.762) / (406 + te – 0.762) = 19.152 te – 14.593/405.2 + te
Or 19.152 te – 14.593 = 42.54 + .105
Or 19.04 te = 57.133
Or te = 57.133 / 19.04 = 3.00
te = 3.00 mm
Calculation for Compensation:
(a) Compensation available from Comp. pad = 2 x 50 x 10 = 1000 mm2
(b) Compensation available from Nozzle:-
h = 2 (20 – 2.76) 52+20 x 28
= 2912.96 2913 mm2
Total Effective Compensating
a + b = 1000 + 2912.96
= 3912.96 mm2
Effective Compensation = A = (a+b) x UTS of Nozzle / UTS of Pl.
= 3912.96 x 31 / 42
= 2888.137 mm2
Imaginary dia = d1 = d – A/T = 446 – 3912.96 / 10.5 = 73.34
Ratio d1/ DT = 73.34 / 912 x 10.5 = 0.7495
h/D = 0.244
Safe factor ‘K’ as read from fig. 23D of IBR = 1.1
Working Pressure of Dished Ends.
= W.P. = 2 x f x (T-C) / DK (Regn. 278)
= 2 x 10.80 (10.5 – 0.75) / 912 x 1.1
= 196.56 / 1003.2
= 0.1959 kg/mm2
= 19.59 kg/cm2
Hence the thickness (12 mm) of dished end proposed is adequate for a W.P. of 10.50 kg/cm2(g).
Contd………..P/4-
: 4 :
Calculation of W.P. of Box Headers :- (Reg. 340)

1) T.P. & E.P.
t = Thk. of T.P. & E.P. = 16 mm.
b = Internal breadth btn supporting side = 189
c = Constant = 3.413
C1 = Constant = 0.8
f = Permissible Stress = 0.36 x 42 / 1.5 = 10.08 kg/mm2
E = Efficiency of ligament between holes = (160 – 76.6) / 160 = 0.521
W = Width (Internal) of header = 118 mm
W.P. = c.f (t – c1)2 / b2 = 3.413 x 10.08 ( 16 – 0.8 )2 / (189)2
= 34.40 x 231.04 / 35721
= 0.2224 kg/mm2
= 22.24 kg/cm2
Or
W.P. = 6.25 f.E.t2 / W2
= 6.25 x 10.08 x 0.521 x (16)2 / (118)2 = 8402.688 / 13924
= 0.6034 kg/mm2
= 60.34 kg/mm2
In the calculations the calculated value is higher than the proposed working pressure. So the selected thickness of plate (16 mm) is
safe and adequate for a working pressure of 10.50 Kg/Cm2(g).
2) Side Ring:
t = 20, f = 10.08 kg/mm2, d = 118, c = 1, k = 0.4
f = 0.36 x 42 / 1.5 = 10.08 kg/mm2
W.P. = f ( t – c)2 / d2k
= 10.08 (20 – 1)2 / (118)2 x 0.4
= 0.653346 kg/mm2
= 65.33 kg/cm2
Hence the size of side ring ( 20 mm thk.) is adequate for a W.P. of 10.50 kg/cm2(g).
Contd………P/5-
: 5 :
Calculation for Stay Bar:

Dia of Stay Pin d = 32
Permissible Stress = 0.36 x 42 / 1.5 = 10.08 kg/mm2
Load Capacity - 10.08 x /4 (32)2 = 8105.28 kg.
W.P. = Load / Area = 8105 / 160 x 160
= 0.3166125 kg/mm2
= 31.66 kg/cm2(g)
Proposed Working Pressure - 10.50 Kg/Cm2(g).
Hence the proposed stay pin is safe and adequate for a W.P. of 10.50 Kg/Cm2(g).
Working Pressure of B.E. Headers:

1) T.P. & E.P.
t = Thk. of t.P. & E.P. = 16 mm.
b = Internal breadth btn supporting side = 154 mm
C1 = Constant = 0.8
f = Permissible Stress = 0.36 x 42 / 1.5 = 10.08 kg/mm2
E = Efficiency of ligament between holes =( 140 – 63.9) / 140 = 0.543
W = Internal Width of header = 118 mm (Max)
W.P. = c.f (t – c1) / b2 = 3.413 x 10.08 ( 16 – 0.8 )2 / (154)2
= 0.335122 kg/mm2
= 33.512 kg/cm2
Or
W.P. = f.E.t2 x 6.25 / W2
When f = 10.08
then W.P. = 6.25 x 10.08 x 0.543 x (16)2 / (118)2
= 0.6289 kg/mm2
= 62.89 kg/cm2
safe and adequate for a working pressure of 10.50/Cm2(g).
Contd……..P/6-
: 6 :
2) Side Ring Plate:

t = 20, f = 10.08 kg/mm2, d = 168, c = 1, k = 0.4
W.P. = f ( t – c)2 / d2k
= 10.08 (20 – 1)2 / (168)2 x 0.4 = 10.08 x 361 / 11289.6
= 0.32232 kg/mm2
= 32.23 kg/cm2
Hence the size of side ring plate ( 20 mm thk. ) is safe and adequate for a W.P. of 10.50
kg/cm2(g).
Calculation for Stay Pins:
Permissible Stress = 10.08 kg/mm2.
Load Developed - 10.5 x (140)2 = 2058 kg.
Stress on stay = 2058 / /4 (32)2 = 2.56 kg/mm2 = 256 Kg/Cm2.
Hence the proposed size is adequate for a W.P. of 10.50 kg/cm2(g).
W.P. = Load / Area = 7141.7 / 160 x 160
= 0.2789 kg/mm2
= 27.89 kg/cm2(g)
Working Pressure of Tubes:

(a) (Generating, Roof, Riser and Down Comer)
d = 76.2, t = 3.25, c = 0.75 constant, Min. UTS = 31 kg/mm2
e = Constant = 1 f = 0.36 x 31 / 1.5 = 7.44 kg/mm2
W.P. = 2 x fe ( t – c ) / d-t+c
= 2 x 7.44 x 1 x ( 3.25 – 0.75 ) / 76.2 – 3.25 – 0.75
= 0.5152 kg/mm2
= 51.52 kg/cm2(g)
Contd…….P/7-
: 7 :
(b) Inbed Tubes:
d = 63.5 , t = 4.06
W.P = 2 x 7.44 x 1 (4.06 – 0.75) /(63.5 – 4.06 + 0.75)
= 0.8183 kg/mm2
= 81.83 kg/cm2(g).
Hence the proposed thickness of tube is safe and adequate for a W.P. of 10.50 Kg/Cm2(g).
Calculation for Compensation of Stubs (For BE DC) on Drum (Reg. 279)

B.E. Down Comer Stub= 114.3 OD x 8.56 thk.
I.D. of Drum = 892 mm.
e = Constant = 1, Eqv. Thk. of Shell = es
Permissible Stress = f = 7.44kg/mm2, c = constant 0.762 UTS = 31 kg/mm2
f = 0.36 x 31/ 1.5 = 7.44
I.D. of Stubs = 114.3 – 2 x 8.56 = 97.18
W.P = 2 x f x e (es – c )/ ( D + es – c)
= 0.105 = 2 x 7.44 x 1 (es – 0.762) / (892 + es – 0.762)
es = (892 – 0.762) 0.105 + 2 x 7.44 x 0.762 / ( 2 x 7.44 – 0.105)
= 7.09 mm.
Compensation Required = x = dn x es
= 97.18 x 7.69 = 689.00 mm2
Let Eqv. Thk. of Nozzle = en
UTS of Nozzle = 31 kg/mm2
fn = 0.36 x 31 / 1.5 = 7.44 kg/mm2
en = (97.18 – 0.762) x 0.105 + 2 x 7.44 x 0.762 / (2 x 7.44 – 0.105)
= 1.452 mm.
Thickness of Shell = ts = 10 mm
b = Least Value of 2.5 ts Or 2.5 tn
= 2.5 x 10 Or 2.5 x 8.56 = 25 Or 21.4
: 8 :
b = 21.4
C1 = Greater of ( ts + 75 ) Or dn / 2
= ( 10 + 75 ) Or 97.18 / 2
= 85 Or 48.59
C1 = 85
Cw = Agregate area of Fillet Weld = 2 x (8.56)2 x ½
= 73.27 mm2
fn / ts = 7.44/10 = 0.744
Compensation = Available = Y = 2 ( tn - en ) b. fn / ts + 2. tn . b. fn / ts + 2. ( ts – es) C1 + Cw
= 2 x ( 8.56 – 1.452 ) 21.4 x 0.744
+ 2 x 8.56 x 21.4 x 0.744
+ 2 ( 10 – 7.09 ) 85 + 73.27
= 1066.88 mm2
Y X
Hence there is no need of extra compensation.
Calculation for Compensation of Stubs (For BER) on Drum (Reg. 279)

B.E. Down Comer Stub = B.E. Riser Stub = 141.3 OD x 9.53 thk.
Permissible Stress = f = 7.44 kg/mm2, c = constant 0.762
I.D. of Stubs = 141.3 – 2 x 9.53 = 122.24
W.P = 2 x f x e (es – c ) / ( D + es – c)
= 0.105 = 2 x 7.44 x 1 (es – 0.762) / (892 + es – 0.762)
es = (892 – 0.762) 0.105 + 2 x 7.44 x 0.762 / ( 2 x 7.44 – 0.105)
= 7.10 mm.
= 122.24 x 7.10 = 867.90 mm2
Contd….P/9-
: 9:

l = 0.36 x 47 / 1.5 = 7.44 kg/mm2
en = ( (122.24 – 0.762) x 0.105 + 2 x 7.44 x 0.762) / (2 x 7.44 – 0.105)
= 1.63 mm.
= 2.5 x 10 Or 2.5 x 9.53
= 25 Or 23.825
b = 23.825
= ( 10 + 75 ) Or 122.24 / 2
= 85 Or 61.12
C1 = 85
= 90.82 mm2
fn / ts = 7.44 / 10 = 0.744
Compensation = Available = Y = 2 ( tn - en ) b. fn / ts + 2. tn . b. fn / ts + 2. ( ts – es) C1 + Cw
= 2 x ( 9.53 – 1.63 ) 23.825 x 0.744
+ 2 x 9.53 x 23.825 x 0.744
+ 2 ( 10 – 7.10 ) 85 + 90.82
= 1201.73 mm2
Y X

Contd….P/10-
: 10 :
Heating Surface:
1) Generating Tubes:-
d = 76.2, l = 6050, n = 81
H.S. = x 76.2 x 6050 x 81 / 106 = 117.313
2) Roof Tubes :- (Half Exposed)

d = 76.2, l = 5779, n = 6
HS2 = x 76.2 x 5779 x 6 /( 2 x 106 ) = 4.149 M2
3) Down Comer :- ( Half Exposed )

d = 76.2, l = 739, n = 5
HS3 = x 76.2 x 739 x 5 /( 2 x 106 ) = 0.442 M2
4) Part of Drum :- ( Quarterly Exposed )

d = 912, l = 1960
HS4 = x 912 x 1960 / 106 x 4 = 1.40
5) In Bed Tubes:-
d = 63.5 , l = 2360, n = 38
HS5 = x 63.5 x 2360 x 38 / 106 = 17.89
Total Heating Surface:-

HS = 117.313 + 4.149 + 0.442 + 1.40 + 17.89
= 123.30 + 17.89
= 141.194 M2
Calculation for Safety Valve :- (Reg. 293)
Total Evaporation = 30 x 141.194 = 4235.7 Kgs/Hr. ( Take it as minimum 5000 Kgs/Hr. from
IBR for Safety Valve Calculation).
E = C A P Where C = 0.1 Maker’s Certificate.
5000 = 0.1 x A x 11.5 P = 10.5 + 1.0 = 11.50 Kg/Cm2 (g)
A = 5000/ 0.1 x 11.5
= 4347 cm2 ( For two sides )
Contd…….P/11-
: 11 :
As area is always found in mm2 as follows from IBR 293.

So area is 4347 mm2 (For two sides )
For one side area is
= 4347 / 2 = 2173.9 mm2
As we know that area = /4 d2
So /4 d2 = 2173.9
d2 = 2173.9 x 4 / 3.141
d2 = 2768.41
d = 2768.41
= 52.61 mm
Hence, the provision of 2 ½” D.P. Safety Valve is safe and adequate.

FOR PRESSELS PVT. LTD.
( S. K. MULLICK )
bp/sm/pkb.
291,293,288,287,Revised-287,290,187,Eco.,295
2- 12-19-26- 37-39-47-56-57
CALCULATION SHEET
BOILER MAKER’S NO. - WT/SD-300/F/291

WORKING PRESSURE - 17.5 KG/CM2(G)
WORKING TEMPERATURE - 2070 C.
HYD. TEST PRESSURE - 26.25 KG/CM2(G)
REFERENCE DRAWINGS - WT/SD-300/F/25.1,R0
WT/SD-300/F/25.2,Sh.1/2, R0
WT/SD-300/F/25.2,Sh.2/2, R0
WT/SD-300/F/25.3,Sh.1/2, R0
WT/SD-300/F/25.3,Sh.2/2, R0
WT/SD-300/F/25.4,Sh.1/2, R0
WT/SD-300/F/25.4,Sh.2/2, R0
WT/SD-300/F/25.5,Sh.1/2, R0
WT/SD-300/F/25.5,Sh.2/2, R0
:: 2 ::
WORKING PRESSURE CALCULATION FOR DRUM:
Max. Working Temp.<4540 C.

Min. UTS of Plate = 47 kg/mm2
Stress = Et/1.5 = 0.36 x 47/1.5 = 11.28 kg/mm2
Or F = UTS/2.7 = 47/2.7 = 17.41 kg/mm2
\Min. Stress for calculation = f = 11.28 kg/mm2
Ligament Efficiency (E)
i) For RoofTubes : d = 76.6, p = 320

= (p-d) / p = (320-76.6)/320 = 0.760
ii) For Down Comer Tubes: d = 76.6,

p = 330
\E = (p-d) / p = (375-76.6)/375 = 0.767
\Min. Ligament Efficiency for calculation = E = 0.760
I.D of shell = D = 912 – 20 = 892 mm, T = 10 mm. ,C=0.762
\W.P. of shell = 2.f.E (T – c)/(D + T – c)

= 2 x 11.28 x 0.760(10 – 0.762)/(892 + 10 – 0.762)
= 0.1757 kg/mm2
= 17.57 kg/cm2(g)
W.P. CALCULATION FOR DISHED ENDS: (Reg.275, 277, 278)
U.T.S. of d/e = 47 kg/mm2

Thk. of d/e = 12 mm.
Thk. after dishing (12.5% thining) = T = 10.5 mm.
R1 = 762 mm, r2 = 162 mm, D = 912 mm
External Height of d/e = h = R2 - ¨{(R2 - D/2)(R2 + D/2 – 2 r2)} (Eqn.75)
= 762 - ¨{(762 - 912/2)(762 + 912/2 – 2 x 162)}
= 762 - ¨(306 x 894)
= 762 - 523 = 239 mm.
\Ratio (h/d) = 239/912 = 0.262
Opening in dished end in elliptical.

Max.dia of opening = d = 446 mm.
Contd….P/3-
:: 3 ::
Comp. plate thk. = 10 mm.
Width of compensation = 50 mm.
Thk. of nozzle(M.H.Ring) = 20 mm.
Height of nozzle( –do-) = 80 mm
Height above of d/e = 55 mm.
Additional conditions to comply:-
I) T/D £ 0.1, actual T / D = 10.5 / 9.2 = 0.011
II) d/D £ 0.5, actual d / D = 446 / 912 = 0.489
Max. limit of area of reinforcement:-
a) L1 = ¨(2RT) for the width of reinforcing plate.
b) L2 = ¨(d.Tt ) for the height of nozzle.
R = Int. Radious of spherical part of the dished end

= C.R – 1/2T = 762 – 5.25 = 756.75 mm.
T1 = Actual thk. of nozzle = 20 mm.

L1 = Width of compensation = 50 mm
L2 = Height of nozzle ring = 80 mm.
a) So, L1 (max.) = ¨(2RT) = ¨(2 x 756.75 x 10.5) = 126.06

Hence, provided width is, 50 mm is within the limit.
b) L2 (max.) = ¨(d.Tt) = ¨(446 x 20) = 94.45

Actual height provided (80 mm) is within the limit. Hence O.K.
CALCULATION FOR (d1), THE IMAGINARY DIAMETERS:
d = actual dia of opening in head.

T = min. thk. in head.
A = Effective cross section of reinforcement
= actual C/S of comp. plate + C / S of nozzle
support the pressure.
Thickness necessary to support the

Pressure in respect of the nozzle:
W.P = 10.5 kg/cm2, UTS = 47 kg/mm2 for dished end.

= 47 kg/mm2 for nozzle & comp. pad.
f = 11.28 kg/mm2 (for d/e)
Contd….P/4-
:: 4 ::
E = 0.95
Te = Equivalent thk. of nozzle for opening of
406 mm at a pressure of 10.5 kg/cm2
c = 0.762
W.P = 2 x f x E (te – c)/(D + t – c)
0.175 = 2 x 11.28 x 0.95 (te – 0.762)/(406 + te – 0.762)
Or te = 4.10 mm.
es = ((892 – 0.762) 0.175 + 2 x 11.28 x 0.95 x 0.762)/(2 x 11.28 x 0.95 – 0.175)

= 8.10 mm.
CALCULATION FOR COMPENSATION:
a) Comp. available for compensation pad.
a = 2 x 10 x 50 = 1000 mm2
b) Comp. available from nozzle
b = 2 ((20 – 4.10) 52 + 20 x 28)) = 2773.6 mm2
Total compensation = a + b = 1000 + 2773.6 = 3773.6 mm2
Effective compensation = A = (a + b) x UTS of Nozzle/UTS of Plate.

= 3773.6 x 47/47
= 3896.4 mm2
\Imaginary dia d1 = d – A/T

= (446 – 3773.6 / 10.5) = 86.61
d1/¨(DT) = 86.61/¨ (912 x 10.5) = 0.885
h/D= 0.262.
\Shape factor K as read from fig.23D = 1.2

\W.P. of dished end = 2.f(T – c)/D.K = (Regn.278)
= 2 x 11.28 (10.5 – 0.75)/(912 x 1.2)
= 0.2010 kg/mm2
= 20.10 kg/cm2
\Selected thickness of dished end is 12 mm safe for W.P. of 17.50 kg/cm2(g)
Contd….P/5-
:: 5 ::
CALCULATION OF W.P. OF HEADER BOX:(Reg.340)

1) T.P. & E.P:
t = thk. of tube plate of hdr. Box = 16 mm.
b = int. breadth between supporting sides = 189
c = constant = 3.413
c1 = constant = 0.8
f = permissible stress = 0.36 x 37/1.5 = 8.88 kg/mm2
E = Efficiency legament between holes = 160 – 76.6/160 = 0.521
W = Width (internal) of hdr. = 118 .
\W.P = c.f.(t – c1)/b2 = 3.413 x 8.88 (16 – 0.8)2 / (189)2

= 0.1960 mm2
= 19.60 kg/cm2
Or W.P= 6.25 f.E.t2/W2 = 6.25 x 162 x 8.88 x .521/(118)2

= 0.5316 kg/mm2
= 53.16 kg/cm2
\In both calculation the value is higher than the proposed working pressure. So the selected thk. of plate i.e. 16 mm is safe &
adequate for a working pressure of 17.50 kg/cm2(g).
2) SIDE RING PLATE CALCULATION:

Side ring plate thk. = 20 mm.
p = Permissible stress = 0.36 x 37/1.5 = 8.88 kg/mm2
d = least width between walls of hdr. = 118.
c = constant = 1 mm
e= =1
W.P = f(t – c)2/d2k {Eqn.89(a)}

= 8.89 (20 – 1)2/{(118)2 x 0.4}
= 0.5756 kg/mm2
= 57.56 kg/cm2
\Selected thk. of side ring plate is safe.
CALCULATION FOR STAY PINS:

Dia of stay pin = d = 32
Stress on each stay = 10.5 x 16 x 16/p/4 x (32)2 = 3.342 kg/mm2
= 334.2 kg/cm2
Alternately,
Load = 8.88 x p/4 x (32)2
= 7141.7 kg.
W.P = 7141.72/(160 x 160)
= 0.2789 kg/mm2
= 27.89 kg/cm2
Contd….P/6-
:: 6 ::
Min. UTS of Stay Bar = 37 kg/mm2
\Permissible stress = 0.36 x 37/1.5 = 8.88 kg/mm2
= 888 kg/cm2
Proposed working pressure = 17.50 kg/cm2(g)
Hence, the provided dia 32 mm of stay bar is adequate for a working pressure of 17.50 kg/cm2(g)
CALCULATION OF W.P. FOR B.E. HEADERS (Reg.340)

1) Tube Plate & End Plate.
t = thk. of T.P & E.P = 16 mm.

c1 = constant = 0.8
b = internal breadth between supporting sides = 154 mm
w = internal width of header = 168 mm.
f = permissible stress =( 0.36 x 37)/1.5 = 8.88 kg/mm2
E = efficiency of ligament between holes = (140 – 63.9)/140 = 0.543
W.P = c.f (t – 1)2 / b2 = 3.413 x 8.88 (16 – 0.8)2/(154)2

= 0.2953 kg/mm2
= 29.53 kg/cm2
Or W.P.=( f.E.t2 x 6.25)/W2 ={ 6.25 x 8.88 x 0.543 x (16)2}/(168)2
= 0.2734 kg/mm2
= 27.34 kg/cm2
In both the calculations, the calculated value is higher than the proposed working pressure. So the selected thickness of plate (16
mm) is safe and adequate for a working pressure of 17.50 kg/cm2(g).
2) Side Ring: (Reg.340)f
t = 20,f = 8.88 kg/mm2,d = 168, C = 1, K = 0.4

W.P = f (t – c)2/(d2K)
= 8.88 (20 – 1)2/{(168)2 x 0.4}
= 0.2839 kg/mm2
= 28.39 kg/cm2(g)
\Hence, proposed size of plate (20 mm) is safe & adequate for a W.P. of 17.50 kg/cm2(g).
3) Stay Pins:
Dia of stay pin = 32 mm.
Permissible Stress at each stay = 8.88 kg/mm2
Load developed = 10.5 x (140)2 = 2058 kg.
Stress on stay = 2058/p/4(32)2
= 2.56 kg/mm2
= 256 kg/cm2
Hence the proposed size is adequate for a W.P. of 17.50 kg / cm2(g).
Contd….P/7-
:: 7 ::
Working Pressure Of Tubes:
Min. UTS = 31 kg/mm2

t = thickness
d = 76.2 mm,
Permissible stress = f = 0.36 x 31/1.5 = 7.44 kg/mm2
c = constant = 0.75
e = weld efficiency = 1
\W.P = 2.f x e (t – c) / (d – t + c)
1) Generating, Roof, Riser & Down Comer Tube:
d = 76.2 mm,
t = 3.25 mm.
\W.P = 2 x 7.44 x 1 (3.25 – 0.75)/(76.2 – 3.25 + 0.75)

= .5048 kg/mm2
= 50.48 kg/cm2
2) In Bed Tube:
d = 63.5 mm
t = 4.06
\W.P = 2 x 7 x 1 (4.06 – 0.75)/(63.5 – 4.06 + 0.75)

= 0.8183 kg/mm2
= 81.83 kg/cm2
3) B.E. Riser Tube:

d = 88.9 mm
t = 5.49
\W.P = 2 x 7.44 x 1 (5.49 – 0.75)/(88.9 – 5.49 + 0.75)
= 0.8381 kg/mm2
= 83.81 kg/cm2
4) B.E.Down Comer Tube:

d = 76.2 mm
t = 3.25 mm.
\W.P = 2 x 7.44 x 1(3.25 – 0.75)/ (76.2 – 3.25 + 0.75)
= 0.5048 kg/mm2
= 50.48 kg/cm2
\In all the cases the calculated value is more than proposed W.P. Hence, the selected thk. of tube are adequate for a W.P. of 17.50
kg/cm2
Contd….P/8-
:: 8 ::
Calculation for compensation of Stubs (for B.E. Down Comer

& Riser) on Drum: (Regn.279)
B.E. Down Comer Stub size = 114.3 OD x 8.56 thk.
ID of Drum = D = 892 mm.

e = constant = 1
Eqv. Thk. of shell = es
Permissible stress = f = 11.28 kg/mm2
C = constant = 0.762
ID of stub = 141.3 – 2 x 8.56
=97.18
W.P = 2 x f x e (es - c)/(D + es – c)
Or 0.175 = 2 x 11.28 x 1(es- .762)/(892 + es – 0.762)

\es =( (892 – 0.762)0.175 + 2 x 11.28 x 0.762)/(2 x 11.28 – 0.175)
= 7.74 mm.
Comp. required = X = dn x es = 97.18 x 7.74 = 752.17 mm2
Let Equivalent thk. of nozzle = en

UTS of nozzle = 47 kg/mm2
f = 0 .36 x 47/1.5 = 11.28 kg/mm2
en = ((97.18 - 0.762) x 0.175 + 2 x 11.28 x 0.762)/(2 x 7.44 – 0.175)
= 1.52 mm
thickness of shell = ts = 10 mm.
b = least value of 2.5 ts or 2.5 tn
= 2.5 x 10 or 2.5 x 8.56
= 25 or 21.4
\b = 25
C1 = Greater of ts + 75 or dn / 2
= 10 + 75 or 97.18 / 2
= 85 or 48.59
c1 = 85
\Cw = Agregated area of fillet weld = 2 x (8.56)2 x ½
= 73.27 mm2
fn/fs = 11.28/11.28 = 1
Compensation available = Y = 2(tn - en) b. fn / fs + 2. tn. b fn / fs + 2 (ts – es) C1 + Cw

= 2(8.56 – 1.52) 25 x 1 + 2 x 8.56 x 25 x 1
+ 2(10 – 7.74) 85 + 73.27
= 1237.47
Y>X
Contd….9/-
:: 9 ::
HEATING SURFACE:
1) Generating Tubes:
d = 76.2
l = 6050 mm
n = 74
H.S1 = p x 76.2 x 6050 x 74/ 106

= 107.175 m2
2) Roof Tubes:
d = 76.2
l = 5779
n=6
H.S2 = p x 76.2 x 5779 x 6 / 2 x 106

= 4.15 m2
3) Down Comer Tubes (Half Exposed):

d = 76.2
l = 739
n=5
H.S3 = p x 76.2 x 739 x 5 / 2 x 106

= 0.44 m2
4) Part of Drum (quarterly exposed):

d = 912
l = 1800
H.S4 = p x 912 x 1800/ 106 x 4
= 1.29 m2
5) In Bed Tubes:
d = 63.5
l = 2250
n = 29
H.S5 = p x 63.5 x 2250 x 34 / 106

= 13.565 m2
Total Heating Surface = H.S1 + HS2 + HS3 + HS4 + HS5

= 107.175 + 4.15 + 0.44 + 1.29 + 13.565
= 126.62 m2
Contd….P/10-
:: 10 ::
CALCULATION FOR SAFETY VALVE : (Reg.293)
Total evaporation = 30 x 126.62 = 3798.6 kgs/hr.
E = CAP, where, C = 0.4 maker’s constant
3798.6 = 0.4 x A x 11.5 , P = 10.5 + 1.0 = 11.50 kg/cm2(g)
\A = 3798.6 / (0.4 x 11.5)
= 3303.13 mm2
p / 4 d2 = 3303.13
\d = Ö{( 3303.13 x 4)/ p} = 32.43 mm.
Hence, the position of 2 ² D.P. Safety Valve is safe and adequate.
PRESSELS PVT. LTD.
(P. Swain )
Design Engineer
IBR CALCULATION
BOILER MAKER’S NO. - WT/SD – 400/F/293

WORKING PRESSURE - 10.5 Kg/Cm2(g)
WORKING TEMP. - 185oC.
EVAPORATION - 4000 Kgs/Hr.
HEATING SURFACE - 189.780 M2
REF. DRAWING NOS. WT/SD-400/F/28.1 R0
WT/SD-400/F/28.2, Sh.1/2 R0
WT/SD-400/F/28.2, Sh.2/2 R0
WT/SD-400/F/28.3, Sh.1/2 R0
WT/SD-400/F/28.3, Sh.2/2 R0
:: 2 ::
DRUM
1) Shell
Max. Working Temp. = 185oC. < 454oC.
Min. UTS of Pl . = 47 Kg/Cm2(g)
Permissible Stress = f = 0.36 x 47 / 1.5 = 11.28 Kg/Cm2(g)
E1 = P-d/p = (410 – 76.6)/410 = 0.813
(b) For Roof Tubes :- d = 76.6, P = 320
E2 = P-d/p = (320 – 76.6 ) / 320 = 0.760
Taking minimum of the two, ligament efficiency for further calculations = E = 0.760
O.D. of Shell = 912 mm
\ I.D of shell = D = 9.2 – 10 x 2 = 892 mm
\ W.P. = 2.f.E (T-C) / (D + T-C ) Where, C = 0.762 (Constant)
= 2 x 11.28 x 0.760 (10-0.762) / ( 892 + 10 – 0.762)
= 0.1757 Kg/mm2
= 17.57 Kg/Cm2(g)
Kg/Cm2 (g).
2) Dished End
UTS of d/e = 47 kg/mm2, \ f = 0.36 x 47 / 1.5 = 11.28 Kg/mm2
Thk. of d/e = 12 mm
Thk. of d/e after dishing (considering 12.5% thinning)
= 12 – 0.125 x 12 = 10.50 mm.
R2 = 762, d2 = 162
\ h = R2 - Ö{(R2 – D/2) (R2 + D/2 – 2 r2)}
= 762 - Ö{(762 – 9.2/2) (762 + 412 / 2 – 2 x 162)}
= 762 – 523
= 239
h/D ratio = 239 / 912 = 0.262
Contd…….P/3-
:: 3 ::

T / D £ 0.1, Actual T/D = 10.5 / 912 = 0.011
d / D £ 0.1, Actual d/D = 446 / 912 = 0.489
L1 (Max.) = Ö 2RT R = 762 – 10.5 = 751.5
= Ö (2 x 751.5 x 10.5)
= 125.62 mm
Hence, the provided width (50 mm) is within the limit.
L2 (Max.) = Ö d.Tt
= Ö (446 x 20)
= 94.44
Hence, it is within the limit.
Thickness necessary to support the pressure in respect of nozzle (te)
W.P. = 2.f e ( te – c) / (D + te – c ) ( e = 0.95)
0.105 = 2 x 11.28 x 0.95 x (te – 0.762) / (406 + te – 0.762)
\ te = 0.105 (406 – 0.762) + 2 x 11.28 x 0.95 x 0.762 / (2 x 11.28 x 0.95 – 0.105)
= 2.76 mm
Compensation available from Comp. pad = 2 x 50 x 10 = 1000 mm2
Compensation available from MH Ring.
= 2 {(20 – 2.76) 52- 20 x 28}
= 2912.96 » 2913 mm2
Contd………P/4-
: 4 :
= 1000 x 42 / 47 + 2913 x 42/47
= 893.62 + 2603.11
= 3496.73 mm2
d1 = d – A/T = 446 – 3496.73 / 10.5 = 112.98
Ratio d1/ Ö DT = 112.98 / Ö(912 x 10.5)
= 1.15
Valve of ‘K’ from fig. 23(D) of IBR = 1.3
Working Pressure of d/e
= W.P. = 2.f (T-C) / DK (Reg. 278)
= 2 x 11.28 (10.5 – 0.75) / 912 x 1.3 (\ c = 0.78 )
= 0.1855 kg/mm2
= 18.55 kg/cm2
Calculation for Headers (Reg. 340)

a) Tube Plates
t = 16, w = 118, b = 189, c = 3.413. c1 = 0.8
Min. UTS of Pl. = 42 kg/mm2
f = 0.36-42 / 1.5 = 10.08 kg/mm2
I) \ W.P. = c.f (t – c1)2 / b2 = 3.413 x 10.08 ( 16 – 0.8 )2 / (189)2

= 0.2225 kg/mm2
= 22.25 kg/cm2
Or
II) W.P. = 6.25 f.E.t2 / W2
= 6.25 x 10.08 x 0.521 x (16)2 / (118)2 E = 160 – 76.6 / 160
= 0.6035 kg/mm2 = 0.521
= 0.6035 kg/mm2
= 60.35 kg/cm2(g)
In both the cases the calculated value is higher than the proposed W.P. Hence the size of t.p. proposed is adequate for a W.P. of 10.50
kg/cm2(g).
Contd…….P/5-
: 5 :
(b) Side Ring

UTS of Pl. = 37 Kg/mm2 k = 0.4, c = 1, t = 20, d = 118
\ f = 0.36 x 37 / 1.5 = 8.88 kg/mm2
\ W.P. = f ( t – c)2 / d2k
= 8.88 (20 – 1)2 / (118)2 x 0.4
= 0.5756 kg/mm2
= 57.56 kg/cm2
Hence the size of side ring (20 mm thk.) is adequate for a W.P. of 10.50 kg/cm2(g).
Stay Pins
Load on stay = 10.5 x 160 x 160 = 2688 Kg.
Stress on Stay = 2688 / p/4 d2 , d = 32 mm ( dia of stay pin )
= 2688 / p /4 (32)2
= 3.342 kg/mm2
= 334.2 kg/cm2
Min UTS of stay pin = 37 kg/mm2
Stress = f = 0.36 x 37 / 1.5 = 8.88 kg/mm2
= 888 kg/cm2 (g).
The developed stress is less than the stress capacity of the stay pin. Therefore the proposed stay pin is safe and adequate for a W.P.
of 10.50 kg/cm2(g).
Working Pressure of Tubes: (Generating, Roof, Riser and Down Comer)

e = Constant = 1 \ f = 0.36 x 31 / 1.5 = 7.44 kg/mm2
\ W.P. = 2 x fe ( t – c ) / d-t-c
= 2 x 7.44 x 1 x ( 3.25 – 0.75 ) / (76.2 – 3.25 – 0.75)
= 0.5152 kg/mm2
= 51.52 kg/cm2(g)
Contd……..P/6-
:: 6 ::
Heating Surface
d = 76.2, l = 6050, n = 127
H.S. = p x 76.2 x 6050 x 127 / 106 = 183.93 M2
d = 76.2, l = 5779, n = 6
\ HS2 = p x 76.2 x 5779 x 6 / 2 x 106 = 4.15 M2

d = 76.2, l = 739, n = 5
\ HS3 = p x 76.2 x 739 x 5 / 2 x 106 = 0.44 M2
4) Part of Drum :- ( 81o Exposed )

d = 912, l = 1955
\ HS4 = p x 912 x 1955 x 81 / (360 x 106 )
= 1.26 M2
Total Heating Surface :-

HS = HS1 + HS2 + HS3 + HS4
= 183.93 + 4.15 + 0.44 + 1.26
= 189.78 M2
Calculation for Safety Valve

Min. Evaporation = 30 Kgs/Hr/M2
Total Evaporation = E = 30 x 189.78 = 5693.4 Kgs/Hr.
E = C A P Maker’s Certificate C = 0.4 For high lift S.V.
P = 10.5 + 1 = 11.5 Kg/Cm2 (g)
5693.4 = 0.4 x A x 11.5
\ A = 5693.4 / 0.4 x 11.5 = 1237.69 mm2
p / 4 d2 = 1237.69
\ d = Ö 1237.69
= 39.69 mm
Contd………P/7-
: 7 :
Bore of stand pipe required = 1.41 x 39.69

= 55.96 mm
Therefore 20 D.P. Safety Valve is adequate.
( P. SWAIN )
JR. MANAGER (Q.A.)
CALCULATION SHEET

WT/SD-400/F/26.2,Sh.1/2, R0
WT/SD-400/F/26.2,Sh.2/2, R0
WT/SD-400/F/26.3,Sh.1/2, R0
WT/SD-400/F/26.3,Sh.2/2, R0
:: 2 ::

Stress = Et/1.5 = 0.36 x 47/1.5 = 11.28 kg/mm2
Or F = UTS/2.7 = 47/2.7 = 17.41 kg/mm2

= (p-d) / p = (320-76.6)/320 = 0.760

p = 410
\E = (p-d) / p = (410-76.6)/410 = 0.813

= 2 x 11.28 x 0.760(10 – 0.762)/(892 + 10 – 0.762)
= 0.1757 kg/mm2
= 17.57 kg/cm2(g)

R1 = 762 mm, r2 = 162 mm, D = 912 mm
= 762 - ¨{(762 - 912/2)(762 + 912/2 – 2 x 162)}
= 762 - ¨(306 x 894)
= 762 - 523 = 239 mm.
\Ratio (h/d) = 239/912 = 0.262
Opening in dished end in elliptical.

Contd….P/3-
:: 3 ::
Thk. of nozzle(M.H.Ring) = 20 mm.
Height of nozzle( –do-) = 80 mm
Height above of d/e = 55 mm.

I) T/D £ 0.1, actual T / D = 10.5 / 9.2 = 0.011
II) d/D £ 0.5, actual d / D = 446 / 912 = 0.489


= C.R – 1/2T = 762 – 5.25 = 756.75 mm.

a) So, L1 (max.) = ¨(2RT) = ¨(2 x 756.75 x 10.5) = 126.06

b) L2 (max.) = ¨(d.Tt) = ¨(446 x 20) = 94.45




f = 11.28 kg/mm2 (for d/e) contd….P/4-
:: 4 ::
E = 0.95
c = 0.762
W.P = 2 x f x E (te – c)/(D + t – c)

0.175 = 2 x 11.28 x 0.95 (te – 0.762)/(406 + te – 0.762)
Or te = 4.10 mm.
es = ((892 – 0.762) 0.175 + 2 x 11.28 x 0.95 x 0.762)/(2 x 11.28 x 0.95 – 0.175)

= 8.10 mm.
a = 2 x 10 x 50 = 1000 mm2
b = 2 ((20 – 4.10) 52 + 20 x 28)) = 2773.6 mm2

= 3773.6 x 47/47
= 3896.4 mm2

= (446 – 3773.6 / 10.5) = 86.61
d1/¨(DT) = 86.61/¨ (912 x 10.5) = 0.885
h/D= 0.262.
\Shape factor K as read from fig.23D = 1.2

\W.P. of dished end = 2.f(T – c)/D.K = (Regn.278)
= 2 x 11.28 (10.5 – 0.75)/(912 x 1.2)
= 0.2010 kg/mm2
= 20.10 kg/cm2
Contd….P/5-
:: 5 ::

1) T.P. & E.P:
c1 = constant = 0.8
E = Efficiency legament between holes = 160 – 76.6/160 = 0.521
\W.P = c.f.(t – c1)/b2 = 3.413 x 8.88 (16 – 0.8)2 / (189)2

= 0.1960 mm2
= 19.60 kg/cm2
Or W.P= 6.25 f.E.t2/W2 = 6.25 x 162 x 8.88 x .521/(118)2

= 0.5316 kg/mm2
= 53.16 kg/cm2
adequate for a working pressure of 17.50 kg/cm2(g).

c = constant = 1 mm
e= =1
W.P = f(t – c)2/d2k {Eqn.89(a)}

= 8.89 (20 – 1)2/{(118)2 x 0.4}
= 0.5756 kg/mm2
= 57.56 kg/cm2
\Selected thk. of side ring plate is safe.
CALCULATION FOR STAY PINS:

Dia of stay pin = d = 32
Stress on each stay = 10.5 x 16 x 16/p/4 x (32)2 = 3.342 kg/mm2
= 334.2 kg/cm2
Alternately,
Load = 8.88 x p/4 x (32)2
= 7141.7 kg.
W.P = 7141.72/(160 x 160)
= 0.2789 kg/mm2
= 27.89 kg/cm2
Contd….P/6-
:: 6 ::
Min. UTS of Stay Bar = 37 kg/mm2
\Permissible stress = 0.36 x 37/1.5 = 8.88 kg/mm2
= 888 kg/cm2
Proposed working pressure = 17.50 kg/cm2(g)
Hence, the provided dia 32 mm of stay bar is adequate for a working pressure of 17.50 kg/cm2(g)
HEATING SURFACE:
d = 76.2
l = 6050 mm
n =104
H.S1 = p x 76.2 x 6050 x 104/ 106

= 150.623 m2
2) Roof Tubes:
d = 76.2
l = 5779
n=6
H.S2 = p x 76.2 x 5779 x 6 / 2 x 106

= 4.15 m2
3) Down Comer Tubes :

d = 76.2
l = 739
n=5
H.S3 = p x 76.2 x 739 x 5 / 106

= 0.884 m2
4) Riser Tubes (Half Exposed):
d = 76.2
l = 739
n=5
H.S4 = p x 76.2 x 100 x 56/2x 106

= 0.07 m2
d = 912
l = 1955
H.S4 = p x 912 x 1955/ 106 x 4
= 1.40 m2
Contd….P/7-
:: 7 ::

= 150.623 + 4.15 + 0.884 + 0.07 + 1.40
= 157.127 m2
4713.81 = 0.4 x A x 11.5 , P = 17.5 + 1.0 = 18.50 kg/cm2(g)
\A = 4713.81 / (0.4 x 18.5)
= 637 mm2
p / 4 d2 = 637
\d = Ö{( 637 x 4)/ p} = 28.47 mm.
Hence, the position of 2 ² D.P. Safety Valve is safe and adequate.
PRESSELS PVT. LTD.
(P. Swain )
Design Engineer
CALCULATION SHEET

HYDRAULIC TEST PRESSURE - 26.25 KG/CM2(G)
HEATING SURFACE - 345.52 M2
WT/SD-1000/F/2.2,Sh.1/2, R0
WT/SD-1000/F/2.2,Sh.2/2, R0
WT/SD-1000/F/2.3,Sh.1/2, R0
WT/SD-1000/F/2.3,Sh.2/2, R0
WT/SD-1000/F/2.4,Sh.1/2, R0
WT/SD-1000/F/2.4,Sh.2/2, R0
WT/SD-1000/F/2.5,Sh.1/2, R0
WT/SD-1000/F/2.5,Sh.2/2, R0
: 2 :
1. DRUM:
Max. Temp. = 2070C. \Working Metal Temp. = 207 + 10 = 2170C.
Min. UTS of shell plate = 47 kg/mm2
I. f = Et/1.5 = 0.36 x 47/1.5 = 11.28 kg/mm2

Or UTS/2.7 = 47/2.7 = 17.41 kg/mm2.
\Min. stress for calculations = f = 11.28 kg/mm2
II. Ligament Efficiency (E) (Reg.215)
- For Roof Tubes, d = 76.6, P = 310

\E = p-d/p = 310 – 76.6/310 = 0.753.
- For Down Comer Tubes, d = 76.6, p = 325
\E = (p-d)/p = 325 – 76.6/325 = 0.764
\ Min. efficiency for calculation = E = 0.753
OD of shell = 1050 mm.
\W.P = 2.f.E (t – c)/(d – t – c) (c = 0.762)
0.175 = 2 x 11.28 x 0.753 (t – 0.762)/(1050 – t – 0.762)
\ t = 0.175 (1050 – 0.762) + 2 x 11.28 x 0.753 x 0.762/(2 x 11.28 x 0.753 + 0.175)

= 11.45 mm.
Proposed thickness of shell = 12 mm which is adequate for a W.P. of 17.50 kg/cm2(g)
DISHED ENDS: (Reg. 275, 277, 278)
UTS of d/e = 52 kg/mm2, thk. of d/e = 12 mm.
\f =( 0.36 x 52)/1.5 = 12.52 kg/mm2
thk. of d/e. after dishing (12.5% thining) = 10.5 mm.
R1 = 912, r2 = 162.
Contd….P/3-
: 3 :
\h = R2 - Ö{(R2 – D/2) (R2 + D/2 – 2r2)}

= 912 - Ö{(912 – 1050/2) (912 + 1050/2 – 2 x 162)}
= 912 – 656.3
= 255.7
\Ratio h/d = 255.7/1050 = 0.2435
Opening of d/e is elliptical in shape.
Max. dia. of opening = d = 446

Compensating pad thickness = 12 mm
Width = 65 mm
Man Hole Ring thickness = 20 mm.
Height = 85 mm.
Height of ring above the internal surface of d/e = 57
Height of ring below the internal surface of d/e = 28
Additional conditions to comply:
I) T/D £ 0.1, actual T/D = 10.5/1050 = 0.01

II) d/D £ 0.5, actual d/D = 446/1050 = 0.424
Max. limit of area of reinforcement.
I) L1 = Ö(2RT) for the width of reinforcing plate

II) L2 = d.Tt for the height of nozzle.
R = 912 – 10.5/2 = 906.75 mm.

T1 = Actual thk. of nozzle= 20 mm.
L1 = width of nozzle ring = 85 mm.
So, (I) L1 = Ö(2 x 906.75 x 10.5) = 137.99

Hence, the width provided (65 mm) is within the limit.
II) L2(max.) = Ö(d.Tt)

= Ö(446 x 20)
= 94.45.
Calculation for imaginary diameter (d1)

d = Actual dia. Of opening in head.
Contd….P/4-
: 4 :
T = Min. thk. in head.
A = Effective area of reinforcement.
W.P = 17.50/cm2(g), UTS = 47

f = 11.28 (calculated earlier)
fn= 0.36 x 47/1.5 = 11.28 kg/mm2

E = 0.95
Te= Eqv. thk. of nozzle for opening of 406 mm at a pressure of 17.50 kg/cm2(g)
c = 0.762 (constant)
W.P = 2 x f x e (te – c)/(D + t – c)
0.175 = 2 x 11.28 x 0.95 (te – 0.762)/(406 + t – 0.762)
\te = (406 – 0.762) 0.175 + 2 x 11.28 x 0.95 x 0.762/(2 x 11.28 x 0.95 – 0.175)
= 4.22 mm.
Compensation:
a) compensation available from comp. pad = 2 x 12 x 65 = 1300 mm2
b) compensation available from nozzle =2(20 – 4.22)57 + 20 x 28)

= 2918.92 mm2
Total effective compensations
= (1300 + 2918.92) 47/52 = 3813.25 mm2
Imaginary dia = d1 = d – A/T = 446 – 3813.25/10.5 = 82.83 mm.
d1/Ö(DT) = 82.83/Ö(1050 x 10.5) = 0.788

h/D ratio = 0.2435
\Shape factor (K) as read from fig 23D = 1.1
\W.P. of dished ends = 2.f(T – c)/D.K. (Reg.278)
= 2 x 12.48(10.5 – 0.75)/(1050 x 1.1)

= 0.2107 kg/mm2
= 21.07 kg/cm2(g)
Hence, the proposed thickness of d/e (12 mm) is safe & adequate for a W.P1 of
17.50 kg/cm2(g)
Contd….P/5-
: 5 :
Calculation for W.P. of Box Headers : (Reg. 340)
1) T.P & E.P:

b= internal breadth between the supporting sides = 189
c= constant = 3.413 min. UTS of plates = 47 kg/mm2
c1= constant = 0.8
f = permissible stress = (0.36 x 47)/1.5 = 11.28 kg/mm2
E= efficiency of ligament between the holes = (160 – 76.6)/160
= 0.521
W = internal width of header = 168 mm.
\W.P = f(t – c1)2/b2 = 3.413 x 11.l28 (16 – 0.8)2/(189)2

= 0.2490 kg/mm2 = 24.90 kg/cm2(g)
or W.P = 6.25 f.E.t2/W2
= 6.25 x 11.28 x 0.521 x (16)2/(168)2

= 0.3332 kg/mm2
= 33.32 kg/cm2(g)
In both the cases the calculated value is higher than the proposed working pressure. So, the selected thickn ess of plates (16 mm) is
safe & adequate for a W.P. of 17.50 kg/cm2(g).
2. Side Ring Plate

UTS = 47 kg/mm2
t = 20, f = 11.28 kg/mm2 (as calculated earlier)
d = 168, c = 1, K = 0.4
\W.P = f (t – c)2/d2K = 11.28 (20 – 1)2/{(168)2 x 0.4}

= 0.3607 kg/mm2
= 36.07 kg/cm2(g)
3. Stay Pins
d = 32 mm
f = 0;.36 x 37/1.5 = 8.88 kg/mm2
Load capacity = 8.88 x p/4(32)2 = 7141.7 kg.
\W.P = Load/area = 7141.7/(160 x 160)

= 0.2789 kg/mm2(g)
= 27.89 kg/cm2(g)
Proposed W.P. = 17.50 kg/cm2(g)
Contd….P/6-
: 6 :
Hence the size of stay pins proposed is safe & adequate for a W.P.
of 17.50 kg/cm2(g).
Working Pressure for B.E. Headers (Reg.340)
1) T.P & E.P

b = internal breadth between supporting sides = 154 mm.
c = constant = 3.413, c1 = constant = 0.8
f = permissible stress =( 0.36 x 47) / 1.5 = 11.28 kg/mm2
E = efficiency of ligament between holes.
= (140 – 63.9)/140 = 0.543
W = internal width of the header = 208 mm.
\W.P = c.f.(t – c1)/b2
= 3.413 x 11.28 (16 – 0.8)2/(154)2

= 0.3751 kg/mm2
= 37.51 kg/cm2(g)
or W.P = 6.25 f e t2/W2
= 6.25 x 11.28 x 0.543 x (16)2/(208)2

= 0.2265 kg/mm2
= 22.65 kg/cm2(g)
In both the cases the calculated value is higher than the proposed W.P. so the selected
Thickness of T.P is safe & adequate.
2) Side Ring
t = 20, UTS = 47 kg/mm2, f = 11.28 kg/mm2(as calculated earlier)

d = 208, C = 1, K = 0.4
\W.P = f (t – c)2/d2 K = 11.28 (20 – 1)2/{(208)2 x 0.4}
= 0.2353 kg/mm2
= 23.53 kg/cm2
3) Stay Pins
W.P. calculation already under Box Header.
Contd….P/7-
: 7 :
Working Pressure of Tubes
1) Gen., Roof, Riser, Down Comer Tubes
d = 76.2 mm, t = 3.25 mm thk., c = 0.75, e = 1

Min. UTS of tubes = 31 kg/mm2
\f = (0.36 x 31)/1.5
W.P = 2.f.e. (t – c)/(d – t + c)
\W.P = 2 x 7.44 x 1 x (3.25 – 0.75)/(76.2 – 3.25 + 0.75)

= 0.5047 kg/mm2
= 50.47 kg/cm2(g)
2) Inbed Tubes : d = 63.50 mm, t = 4.06
\W.P = 2 x 7.44 x 1 x (4.06 – 0.75)/(63.5 – 4.06 + 0.75)
= 0.8183 kg/mm2
= 81.83 kg/cm2(g)
3) Bed Element Down Comer
d = 141.3 mm, t = 6.55 mm
\W.P = 2 x 7.44 x 1(6.55 – 0.75)/(141.3 – 6.55 + 0.75)
= 0.6369 kg/mm2
= 63.69 KG/cm2(g)
4) Bed Element Riser
d = 168.3 mm, t = 7.11 mm
\W.P = 2 x 7.44 x 1(7.11 – 0.75)/(168.3 – 7.11 + 0.75)

= 0.5844 kg/mm2
= 58.44 kg/cm2(g)
Calculation for Compensation of Stubs (For B.E.Down Comer &

B.E. Riser) on Drum (Reg.279)
B.E. Down Comer Stub = 141.3 OD x 9.53 thk.
B.E. Down Comer Stub = 168.3 OD x 10.97 thk.

Contd….P/8-
: 8 :
I.D. of drum = 1026 mm
e = constant = 1, eqv. Thk. of shell = es
Permissible stress = f = 11.28 kg/mm2
I) B.E.D.C. Stub: D = 141.3 – 2 x 9.53 = 122.24
\W.P. = 2.f.e (es – c)/(D + es – c)
or 0.175 = 2 x 11.28 (es – 0.762)/(1026 + es – 0.762)
or es = (1026 - 0.762) 0.175 + 3 x 11.28 x 0.762/(2 x 11.28 – 0.175)

= 8.78 mm.
Compensation required (X) = dn x es
= 122.24 x 8.78
= 1073.27 mm2
Let, eqv. thk. of nozzle = en
UTS of pipe = 47 kg/mm2
\f = 0.36 x 47/1.5 = 11.28 kg/mm2
\en = (122.24 – 0.762) x 0.175 + 2 x 11.28 x 0.762/(2 x 11.28 – 0.175)

=1.72 mm.
thickness of shell = ts = 12 mm.
b = least value of 2.5 ts or 2.5 tn
b = 2.5 x 12 or 2.5 x 9.53
=30 or 23.825
\b = 23.825
C1 = Greater of (ts + 75) or dn/2
= Greater of (12 + 75) or 122.24/2
= Greater of 87 or 61.12
Contd….P/9-
: 9 :
\C1 = aggregate area of fillet weld.
=2 x (9.53)2 x ½ = 90.82 mm2
fn/fs = 11.28/11.28 = 1
Compensation available (Y):-
=2 (tn - en).b. fn/fs + 2, tn.b. fn/fs + 2 (ts – es) C1 + Cw
= 2(9.53 – 1.72) 23.825 X 1 + 2 X 9.53 X 23.825 X 1 +2( 12 – 8.78) 87 + 90.82
= 372.15 + 454.11 + 560.28 + 90.82
= 1477.36 mm2
Y>X
Hence, there is no need of extra compensation.
II) B.E.R Stub: I.D = 168.3 – (2 x 10.97) = 146.36 mm.
\es =[ (D – c) W.P + 2 x f x c]/(2 x f – W.P)
=[ (1026 – 0.762) 0.175 + 2 x 11.28 x 0.762]/[2 x 11.28 – 0.175]

= 8.78 mm
Compensation required (X) = dn x es

= 146.36 x 8/78
= 1285.04 mm2
fn = 11.28 kg/mm2 (calculated earlier)
Let, eqv. thk. of nozzle = en
\en =[ (146.36 – 0.762) 0.175 + 2 x 11.28 x 0.762]/[2 x 11.28 – 0.175]

= 1.91
ts = 12 mm
b = Least value of 2.5 ts or 2.5 tn

= Least value of 2.5 x 12 or 2.5 x 10.97
= Least value of 30 or 27.425
\b = 27.425
Contd….P/10-
: 10 :
C1 = Greater of (ts + 75) or dn/2

= Greater of (12 + 75) or 146.36/2
= Greater of 87 or 73.18
\C1 = 87.
Cw = Agregate area of fillet weld.
= 2 x (10.97)2 x ½ = 120.34 mm2

fn/fs = 11.28 (calculated earlier)
Compensation available (Y)
= 2(tn – en)b fn/fs + 2.tn.b.fn/fs + 2 (ts – es) C1 + Cw
= 2 (10.97 – 1.91) 27.425 x 1 + 2 x 10.97 x 27.425 x 1 + 2(12 – 8.78) 87 + 120.34
= 496.94 + 601.71 + 560.28 + 120.34
= 1779.27 mm2
Y>X
Hence, there is no need of extra compensation.
HEATING SURFACE:
1) Gen. tubes: d = 76.2, l = 7250, n 1 171
\HS1 = p x 76.2 x 7250 x 171/106 = 296.78 M2
2) Roof Tubes:
\HS2 = p x 76.2 x 6905 x 8/106 = 6.61 M2
3) Part of Drum:
\HS3 = p x 1050 x 2600 x 83/360 x 106 = 1.98 M2
Contd….P/11-
: 11 :
4) In Bed Tubes : d = 63.5l, l = 2348, n = 70
\HS4 = p x 63.5 x 2348 x 70/106 = 32.79 M2
5) Headers:
\HS5 = [2560 x 1790 - p/4 x (76.26) x 171 - p/4 (32)2 x 155/106] x 2

= 7.36 M2
Total (H.S) = HS1 + HS2 + HS3 + HS4 + HS5
= 296.78 + 6.61 + 1.98 + 32.79 + 7.36
= 312.73 + 32.79
= 345.52 M2
SAFETY VALVE:
Heating surface = 345.52 M2
Evaporation = 30 kgs/hr/m2
\Total Evaporation = E = 345.52 x 30
= 10365.6 kgs/hr.
C = 0.4 (Maker’s Constant), P = 18.5
E = CAP
\A = 10365.6/(0.4 x 18.5) = 1400.76
\d = Ö{(1400.76 x 4)/ p}= Ö(1414.18)

= 42.23 mm.
Safety valve proposed = 2 ½ ² NB D.P. Safety Valve.
Hence safe and adequate.
( P. SWAIN )
REVISED CALCULATION FOR BOILER MAKER’S NO.WT/SD-1000/F/287
HEATING SURFACE:
1) Gen. tubes: d = 76.2, l = 7250, n 1 171
\HS1 = p x 76.2 x 7250 x 171/106 = 296.78 M2
2) Roof Tubes:
\HS2 = p x 76.2 x 6952 x 8/106 = 6.66 M2
3) Part of Drum:
\HS3 = p x 1050 x 2600 x 83/360 x 106 = 1.98 M2
4) In Bed Tubes : d = 63.5l, l = 2348, n = 70
\HS4 = p x 63.5 x 2348 x 70/106 = 32.79 M2
5) Headers:
\HS5 = [2560 x 1790 - p/4 x (76.26) x 171 - p/4 (32)2 x 155/106] x 2

= 7.36 M2
Total ( H.S ) = HS1 + HS2 + HS3 + HS4 + HS5

= 296.78 + 6.66 + 1.98 + 32.79 + 7.36
= 312.78 + 32.79
= 345.57 M2
SAFETY VALVE:
Heating surface = 345.57 M2
Evaporation = 30 kgs/hr/m2
\Total Evaporation = E = 345.57 x 30
= 10367.1 kgs/hr.
C = 0.4 (Maker’s Constant), P = 18.5
E = CAP
Contd….P/2-
:: 2 ::
\A = 10367.1 / (0.4 x 18.5) = 1400.96
\d = Ö{(1400.96 x 4)/ p}= Ö(1783.76)

= 42.24 mm.
Safety valve proposed = 2 ½ ² NB D.P. Safety Valve.
Hence safe and adequate.
( P. SWAIN )
Design Engineer
PRESSURE CALCULATION
BOILER MAKER’S NO. - WT/VSSD – 800/290

WORKING TEMP. - 216.233OC.
HEATING SURFACE - 420 M2
REF. DRAWINGS - WT/SD-800/9.1
WT/SD-800/9.2
WT/SD-800/9.3
WT/SD-800/9.4
WT/SD-800/9.5
WT/SD-800/9.6
WT/SD-800/9.7
WT/SD-800/9.8
WT/SD-800/9.10
WT/SD-800/9.11
: 2 :
Headers:
1) From Wall Panel Top and Bottom Headers and Rear Wall Panel Top and Bottom Headers -
d = 141.3, Min Thickness t = 6.55,
Min. pitch ( taken) = 76, E = 76 – 51.2 / 76 = 0.326
UTS = 47 Kg/mm2, \ f = 0.36 x 47 / 1.5 = 11.28 Kg/mm2
\ W.P. = 2 f E ( t – c ) /( d - t – c)
= 2 x 11.28 x 0.326 (6.55 – 0.762) / (141.3 – 6.55 - 0.762)
= 0.3177 Kg/mm2
= 31.77 Kg/Cm2(g)
Therefore this material proposed for the headers is safe and adequate for a W.P. of
21 Kg/Cm2(g)
2) LHS and RHS Wall Top and Bottom Headers:-

d = 168.3, t = 7.11, UTS = 47 Kg/mm2
f = 0.36 x 47 / 1.5 = 11.28 Kg/mm2
Pitch (Lineer) = 76, d1 = 51.2
\ E = 76 – 51.2 / 76 = 0.326
W.P. = 2 x 11.28 x 0.326 x (7.11 – 0.762) / (168.3 – 7.11 – 0.762)
= 0.2910 kg/mm2
= 29.10 kg/cm2(g)
Stub on Side Wall Headers:

Stub Size = 168.3 Æ x 7.11, 141.3 x 6.55 thk.
dn1 = 168.3 – 217.11, dn2 = 141/3 – 2 x 6.55, tn2 = 6.55
= 154.08 = 128.2,
tn1 = 7.11
f = 11.28 kg/mm2 ( As calculated Earlier)
e = 1, c = 0.762 , ds = 168.3 , ts = 7.11
I) For 168.3 OD Stubs
\ WP = 2 f e ( es – c) / ds – es – c
0.21 = 2 x 11.28 x 1 ( es – 0.762) / 168.3 - es - 0.762
Contd….P/3-
:: 3 ::
\ es = (168.3 – 0.762) 0.21 + 2 x 11.28 x 0.762 / (2 x 11.28 + 0.21)
= 2.3 mm
Compensation Required = X = dn x es
= 154.08 x 2.3
= 354.384 mm2
Similarly , en = 2.3 mm
Constant (C1) = 76 + ts Or dn/2 (whichever is greater)
= 76 + 7.11 Or 154.08 / 2 (whichever is greater)
= 83.11 Or 77.04 (whichever is greater)
= C1 = 83.11
b = Max. of 2.5 ts Or 2.5 tn
= Max. of 2.5 x 7.11 Or 2.5 x 7.11
= Max. of 17.775 Or 17.775
\ b = 17.775
\ Compensation available (Y)
= 2 [ ( tn – en) b + 2 tn b + 2 (ts – es) C1 + Cw ] fn / fs
= [ 2 ( 7.11 – 2.3) 17.775 + 2 x 7.11 x 17.775 + 2 (7.11 – 2.3) 83.11 + 0] x 1
= 1223.27 mm2
Y>X
There is no need of extra compensation for
II) 141.3 OD stub.
ds = 168.3 – 2 x 7.11 = 154.08, ts = 7.11
dn = 141.3 – 2 x 6.55 = 128.2 mm , tn = 6.55 mm
es = 2.3 mm (Calculated Earlier)
en = (141.3 – 0.762) 0.21 + 2 x 11.28 x 0.762 /(2 x 11.28 + 0.21)
= 2.051 mm
C1 = Greater of (76 + 7.11) Or 128.2 / 2
= Greater of 83.11 Or 64.1
\ C1 = 83.11
b = Min. of 2.5 x 7.11 Or 2.5 x 6.55
= Min. of 17.775 Or 16.375
Contd….P/4-
:: 4 ::
Compensation Required = X = dn x es
= 128.2 x 2.3
= 294.86 mm2
Compensation available = Y
= [ 2 ( tn – en ) b + 2 x (ts – es) C1 + 2. tn.b + Cw ] tn / fs
= [ 2 ( 6.55 – 2.051) 16.375 + 2 x 6.55 x 16.375 + 2 ( 7.11 – 2.3) 83.11 + 0 ] 1
=Y>X
There is no need of extra compensation.
Front, Rear, LHS & RHS Wall Tubes.
d = 50.8, Min Thickness = 3.66 mm, f = 11.28 kg/mm2 (as calculated earlier).
e = 1, Taking 12.5 % thinning at bends, t = 3.66 – 0.125 x 3.66
= 3.2025 mm
\ W.P. = 2 f e ( t – c) /( d – t + c ) C = 0.75
= 2 x 11.28 x 1 (3.2025 – 0.75) / (50.8 – 3.2025 + 0.75)
= 1.144 kg/mm2
= 114.4 kg/cm2(g)
Economiser Connecting Pipes:

D = 50.8, t = 3.66
Taking 12.5% thinning at bends, t = 3.66 – 0.125 x 3.66
= 3.2025
f = 11.28 calculated earlier.
e = 1, c = 0.75
\ W.P. = 2 f e ( t – c ) /( d – t + c)
= 2 x 11.28 x 1 ( 3.2025 –0.75) /( 50.8 – 3.2025 + 0.75)
= 1.144 kg/mm2
= 114.4 kg/cm2 (g)
1) Shell:
UTS = 47 kg/mm2, \ f = 0.36 x 47 / 1.5 = 11.28 kg/mm2
d = 1000, t = 16 mm, c = 0.762
Contd….P/5-
:: 5 ::
\ W.P. = 2 f E ( t – c) /( d-t-c)
= 2 x11.28 x 0.95 ( 16 – 0.762 ) /( 1000 – 16 – 0.762)
= 0.3321 kg/mm2
= 33.21 kg/cm2 (g)
Therefore the thickness proposed ( 16 mm) is safe and adequate for a W.P of 21.0 Kg/Cm2(g).
Stubs on Shell : - D = 1000 – 2 x 16 = 968, f = 11.28 kg/mm2 (Calculated Earlier)

[ dn = 168.3 mm, tn = 10.97 mm]
en = (146.36 – 0.762) 0.21 + 2 x 11.28 x 0.762 / (2 x 11.28 - 0.21)
= 2.14 mm
X = 146.36 x 9.85 = 1441.646 mm2
fn = 11.28
es = (968 – 0.762) 0.21 + 2 x 11.28 x 0.762 /( 2 x 11.28 – 0.21)
= 9.85 mm
b = 27.425
C1 = 91
Cw = 120.34
fn / fs = 1
\ Y = 2 ( 10.97 – 2.14) 27.425 + 2 x 10.97 x 27.425 + 2 (16 – 9.85) 91 + 120.34
= 2325.67 mm2
Y>X
\ There is no need of extra compensation.
Dished Ends:
OD = 1000 mm f = 11.28 kg/mm2 , t = 16
CR = 780
KR =150
SF = 50 thk of dished ends after dished = 14.0 mm.
h = 796 - Ö{ ( 796 – 500) ( 796 + 500 – 2 x 166)}
= 796 - Ö { 296 x 964}
= 261.8
h/d = 261.8 / 1000 = 0.262
Contd….P/6-
:: 6 ::
Opening in d/e = 446 x 345 mm
Comp. Pad Thick = 16 mm
Width of comp. pad = 65 mm
M.H. Ring height = 85 mm
M.H. Ring Thickness = 20 mm
Height above the internal surface of d/e = 57 mm
Height below the internal surface of d/e = 28 mm
i) T/D £ 0.1, Actual T/D = 14.0/ 1000 = 0.0175
ii) d /D £ 0.5, Actual d/D = 446/1000 = 0.446
R = 2 x (800 – 14.0/2 ) = 791.25 mm
L1 = Ö( 2 RT) = Ö (2 x 791.25 x 17.5)
= Ö 27693.75 = 166.41
Provided width 65 mm is within the limit.
L2 = Ö( d.Tt)
= Ö (446 x 20) = 94.45
Actual height provided = 85 mm is within the limit.
Calculation of Imaginary Dia (d)
fn = 0.36 x 42 / 1.5 = 10.08 kg/mm2 , E = 0.95
C = 0.762
0.21 = 2 x11.28 x 0.95 ( te – 0.762) /( 406 + te – 0.762)
\ te = ( 406 – 0.762) 0.21 + 2 x 11.28 x 0.95 x 0.762 / (2 x 11.28 x 0.95 – 0.21)
= 4.78 mm
i) Compensation available from M.H. Ring.
= 2 x 16 x 50 = 1200 mm2
ii) Compensation available from M.H. Ring.
= 2 x [ ( 20 – 4.78) 57 + 20 x 28 ]
= 2855.08 mm2
A = 1200 + 2855.08 = 4055.08 mm2
\ d1 = 446 = 4055.08 / 14.0 = 156.35
d1 / ÖDT = 156.35 / Ö (1000 x 14) = 1.32
\ Shape Factor (K) as read from fig. 23D = 1.25
Contd….P/7-
:: 7 ::
\ W.P. = 2 x 11.28 ( 14 – 0.75) / 1000 = 0.2391 Kg/mm2
= 23.91 Kg/Cm2(g)
Steam Collecting Header, Main Down Commer and Bottom Rear Cross Header:-
d = 168.3, t = 7.11, f = 11.28 kg/mm2 ( As calculated earlier)

Taken g 12.5% thinning at bends, t = 7.11 – 0.125 x 7.11 = 6.22125
E = 0.95, C = 0.762
\ W.P. = 2 x 11.26 x 0.95 x (6.22125 – 0.762) /( 168.3 – 6.22125 – 0.762)
= 0.7253 kg/mm2
= 72.53 Kg/Cm2 (g)
Stubs on Steam Collecting Header:-

Refer calculations under stubs on side wall headers.
Connecting Headers:-
d = 141.3, t = 6.55 – 0.125 x 6.55 = 5.73125
E = 0.95, C = 0.762, f = 11.26 kg/mm2
\ W.P. = 2 x 11.26 x 0.95 ( 5.73125 –0.762) / (141.3 – 5.73125 – 0.762)
= 0.7900 Kg/mm2
= 79.00 Kg/Cm2 (g)
Heating Surface:
1) Boiler = 350 M2
2) Economiser = 70 M2
Total - 420 M2
Safety Valves:
E = CAP
A = E / CP
= 420 x 30 / 0.4 x 22 ( Making Contact = 0.4 )
= 1431.82
Contd….P/8-
:: 8 ::
\ d = Ö 1421.82 x 4 / p
= 42.69 mm
Therefore process of 2 nos. of single post safety valves are adequate.
( P. SWAIN )
CALCULATION SHEET
BOILER MAKER’S NO. - WT/SD-600/F/187.

WORKING PRESSURE - 10.50 KG/CM2(G),
WORKING TEMP. - 185oC.
REFERENCE DRGS. - WT/SD-600/F/18.1, Sh.1/2
WT/SD-600/F/18.1, Sh.2/2
: 2 :
WORKING PRESSURE FOR DRUM:

a) Shell : Min. UTS of plate = 47 Kg/mm2.
Stress = (f) = 0.36 x 47/1.5 Or 47/2.7
= 11.28 Or 17.41
\ Min. stress for calculation = 11.28 Kg/mm2
Ligament efficiency (E) :-
For Roof Tubes, P = 320, d = 76.6, \ E = P- d/P = 320 – 76.6/320 = 0.76
For Down Comer Tubes, P = 625, d = 114.7, \ D = P - d/P = 625 – 114.7/625 = 0.88
Min. Ligament Efficiency for Calculation = E = 0.76
I.D. of Shell = D = 1224 – 20 = 1204
\ W.P. of Shell = 2.f.E (T-c) / (D+T-c )
= 2 x11.28 x 0.76 (10 – 0.762)/(1204 + 10 – 0.762)
= 0.1306 Kg/mm2
= 13.06 Kg/Cm2
Hence, proposed thk. (10 mm) of shell is safe and adequate for a W.P. of 10.50 Kg/Cm2(g).
b) Dished End: (Regn. 275, 277, 278)

UTS of D/E = 47 Kg/mm2.
\ Stress (f) = 11.28 Kg/mm2 (as Calculated earlier).
thk. of d/e = 16 mm,
thk. after dishing considering 12.5% thinning, T = 14 mm.
H = 995, r2 = 191, D = 1224
External height of d/e = h = R2 - Ö (R2 – D/2) (R2 + D/2 – 2 r2) Eqn. 75
= 995 - Ö (995 – 912/2) (995 + 912/2 = 2 x 191)
= 235.93 » 236
thk. of d/e = 16 mm
Ratio H/D = 236/1224 = 0.193
Opening in d/e is elliptical.
Max. dia of opening = 446 mm.
Comp. Pad thk. = 16 mm.
: 3 :
Width of Comp. Pad = 65 mm.
Height of M.H. Ring = 85 mm.
Height of portion of ring above the lower portion of d/e = 57 mm
″ below the -do- = 28 mm
I) T/D £ 0.1 Actual T/D = 14/1224 = 0.011
II) d/D £ 0.5, Actual d/D = 446/1224 = 0.364
a) L1 = Ö (2RT) for the width of reinforcing plate.
b) L2 = Ö( d.Tt ) for the height of ring.
R = Int. radious of spherical part of the dished end = C.R – 1/2T = 995 – 7 = 985.
Tt = Actual thk. of ring = 20 mm.
L1 = Width of compensation = 65 mm.
L2 = Height of M.H. Ring = 85 mm.
a) L1 (max.) = Ö 2 x 955 x 14 = 166

Therefore the provided width (65 mm) is within the limit.
b) L2 (max) = d.T1 = Ö (446 x 20) = 94.45
Actual height provided = 85 mm is within the limit. Hence, O.K.
Thickness necessary to support the pressure in respect of ring:
W.P. = 10.50 Kg/Cm2, f = 11.28 kg/mm2 for d/e
E = 0.95 = 8.88 kg/mm2 for ring.
Te = Eqv. Thk. of ring for (UTS of ring = 37 kg/mm2) a opening of 406 mm at a pressure of 10.50 kg/mm2.
C = 0.762
W.P. = 2.f.E (te – c )/D + te – c
0.105 = 2 x 22 x 11.28 x 0.95 (te – 0.762)/406 + te – 0.762
\ te = (406 – 0.762) 0.105 +2 x 11.28 x 0.95 x 0.762/2 x 11.28 x 0.95 – 0.105
= 2.76 mm.
: 4 :
Compensation:
a) Comp. available from Comp. Pad
a = 2 x 10 x 50 = 1300 mm2
b = Comp. available from ring.
b = 2 [ (20 – 2.76) 57 + 20 x 28 ] = 3085.36
Effective compensation = 4385.36 x 37/47 = 3452.3 mm2
Imaginary dia (d1) = d – A/T = 446 – 3452.3/14 = 199.42
Ratio d1/ÖDT = 199.42/Ö1224 x 14 = 1.52
h/D ratio = 0.193
\ Shape factor (K) as read from fig. 23D = 1.6
\ W.P. of d/e = 2.f. (T – c )/D.K (Regn. 278) = 2 x 11.28 (14 – 0.75)/(1224 x 1.6)
= 0.1526 kg/mm2.
= 15.26 kg/cm2.
\ The selected thk. (16 mm) of d/e is safe for a W.P. of 10.50 kg/cm2(g).
2. BOX HEADERS: (Reg. 340)

a) T.P & E.P :- E = 160 – 76.0/160 = 0.521
Taking min. UTS of plate = 37 kg/mm2
f = 0.36 x 37/1.5 Or 37/2.7
= 8.88 kg/mm2 Or 13.7 kg/mm2.
Thk. of plate = T = 16 mm, C1 = Constant = 0.8
C = Constant = 3.413-
b = Internal width between supporting sides = 189 mm.
W = Internal width of header = 168 mm.
I) W.P = c.f (T - C1)/b2 = 3.413 x 8.88 (16 – 0.8)2/(189)2 = 0.1960 kg/mm2
= 19.60 Kg/Cm2.
II) W.P = 6.25 f.E t2/W2 = 6.25 x 8.88 x 0.521 x (16)2/(168)2 = 0.2623 kg/mm2
= 26.23 kg/cm2
We both the cases, the calculated value is more than the proposed working pressure. So,
selected thickness of plate is 16 mm is safe.
: 5 :
b) Side Ring Plates:-
f = 8.88 Kg/mm2 (as calculated earlier)
d = least width of wall header = 168
c = constant = 1 mm.
K = constant = 0.4
W.P = f (t – c)2/d2k = 8.88 (20 – 1)2/(168)2 x 0.4 = 0.2839 kg/mm2
= 28.39 kg/cm2.
Selected thk. of side ring is safe for a W.P. of 10.5 Kg/Cm2(g).
c) Stay Pins:
d = 32
Stress on each stay = 10.5 x 16 x 16 /Õ/4 x (32)2 = 3.342 kg/mm2
= 334.2 kg/cm2
Min. UTS of stay = 37 kg/mm2.
\ Permissible Stress = 0.36 x 37/1.5 = 8.88 kg/mm2
= 888 kg/cm2
Hence, the provided dia (32 mm) is safe for a working pressure of 10.5 kg/cm2(g).
3) CALCULATION FOR B.E. HEADERS (Regn. 340)

a) T.P. & E.P = 16 mm. C = 3.413 mm
E = 140 – 63.9/140 = 0.5
b = 154, C1 = 0.8, W = 208.
I) W.P = c.f (t – c)/b2 = 3.413 x 8.88 (16 – 0.8)2/(154)2 = 0.2952 kg/mm2
= 29.52 kg/cm2
Proposed tube plates are safe for a W.P. of 10.50 kg/cm2(g).
b) Side Ring:
f = 8.88 kg/mm2
d = 208, K = 0.4, T = 20
W.P. = 8.88 ( 20 – 1 )2/(208)2 x 0.4 = 0.1852 kg/mm2
= 18.52 kg/cm2(g)
c) Stay Pins:
Stress on each stay = 10.5 x 14 x 14 / Õ/{4 x (32)2} = 2.559 kg/mm2
= 255.9 kg/cm2.
Min. UTS of stay = 37 kg/mm2
: 6 :
\ Permissible Stress = 0.36 x 37/1.5 = 8.88 kg/mm2
= 888 kg/cm2.
Hence, provided dia (32 mm) is safe for a W.P. of 10.50 kg/cm2(g).
4) B.E. DOWN COMMER AND RISER (Regn. 279)

B.E.D.C stub size (provided) = 141.3 OD x 12.7 thk.
B.E.R. 168.3 = ‫ ״‬OD x 10.97 thk.
Out of the B.E.R. Pipe is of higher OD and having lower thickness.
Therefore take the case of BER for calculation.
ID of drum D = 1204 mm.
e = constant = 1
es = eqv. Thk. of shell.
f = permissible stress= 11.28 kg/mm2.
c = 0.762 (constant)
ID of riser stub = 168.3 – 2 x 10.97 = 146.36 mm.
W.P = 2 x 11.28 x 1 (es – 0.762) /( 146.36 + es – 0.762)
0.105 x (145.598 + es) = 22.56 es - 17.191
\ es = 0.105 x 145.598 + 17.191 / (22.56 – 0.105) = 1.45 mm.
Comp. required (X) = dn x es
= 146.36 x 1.45 = 212.222 mm2.
Eqv. thk. of nozzle = en
UTS of nozzle = 31 kg/mm2,
f = 0.36 x 31/1.5 = 7.44 kg/mm2
\ en = (146.36 – 0.762) x 0.105 + 2 x 7.44 x 0.762 /( 2 x 7.44 – 0.105) = 1.8 mm.
ts = 10 mm.
b = 2.5 ts or 2.5 tn (least one)
= 25 Or 27.825
\ b = 25
C1 = Greater of ts + 75 Or dn/2
= 10 + 75 Or 146.36 / 2
= 85 Or 73.18
: 7 :
\ C1 = 85.
Cw = O area of fillet weld
Compensating available = Y = 2 (tn – en) b fn/fs + 2 tn.b. fn/fs + 2 (ts – es) c1 + cw
= 2 (10.97 – 1.80) 25 x 31/(47 + 2 x 10.97)
25 x 31/47 + 2 (10 – 1.45) 85 + 0 = 2117.69 mm2.
Y >X
Therefore, there is no need of extra compensation.
5) W.P. OF TUBES
Min. UTS = 31 kg/mm2
f = 0.36 x 31/ 1.5 Or 31/2.7
\ W.P. = 2fe (t – c) / d – t + c
= 7.44 kg/mm2 Or 11.48 kg/mm2.
C = constant = 0.75, e = weld efficiency = 1.
a) Gen, Roof & Riser:
d = 76.2 mm, t = 3.25 mm thk.
\ W.P = 2 x 7.44 x 1 ( 3.25 – 0.75) / (76.2 – 3.25 + 0.75)
= 0.5047 kg/mm2 = 50.47 kg/cm2
b) Dn. Comer:
d = 114.3, t = 6.02
\ W.P = 2 x 7.44 x 1 (6.02 – 0.75) / 114.3 – 6.02 + 71.92 kg/cm2.
c) Inbed Tubes:
d = 63.5, t = 4.06
\ W.P = 2 x 7.44 x 1 (4.06 – 0.75) /( 63.5 – 4.06 + 0.75)
= 0.8183 kg/mm2 = 81.83 kg/cm2
d) B.E. Down Comer:

D = 141.3, t = 6.55
\ W.P = 2 x 7.44 x 1 (6.55 – 0.75 ) / (141.3 – 6.55 + 0.75) = 0.8183 kg/mm2
= 63.69 kg/cm2
: 8 :
e) B.E. Riser:
d = 168.3, t = 7.11
W.P = 2 x 7.44 x 1 (7.11 – 0.75) /( 168.3 – 7.11 + 0.75)
= 0.5844 kg/mm2
= 58.44 kg/cm2.
In all the cases the calculated valueis higher than the design value. Hence the proposed
tubes/pipes are safe for a W.P. of 10.50 kg/cm2(g).
6. HEATING SURFACE:
Surface area exposed to heat on one side and coming in contact with water on other side are :
Generating, roof, down comer portion of drum, in bed tubes in the furnace.
1) Gen Tubes:
d = 76.2, L = 6050, N = 121
H.S1 = Õ x 76.2 x 6050 x 121 / 106 = 175.245 M2
2) Roof Tubes (half exposed)

d = 76.2, L = 5642, N = 7
H.S2 = p x 76.2 x 5642 x 7 /( 2 x 106) = 4.727 M2
3) Part of drum : (Quarterly Exposed)

d = 1224, L = 2276.
HS3 = p / 1224 x 2276 /( 4 x 106) = 2.188 M2
4) In Bed Tubes:
d = 63.5, L = 2214, N = 43
H.S4 = p x 63.5 x 2214 x 43 / 106 = 18.99 M2
Total H.S = HS1 + HS2 + HS3 + HS4
= 175.245 + 4.727 + 2.188 + 18.99 = 201.15 M2
7. SAFETY VALVE: (Reg.293)
HS = 201.15 M2
Rated Capacity = 30 Kg/Hr/M2
\ E = 201.15 x 30 = 6034.5 kg/hr.
P = 10.5 + 1 = 11.5 kg/cm2
: 9 :
C = 0.1 (for high lift S.V.)
E = CAP \ A = E / c. P. = 6034.5 /( 0.1 x 11.5) = 5247.39
2 x p/4 d2 = 5247.39
\ d = Ö( 5247.39 )x 4 / 2 p = 57.79 mm
2 ½” Safety Valve is adeauate.
Bore of stand pipe = 1.25 x 57.79 = 72.2375 mm.
\ Provided stand pipe = 88 NB. Hence adequate.
( P. SWAIN )
PRESSURE CALCULATION FOR SPARE ECONOMIZER BEARING

JOB NO.P-180 FOR BOILER REGISTRATION NO.GT3455
Header size – 114.3 Æ x 8.56 thk.

Economiser tube size : 38.1 Æ x 3.66 thk.
W.P. = 12.50 kg/cm2(g), P = 125, d = 39, E = (125 – 39) / 125 = 0.688
Min. UTS for Tubes/Pipes = 31 kg/mm2,

\f = (0.36 x 31) / 1.5 = 7/44 kg/mm2
e = 1, c = 0.762 for headers, C1 = 0.75 for tubes.
HEADERS
\W.P. = 2 f E (t – c )/D – t + c = { 2 x 7.44 x 0.688 (8.56 – 0.762)} /( 114.3 – 8.56 + 0.762)
= 0.7496 kg/mm2
= 74.96 kg/cm2 (g)
Therefore the thickness of pipe proposed for header is adequate for a W.P. of 12.50 kg/cm2(g)
TUBES
Taking a thinning effect of 12.5% at the bends

t = 3.25 – 0.125 x 3.66 = 3.2025
\W.P = 2 x 7.44 x 1 (3.2025– 0.75)/(38.1 – 3.2025+ 0.75)
= 1.024 kg/mm2
= 102.4 kg/cm2(g)
Hence, the thickness of tubes proposed is adequate for a w.p of 12.50 kg/cm2(g)
HEATING SURFACE
d = 38.1, exposed length of each coil = l = 40556 mm.

No. of coils = 9
\HS = π x 38.1 x 40556 x 9 / (10)6 = 43.6 M2

(P. SWAIN)
Jr. Manager (Q.A)
CALCULATION SHEET

WT/SD-450/F/2.2,Sh.1/2, R0
WT/SD-450/F/2.2,Sh.2/2, R0
WT/SD-450/F/2.3,Sh.1/2, R0
WT/SD-450/F/2.3,Sh.2/2, R0
WT/SD-450/F/2.4,Sh.1/2, R0
WT/SD-450/F/2.4,Sh.2/2, R0
WT/SD-450/F/2.5,Sh.1/2, R0
WT/SD-450/F/2.5,Sh.2/2, R0
:: 2 ::
Stress = Et/1.5 = 0.36 x 47/1.5 = 11.28 kg/mm2
Or F = UTS/2.7 = 47/2.7 = 17.41 kg/mm2

= (p-d) / p = (320-76.6)/320 = 0.760

p = 410
\E = (p-d) / p = (410-76.6)/410 = 0.813

= 2 x 11.28 x 0.760(10 – 0.762)/(1040 + 10 – 0.762)
= 0.1524 kg/mm2
= 15.24 kg/cm2(g)
Therefore the thickness (10 mm) of shell plate proposed is adequate for a W.P. of
10.50 kg/cm2(g).

R1 = 912 mm, r2 = 162 mm, D = 1050 mm
= 912 -¨{(912 - 912/2)(912 - 1050/2 – 2 x 162)}
= 912 - ¨(306 x 894)
= 762 - 523 = 255.7 mm.
\Ratio (h/d) = 255.7/1050 = 0.244
Opening in dished end in elliptical by (345 x 446) mm.

Contd….P/3-
:: 3 ::
Thk. of M.H. Ring = 20 mm.
Height of M.H. Ring below the inside surface of d/e = 28 mm
Height of M.H. Ring above the inside surface of d/e = 52 mm

I) T/D £ 0.1, actual T / D = 10.5 / 1050 = 0.01
II) d/D £ 0.5, actual d / D = 446 / 1050 = 0.425


= C.R – 1/2T = 912 – 5.25 = 906.75 mm.

a) So, L1 (max.) = ¨(2RT) = ¨(2 x 906.75 x 10.5) = 137.99

b) L2 (max.) = ¨(d.Tt) = ¨(446 x 20) = 94.45




f = 11.28 kg/mm2 (for d/e) contd….P/4-
:: 4 ::
E = 0.95
c = 0.762
W.P = 2 x f x E (te – c)/(D + t – c)

0.175 = 2 x 11.28 x 0.95 (te – 0.75)/(406 + te – 0.762)
Or te = 2.76 mm.
a = 2 x 10 x 50 = 1000 mm2
b = 2 ((20 – 2.76) 52 + 20 x 28)) = 2912.96 2913 mm2

= 3912.96 x 47/47
= 3912.96 mm2

= (446 – 3912.96 / 10.5) = 73.34
d1/¨(DT) = 73.34/¨ (1050 x 10.5) = 0.698
h/D= 0.244.
\Safe factor K as read from fig.23D = 1.1

\W.P. of dished end = 2.f(T – c)/D.K (Regn.278)
= 2 x 11.28 (10.5 – 0.75)/(1050 x 1.1)
= 0.1904 kg/mm2
= 19.04 kg/cm2
Contd….P/5-
:: 5 ::

1) T.P. & E.P:
c1 = constant = 0.8
E = Efficiency legament between holes = (160 – 76.6)/160 = 0.521
\W.P = c.f.(t – c1)/b2 = 3.413 x 8.88 (16 – 0.8)2 / (189)2

= 0.1960 mm2
= 19.60 kg/cm2
Or W.P= 6.25 f.E.t2/W2 = 6.25 x 162 x 8.88 x .521/(118)2

= 0.5316 kg/mm2
= 53.16 kg/cm2
adequate for a working pressure of
10.50 kg/cm2(g).

c = constant = 1 mm
e= =1
W.P = f(t – c)2/d2k {Eqn.89(a)}

= 8.89 (20 – 1)2/{(118)2 x 0.4}
= 0.5756 kg/mm2
= 57.56 kg/cm2
Hence the size of side ring (20 mm thk.) is adequate for a W.P. of 10.50 kg/cm2(g).
CALCULATION FOR STAY BAR:

Permissible Stress = 0.36 x 37 / 1.5
= 8.88 kg/mm2
Load Capacity 8.88 x /4 (32)2 = 7141.7 kg.
\W.P. = Load / Area = 7141.7 / 160 x 160

= 0.2789 kg/mm2
= 27.89 kg/cm2(g)
Contd….P/6-
:: 6 ::
Proposed Working Pressure = 10.50 kg/cm2(g).
Hence the proposed stay pin is safe and adequate for a W.P. of 10.50 kg/cm2(g).

1) T.P. & E.P.
t = Thk. of T.P. & E.P. = 16 mm.
C1 = Constant = 0.8
f = Permissible Stress
= 0.36 x 37 / 1.5 = 8.88 kg/mm2
E = Efficiency of ligament between holes
=( 140 – 63.9) / 140 = 0.543
\ W.P. = c.f (t – c1) / b2 = 3.413 x 8.88 ( 16 – 0.8 )2 / (154)2
= 0.2953 kg/mm2
= 29.53 kg/cm2
Or
W.P. = f.E.t2 x 6.25 / W2
= 6.25 x 8.88 x 0.543 x (16)2 / (118)2
= 0.2734 kg/mm2
= 27.34 kg/mm2
safe and adequate for a working pressure of 10.50/Cm2(g).
2) Side Ring Plate:

t = 20, f = 8.88 kg/mm2, d = 168, c = 1, k = 0.4
\ W.P. = f ( t – c)2 / d2k
= 8.88 (20 – 1)2 / (168)2 x 0.4
= 0.2839 kg/mm2
= 28.39 kg/cm2
Hence the size of side ring plate ( 20 mm thk. ) is safe and adequate for a W.P. of 10.50 kg/cm2(g).
Contd….P/7-
:: 7 ::
Stress on stay = 2058 / Õ/4 (32)2
= 2.56 kg/mm2
= 256 Kg/Cm2.
\ W.P. = Load / Area = 7141.7 / 160 x 160
= 0.2789 kg/mm2
= 27.89 kg/cm2(g)
Proposed Working Pressure = 10.50 Kg/Cm2(g).

e = Constant = 1 \ f = 0.36 x 31 / 1.5 = 7.44 kg/mm2
\ W.P. = 2 x fe ( t – c ) / d-t+c
= 2 x 7.44 x 1 x ( 3.25 – 0.75 ) / 76.2 – 3.25 – 0.75
= 0.5048 kg/mm2
= 50.48 kg/cm2(g)
(b) Inbed Tubes:
d = 63.5 , t = 4.06
\ W.P = 2 x 7.44 x 1 (4.06 – 0.75) /(63.5 – 4.06 + 0.75)
= 0.8183 kg/mm2
= 81.83 kg/cm2(g).
Hence the proposed thickness of tube is safe and adequate for a W.P. of
10.50 Kg/Cm2(g).
Contd….P/7-
:: 7 ::
Calculation for Compensation of Stubs
(For BE DC) on Drum (Reg. 279)
B.E. Down Comer Stub = B.E. Riser Stub

= 114.3 OD x 8.56 thk.
I.D. of Stubs = 114.3 – 2 x 8.56 = 97.18
\ W.P = 2 x f x e (es – c ) /( D + es – c)
= 0.105 = 2 x 11.28 x 1 (es – 0.762) / (1030 + es – 0.762)
\ es = (1030 – 0.762) 0.105 + 2 x 11.28 x 0.762 / ( 2 x 11.28 – 0.105)
= 5.578 mm.
= 97.18 x 5.578 = 542.07 mm2
\ l = 0.36 x 47 / 1.5 = 11.28 kg/mm2
\ en = (97.18 – 0.762) x 0.105 + 2 x 11.28 x 0.762 / (2 x 11.28 – 0.105)
= 1.216 mm.
= 2.5 x 10 Or 2.5 x 8.56
= 25 Or 21.4
\b = 21.4
C1 = Greater of (ts + 75) Or dn / 2
= (10 + 75) Or 97.18 / 2
= 85 Or 48.59
\C1 = 85
Cw = Agregate area of fillet weld = 2 x (8.56)2 x ½
= 73.27 mm2
fn /ts = 11.28 / 11.28 = 1
Contd….P/8-
:: 8 ::
Compensation = Available = Y = 2 (tn – en)b. fn/tn + 2.tn.b.fn/ts + 2 (tn – en) C1 + Cw
= 2 x (8.56 – 1.216) 21.4 x 1 + 2 x 8.56 x 21.4 x 1 + 2(10 – 5.578) 85 + 73.27
= 1505.7 mm2
Y X
Calculation for Compensation of Stubs (For BER) on Drum (Reg.279)
B.E. Down Comer Stub = B.E Riser Stub = 141.3 OD x 9.53 thk.
E = Constant = 1, Eqv. Thk. of Shell = en
I.D. of Stubs = 141.3 – 2 x 9.53 = 122.24
\W.P. = 2 x f x e (es – c ) / (D + es – c)
= 0.105 = 2 x 11.28 x 1 (es – 0.762) / (1030 + es – 0.762)
\es = (1030 – 0.762) 0.105 + 2 x 11.28 x 0.762 / (2 x 11.28 – 0.105)
= 5.578 mm
Compensation Required = x = dn x en
= 122.24 x 5.578 = 681.855 mm2
Let Eqv. Thk. of nozzle = en
UTS of Nozzle = 47 kg/mm2.
\l = 0.36 x 47 / 1.5 = 11.28 kg/mm2
\en = (122.24 – 0.762) x 0.105 + 2 x 11.28 x 0.762) / (2 x 11.28 – 0.105)
= 1.334 mm
Thickness of Shell = ts = 10 mm.
b = Least value of 2.5 ts Or 2.5 tn
= 2.5 x 10 Or 2.5 x 9.53
= 25 Or 23.825
\b = 23.825
C1 = Greater of (ts + 75) Or dn / 2
= (10 + 75) Or 122.24 / 2
= 85 Or 61.12
\C1 = 85
Contd….P/9-
:: 9 ::
Cw = Agregate area of fillet weld = 2 x (9.53)2 x ½
= 90.82 mm2
fn / ts = 11.28 / 11.28 = 1
Compensation Available = Y = 2 (tn – en )b.fn / tn + 2.tn.b.fn/ts + 2.(ts – es) C1 + Cw
= 2 x (9.53 – 1.334) 23.825 x 1 + 2 x 9.53 x 23.825 x 1 +
2 (10 – 5.578) 85 + 90.82
= 1687.2 mm2
Y X
HEATING SURFACE:
d = 76.2
l = 6050 mm
n =81
H.S1 = p x 76.2 x 6050 x 81/ 106
= 117.313 m2
2) Roof Tubes:
d = 76.2
l = 5710
n=6
H.S2 = p x 76.2 x 5710 x 6 / 2 x 106
= 4.101 m2
3) Down Comer Tubes :
d = 76.2
l = 670
n=5
H.S3 = p x 76.2 x 670 x 5 / 106
= 0.401 m2
4) Inbed Tubes:
d = 63.5
l = 2360
n = 38
H.S4 = p x 63.5 x 2360 x 38x 106
= 17.89 m2
d = 1050
l = 1960
H.S5 = p x 1050 x 1960/ 106 x 4
= 1.616 m2
Contd….P/10-
:: 10 ::
= 117.313 + 4.101 + 0.401 + 17.89 + 1.616
= 141.321 m2
2723.7 = 0.4 x A x 11.5 , P = 10.5 + 1.0 = 11.50 kg/cm2(g)
\A = 3123 / (0.4 x 11.5)
p / 4 d2 = 3123/(0.4 x 11.5)
\d = Ö{( 3123 x 4)/ 0.4 x 11.5 x p} = 29.40 mm.
Hence, the position of 1 ½ ² D.P. Safety Valve is safe and adequate.
PRESSELS PVT. LTD.
(P. Swain )
Jr. Manager (Q.A)
CALCULATION OF W.P. FOR FEED LINE OF BOILER MAKER’S NO.SIHHF-20/142
Max. W.P. 9.0 Kg/cm2 (g)

Size of pipes proposed = 26.7 OD x 2.87
21.3 OD x 2.77
W.P. = {2 x f x e (t – c)} / d – t – c f = (0.36 x 31) / 1.5 = 7.44 kg/mm2
e = 1, c = 0.75
d = O.D of tube, t=thk. of tube proposed.
t1 = thk. of tube after adding 12.5% for
thining at bends.
OD of Tube t t1 W.P.(kg/cm2) Remarks

Proposed (d) in mm in mm as per
In (mm) above
Formula.
21.3 2.77 2.42 137.5 Safe & Adequate

for the proposed
W.P.
26.7 2.87 2.51 111.7 -do-
Therefore the size of pipes proposed is safe and adequate for a W.P. of 9.0 kg/cm2(g).
( P. SWAIN )
IBR CALCULATION
Boiler Maker’s No. - WT/SD – 800/F/1001

Working Pressure - 17.5 Kg/Cm2(g)
Working Temp. - 207oC.
Hyd. Test Pressure - 26.25 Kg/Cm2 (g)
Ref. Drawing Nos. - WT/SD-800/F/9.1 R0
WT/SD-800/F/9.2, Sh.1/2 R0
WT/SD-800/F/9.2, Sh.2/2 R0
WT/SD-800/F/9.3, Sh.1/2 R0
WT/SD-800/F/9.3, Sh.2/2 R0
WT/SD-800/F/9.4, Sh.1/2 R0
WT/SD-800/F/9.4, Sh.2/2 R0
WT/SD-800/F/9.5, Sh.1/2 R0
WT/SD-800/F/9.5, Sh.2/2 R0
Drum:
1) Shell : -
Max. Working Temp. 454oC.
Min. UTS of Pl . = 42.19 Kg/mm2(g)
Permissible Stress = f = 0.36 x 42.19/1.5 = 10.12 Kg/mm2(g)
And, f = UTS / 2.7 = 42.19 / 2.7 = 15.62 Kg/mm2
E =( P-d)/p =(325 – 76.6)/325 = 0.76
(b) For Roof Tubes : - d = 57.4, P = 205
E =( P-d )/p =( 205 – 57.4) / 205 = 0.72
Taking the minimum of the two, ligament efficiency for further calculations E = 0.72
I.D. of Shell = 1224 – 32 = 1192 mm
W.P. = 2.f.E (T-C) /( D + T-C) Where, C = 0.762 (Constant)
= 2 x 10.12 x 0.760 (16 - 0.762) / (1192 + 16 – 0.762)
= 0.1839 Kg/mm2
= 18.39 Kg/Cm2(g)
Kg/Cm2(g).
2) Dished End :- (Reg. 275, 277, 278)

UTS of d / e = 42.19 kg/mm2, f = 0.36 x 42.19 / 1.5 = 10.12 Kg/mm2
Thk. of d / e = 16 mm
Thk. of d / e after dishing (considering 10 % thinning )
= 16 – 0.1 x 16 = 14.4 mm.
r2 = 191 and R2 = 995
D = 1224 mm
h = R2 - (R2 – D/2) (R2 + D/2 – 2 r2)
= 995 - (995 – 1224/2) (995 + 1224/2 – 2 x 191)
= 995 – 383 x 1225
= 995 – 684.963
= 995 – 684.963 = 310.037
h/D ratio = 310.037 / 1224 = 0.25
Contd………P/2-
: 2 :

(i) T/D 0.1, Actual T/D = 14.4 / 1224 = 0.01
(ii) d/D 0.5, Actual d/D = 446 / 1224 = 0.364
(a) L1 (Max.) = 2RT for the width of reinforcing plate.
(b) L2 (Max.) = d.Tt for the height of nozzle.
R int. Radious of spherical part of the dished end = 979 mm
Tt = Actual thk. of nozzle = 20 mm
L1 = Width of Compensating = 50 mm
L2 = Height of nozzle ring = 85 mm
So (a) L1 = 2 RT = 2 x 979 x 14.4 = 167.914 mm
Hence, the width provided ( 50 mm ) is within the limit.
(b) L2 (Max.) = d Tt = 446 x 20 = 94.45
Hence O.K.
Calculation for Imaginary Diameter (d1)
d = Actual dia of opening in head.
T = Min. thk. in Head.
A= Effective Cross Section of Reinforcement.
W.P. = 17.5 Kg/Cm2, UTS of d/e = 42.19 Kg/mm2
UTS of Nozzle & Comp. Pad = 42.19 Kg/mm2
Contd……..P/3-
: 3 :
f = 10.12 Kg/mm2 (For D/E)
E = 0.95
te = Equivalent thk. of nozzle for opening of 406 mm at a pressure of 17.5 Kg/mm2
C = 0.762
W.P. = 2 x f x E (te – c) /( D + t – C)
te =( w.p x d / 2fe – wp) + 0.762
te = ( 0.175 x 406/ 2x10.12x0.95 – 0.175 ) + 0.762
= 4.49 mm
Calculation for Compensation:
(a) Compensation available from Comp. pad = 2 x 65 x 12 = 1560 mm2
(b) Compensation available from Nozzle:-
h = 2 (20 – 4.49) 57 + 20 x 28
= 2888.14 mm2
a + b = 1560 + 2888.14
= 4448.14 mm2
Effective Compensation = A = (a+b) x UTS of Nozzle / UTS of Pl.
= 4448.14 mm2
Imaginary dia = d1 = d – A/T = 446 – 4448.14 / 14.4 = 137.102
Ratio d1/ DT = 137.102/ 1224 x 14.4 = 1.03
H / D = 0.25
Safe factor ‘K’ as read from fig. 23D of IBR = 1.2
Working Pressure of Dished Ends.
= W.P. = 2 x f x (T-C) / DK (Regn. 278)
= 2 x 10.12 (14.4 – 0.75) /1224 x 1.2
= 196.56 / 1003.2
= 18.80 kg/cm2
: 4 :
Calculation of W.P. of Box Headers :- (Reg. 340)

1) T.P. & E.P.
t = Thk. of T.P. & E.P. = 16 mm.
b = Internal breadth btn supporting side = 189
C1 = Constant = 0.8
f = Permissible Stress = 0.36 x 42.19 / 1.5 = 10.12 kg/mm2
E = Efficiency of ligament between holes = (160 – 76.6) / 160 = 0.521
W = Width (Internal) of header = 118 mm
W.P. = c.f (t – c1)2 / b2 = 3.413 x 10.12 ( 16 – 0.8 )2 / (189)2
= 34.53 x 231.04 / 35721
= 0.2233 kg/mm2
= 22.33 kg/cm2
Or
W.P. = 6.25 f.E.t2 / W2
= 6.25 x 10.12 x 0.521 x (16)2 / (118)2 = 8436.032 / 13924
= 0.6058 kg/mm2
= 60.58 kg/mm2
safe and adequate for a working pressure of 17.5 Kg/Cm2(g).
2) Side Ring:
t = 20, f = 10.08 kg/mm2, d = 118, c = 1, k = 0.4
f = 0.36 x 49.22 / 1.5 = 11.81 kg/mm2
W.P. = f ( t – c)2 / d2k
= 11.81 (20 – 1)2 / (118)2 x 0.4
= 0.7654 kg/mm2
= 76.54 kg/cm2
Hence the size of side ring ( 20 mm thk.) is adequate for a W.P. of 17.5 kg/cm2(g).
Contd………P/5-
: 5 :
Calculation for Stay Bar:

Permissible Stress = 0.36 x 42 / 1.5 = 10.08 kg/mm2
Load Capacity - 10.08 x /4 (32)2 = 8105.28 kg.
W.P. = Load / Area = 8105 / 160 x 160
= 0.3166125 kg/mm2
= 31.66 kg/cm2(g)

1) T.P. & E.P.
t = Thk. of t.P. & E.P. = 16 mm.
C1 = Constant = 0.8
f = Permissible Stress = 0.36 x 42.19 / 1.5 = 10.12 kg/mm2
E = Efficiency of ligament between holes =( 140 – 63.9) / 140 = 0.543
W.P. = c.f (t – c1) / b2 = 3.413 x 10.12 ( 16 – 0.8 )2 / (154)2
= 0.3364 kg/mm2
= 33.64 kg/cm2
Or
W.P. = f.E.t2 x 6.25 / W2
When f = 10.12 kg/mm2
then W.P. = 6.25 x 10.08 x 0.543 x (16)2 / (118)2
= 20.32 kg/cm2
safe and adequate for a working pressure of 17.5 kg /cm2(g).
Contd……..P/6-
: 6 :
2) Side Ring Plate:

t = 20, f = 11.81 kg/mm2, d = 208, c = 1, k = 0.4
W.P. = f ( t – c)2 / d2k
= 11.81(20 – 1)2 / (154)2 x 0.4 = 11.81 x 361 / 9486.4
= 0.4494 kg/mm2
= 44.94 kg/cm2
Hence the size of side ring plate ( 20 mm thk. ) is safe and adequate for a W.P. of 17.5kg/cm2(g).
Stress on stay = 3430 / /4 (32)2 = 4.26 kg/mm2 = 426 Kg/Cm2.
W.P. = Load / Area = 8105. 287 / 140 x 140
= 0.4135 kg/mm2
= 41.35 kg/cm2(g)

e = Constant = 1 f = 0.36 x 31 / 1.5 = 7.44 kg/mm2
W.P. = 2 x fe ( t – c ) / d-t+c
= 2 x 7.44 x 1 x ( 3.25 – 0.75 ) / 76.2 – 3.25 + 0.75
= 50.47 kg/cm2(g)
Contd…….P/7-
: 7 :
(b) Inbed Tubes:
d = 63.5 , t = 4.06
W.P = 2 x 7.44 x 1 (4.06 – 0.75) /(63.5 – 4.06 + 0.75)
= 0.8183 kg/mm2
= 81.83 kg/cm2(g).
Hence the proposed thickness of tube is safe and adequate for a W.P. of 10.50 Kg/Cm2(g).
Calculation for Compensation of Stubs (For BE DC) on Drum (Reg. 279)

B.E. Down Comer Stub= 168.3OD x 18.26 thk.
I.D. of Drum =1192mm.
c = constant 0.762
UTS = 42.19 kg/mm2
f = 0.36 x 42.19/ 1.5 = 10.12 kg / cm2
I.D. of Stubs = 168.3 – 2 x 18.26 = 131.78 mm2
en = ( WP x D / 2fe - WP ) + 0.762
= (0.175 x 131.78 / 2x10.12 – 0.175) + 0.762
= 1.91 mm
es = (WP x D / 2fe - WP ) + 0.762
= (0.175 x 1192 / 2x10.12x0.72 – 0.175) + 0.762
= 15.25 mm
= 131.78x 15.25 = 2009.64 mm2
= 2.5 x 16 Or 2.5 x 18.26 = 40 Or 45.65 mm
: 8 :
b = 40 mm
= ( 16 + 76 ) Or 131.78 / 2
= 92 Or 65.89 mm
C1 = 92 mm
= 333.427 mm2
fn / fs = 10.12/10.12 = 1
Compensation Available Y = 2 ( tn - en ) b. fn / fs + 2. tn . b. fn / fs + 2. ( ts – es) C1 + Cw
= 2 x ( 18.26 – 1.91 ) 40 x 1 + 2 x 18.26x 40 x 1
+ 2 ( 16 – 15.25) 92 + 333.427
= 3240.227 mm2
Y X
Calculation for Compensation of Stubs (For BER) on Drum (Reg. 279)

B.E. Riser Stub = 141.3 OD x 15.88thk.
Permissible Stress = f = 10.12kg/mm2, c = constant 0.762
I.D. of Stubs = 141.3 – 2 x15.88 = 109.54 mm
W.P = 2 x f x e (es – c ) / ( D + es – c)
= 0.175 = 2 x 10.12 x 1 (es – 0.762) / (1192 + es – 0.762)
es = (1192 – 0.762) 0.175 + 2 x 10.12x 0.762 / ( 2 x 10.12 – 0.175)
= 15.25 mm.
= 109.54 x 15.25 = 1670.485 mm2
Contd….P/9-
: 9:
UTS of Nozzle = 42.19 kg/mm2

l = 0.36 x 42.19 / 1.5 = 10.12 kg/mm2
en = ( (109.54 – 0.762) x 0.175 + 2 x 10.12 x 0.762) / (2 x 10.12 – 0.175)
= 1.71 mm.
= 2.5 x 16 Or 2.5 x 15.88
= 40 Or 39.7mm
b = 39.7 mm
= ( 16 + 76 ) Or 122.24 / 2
= 92 Or 54.77mm
C1 = 92 mm
= 252.174 mm2
fn / fs = 10.12 / 10.12 = 1
Compensation Available Y = 2 ( tn - en ) b. fn / fs + 2. tn . b. fn / fs + 2. ( ts – es) C1 + Cw
= 2 x ( 15.88 – 1.71 ) 40 x 1 + 2 x 15.88 x 40 + 2 ( 16 – 15.25 ) 92
+ 252.174
= 2794.174 mm2
Y X
Contd….P/10-
: 10 :
Heating Surface:
d = 76.2, l = 6050, n = 155
H.S. = x 76.2 x 6050 x 155 / 106 = 224.51

d = 76.2, l = 5623, n = 12
HS2 = x 76.2 x 5623 x 12/( 2 x 106 ) = 8.074 M2

d = 76.2, l = 583, n = 8
HS3 = x 76.2 x 583 x 8 /( 2 x 106 ) = 0.558 M2
4) Part of Drum :- ( Quarterly Exposed )

d = 912, l = 2600
HS4 = x 1224 x 1960 / 106 x 4 = 2.499 m2
5) In Bed Tubes:-
d = 63.5 , l = 2373, n = 53
HS5 = x 63.5 x 2373 x 53 / 106 = 25.08 m2
Total Heating Surface:-

HS = 224.51 + 8.074 + 0.558 + 2.499 + 25.08
= 235.637 + 25
= 260.717 M2
Calculation for Safety Valve :- (Reg. 293)
Total Evaporation = 30 x 260.717 = 7821 Kgs/Hr
E = C A P Where C = 0.1 Maker’s Certificate.

7821.51 = 0.1 x A x 18.5 P = 17.5 + 1.0 = 18.5 Kg/Cm2 (g)
A = 7821.51/ 0.1 x 18.5
= 4227.837 cm2 ( For two sides )
Contd…….P/11-
: 11 :
As area is always found in mm2 as follows from IBR 293.

So area is 4227.837 mm2 (For two sides )
For one side area is
= 4227.837 / 2 = 2113.918 mm2
As we know that area = /4 d2
So /4 d2 = 2113.918
d2 = 2113.918 x 4 / 3.141
d2 = 2692.032
d = 2692.032
= 51.88 mm
Hence, the provision of 2 ½” D.P. Safety Valve is safe and adequate.
( S. K. MULLICK )
sm
Posted 8th March 2015 by kishorereddy kattukolu
View comments

Boiler Calculation

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Boiler Calculation

Uploaded by

Copyright:

Available Formats

8th March 2015 boiler calculation

Boiler Maker’s No. - WT/SD – 500/F/208

2) Dished End :- (Reg. 275, 277, 278)

Opening in the d/e is elliptical by (345 x 446) mm

Calculation of W.P. of Box Headers :- (Reg. 340)

Calculation for Stay Bar:

Working Pressure of B.E. Headers:

2) Side Ring Plate:

Working Pressure of Tubes:

Calculation for Compensation of Stubs (For BE DC) on Drum (Reg. 279)

Hence there is no need of extra compensation.

Calculation for Compensation of Stubs (For BER) on Drum (Reg. 279)

UTS of Nozzle = 31 kg/mm2

Hence there is no need of extra compensation.

2) Roof Tubes :- (Half Exposed)

3) Down Comer :- ( Half Exposed )

4) Part of Drum :- ( Quarterly Exposed )

Total Heating Surface:-

As area is always found in mm2 as follows from IBR 293.

Hence, the provision of 2 ½” D.P. Safety Valve is safe and adequate.

BOILER MAKER’S NO. - WT/SD-300/F/291

Max. Working Temp.<4540 C.

Ligament Efficiency (E)

i) For RoofTubes : d = 76.6, p = 320

ii) For Down Comer Tubes: d = 76.6,

\E = (p-d) / p = (375-76.6)/375 = 0.767

\Min. Ligament Efficiency for calculation = E = 0.760

I.D of shell = D = 912 – 20 = 892 mm, T = 10 mm. ,C=0.762

\W.P. of shell = 2.f.E (T – c)/(D + T – c)

W.P. CALCULATION FOR DISHED ENDS: (Reg.275, 277, 278)

U.T.S. of d/e = 47 kg/mm2

= 762 - ¨{(762 - 912/2)(762 + 912/2 – 2 x 162)}

= 762 - ¨(306 x 894)

= 762 - 523 = 239 mm.

\Ratio (h/d) = 239/912 = 0.262

Opening in dished end in elliptical.

Additional conditions to comply:-

I) T/D £ 0.1, actual T / D = 10.5 / 9.2 = 0.011

II) d/D £ 0.5, actual d / D = 446 / 912 = 0.489

The conditions are therefore satisfied.

Max. limit of area of reinforcement:-

a) L1 = ¨(2RT) for the width of reinforcing plate.

b) L2 = ¨(d.Tt ) for the height of nozzle.

R = Int. Radious of spherical part of the dished end

T1 = Actual thk. of nozzle = 20 mm.

a) So, L1 (max.) = ¨(2RT) = ¨(2 x 756.75 x 10.5) = 126.06

b) L2 (max.) = ¨(d.Tt) = ¨(446 x 20) = 94.45

CALCULATION FOR (d1), THE IMAGINARY DIAMETERS:

d = actual dia of opening in head.

Thickness necessary to support the

W.P = 10.5 kg/cm2, UTS = 47 kg/mm2 for dished end.

es = ((892 – 0.762) 0.175 + 2 x 11.28 x 0.95 x 0.762)/(2 x 11.28 x 0.95 – 0.175)

CALCULATION FOR COMPENSATION:

a) Comp. available for compensation pad.

b) Comp. available from nozzle

b = 2 ((20 – 4.10) 52 + 20 x 28)) = 2773.6 mm2

Total compensation = a + b = 1000 + 2773.6 = 3773.6 mm2

Effective compensation = A = (a + b) x UTS of Nozzle/UTS of Plate.

\Imaginary dia d1 = d – A/T

d1/¨(DT) = 86.61/¨ (912 x 10.5) = 0.885

\Shape factor K as read from fig.23D = 1.2

\Selected thickness of dished end is 12 mm safe for W.P. of 17.50 kg/cm2(g)

CALCULATION OF W.P. OF HEADER BOX:(Reg.340)

\W.P = c.f.(t – c1)/b2 = 3.413 x 8.88 (16 – 0.8)2 / (189)2