Beruflich Dokumente
Kultur Dokumente
WT/SD 500/F/208
Working Pressure
10.5 Kg/Cm2(g)
Working Temp.
185oC.
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)
= 42 Kg/mm2(g)
(b)
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)
Eqn. 75
: 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 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 :
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).
ContdP/5-
: 5 :
Calculation for Stay Bar:
Dia of Stay Pin
d = 32
: 6 :
2)
10.50
kg/cm2(g).
Calculation for Stay Pins:
Dia of Stay Pin
d = 32
e = Constant = 1
W.P. = 2 x fe ( t c ) / d-t+c
(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).
= 25 Or 21.4
Contd..P/8:
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
= 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.
Contd.P/10-
: 10 :
Heating Surface:
1)
2)
3)
4)
5)
: 11 :
( 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 MAKERS NO.
WT/SD-300/F/291
WORKING PRESSURE
17.5 KG/CM2(G)
WORKING TEMPERATURE
2070 C.
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 =
Or F = UTS/2.7
=
47/2.7
=
Min. Stress for calculation = f = 11.28 kg/mm2
11.28 kg/mm2
17.41 kg/mm2
For RoofTubes
ii)
=
=
76.6, p = 320
(p-d) / p = (320-76.6)/320 = 0.760
d
p
=
=
76.6,
330
= 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)
0.262
446 mm.
:: 3 ::
10 mm.
50 mm.
20 mm.
80 mm
55 mm.
Ratio (h/d) =
239/912
Contd.P/3=
=
=
=
=
L1
(2RT)
b)
L2
(d.Tt )
=
=
T1
L1
L2
=
=
=
a)
So, L1 (max.) =
(2RT)
=
(2 x 756.75 x 10.5)
Hence, provided width is, 50 mm is within the limit.
=
=
=
20 mm.
50 mm
80 mm.
b)
L2 (max.)
=
(d.Tt) =
(446 x 20)
=
Actual height provided (80 mm) is within the limit. Hence O.K.
CALCULATION FOR (d1), THE IMAGINARY DIAMETERS:
d
T
A
=
=
=
=
94.45
= 126.06
=
=
E
Te
=
=
0.95
Equivalent thk. of nozzle for opening of
406 mm at a pressure of 10.5 kg/cm2
0.762
W.P =
0.175 =
Or te =
2 x f x E (te c)/(D + t c)
2 x 11.28 x 0.95 (te 0.762)/(406 + te 0.762)
4.10 mm.
es
=
=
b)
2 x 10 x 50 = 1000 mm2
= 3773.6 mm2
= d A/T
= (446 3773.6 / 10.5) = 86.61
= 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)
=
=
=
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
=
b
=
int. breadth between supporting sides =
c
=
constant
=
c1
=
constant
=
f
=
permissible stress = 0.36 x 37/1.5
=
E
=
Efficiency legament between holes =
W
=
Width (internal) of hdr.
=
W.P =
c.f.(t c1)/b2
Or W.P=
6.25 f.E.t2/W2 =
=
=
16 mm.
189
3.413
0.8
8.88 kg/mm2
160 76.6/160 = 0.521
118
.
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)
=
=
=
=
= 8.88 kg/mm2
= 118.
= 1 mm
=1
= d = 32
= 10.5 x 16 x 16//4 x (32)2
=
=
3.342 kg/mm2
334.2 kg/cm2
Alternately,
Load = 8.88 x /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
Proposed working pressure
= 8.88 kg/mm2
= 888 kg/cm2
= 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
c
c1
b
w
f
E
3)
Hence, proposed size of plate (20 mm) is safe & adequate for a W.P. of 17.50
kg/cm2(g).
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//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 ::
= 31 kg/mm2
= 0.36 x 31/1.5 = 7.44 kg/mm2
= 0.75
=1
W.P = 2.f x e (t c) / (d t + c)
1)
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)
4)
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
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
c1
Cw
fn/fs
= 10 + 75 or 97.18 / 2
= 85
or 48.59
= 85
= Agregated area of fillet weld = 2 x (8.56)2 x
= 73.27 mm2
= 11.28/11.28 = 1
Compensation available = Y =
1237.47
Y> X
Hence there is no need of extra compensation.
Contd.9/:: 9 ::
HEATING SURFACE:
1)
Generating Tubes:
d = 76.2
l = 6050 mm
n = 74
H.S1
2)
=
=
Roof Tubes:
d = 76.2
l = 5779
n=6
=
x 76.2 x 5779 x 6 / 2 x 106
=
4.15 m2
Down Comer Tubes (Half Exposed):
d = 76.2
l = 739
n=5
H.S2
3)
H.S3
4)
=
=
5)
1.29 m2
In Bed Tubes:
d = 63.5
l = 2250
n = 29
H.S5
13.565 m2
:: 10 ::
CALCULATION FOR SAFETY VALVE : (Reg.293)
Total evaporation
E
/ 4 d2 = 3303.13
d
IBR CALCULATION
BOILER MAKERS 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
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.
= 47 Kg/Cm2(g)
Min. UTS of Pl .
(b)
= 76.6, P = 410
= P-d/p = (410 76.6)/410 = 0.813
= 76.6, P = 320
= 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
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
= 446 mm
= 10 mm
= 50 mm
= 20 mm
= (2 x 751.5 x 10.5)
= 125.62 mm
Hence, the provided width (50 mm) is within the limit.
L2 (Max.) = d.Tt
= (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)
Ratio d1/ DT
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)
II)
= 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
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 / /4 d2 ,
= 2688 / /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).
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
1)
2)
3)
4)
/ 4 d2 = 1237.69
d = 1237.69
= 39.69 mm
ContdP/7: 7
( P. SWAIN )
JR. MANAGER (Q.A.)
CALCULATION SHEET
BOILER MAKERS NO.
WT/SD-400/F/288
WORKING PRESSURE
17.5 KG/CM2(G)
WORKING TEMPERATURE
2070 C.
26.25 KG/CM2(G)
REFERENCE DRAWINGS
WT/SD-400/F/26.1,R0
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 ::
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 =
Or F = UTS/2.7
=
47/2.7
=
Min. Stress for calculation = f = 11.28 kg/mm2
11.28 kg/mm2
17.41 kg/mm2
For RoofTubes
ii)
=
=
76.6, p = 320
(p-d) / p = (320-76.6)/320 = 0.760
d
p
=
=
76.6,
410
= 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)
Ratio (h/d) =
239/912
0.262
446 mm.
Contd.P/3-
=
=
=
=
=
:: 3 ::
10 mm.
50 mm.
20 mm.
80 mm
55 mm.
L2
(d.Tt )
=
=
T1
L1
L2
=
=
=
a)
So, L1 (max.) =
(2RT)
=
(2 x 756.75 x 10.5)
Hence, provided width is, 50 mm is within the limit.
=
=
=
20 mm.
50 mm
80 mm.
b)
L2 (max.)
=
(d.Tt) =
(446 x 20)
=
Actual height provided (80 mm) is within the limit. Hence O.K.
CALCULATION FOR (d1), THE IMAGINARY DIAMETERS:
d
T
A
=
=
=
=
94.45
= 126.06
W.P
=
=
:: 4 ::
E
Te
=
=
0.95
Equivalent thk. of nozzle for opening of
406 mm at a pressure of 10.5 kg/cm2
0.762
W.P =
0.175 =
Or te =
2 x f x E (te c)/(D + t c)
2 x 11.28 x 0.95 (te 0.762)/(406 + te 0.762)
4.10 mm.
es
=
=
b)
2 x 10 x 50 = 1000 mm2
= 3773.6 mm2
= d A/T
= (446 3773.6 / 10.5) = 86.61
= 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 ::
CALCULATION OF W.P. OF HEADER BOX:(Reg.340)
1)
T.P. & E.P:
t
=
thk. of tube plate of hdr. Box
=
b
=
int. breadth between supporting sides =
c
=
constant
=
c1
=
constant
=
f
=
permissible stress = 0.36 x 37/1.5
=
E
=
Efficiency legament between holes =
W
=
Width (internal) of hdr.
=
W.P =
c.f.(t c1)/b2
Or W.P=
6.25 f.E.t2/W2 =
=
=
16 mm.
189
3.413
0.8
8.88 kg/mm2
160 76.6/160 = 0.521
118
.
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)
=
=
=
=
= 8.88 kg/mm2
= 118.
= 1 mm
=1
3.342 kg/mm2
334.2 kg/cm2
Alternately,
Load = 8.88 x /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
Proposed working pressure
= 8.88 kg/mm2
= 888 kg/cm2
= 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)
Hence there is no need of extra compensation.
HEATING SURFACE:
1)
Generating Tubes:
d = 76.2
l = 6050 mm
n =104
H.S1
2)
=
=
Roof Tubes:
d = 76.2
l = 5779
n=6
=
x 76.2 x 5779 x 6 / 2 x 106
=
4.15 m2
Down Comer Tubes :
d = 76.2
l = 739
n=5
H.S2
3)
=
x 76.2 x 739 x 5 / 106
=
0.884 m2
Riser Tubes (Half Exposed):
d = 76.2
l = 739
n=5
H.S3
4)
H.S4
=
=
5)
1.40 m2
Contd.P/7:: 7 ::
= CAP, where,
/ 4 d2 = 637
d
CALCULATION SHEET
BOILER MAKERS NO.
WT/SD-1000/F/287
WORKING PRESSURE
17.50 KG/CM2(G)
WORKING TEMPERATURE
2070 C.
26.25 KG/CM2(G)
HEATING SURFACE
345.52 M2
REFERENCE DRAWINGS
WT/SD-1000/F/2.1,R0
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.
II.
(Reg.215)
(c = 0.762)
= 912 10.5/2
= 906.75 mm.
= Actual thk. of nozzle= 20 mm.
= width of nozzle ring = 85 mm.
L2(max.) = (d.Tt)
= (446 x 20)
= 94.45.
= 57
= 28
te
Compensation:
a)
b)
= 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)
2.
3.
Stay Pins
d = 32 mm
f = 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(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)
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
Contd.P/7: 7 :
Working Pressure of Tubes
1)
2)
3)
4)
= 47 kg/mm2
= 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
= Greater of
(12 + 75) or
87
122.24/2
or 61.12
Contd.P/9: 9 :
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)
= dn x es
= 146.36 x 8/78
= 1285.04 mm2
or 2.5 tn
or dn/2
or 146.36/2
or 73.18
C1
= 87.
Cw
fn/fs
Y> X
Hence, there is no need of extra compensation.
HEATING SURFACE:
1)
2)
Roof Tubes:
HS2 = x 76.2 x 6905 x 8/106 = 6.61 M2
3)
Part of Drum:
HS3 = x 1050 x 2600 x 83/360 x 106 = 1.98 M2
Contd.P/11-
: 11 :
4)
5)
Total (H.S)
SAFETY VALVE:
Heating surface
= 345.52 M2
Evaporation
= 30 kgs/hr/m2
Total Evaporation
=E
= 345.52 x 30
= 10365.6 kgs/hr.
( P. SWAIN )
REVISED CALCULATION FOR BOILER MAKERS NO.WT/SD-1000/F/287
HEATING SURFACE:
1)
2)
Roof Tubes:
3)
4)
5)
Total ( H.S )
SAFETY VALVE:
Heating surface
= 345.57 M2
Evaporation
= 30 kgs/hr/m2
Total Evaporation = E
= 345.57 x 30
= 10367.1 kgs/hr.
:: 2 ::
A = 10367.1 / (0.4 x 18.5) = 1400.96
d = {(1400.96 x 4)/ }= (1783.76)
= 42.24 mm.
Safety valve proposed = 2 NB D.P. Safety Valve.
Hence safe and adequate.
FOR PRESSELS PVT. LTD.
( P. SWAIN )
Design Engineer
PRESSURE CALCULATION
BOILER MAKERS NO.
WT/VSSD 800/290
WORKING PRESSURE
21.0 KG/CM2(G)
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
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)
= 128.2,
tn1 = 7.11
f = 11.28 kg/mm2 ( As calculated Earlier)
e = 1, c = 0.762 , ds = 168.3 , ts = 7.11
:: 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
= 83.11
= C1 = 83.11
b = Max. of 2.5 ts
Or 2.5 tn
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
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
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
Opening in d/e
:: 6 ::
= 446 x 345 mm
= 16 mm
= 65 mm
= 85 mm
= 20 mm
ii)
:: 7 ::
W.P. = 2 x 11.28 ( 14 0.75) / 1000 = 0.2391 Kg/mm2
= 23.91 Kg/Cm2(g)
Stubs on Steam Collecting Header:Refer calculations under stubs on side wall headers.
= 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 = 1421.82 x 4 /
= 42.69 mm
Therefore process of 2 nos. of single post safety valves are adequate.
( P. SWAIN )
CALCULATION SHEET
BOILER MAKERS 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 :
Or 17.41
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)
thk. of d/e
= 16 mm,
= 446 mm.
= 16 mm.
: 3 :
Width of Comp. Pad
= 65 mm.
= 20 mm
below the
-do-
= 28 mm
= 20 mm.
L1 = Width of compensation
= 65 mm.
= 85 mm.
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
Total compensation = a + b = 1300 + 3085.36 = 4385.36 mm2
Effective compensation = 4385.36 x 37/47 = 3452.3 mm2
Imaginary dia (d1) = d A/T = 446 3452.3/14 = 199.42
Ratio d1/DT = 199.42/1224 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)
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 = 3.413b = Internal width between supporting sides = 189 mm.
W = Internal width of header
= 168 mm.
= 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 :
= 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
= 0.2952 kg/mm2
= 29.52 kg/cm2
168.3 =
OD x 10.97 thk.
es - 17.191
= 31 kg/mm2,
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
: 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 = 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 = x 76.2 x 5642 x 7 /( 2 x 106) = 4.727 M2
3) Part of drum : (Quarterly Exposed)
d = 1224, L = 2276.
HS3 = / 1224 x 2276 /( 4 x 106) = 2.188 M2
4) In Bed Tubes:
d = 63.5, L = 2214, N = 43
H.S4 = 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 :
( P. SWAIN )
(P. SWAIN)
Jr. Manager (Q.A)
CALCULATION SHEET
BOILER MAKERS NO.
WT/SD-400/F/295
WORKING PRESSURE
10.50 KG/CM2(G)
WORKING TEMPERATURE
1850 C.
15.75 KG/CM2(G)
REFERENCE DRAWINGS
WT/SD-450/F/2.1,R0
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 ::
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
ii)
=
=
76.6, p = 320
(p-d) / p = (320-76.6)/320 = 0.760
d
p
=
=
76.6,
410
= 2.f.E (T c)/(D + T c)
= 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).
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 = 912 mm, r2 = 162 mm, D = 1050 mm
External Height of d/e =
h
=
R2 - {(R2 - D/2)(R2 + D/2 2 r2)} (Eqn.75)
Ratio (h/d) =
255.7/1050
0.244
:: 3 ::
Comp. plate thk.
=
10 mm.
Width of compensation
=
50 mm.
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
Additional conditions to comply:I) T/D 0.1, actual T / D =
L2
(d.Tt )
=
=
T1
L1
L2
=
=
=
a)
So, L1 (max.) =
(2RT)
=
(2 x 906.75 x 10.5)
Hence, provided width is, 50 mm is within the limit.
=
=
=
20 mm.
50 mm
80 mm.
b)
L2 (max.)
=
(d.Tt) =
(446 x 20)
=
Actual height provided (80 mm) is within the limit. Hence O.K.
= 137.99
94.45
=
=
=
=
=
=
:: 4 ::
E
Te
=
=
W.P =
0.175 =
Or te =
0.95
Equivalent thk. of nozzle for opening of
406 mm at a pressure of 10.5 kg/cm2
0.762
2 x f x E (te c)/(D + t c)
2 x 11.28 x 0.95 (te 0.75)/(406 + te 0.762)
2.76 mm.
b)
2 x 10 x 50 = 1000 mm2
= 3912.96 mm2
= d A/T
= (446 3912.96 / 10.5) = 73.34
= 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
Selected thickness of dished end is 12 mm safe for W.P. of 10.50 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
=
b
=
int. breadth between supporting sides =
c
=
constant
=
c1
=
constant
=
f
=
permissible stress = 0.36 x 37/1.5
=
E
=
Efficiency legament between holes =
W
=
Width (internal) of hdr.
=
W.P =
c.f.(t c1)/b2
Or W.P=
6.25 f.E.t2/W2 =
=
=
16 mm.
189
3.413
0.8
8.88 kg/mm2
(160 76.6)/160 = 0.521
118
.
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
10.50 kg/cm2(g).
2)
=
=
=
=
= 8.88 kg/mm2
= 118.
= 1 mm
=1
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:
Dia of Stay Pin d
=
32
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 ::
2
Proposed Working Pressure = 10.50 kg/cm (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)
= 16 mm.
= 3.413
C1 = Constant
= 0.8
= Permissible Stress
= 0.36 x 37 / 1.5 = 8.88 kg/mm2
Contd.P/7:: 7 ::
Calculation for Stay Pins:
Dia of Stay Pin
Permissible Stress
= 32
= 8.88 kg/mm2.
e = Constant = 1
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 ::
I.D. of Drum
= 1030 mm.
= 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)
= x = dn x es
= 97.18 x 5.578 = 542.07 mm2
= en
= 47 kg/mm2
= 21.4
C1
C1 = 85
Cw
= 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)
= x = dn x en
= 122.24 x 5.578 = 681.855 mm2
b = 23.825
C1
C1 = 85
Contd.P/9:: 9 ::
Cw
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
Hence there is no need of extra compensation.
HEATING SURFACE:
1)
2)
3)
4)
5)
Generating Tubes:
d = 76.2
l = 6050 mm
n =81
H.S1 =
x 76.2 x 6050 x 81/ 106
=
117.313 m2
Roof Tubes:
d = 76.2
l = 5710
n=6
H.S2 =
x 76.2 x 5710 x 6 / 2 x 106
=
4.101 m2
Down Comer Tubes :
d = 76.2
l = 670
n=5
H.S3 =
x 76.2 x 670 x 5 / 106
=
0.401 m2
Inbed Tubes:
d = 63.5
l = 2360
n = 38
H.S4 =
x 63.5 x 2360 x 38x 106
=
17.89 m2
Part of Drum (quarterly exposed):
d = 1050
l = 1960
H.S5 =
x 1050 x 1960/ 106 x 4
=
1.616 m2
Contd.P/10:: 10 ::
Total Heating Surface = H.S1 + HS2 + HS3 + HS4 + HS5
= 117.313 + 4.101 + 0.401 + 17.89 + 1.616
= 141.321 m2
CALCULATION FOR SAFETY VALVE : (Reg.293)
Total evaporation
= CAP, where,
/ 4 d2 = 3123/(0.4 x 11.5)
d
26.7 OD x 2.87
21.3 OD x 2.77
W.P. = {2 x f x e (t c)} / d t c
OD of Tube
Proposed (d)
In (mm)
t
in mm
t1
in mm
W.P.(kg/cm2)
as per
above
Formula.
Remarks
21.3
2.77
2.42
137.5
26.7
2.87
2.51
111.7
Therefore the size of pipes proposed is safe and adequate for a W.P. of 9.0 kg/cm2(g).
FOR PRESSELS PVT. LTD.
( P. SWAIN )
IBR CALCULATION
WT/SD 800/F/1001
Working Pressure
17.5 Kg/Cm2(g)
Working Temp.
207oC.
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)
= 42.19 Kg/mm2(g)
(b)
Taking the minimum of the two, ligament efficiency for further calculations E = 0.72
I.D. of Shell = 1224 32 = 1192 mm
Thk. of shell plate = T = 16 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)
Therefore the thickness (16 mm) of shell plate proposed is adequate for a W.P. of 17.5
Kg/Cm2(g).
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 = 57 mm
Additional Conditions to Comply :(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
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. 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
Actual height provided (85 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. = 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
Total Effective Compensating
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
Hence the thickness (16 mm) of dished end proposed is adequate for a W.P. of 17.5 kg/cm2(g).
Contd..P/4-
: 4 :
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).
ContdP/5-
: 5 :
Calculation for Stay Bar:
Dia of Stay Pin
d = 32
: 6 :
2)
Hence the size of side ring plate ( 20 mm thk. ) is safe and adequate for a W.P. of
17.5kg/cm2(g).
Calculation for Stay Pins:
Dia of Stay Pin
d = 32
e = Constant = 1
W.P. = 2 x fe ( t c ) / d-t+c
: 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).
8 :
b = 40 mm
C1 = Greater of ( ts + 76 ) Or dn / 2
= ( 16 + 76 ) Or 131.78 / 2
= 92 Or 65.89 mm
C1 = 92 mm
Cw = Agregate area of Fillet Weld = 2 x (18.26)2 x
= 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
Hence there is no need of extra compensation.
: 9:
Contd.P/10-
: 10 :
Heating Surface:
1)
2)
3)
4)
5)
Contd.P/11-
: 11 :
( S. K. MULLICK )
sm