MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR by G. Subhash Reddy, Rtd. Director of Boilers shell - Reg.

270 efficiency of ligament - Reg. 215 p= 100 mm - pitch of tube holes d= 50 mm - diameter of tube holes E= 0.5 (p-d)/p - efficiency of ligament T= 6 mm - thickness, min. 6 D= 600 mm - max. internal diameter f= 1406 kg/sq.cm - permissible working stress at temp upto 250 C for SA515-70 WP = 12.1682 kg/sq.cm - 2 X f X E X(T-0.762)/(D+T-0.762) - working pressure tube/end plate 1 pitch of the tubes -Reg.580 p= 86 mm - min. pitch of tube hole D= 64.3 mm - diameter of the tube hole L= 20.7375 mm - D/8+12.7 - ligament required L1 = 21.7 mm - (p-D) - ligament provided 2 stayed flat surface - Reg. 574 e= 10 mm - thickness, min. 8 d= 200 mm - diameter of the largest circle taken between staying points of the plate f= 1406 kg/sq.cm - permissible working stress at temp upto 250 C for SA515-70 f1 = 1195.1 kg/sq.cm - 0.85 X f e1 = 0.75 mm C= 0.4 P= 15.9775 kg/sq.cm - f1 X ((e-e1)/(C X d))2 - design pressure headerl - Reg. 342(a) & eq. 72 efficiency of ligament - Reg. 215 p= mm - pitch of tube holes d= mm - diameter of tube holes E = (p-d)/p - efficiency of ligament Tn = mm -nominal thickness T= mm - 0.875 X Tn - min. thickness Do = mm - outside diameter D = mm - (Do-2XT) - max. internal diameter f= 1202 kg/sq.cm - permissible working stress at temperature upto 250 C for SA106-Gr.B WP = kg/sq.cm - 2 X f X E X(T-0.762)/(D+T-0.762) - working pressure p 100 100 d 50.8 50.8 E 0.492 0.492 Tn 5.49 3.91 T 4.6665 3.3235 Do 88.9 60.3 D 79.567 53.653 f W.P. 1202 55.325682 1202 53.89464

fire tube eq. XII/14 t= 3.25 mm - min. thickness of tube D= 63.5 mm - outside tube diameter C= 0.75 mm - corrosion allowance f= 870 kg/sq.cm - permissible working stress WP = 54.8031 kg/sq.cm - 1.6 X f X (T-C)/D - working pressure water tube Reg. 338

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR by G. Subhash Reddy, Rtd. Director of Boilers T= 3.25 mm - min. thickness of tube D= 50.8 mm - external diameter of the tube C= 0.75 mm - corrosion allowance f= 870 kg/sq.cm - permissible working stress WP = 90.0621 kg/sq.cm - 2 X f X (T-C)/(D-T+C) - working pressure header end plates Reg. 342(b) t= 10 mm - min. thickness of plate d= 200 mm - diameter of plate C= 1 mm - corrosion allowance f= 1312 kg/sq.cm - permissible working stress K= 0.28 for ends directly strength welded to header/shell WP = 9.48857 kg/sq.cm - f X (T-C)2/(d2XK) - working pressure stay tubes Reg.577 Tp 5.08 D 48.3 A 20000 C 1 T 4.08 f 713 a 566.8 WP 20.2064

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

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

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

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR by G. Subhash Reddy, Rtd. Director of Boilers elliptical manhole cover, reg166 a 305 mm minor axis of the opening to which door is fitted b 410 mm major axis of the opening to which door is fitted d 20 mm root diameter of stud tp 16 mm provided thickness 2 P 10 kg/cm design pressure allowed pressure f 1300 kg/cm2 design stress value of stud up to 300 0C = 50 N/mm2 fb 509.684 kg/cm2 W 178471 kg full load capacity of one stud = pi/4*d2*fb t 12.9902 mm calculated thickness =squre root of {(0.35*(2a-b)a^2+W)/f} circular manhole cover, reg166 d 305 mm diameter of the opening to which door is fitted ds 20 mm root diameter of stud 2 P 10 kg/cm design pressure f 1300 kg/cm2 allowed pressure design stress value of stud up to 300 0C = 50 N/mm2 fb 509.684 kg/cm2 W 178471 kg full load capacity of one stud = pi/4*d2*fb t 20.348 mm calculated thickness =squre root of {(0.35*d^2+W)/f} stay bars longitudinal stay bars, Reg.587 D 50 A 74000 C 655.4 W.P. 22.1419 gusset , Reg 591 w 100 40 tp A 110000 result 4922 f 703.143 L/L' 0.866 W.P. 22.1426 mm mm mm2 kg/cm2 kg/cm2 kg/cm2 material specification width at its tangential section provided thickness, not < 7/8 of shell thick & 11.113 mm area supported by one stay tensile stress allowable stress =R / 7 cos( angle with shell) for 300 it is 0.866 max. allowed working pressure = f X w x tp X L / L' /A mm mm2 kg/cm2 kg/cm2 W.P. diameter at its smallest part area supported by one stay depends on ten.strength,44.1-50.4=607.5, 47.25-53.55=655.4 max. allowed working pressure = C X D2/A

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

kg/cm2 mm2 kg/cm2

allowable shear stress for pin, double shear, Reg 591(ss-562.5) area supported by one gusset/anchor plate design pressure

MAX. WORKING PRESSURE CALCULATIONS OF PARTS AS PER IBR by G. Subhash Reddy, Rtd. Director of Boilers d n w t tg Rl Et fb fl Sp result Sl result Sb Sba result fw La Sw result 45 3 120 20 40 4216 1652 1239 602.286 444.637 OK 272.197 OK 453.661 453.661 OK 10 700 kg/cm2 not safe mm kg/cm2 mm mm mm kg/cm2 mm kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm3 mm mm kg/cm2 diameter of pin number of pins per gusset width of link stay thickness of link stay thichness of anchor plate tensile strength of link sec IID yield stress of link/gusset at metal temperature bearing stress for link and gusset=0.75Xyield stress at t, IS800 allowable stress for link = Rl/7 , Reg 591 shear stress induced in pin, double shear =P X A /(nX0.7854Xd 2) fp > Sp stress induced in link =P X A /{2XnX(w-d)XtX0.866} fl > Sl bearing stress induced in link = PXA/(0.866X2XnXdXt) bearing stress induced in gusset = PXA/(0.866XnXdXtg) fb. > max(Sb,Sba) fillet leg for anchor plate to shell/ tube sheet length of shortest anchor plate stress in weld = P*A/(2*La*fw*0.7*0.55) Sw < 1100