Regn.No.

_ Paper- 1

Name: ----------------
(To be written by the candidate)

EXAMINATION FOR COMPETENT PERSONS FOR INSPECTION

AND CERTIFICATION OF BOILERS - OCTOBER 2015

BOILER DESIGN ENGINEERING

Date: 11/10/2015 Time: 09:30 - 11:30 Hrs.

Marks: 100
Question I 5 x 2 = 10 marks

a. 1) Whether Inspecting authority can inspect a boiler meant for export?

What is the form in which he will certify?
2) What is the minimum thickness of the boiler plate allowed by IBR?

b. 1) When a shell is made of more than one ring, how the longitudinal joints
of the adjacent rings are placed?
2) In the tube thickness calculations, how the constant "c" varies with the
working pressure?
~
c. 1) Name any three. boiler mounting fittings to be provided essentially in w
every boiler. en
2) In shell type boilers, is it allowed to form the uptakes and cross tubes
through ERW process?

d. What are the limiting criteria for using?

1) Ellipsoidal heads
2) Partial spherical heads

e) After how many hours/years the boilers shall be tested for Remnant Life
Assessment Organization of its components.
1) The boilers which are operating at a temperature of 400C (main steam
outlet temperature)
2) The boilers which are operating at a temperature of less than 400C
(main steam outlet temperature)
Question II 30 marks
Design a Boiler Drum with the following parameters
Design Pressure 170 Kg/ Cm2
Design temperature 354C
Drum inside diameter 1778 mm
Drum thickness 155 mm
Drum material SA299
Stress values for the Shell plate
BOILER DESIGN ENGINEERING 1
 Temp'iC 300 325 350 375
Stress Value Kg/Cm2 1454 1420 1380 1309
Hole drilling pattern in the Drum is as per the attached Sketch.
Assume that the down comer pipe and eco inlet connection pipe are self- compen-
sated. Diagonal efficiency need not be considered.
a) Calculate the minimum ligament efficiency.
b) Calculate the maximum working Pressure for the Drum as per the code.
c) Check whether the Down comer Nozzle needs compensation for the
given design parameters.
DRUM

t---1f---EtM7ffi----ff~H-ffi---ffi---ft'r___t---"-tP1.:...:....:01-A(Rises )@650Pitch, 17 .5-B(lnst tapping)@midleofthepitch

~f--f-H---f++---f+I--+H-f-H---f++---f+~+---'I'-J..>..l-A(Rises )@650 Pitch
t---1f---ffi----ffi.--fFr--flr-ffi----ffi.--fF~t---"-tP1.:...:....:0 1-A( Rises )@650Pitch

-f-1-t++--+++-H-}++++-II-+t++_t--"-tP2=.=72-C DownComer@1200Pitch

Question III 10 marks

Manifold Header with Hemi Spherical dish end for the followingdesign condition.
Header Outside diameter =127mm
1

Drum pressure = 56kg/Cm2

Header Pressure drop before drum=3kg/ Cm2
Medium Temperature = 271 Degree C
Thickness = 18mm
Header material = SA234WPC
Assume C Value
Height = 61.50mm
The Hemi Spherical Header dish end is located outside the furnace. Check whether
the provided thickness is sufficient.

Question IV 30 marks

Refer the sketches 1 to 3. The horizontal multi tubular boiler is to be designed for a
maximum working pressure of 10.54 kg/cm2

Check whether the thickness provided for: (a) Furnace and (b) Shell end plates.

Material used for construction is conforming to SA 515 Gr.70. The saturation

temperature is 185C

BOILER DESIGN ENGINEERING 2

=o
t=
~ 370Q 1.PRESSURE GAUGE
e 2.SAFETY VALVE

I
3.AUXIUARY VALVE
.STlffENER RING
5.MANHOLE
6.MAIN STEAM STOP VALVE

:T'
~ 18
a~ REVERSING
REAR EN;HAMBER
-rT
' +-T
!1 SHELL REAR PLATE\ a
~
!:
cl
I.. aooX4oo .1 END PLATE 1 1

~ ~ (OPENING)
I:)
='1-_,_1- :
~ - - - - -.~

FRONT REVERSING
END 1. 111 18
CHAMBER

Ie DETAIL - A
----~-----.-
Cl._OF~ ---U-OF~
---- ---- _

~'i Cl.OF~) . _
-----------------
8 8
ACCESS PIPE
14mm THK
14mm THK
2SOO

ASH DROP OUT PIPE

11273.1

<478
3560 38I!KI

SECTIONAL ELEVATION SKETCH 1 FOR QUESTION 4-

Co)
 GUSSET

N.W.L

CL or
BOILER

CL OF
REVERSING
CHAMBER

STAY TUBES

REVERSING CHAMBER

STAY ROD

PRESSURE CIRCLE DIAGRAM FOR SHELL REAR END PLATE

SKETCH Z. FOR QUESTION 4-

BOILER DESIGN ENGINEERING 4

 GUSSET

N.W.L

CL or
CL or BOILER
rUR(2)
I
CL or
FUR:1

STAY TUBES
FURNACE-I

PRESSURE CIRCLE DIAGRAM FOR SHELL FRONT END PLATE

SKETCH 3 FOR QUESTION 4-

BOILER DESIGN ENGINEERING 5

Question V 20 marks

During renovation ofa boiler, the owner was planning to install an integral economizer
coil with the tube of size OD 51mm and material SA210Gr Al in the convection pass
of the boiler. The various tube thicknesses available are 4.5mm, 5mm and 5.2 mm.
Previous to the installation the economizer working pressure was 225 KgjCm2 and
the design temp was 345C. What is the minimum thickness required for the tube
and justify.

Allowable stress values can be taken from the table below:

Ternp'[C 325 350 375 375

Stress Value KgjCm2 1202.3 1177.0 1071.2. 1309

--------- End of Question Paper ---------

BOILER DESIGN ENGINEERING 6