Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd.

1 TPH Boiler

1 TPH BOILER DESIGN CALCULATIONS

Customer STOCK ITEM
Design Code IBR - 1950
Drawing No.
JOB ID.

BOILER TYPE : INDUSTRIAL BOILER

DESIGN CODE : IBR - 1950

DESIGN PRESSURE : 10.54 Kg/sq. cm

PROJECT :

DOC. NO :

REFERENCE DRGS. :
(ASSEMBLY & DETAILS)

DESIGN DATA

Parameters
Internal Pressure Kg/cm 2 10.54
Maximum Temperature 0C -
Saturation Temperature 0C 183.1
Flow Kg/hr 1 Tons / Hr of Steam
Radiography As per code
Stress Relieving As per code
Hydrostatic Test Pressure kg/cm 2 15.81

Material Schedule and Overall Dimensional Data

Description Material Specifications Diameter Length / I.D. Thickness

Main Shell, I.D. SA-516 GR.70 1900 2840 10
Furnace, O.D. SA-516 GR.70 1024 2230 12
Comb. Chamber, O.D. SA-516 GR.70 1440 522 16
Front Tube Plate SA-516 GR.70 1900 1024 16
Back Tube Plate SA-516 GR.70 1900 420 16
C.C. Front Tube Plate SA-516 GR.70 1408 1024 16
C.C. Back Tube Plate SA-516 GR.70 1408 420 16
II pass Stay Tubes BS 3059 ERW 360 63.5 2160 3.66
III pass Stay Tubes BS 3059 ERW 360 63.5 2790 3.66
Manhole SA-516 GR.70 305 410 25
Headhole SA-516 GR.70 250 350 20

Calculation of minimum furnace diameter

Refer fig. XII/20A

Total heat input in furnace = Tons / hr x Enthalpy of steam

= 1 x 10000 x (668 - 100) kcal / hr

= 568000 kcal / hr

= 0.6642444 MW

Therefore, min furnace diameter = 1000 mm

Proivded 1 no. furnace of 1000 mm I.D. is adequate.

Page 1, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

Design Temprature & Allowable Stresses

1 Main Shell: Reg. No. 271 (Ammendment)

The working temp. Shall be taken as for saturated Steam, Drum or Shell,

The saturation temp. Corresponding to the working pressure + 27.78 Deg. C

Working Pressure = 10.54 Kg/Cm2

Saturation steam temp. = 183.1 Deg. C
Design temp. For main shell = 183.1+27.78
= 210.88 Deg. C
= 411.58 Deg. F

Allowable stress for material SA 516 Gr. 70 @ Design temp.

Ultimate tensile Strength, = 70000 Psi
Yeild Strength, @ Design Temp. Et = 31000 Psi
Allowable stress, as per ASME sec II part D = 20000 Psi
= 1406 Kg/Cm2

2 Furnace: Reg. No. 592, Note No. 4 (Ammendment)

The design temp. Of the Furnace =

Saturated steam temp. At W.P. + 4 x Furnace thk. + 15
Saturated Temp. At W.P. = 183.1 Deg. C
Design temp. For Furnace = 183.1+4x12+15
= 246.1 Deg. C
= 474.98 Deg. F

Allowable stress for material SA 516 Gr. 70 @ Design temp.

Ultimate tensile Strength, = 70000 Psi
Yeild Strength, @ Design Temp. Et = 31000 Psi
Allowable stress, as per ASME sec II part D = 20000 Psi
= 1406 Kg/Cm2

3 Combustion Chamber: Reg. No. 592, Note No. 4 (Ammendment)

The design temp. Of the Combustion Chamber =

Saturated steam temp. At W.P. + 4 x Combustion Chamber Thk. + 15
Saturated Temp. At W.P. = 183.1 Deg. C
Design temp. For Combustion Chamber = 183.1+4x16+15
= 262.1 Deg. C
= 503.78 Deg. F

Allowable stress for material SA 516 Gr. 70 @ Design temp.

Ultimate tensile Strength, = 70000 Psi
Yeild Strength, @ Design Temp. Et = 29100 Psi
Allowable stress, as per ASME sec II part D = 19400 Psi
= 1364 Kg/Cm2

Page 2, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

4 Shell Tube Plate:

For Tube Plate where the gas entry temp. Is not greater than 800 deg. F =
Saturated steam temp. At W.P. + 2 x Tube Plate Thk.
Saturated Temp. At W.P. = 183.1 Deg. C
Design temp. For Tube Plate = 183.1+2*16
= 215.1 Deg. C
= 419.18 Deg. F

Allowable stress for material SA 516 Gr. 70 @ Design temp.

Ultimate tensile Strength, = 70000 Psi
Yeild Strength, @ Design Temp. Et = 31000 Psi
Allowable stress, as per ASME sec II part D = 20000 Psi
1406 Kg/Cm2
5 Combustion chamber Tube Plate:

For Tube Plate where the gas entry temp. Is not greater than 800 deg. F =
Saturated steam temp. At W.P. + 2 x Tube Plate Thk.
Saturated Temp. At W.P. = 183.1 Deg. C
Design temp. For Combustion Chamber Tube Plate = 183.1+2*16
= 215.1 Deg. C
= 419.18 Deg. F

Allowable stress for material SA 516 Gr. 70 @ Design temp.

Ultimate tensile Strength, = 70000 Psi
Yeild Strength, @ Design Temp. Et = 31000 Psi
Allowable stress, as per ASME sec II part D = 20000 Psi
1406 Kg/Cm2
6 Tube: Reg. no. 338 (b)

Saturated steam temp. At W.P. = 183.1 Deg. C

Saturated Temp. At Working W.P. + 27.78 Deg. C = 183.1+27.78
Design temp. For Tube = 210.88 Deg. C
= 411.58 Deg. F

Allowable stress for material BS 3059 @ Design temp.

Yeild Strength, @ Design Temp. Et = 21200 Psi
Allowable stress, f = Min ( UTS/2.7, YS/1.5) = 14133.3 Psi
= 994 Kg/Cm2

7 Nozzle Necks

Saturated steam temp. At W.P. = 183.1 Deg. C

Saturated Temp. At Working W.P. + 27.78 Deg. C = 183.1+27.78
Design temp. For Nozzle Neck = 210.88 Deg. C
= 411.58 Deg. F

Allowable stress for material A 106 GR. B @ Design temp.

Ultimate tensile Strength, = 60000 Psi
Yeild Strength, @ Design Temp. Et = 28500 Psi
Allowable stress, as per ASME sec II part D = 17100 Psi
= 1202 Kg/Cm2

Page 3, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

SHELL THICKNESS CALCULATIONS WITH INTERNAL PRESSURE

Ref. Regulation Nos. 563 & 564 and 270 & 271 of IBR
Cylindrical Shells under internal Pressure

W.P.( Cal.) = 2xfxEx(t-C)

D + (t-C)

t= Thickness of Shell 10 mm
W.P.= Working Pressure 10.54 Kg/Cm2
D= Inside Diameter of Shell 1900 mm
f = Allowable Stress of material 1406 Kg/Cm2
E= Weld Factor 1
C= Corrosion allowance 0.762

W.P.(Cal) = 2x1406x1x(10-0.762)
1900+(10-0.762)

W.P. = 13.61 Kg/Cm2

For specified design pressure, provided thickness 10 mm

is adequate

CYLINDRICAL PLAIN FURNACES THICKNESS CALCULATIONS SUBJECTED TO EXTERNAL

PRESSURE

Ref. Regulation No. 592 of IBR

Cylindrical Plain furnaces and subject to External Pressure

Formula A,

P = 2 x Et x ( e - C ) x 1 + d/15L ....Eqn. XII/25

S1 x d 1 + 0.03 x d x u
(e-C) x (1+ d/0.3L)

Formula B,

P = 1.73 x E x ( e - C )^2.5 ....Eqn. XII/25A

S2 x L x d^1.5

P= Design Pressure 10.54 Kg/Cm2

d= Mean Diameter of Furnace 1012 mm
L= Length of the section between the centers of points 400 mm
of substential supports
e= Thickness of Furnace, mm 12 mm
Et= Specified Min. Elevated Temp. Yeild Strength Or 2109 Kg/Cm2
0.2% Proof Stress at Design Temp.
S1= Factor of Safety for class I boiler 2.5
u= Percentage out of roundness 1.5
C= Corrosion allowance 0.75 mm
E= Youngs modulus of elasticity at design Temp. 1896000 Kg/Cm2
s2= Factor of Safety for class I boiler 3

Formula A,

P= 2x2109x(12-0.75) x 1+1012/15x400
2.5x1012 1 + 0.03x1012x1.5
(12-0.75)x(1+1012/0.3x400)

W.P.= 15.34 Kg/Cm2

Formula B,

P= 1.73x1896000x(12-0.75)^2.5
3x400x1012^1.5

W.P.= 36.04 Kg/Cm2

For specified design pressure, provided thickness 12 mm

is adequate

Page 4, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMBUSTION CHAMBER WRAPER PLATE THICKNESS CALCULATIONS SUBJECTED TO EXTERNAL

PRESSURE

Ref. Regulation No. 592 of IBR

Combustion chamber wrapper plate subject to External Pressure

Formula A,

P = 2 x Et x ( e - C ) x 1 + d/15L ....Eqn. XII/25

S1 x d 1 + 0.03 x d x u
(e-C) x (1+ d/0.3L)

Formula B,

P = 1.73 x E x ( e - C )^2.5 ....Eqn. XII/25A

S2 x L x d^1.5

P= Design Pressure 10.54 Kg/Cm2

d= Mean Diameter of Combustion Chamber 1424 mm
L= Length of the section between the centers of points 466 mm
of substential supports
e= Thickness of Combustion Chamber 16 mm
Et= Specified Min. Elevated Temp. Yeild Strength Or 2045.73 Kg/Cm2
0.2% Proof Stress at Design Temp.
S1= Factor of Safety for class I boiler 2.5
u= Percentage out of roundness 1.5
C= Corrosion allowance 0.75 mm
E= Youngs modulus of elasticity at design Temp. 1896000 Kg/Cm2
s2= Factor of Safety for class I boiler 3

Formula A,

P= 2x2045.73x(16-0.75) x 1+1424/15x466
2.5x1424 1 + 0.03x1424x1.5
(16-0.75)x(1+1424/0.3x466)

W.P.= 15.34 Kg/Cm2

Formula B,

P= 1.73x1896000x(16-0.75)^2.5
3x466x1424^1.5

W.P.= 39.65 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

Page 5, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

ACCESS DOOR PLATE THICKNESS CALCULATIONS SUBJECTED TO EXTERNAL PRESSURE

Ref. Regulation No. 592 of IBR

Access Door subject to External Pressure

Formula A,

P = 2 x Et x ( e - C ) x 1 + d/15L ....Eqn. XII/25

S1 x d 1 + 0.03 x d x u
(e-C) x (1+ d/0.3L)

Formula B,

P = 1.73 x E x ( e - C )^2.5 ....Eqn. XII/25A

S2 x L x d^1.5

P= Design Pressure 10.54 Kg/Cm2

d= Mean Diameter of access door 410 mm
L= Length of the section between the centers of points 164 mm
of substential supports
e= Thickness of Access Door 10 mm
Et= Specified Min. Elevated Temp. Yeild Strength Or 2045.73 Kg/Cm2
0.2% Proof Stress at Design Temp.
S1= Factor of Safety 2.5
u= Percentage out of roundness 1.5
C= Corrosion allowance 0.75 mm
E= Youngs modulus of elasticity at design Temp. 1896000 Kg/Cm2
s2= Factor of Safety 3

Formula A,

P= 2x2045.73x(10-0.75) x 1+410/15x164
2.5x410 1 + 0.03x410x1.5
(10-0.75)x(1+410/0.3x164)

W.P.= 35.49 Kg/Cm2

Formula B,

P= 1.73x1896000x(10-0.75)^2.5
3x164x410^1.5

W.P.= 208.98 Kg/Cm2

For specified design pressure, provided thickness 10 mm

is adequate

Page 6, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

BACK TUBE PLATE THICKNESS CALCULATIONS

Ref. Regulation No. 574 of IBR

Stayed Surface

W.P.( Cal.) = (e - e1) ^2 x f1

(c x d)

P= Design Pressure 10.54 Kg/Cm2

d= Diameter of Largest Circle taken between Stays. 280 mm
e= Thickness of Back Tube Plate 16 mm
f1= 0.85* Allowable Stress 1195.1 Kg/Cm2
e1= Additional Thickness 0.75
C= Coefficient (0.4 + 0.3425 + 0.4) / 3 0.38083
= 0.4 Gusset stays
= 0.3425 for Shell / Furnace stays
= 0.4 for Stay Bars & Stay Tubes
= 0.4 for Accessories

W.P. = (16-0.75) 2 x 1195.1

(0.38083x280)

W.P.= 24.44 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

Page 7, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

FRONT TUBE PLATE THICKNESS CALCULATIONS

Ref. Regulation No. 576 of IBR

Wide Water Space between and around the Tube Nest.

W.P.( Cal.) = (e - e1) 2 x f1

C2 (A2 + B2)

W.P= Design Pressure 10.54 Kg/Cm2

A= Width of Water Space between Nests. 206 mm
B= Pitch of Tube 85
e= Thickness of front Tube Plate 16 mm
f1= 0.85* Allowable Stress 1195.1 Kg/Cm2
e1= Additional Thickness 0.75
C= Coefficient (0.4 + 0.3425 + 0.4) / 3 0.38083
= 0.4 Gusset stays
= 0.3425 for Shell / Furnace stays
= 0.4 for Stay Bars & Stay Tubes
= 0.4 for Accessories

W.P. = (16-0.75)^2 x 1195.1

0.38083^2 (206^2+85^2)

W.P.= 38.59 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

Ref. Regulation No. 574 of IBR

Stayed Surface

W.P.( Cal.) = (e - e1) ^2 x f1

(c x d)

Ref. Regulation No. 574 of IBR

P= Design Pressure 10.54 Kg/Cm2

d= Diameter of Largest Circle taken between Stays. 280 mm
e= Thickness of front Tube Plate 16 mm
f1= 0.85* Allowable Stress 1195.1 Kg/Cm2
e1= Additional Thickness 0.75
C= Coefficient (0.3425 + 0.3425 + 0.4) / 3 0.36166
= 0.4 Gusset stays
= 0.3425 for Shell / Furnace stays
= 0.4 for Stay Bars & Stay Tubes
= 0.4 for Accessories

W.P. = (16-0.75) 2 x 1195.1

(0.36166*280)

W.P.= 27.10 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

Page 8, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMBUSTION CHAMBER FRONT TUBE PLATE THICKNESS CALCULATIONS

Ref. Regulation No. 574 of IBR

Stayed Surface

W.P.( Cal.) = (e - e1) ^2 x f1

(c x d)

P= Design Pressure 10.54 Kg/Cm2

d= Diameter of Largest Circle taken between Stays. 214 mm
e= 0.9 x Thickness of Back Tube Plate 14.4 mm
f1= 0.85* Allowable Stress 1195.1 Kg/Cm2
e1= Additional Thickness 0.75
C= Coefficient ( 0.3425 + 0.4 ) / 2 0.37125
= 0.4 Gusset stays
= 0.3425 for Shell / Furnace stays
= 0.4 for Stay Bars & Stay Tubes
= 0.4 for Accessories

2
W.P. = (14.4-0.75) x 1195.1
(0.37125x214)

W.P.= 35.28 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

COMBUSTION CHAMBER BACK TUBE PLATE THICKNESS CALCULATIONS

Ref. Regulation No. 574 of IBR

Stayed Surface

W.P.( Cal.) = (e - e1) ^2 x f1

(c x d)

P= Design Pressure 10.54 Kg/Cm2

d= Diameter of Largest Circle taken between Stays. 308 mm
e= 0.9 x Thickness of Back Tube Plate 14.4 mm
f1= 0.85* Allowable Stress 1195.1 Kg/Cm2
e1= Additional Thickness 0.75
C= Coefficient ( 0.4 + 0.4 ) / 2 0.4
= 0.4 Gusset stays
= 0.3425 for Shell / Furnace stays
= 0.4 for Bar stays & Stay Tubes
= 0.4 for Accessories

2
W.P. = (14.4-0.75) x 1195.1
(0.4x308)

W.P.= 14.67 Kg/Cm2

For specified design pressure, provided thickness 16 mm

is adequate

Page 9, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

II PASS STAY TUBE THICKNESS CALCULATIONS

Ref. Regulation No. 581 & 148 of IBR

Required Sec. Area of Stay Tubes = (A-a) x P

f1
For II Pass
P= Design Pressure 10.54 Kg/Cm2
A= Area of that portion of tube Plate 7142 Sq.mm
supported by stay tube
a= Aggregate Area of holes in the tube Plate, i.e 1 holes 3166.92 Sq.mm
f1= Tensile strength Allowable (As per Reg.148) 713 Kg/Cm2
OD= Outside diameter of Stay Tubes 63.5 mm

Required Sec. Area of Stay Tubes = (7142-3166.92174435936)*10.54

713

Required Sec. Area of Stay Tubes = 58.762026 mm2

Inside Diameter of Stay Tube = (Tube OD^2-Sectional Area x 4/PI)^0.5

= 62.908122 mm

Thickness of Stay Tubes = (OD -ID)/ 2

= 0.2959388 mm

Actual Sec. area of stay tubes = 606.65016 ……… Consindering 12.5% allw

W.P.= f1 x Stay Tube C/S / (A-a)

W.P.= 95.21 Kg/Cm2

For specified design pressure, provided thickness 3.66 mm

is adequate

III PASS STAY TUBE THICKNESS CALCULATIONS

Ref. Regulation No. 581 & 148of IBR

Required Sec. Area of Stay Tubes = (A-a) x P

f1
For III Pass
P= Design Pressure 10.54 Kg/Cm2
A= Area of that portion of tube Plate 20150 Sq.mm
supported by stay tube
a= Aggregate Area of holes in the tube Plate, i.e 1 hole 3166.92 Sq.mm
f1= Tensile strength Allowable 713 Kg/Cm2
OD= Outside diameter of Stay Tubes 63.5 mm

Required Sec. Area of Stay Tubes = (20150-3166.92)*10.54

713

Required Sec. Area of Stay Tubes = 251.0542 mm2

Inside Diametr of Stay Tube = (Tube OD^2-Sectional Area x 4/PI)^0.5

= 60.931091 mm

Thickness of Stay Tubes = (OD -ID)/ 2

= 1.2844544 mm

Sectional area of stay tubes = 606.65016 ……… Consindering 12.5% allw

W.P.= f1 x C/S of stay tubes / (A-a)

W.P.= 25.469 Kg/Cm2

For specified design pressure, provided thickness 3.66 mm

is adequate

Page 10, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMPENSATING PAD FOR MANHOLE

Comp. pad for Manhole SA-516 GR. 70

Ref. Regulation No. 570, 571 of IBR

Reinforcement of opening for manhole

Width of opening in shell, W 460 mm 18.11 in

Actual thickness of shell, Ts 10 mm 0.394 in

Calculated thickness of shell, T1

Reg. 564
Inner dia shell, D 1900 mm 74.8 in
W.P.= Working Pressure 10.54 Kg/Cm2
E= Weld Factor 1
f = Allowable Stress of material 1406 Kg/Cm2

T1.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P

T1.( Cal.) = 10.54x1900

"+0.762"
2x1406x1-10.54

T1 = 7.910 mm 0.311 in

Actual thickness of manhole ring, Tn 25 mm 0.984 in

T2.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P

T2.( Cal.) = 10.54x460

"+0.762"
2x1406x1-10.54

T2 = 2.493 mm 0.098 in

T3 = 3.175 mm 0.125 in
Area to be compensated X = W x T1 = 5.6401 sq.in

A} Portion of shell available for compensation

As= 2 ( 3 + Ts ) x ( Ts - T1 )
As= 0.558379895 sq.in

B} Portion of branch available for compensation

An= 2 ( 4 + Ts ) x ( 0.875 x Tn -(T2+ T3)) x f2 nozzle neck / f1 comp. plate

An= 5.607099444 sq.in

Area available for compensation, As + An 6.17 sq.in

C} Portion of Pad available

Ap= W x tp

Width of compensation pad,W= 50 mm

Thickness of compensation pad,tp= 10 mm
Ap= 500 sq.mm 0.78 sq.in

Compensation area provided, A+B+C= 7.4989 sq.in

Page 11, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

MANHOLE COVER PLATE THICKNESS CALCULATION

Ref. Regulation No. 166 of IBR, Ammedment 2006

Stayed Surface

0.5
t= 0.35 x P x (2 - a / b) x a ^2 + W + e1
f1

P= Design Pressure 10.54 kgf/sq.cm

a = Minor Diameter of Man Hole 305 mm
b = Major Diameter of Man Hole 410 mm
t = Required min. thickness of Man Hole cover Plate 22.5 mm
f1= 0.85 x Allowable Stress 1195.1 kgf/sq.cm
e1= Additional thickness 0.75 mm

Ab = Effective area of one stud 2.56 sq.cm

Sb = Design allowable stress of stud (assumed as per code) 500 kgf/sq.cm

W = Full load capacity of one stud

W= Ab x Sb

W= (500 x 2.56) kgf

W= 1280 kgf

0.5
t= 0.35 x 10.54 x (2 - 305 / 410 ) x 305^2 + 1280 + 0.75
1195.1

t= 19.77 mm

For specified design pressure, provided thickness 25 mm

is adequate

Page 12, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

FURNACE STIFFENER CALCULATIONS

Ref. Regulation No. 592 of IBR (Ammended)

Second moment of innertia of stiffener plate

Is = P x D^3 x L
1.33 x 1E07

P= Design Pressure 10.54 kgf/sq.cm

d= Mean Diameter of Furnace 1012 mm
t= Thickness of Furnace Shell 12 mm
L= Length of the section between the centers of points 400 mm
of substential supports
Is = Requirement min second moment of innertial of stiffener

D = Depth of stiffener plate 64 mm

W = Width of stiffener plate 16 mm

Required moment of inertia

Ir = P x D^3 x L
1.33 x 1E07

Ir = 10.54 x 1012^3 x 400

1.33 x 1E+07

Ir = 328541.699 mm^4

Moment of innertia available in stiffener plate Moment of innertial in Furnace Wall

Is = W x D^3 Lf = 2 x 0.55 x (D x tf) ^0.5

12

Is = 16 x 64^3 Lf = 2 x 0.55 x ( 1012 x 12)^0.5

12
Lf = 121.22 mm
Is = 349525.3333 mm^4

If = Lf x tf ^ 3 / 12

If = 17455.7 mm^4
Combined section C.G.

Yg = As x Ys + Af x Yf'
( As + Af )

Yg = ( 16 x 64 ) x 0.5 x ( 64 + 12 ) + ( 121.22 x 16 ) x ( 0.5 x 12 )

( 16 x 64 ) + ( 121.22 x 16 )

Yg = 21.70 mm

Combined MI

Ia = Is + If + As x ( Yg - Ys )^2 + Af x ( Yg - Yf )^2

867778.5803 mm^4

Ratio = Ir / Ia = 0.378600839524577

Since available moment of inertia Ia is more than require Is, stiffener is adequate.

Page 13, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMPENSATING PAD FOR HEADHOLE

Comp. pad for Headhole SA-516 GR. 70

Ref. Regulation No. 570, 571 of IBR

Reinforcement of opening for headhole

Width of opening in shell, W 390 mm 15.35 in

Actual thickness of shell, Ts 10 mm 0.394 in

Calculated thickness of shell, T1

Reg. 564
Inner dia shell, D 1900 mm 74.8 in
W.P.= Working Pressure 10.54 Kg/Cm2
E= Weld Factor 1
f = Allowable Stress of material 1406 Kg/Cm2

T1.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P

T1.( Cal.) = 10.54x1900

"+0.762"
2x1406x1-10.54

T1 = 7.910 mm 0.311 in

Actual thickness of headhole ring, Tn 20 mm 0.787 in

T2.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P

T2.( Cal.) = 10.54x390

"+0.762"
2x1406x1-10.54

T2 = 2.229 mm 0.088 in

T3 = 3.175 mm 0.125 in
Area to be compensated X = W x T1 = 4.7819 sq.in

A} Portion of shell available for compensation

As= 2 ( 3 + Ts ) x ( Ts - T1 )
As= 0.558379895 sq.in

B} Portion of branch available for compensation

An= 2 ( 4 + Ts ) x ( 0.875 x Tn -(T2+ T3)) x f2 nozzle neck / f1 comp. plate

An= 4.18463455 sq.in

Area available for compensation, As + An 4.7430 sq.in

C} Portion of Pad available

Ap= W x tp

Width of compensation pad,W= 50 mm

Thickness of compensation pad,tp= 10 mm
Ap= 500 sq.mm 0.78 sq.in

Compensation area provided, A+B+C= 6.0764 sq.in

Page 14, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

HEADHOLE COVER PLATE THICKNESS CALCULATION

Ref. Regulation No. 166 of IBR, Ammedment 2006

Stayed Surface

0.5
t = 0.35 x P x (2 - a / b) x a ^2 + W + e1
f1

P= Design Pressure 10.54 kgf/sq.cm

a = Minor Diameter of Head Hole 250 mm
b = Major Diameter of Head Hole 350 mm
t = Required min. thickness of Head Hole cover Plate 18 mm
f1= 0.85 x Allowable Stress 1195.1 kgf/sq.cm
e1= Additional thickness 0.75 mm

Ab = Effective area of one stud 2.56 sq.cm

Sb = Design allowable stress of stud (assumed as per code) 500 kgf/sq.cm

W = Full load capacity of one stud

W= Ab x Sb

W= (500 x 2.56) kgf

W= 1280 kgf

0.5
t= 0.35 x 10.54 x (2 - 250 / 350 ) x 250^2 + 1280 + 0.75
1195.1

t= 16.53 mm

For specified design pressure, provided thickness 20 mm

is adequate

Page 15, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

II PASS STAY BAR CALCULATIONS

Ref. Regulation No. 581 & 148 of IBR

W.P. = C x D^2
A

P= Design Pressure 10.54 Kg/Cm2

A= Area of that portion of tube Plate 113065 Sq.mm
supported by II pass stay bar
C= Tensile strength Allowable 6.040 kg/sq.mm
D= Diameter of Stay Bar 55 mm

6.04 x 55^2
W.P. =
113065

W.P. = 0.1616 kg/sq.mm

W.P. = 16.16 kg/sq.cm

For specified design pressure, provided diameter 55 mm

is adequate

III PASS STAY BAR CALCULATIONS

Ref. Regulation No. 581 & 148 of IBR

W.P. = C x D^2
A

P= Design Pressure 10.54 Kg/Cm2

A= Area of that portion of tube Plate 79815 Sq.mm
supported by III pass stay bar
C= Tensile strength Allowable 6.04 kg/sq.mm
D= Diameter of Stay Bar 55 mm

W.P. = 6.04 x 55^2

79815

W.P. = 0.2289 kg/sq.mm

W.P. = 22.89 kg/sq.cm

For specified design pressure, provided diameter 55 mm

is adequate

SHORT STAY BAR CALCULATIONS

Ref. Regulation No. 581 & 148 of IBR

W.P. = C x D^2
A

P= Design Pressure 10.54 Kg/Cm2

A= Area of that portion of tube Plate 65767 Sq.mm
supported by short stay bar
C= Tensile strength Allowable 6.04 kg/sq.mm
D= Diameter of Stay Bar 55 mm

W.P. = 6.04 x 55^2

65767

W.P. = 0.2778 kg/sq.mm

W.P. = 27.78 kg/sq.cm

For specified design pressure, provided diameter 55 mm

is adequate

Page 16, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

ASH DROP PIPE THICKNESS CALCULATIONS SUBJECTED TO EXTERNAL PRESSURE

Ref. Regulation No. 592 of IBR

Ash drop pipe thickness subject to External Pressure

Formula A,

P = 2 x Et x ( e - C ) x 1 + d/15L ....Eqn. XII/25

S1 x d 1 + 0.03 x d x u
(e-C) x (1+ d/0.3L)

Formula B,

P = 1.73 x E x ( e - C )^2.5 ....Eqn. XII/25A

S2 x L x d^1.5

P= Design Pressure 10.54 Kg/Cm2

d= Mean Diameter of Ash drop pipe 157.33 mm
L= Length of the section between the centers of points 97 mm
of substential supports
e= Thickness of Pipe, mm 10.97 mm
Et= Specified Min. Elevated Temp. Yeild Strength Or 1803.42 Kg/Cm2
0.2% Proof Stress at Design Temp.
S1= Factor of Safety for class I boiler 2.5
u= Percentage out of roundness 1.5
C= Corrosion allowance 0.75 mm
E= Youngs modulus of elasticity at design Temp. 1840880 Kg/Cm2
s2= Factor of Safety for class I boiler 3

Formula A,

P= 2x1803.42x(10.97-0.75) x 1+157.33/15x97
2.5x157.33 1 + 0.03x157.33x1.5
(10.97-0.75)x(1+157.33/0.3x97)

W.P.= 93.72 Kg/Cm2

Formula B,

P= 1.73x1840880x(10.97-0.75)^2.5
3x97x157.33^1.5

W.P.= 1851.78 Kg/Cm2

For specified design pressure, provided thickness 10.97 mm

is adequate

Page 17, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMPENSATING PAD FOR ASH DROP PIPE

Ash drop pipe SA-516 GR.70

Ref. Regulation No. 570, 571 of IBR

Reinforcement of opening for ash drop pipe

Width of opening in shell, W 168.3 mm 6.626 in

Actual thickness of shell, Ts 10 mm 0.394 in

Calculated thickness of shell, T1

Reg. 564
Inner dia shell, D 1900 mm 74.8 in
W.P.= Working Pressure 10.54 Kg/Cm2
E = Weld Factor 1
f = Allowable Stress of material 1406 Kg/Cm2

T1.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P.

T1.( Cal.) = 10.54x1900

"+0.762"
2x1406x1-10.54

T1 = 7.910 mm 0.311 in

Actual thickness of ash drop pipe neck, Tn 10.97 mm 0.432 in

T2.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P

T2.( Cal.) = 10.54x168.3

"+0.762"
2x1406x1-10.54

T2 = 1.503 mm 0.059 in

T3 = 3.175 mm 0.125 in
Area to be compensated X = W x T1 = 2.0636 sq.in

A} Portion of shell available for compensation

As= 2 ( 3 + Ts ) x ( Ts - T1 )
As= 0.558379895 sq.in

B} Portion of branch available for compensation

An= 2 ( 4 + Ts ) x (0.875 x Tn -(T2+ T3)) x f2 nozzle neck / f1 comp. plate

An= 1.455499541 sq.in

Area available for compensation, As + An 2.0139 sq.in

C} Portion of Pad available

Ap= W x tp

Width of compensation pad,W= 50 mm

Thickness of compensation pad,tp= 10 mm
Ap= 500 sq.mm 0.78 sq.in

Compensation area provided, A+B+C= 3.3473 sq.in

Page 18, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

BRACH / NOZZLES PIPES

As per IBR Reg. 362

t1 = PxD
+c
(2 S e + P) x X

Where :
P= Design pressure 10.54 kg/sq.cm
S= Permissible stress 1202 kg/sq.cm
e= Welding factor 0.95
c= Factor 0.75 mm
D= External Diameter of stand pipe
t1 = Required thickness as per IBR 362
X= Factor 1
tn = Actual pipe thickness provided

All the branches / nozzles are at 90 deg. to the boiler center line

As per IBR Reg. 573

t2 = D / 32 + c

t= Max (t1, t2 ) / 0.875 …… 0.875 is considering 12.5% thinning allowance on

pipe.

Description NB D t1 t2 t tn
Safety valve N1, N2 25 33.4 0.9034202 1.04375 1.193 4.547
Air Vent N3 25 33.4 0.9034202 1.04375 1.193 4.547
Stop valve, N4 80 88.9 1.15835497 2.77813 3.175 7.62
Blowdown N5 40 48.3 0.97186215 1.50938 1.725 5.08
Feed Vavle, N6, N7 40 48.3 0.97186215 1.50938 1.725 5.08
Water level controller N8, N9 25 33.4 0.9034202 1.04375 1.193 4.547
To header N10, N11 25 33.4 0.9034202 1.04375 1.193 4.547

Provided nozzles thicknesses 'tn' are more than 't' and hence are adequate

PAD WELDED TO SHELL OR THE ATTACHMENT WELD SIZE CALCULATIONS

As per IBR Reg. 600

Lo = 2 A - D1 L1
Do

Where :
Lo = Size of fillet weld arround outer periphery mm
L1 = Size of fillet weld arround inner periphery mm
Dn = Opening diameter in shell mm
A= Cross sectional area of opening in shell = Dn x Ts mm
Do = Outer diameter of pad mm
D1 = Inner diameter of pad mm

Description Dn Do D1 A L1 Lo
Manhole pad 460 580 468 4600 10 7.7931
Headhole pad 390 510 398 3900 10 7.4902
Ash drop hole 168.3 275 175 1683 10 5.8764
Handhole pad 140 229 116 1400 10 7.1616

Since provided outer weld sizes are more than Lo calculated, design is safe.

Page 19, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

COMPENSATING PAD FOR HANDHOLE

Comp. Pad for handhole SA-516 GR.70

Ref. Regulation No. 570, 571 of IBR

Reinforcement of opening for handhole

Width of opening in shell, W 140 mm 5.512 in

Actual thickness of shell, Ts 10 mm 0.394 in

Calculated thickness of shell, T1

Reg. 564
Inner dia shell, D 2500 mm 98.43 in
W.P.= Working Pressure 10.54 Kg/Cm2
E= Weld Factor 1
f = Allowable Stress of material 1406 Kg/Cm2

T1.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P.

T1.( Cal.) = 10.54x2500

"+0.762"
2x1406x1-10.54

T1 = 10.168 mm 0.4 in

Actual thickness of handhole neck, Tn 56 mm 2.205 in

T2.( Cal.) = W.P. x D

"+0.762"
2 f E - W.P.

T2.( Cal.) = 10.54x140

"+0.762"
2x1406x1-10.54

T2 = 1.289 mm 0.051 in

T3 = 3.175 mm 0.125 in
Area to be compensated X = W x T1 = 2.2064 sq.in

A} Portion of shell available for compensation

As= 2 ( 3 + Ts ) x ( Ts - T1 )
As= -0.044842232 sq.in

B} Portion of branch available for compensation

An= 2 ( 4 + Ts ) x (0.875 x Tn -(T2+ T3)) x f2 nozzle neck / f1 comp. plate

An= 15.40780039 sq.in

Area available for compensation, As + An 15.3630 sq.in

C} Portion of Pad available

Ap= W x tp

Width of compensation pad,W= 56 mm

Thickness of compensation pad,tp= 50 mm
Ap= 2800 sq.mm 4.34 sq.in

Compensation area provided, A+B+C= 19.6581 sq.in

Page 20, OF 21
Manufacturer - Lotus Boilers Pressure Vessels Pvt. Ltd. 1 TPH Boiler

PITCH OF TUBES
As per IBR Reg. 580
The spacing of tube holes such that the minimum width of ligament
between the tube holes shall be not less than D/8 + ½.
0.84695 inches
Alternatively
Thk and c/s of the plate between the tube holes shall be not less than
0.125 D + 0.2 = minimum thichness in inches 0.54695 inches
0.17 D + 0.025 = minimum cross section in square inches 0.49685 inches

where, D is the diameter of the tube hole in inches

D = tube OD + tolerance on tube hole (0.7 mm)

2.775590551 inch

Pitch for tubes provided = 85 mm and

Minimum thickness of tube plate in tube area be less than.

T= ½ in, Where Tube hole diameter less than 2”

T= 9/16 in, Where Tube hole diameter greater than 2”

Tube plate thikness provided = 20 mm

FLAT PLATE MARGINS

As per IBR Reg. 589
The amount of support in relief of the stays which may be attributed to the shell, furnaces
or flues to which flat plates are attached, shall not exceed that determined by the following
formulae:

Width of margin in inche s = C (t-1) / √WP

where, t = plate thickness in thirt-seconds in an inch. 12.5984

WP = working pressure in PSI. 149.91 PSI
C = 3.47 for plates exposed to flames.
C = 3.70 for plates not exposed to flame. 3.7

Width of margin in inches, W 3.505 inches

89.03 mm

Width of margin provided 85 mm

GUSSET PLATE THICKNESS CALCULATION

As per IBR Reg. 591 (a) & (b)

X= Length along section XX (refer fig. XII/81 & XII/82) mm

Y= Length along section YY (refer fig. XII/81 & XII/82) mm
tg = Provided thickness of gusset plate mm
S= Allowable tensile stress in gusset plate 1406 kgf/sq.cm
Ap = pressure area supported by the gusset sq.mm
P= Design pressure 10.54 kgf/sq.cm
t1 = Min. thk. of gusset plate required to withstand pressure force mm
t2 = Min. thickness of gusset based on shell thk. 8.75 mm
t3 = Min. thickness of gusset = 7/16" 11.11 mm
t= Design thickness of gusset = Max (t1, t2, t3)

t1 = 7 x Ap x P / [ Min (X, Y) x tg x S ]

Description tg Ap Y X t1 t
I 16 56267 196 190 0.971 0.971
II 16 40376 132 135 1.003 1.003

Since provided gusset thickness is more than calculated thickness, design is adequate.

Page 21, OF 21