Concept of save max boiler design

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Concept of Save Max Boiler Design(Fuel-Oil Fired ,Fully Wet Back Boiler)

Prepared By-Archana Prajapati

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vTHERMODYNE We Are Covering Today

Preparation ofDetail Drawing

Save Max Boiler Design

Design Procedu

re

Development of Tube

Plate

Customer Input

vTHERMODYNEAbout Save Max Boiler Design

Save Max Boiler: Boiler uses oil & gas as fuel in arrangement to generate steam.

This model is efficient , cause there is less fuel losses.

The efficiency is 88% as we convert the maximum percentage of fuel into heat.

vTHERMODYNECustomer Inputs

Capacity Pressure Type of Fuels(Oil & Gas)

Through Capacity , we decide how much Heat Surface Area we need to give in design.

Heat Surface Area=HAS(Furnace +2nd pass tubes +3rd+pass tubes + Front Tube Plate +Rear Tube Plate

+Wrapper Drum+ Wrapper Drum Front Tube Plate +Wrapper Drum Rear Tube

Plate +Access Ring)

1 TPH=27 TO 30 m^2 (For Light Density Oil)

vTHERMODYNEDesign Procedure

Determine the Heat Surface Area

Prepare the tube plate

Shell Dia Size Defined as per HSA

Shell Length defined by length of Tube available as per HSA

Calculate Mandatory IBR boiler Calculation

Mechanical Design-Place the Studs & Gussets

Place all Nozzles ,Circumferential Seam , Longitudinal Seam

Material Selection

vTHERMODYNEDesign Parameters

Material Selection


Mandatory Calculation:1. Pitch of Tubes as per IBR Regulation -580

Required Minimum Ligament : (D/8)+12.7 mm D:Diameter of Tubes Holes

2. Thickness of Tubes, t=(PXDX1.6f)+C D:OD of Tube in mm. P:Working Pressure in Kg/cm^2 f:Allowable Stress,(Et/1.5) E:Ultimate Tensile Strength t:Working Metal Temperature c:Corrosion Allowance(0.75mm)


3.Plain Furnace & Wrapper Drum as per IBR Regulation-592(a) We calculate the thickness of plate by two formulas:

e=B/2[1+Sq.rt(1+0.12 dxu/B(1+d/0.3xL)} Where , B=(PxdxS1)/{2XEXt(1+d/15xL)} e:thickness of plate P:Working Pressure d:Mean Dia E:Ultimate Tensile Strength(UTS) S1:2.50(Factor of safety :For furnace in class 1 & class 2) C=0.75mm(Corrosion Allowance) u(Out of roundness):1.50(For Plain Furnace) t:Working Metal Temperature e=d^0.6(LxS2xP/1.73xE)^0.4+CWhere, e:thickness of plate P:Working Pressure d:Mean Dia L:Distance between stiffners C:0.75mm(Corrosion Allowance) E:Young Modulus of elasticity.We consider greater thickness in above two. Then compare the thickness with standard size that

available in market.


4.Stayed Surface as per IBR Regulation-574 e=cxdxsq.rt(P/f1+e1) We check the dia of free surface ,by putting the value of d in above

equation.

e:Thickness of end plates c:0.40(Weld Factor Coefficient for stays bar ) d:Largest Circle dia P:Working Pressure f1:0.85xallowable stress e1:( Additional Thickness : 0.75mm)We use to give stayed surface in design in two places: Between Gusset , Shell ID & tube Between Shell ID , Furnace & Stay Tubes.


Stayed Surface in shell


4.Shell Thickness as per IBR Regulation -270

W.P : {2XfxE(T-0.03)/D+(T-0.03)}

Where, E: For Class 1 Boilers ,the weld factor shall be taken as 1. W.P: Working Pressure f:Permissible Working Stress D:Inner Diameter of shell Permissible Working Stress, f=(Et)/1.5 E:Ultimate Yield Strength t:Working Metal Temperature T:Thickness of shell plates.

vTHERMODYNETube Plate Development

Factors need to be consider Tube plate Developmenta) Tubes ODb) Pitch or Ligament c) Heat Surface Aread) Gusset Placement

vTHERMODYNEPreparing Detail Drawing

Now we are ready for preparing the detail drawing. The drawing is the way of communication from design to

production

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Thank You

Concept of save max boiler design

Engineering