Design of SaveMax Boiler

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Prepared By-Archana Prajapati
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Preparation of
Detail Drawing
Save Max
Boiler
Design
Design
Procedure
Development
of Tube Plate
Customer
Input

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About 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.

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Customer Inputs
v Capacity
v Pressure
v 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)

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Design 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

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Design Parameters
 Material Selection

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Design Parameters
 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)

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Design Parameters
3.Plain Furnace & Wrapper Drum as per IBR Regulation-592(a)
We calculate the thickness of plate by two formulas:
v 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+C
Where, 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.

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Design Parameters
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:
v Between Gusset , Shell ID & tube
v Between Shell ID , Furnace & Stay Tubes.

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Design Parameters
 Stayed Surface in shell

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Design Parameters
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.

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Tube Plate Development
 Factors need to be consider Tube plate Development
a) Tubes OD
b) Pitch or Ligament
c) Heat Surface Area
d) Gusset Placement

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Preparing 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