BOILER DESIGN

TERMS AND DEFINITION

• PURCHASER
Individual or Organization that buys the
complete boiler plant or part thereof from
the manufacture.
• MANUFACTURE
Individual or Organization responsible for the
design , fabrication, testing , installation
where relevant, and compliance with the
requirement of this standard whether
executed by him or subcontractor.
 TERMS AND DEFINITION cont.

• DESIGNER
Individual or Organization that on behalf
of the manufacture, carries out the design
of the boiler plant and the designer
determine the shape, dimensions and
thicknesses of the boiler plant component,
select the materials and details the
method of construction and testing.
 TERMS AND DEFINITION cont.
• MATERIAL SUPPLIER
Individual or Organization, not being
material manufacture, that supplies materials
or prefabricated parts to be used in the
construction of boiler parts or any
component thereof.
• MATERIAL MANUFACTURE
Individual or Organization that produces the
basic materials for the fabrication of boiler
plant components or prefabricated
standardize part
 TERMS AND DEFINITION cont.
• RESPONSIBILITY
This standard indentifies the involvement of
competent organization which are
independent of the manufacture. Such
organization may be notified bodies,
recognized third party organization or user
inspectorates. For the purpose of this
standard all these organizations have been
collectively termed responsible authorities.
 RESPONSIBILITIES

• PURCHASER
Purchase shall be responsible for furnishing the
manufacture with a specification of the normal
working conditions of the boiler plant, together
with details of any transient and /or adverse
condition under which the boiler plant required
to operate and of any special requirement to
facilitate in service inspection.
 RESPONSIBILITIES
• MANUFACTURE
The manufacture shall be responsible for the
completeness and accuracy of all design calculation,
testing and inspection and for compliance with all
applicable requirements of the standard for the whole
boiler plant. (BSEN. ASME, IBR etc)
Manufacture shall ensure that the execution of the
provisions of the European Standard is entrusted to
appropriately qualified and experienced personnel.
DUTIES CARRIED OUT BY OTHER RESPONSIBLE AUTHORITES
SHALL NOT ABSOLVE THE MANUFACTURE FROM HIS
RESPONSIBILTY FOR COMPLIENCE WITH THE APPLICABLE
REQUIREMENTS OF THIS EUROPEAN STANDARD.
 INFORMATION FROM PURCHASER TO
MANUFACTURE

• FOR STEAM BOILER

Steam capacity : Kgs/hr

Working Pressure : Kg/cm2, PSI
Fuel Type : Gas, Liquid, Solid
Feed water temperature : C, F
Calorific Value of fuel : Net, Gross
 BOILER DESIGN

DESIGN DATA
• Design Code(BSEN, IBR, ASME etc)
• Working pressure
• Design pressure
• Test pressure
• Boiler capacity.
 MATERIAL CONSTRUCTION
• Furnace Shell
• Outer Shell
• Tube Plates
• Manhole Ring
• Handhole Ring
• Gusset Stay
• Stay tubes
• Stay Bars
MATERIAL CONSTRUCTION Cont
• Stand pipes
• Access opening shell
• Lifting Lugs
RADIANT HEATING SURFACE

• Furnace length
• Furnace Diameter
 FUEL COMBUSTION
• FUEL : Heavy Oil
Composition of Heavy Fuel Oil is
C = 85.00 %
H2 = 11.40 %
S = 3.00 %
H2O = 0.50 %
N2 = 0.00 %
CO2 = 0.00 %
O2 = 0.00 %
Sediments = 0.10 %
TOTAL = 100.00 %
 FUEL COMBUSTION Cont.

• COMBUSTION EQUATION
C + O2------------ CO2
2H2 + O2--------- 2H2O
S + O2---------- SO2

There for every kg of fuel burnt , 17.38 kg

flue gas is produced.( with 20 % excess
air)
 DESIGN TEMPERATURE

• Design temperature (used to evaluate the

design stress ) is the mean metal
temperature expected under operating
conditions for the part considered at
coincident pressure (not less than 250 oC)
 DESIGN TEMPERATURE Cont.

• Outer shell and gusset

• Flue tube temperature
• Front /Rear tube plate temperature
• Furnace end plate temperature
• Furnace shell plate temperature
• Rare tube plate temperature
 DESIGN STRESS

Design stress : f
Proof stress 0.2 %at design temperature : Et
Tensile strength at room temperature : Rm

Design stress is the lower of Rm/2.4 and Et/1.5

 DESIGN STRESS Cont
• Design Temp P. Stress Et D. Stress, f Youngs M. (°C)
(N/mm²) (N/mm²) (N/mm²)
250.00 180.00 120.00 195000
260.00 174.20 116.13 194200
270.00 168.40 112.27 193400
280.00 162.60 108.40 192600
290.00 156.80 104.53 191800
300.00 151.00 100.67 191000
310.00 149.40 99.60 190000
320.00 147.80 98.53 189000
330.00 146.20 97.47 188000
340.00 144.60 96.40 187000
350.00 143.00 95.33 186000
360.00 142.20 94.80 185000
370.00 141.40 94.27 184000
380.00 140.60 93.73 183000
390.00 139.80 93.20 182000
TUBE PLATE THICKNESS
Design Temp., t = 250 °C
Design Stress, f = 120.00 N/mm²
Corrosion Allow., C = 0.75 mm
Constant b : from drawing
Constant y : from drawing
Constant C4 : From table
Calculation pressure ,Pc: 1.069 N/mm2

ech=C4 b y ( Pc / f )^0.5
FURNACE TUBE LENGTH & DIAMETER

• Furnace tube Diameter vary with Boiler

capacity
• Furnace length : Graph

• Furnace Diameter : Graph

 OUTER SHELL THICKNESS
• Material: BS 1501-152 GR 430 A

Design Temp., t = 250 °C

Design Stress, f = 120.00 N/mm²
Corrosion Allow., C = 0.75 mm
Stress Reduct. Fac., Z = 1.0
Shell In. Radius, Ri = 825.0 mm
Design Pressure, P = 1.069 N/mm²
Endplate Thick., ecp = 15.0 mm
OUTER SHELL THICKNESS Cont

e = P Ri / (f Z - 0.5 P) + C = 8.136 mm
ecs = P Ri / (f X - 0.5 P) , Where, X = 0.800
Therefore,
ecs = 9.242 mm
Ratio ecp/ecs = 1.623 The derived ratio of
ecp/ecs is valid for X factor of 0.800
e1 = ecs + 0.75 = 9.992 mm
 .
MAXIMUM ALLOWABLE PRESSURE
The maximum allowable pressure is the
Maximum pressure for which the boiler
is designed and shall be measured at
the highest point of the shell boiler.
SAFETY VALVE SET PRESSURE
The safety valves(s) set pressure shall not
exceed the maximum allowable pressure.

HYDROSTATIC TEST PRESSURE

The Standard hydrostatic test pressure shall be
not less than that obtained from the following
P=1.25 Pd Rp,a/Rpt
P=1.43 Pd
.

CALCULATION PRESSURE
The calculation pressure shall be not less
than the sum of maximum allowable
pressure and hydrostatic head.
.

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