concept of save max boiler design
TRANSCRIPT
vTHERMODYNE
Concept of Save Max Boiler Design(Fuel-Oil Fired ,Fully Wet Back Boiler)
Prepared By-Archana Prajapati
vTHERMODYNE
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
vTHERMODYNEDesign 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)
vTHERMODYNEDesign Parameters
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.
vTHERMODYNEDesign 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: Between Gusset , Shell ID & tube Between Shell ID , Furnace & Stay Tubes.
vTHERMODYNEDesign Parameters
Stayed Surface in shell
vTHERMODYNEDesign 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.
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
vTHERMODYNE
Thank You