The reducer is a device used in boilers to distribute or collect steam water mixture from connected pipes used in the boilers are hollow cylindrical in shape, the connected reducers are more to suit the connected pipes with different diameters. The reducers in a boiler are subjected to the following loads: Internal steam pressure, Axial tensile load due to dead weight of connecting tubes, wind box, casing, buck stay and refractories, Furnace pressure load, Seismic load and Thermal stress due to uneven temperature distribution across the thickness of the reducer. Of these loads the effect of the internal pressure and axial tensile load due to dead load and thermal load on the reducer are considered in this analysis. Between two tubes of different diameters coactivity is ensured by reducer. The dimensions of the reducer are decided based on manufacturing facilities available and constraints. The reducer is checked to comply with the calculations and other requirements of relevant clause of statutory code, Indian Boiler Regulation (IBR). The aim of the analysis is to estimate exact stress and temperature distribution in reducer under actual working condition using Finite Element Method (FEM).

Key words: Stress andTemperature distribution, Finite Element Method, Solid Modeling, Failure Analysis.