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kettle size

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It all depends in your batch size. I use a 40 quart kettle for 5.25 gallon batches with a boil volume of 6.87 gallons.
 
I use a 60 quart kettle for brew in a bag (BIAB), with total volume up to about 8-8.5 gallons. It's a little overkill for 5.5 gallon batches, but I don't really have to worry about boil overs. Plus, I have the capacity (at least for smaller grain bills) to do 11 gallon batches.
 
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